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Service Manual

T35100, T35100S, T35100L,


T35100SL, T35120L, T35120SL
Telescopic Handler
T35100: S/N A8HD11001 & Above
T35100L: S/N A8GW11001 & Above
T35100SL: S/N A8GT11001 & Above
T35120L: S/N A8GV11001 & Above

Dealer Copy -- Not for Resale


T35120SL: S/N A8GJ11001 & Above

6986766-EN (11-07) Revised (08-12) Printed in Belgium © Bobcat Company 2012

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Dealer Copy -- Not for Resale
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807

CORRECT

Safety Alert Symbol: This symbol with a warning statement,


means: “Warning, be alert! Your safety
is involved!” Carefully read the
message that follows.

P-90216
Never service the Bobcat
VersaHANDLER without instructions.

CORRECT WRONG WRONG

Dealer Copy -- Not for Resale


B-16082 B-16080 B-16079

Cleaning and maintenance are Disconnecting or loosening any Never work on VersaHANDLER
required daily. hydraulic tubeline, hose, fitting, with boom up unless boom is
component or a part failure can held by an approved boom stop.
cause boom to drop. Do not go Replace if damaged.
under boom when raised unless Never modify equipment or add
supported by an approved boom attachments not approved by
stop. Replace if damaged. Bobcat Company.

WRONG WRONG WRONG

B-16081 B-16078 B-6589

Have good ventilation when Keep body, jewelry and clothing Lead-acid batteries produce
welding or grinding painted away from moving parts, flammable and explosive gases.
parts. electrical contact, hot parts and Keep arcs, sparks, flames and
Wear dust mask when grinding exhaust. lighted tobacco away from
painted parts. Toxic dust and gas Wear eye protection to guard batteries.
can be produced. from battery acid, compressed Batteries contain acid which
Avoid exhaust fume leaks which springs, fluids under pressure burns eyes or skin on contact.
can kill without warning. Exhaust and flying debris when engines Wear protective clothing. If acid
system must be tightly sealed. are running or tools are used. contacts body, flush well with
Use eye protection approved for water. For eye contact flush well
type of welding. and get immediate medical
attention.

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation &
Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use
genuine Bobcat replacement parts.
MSW12-0409

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CONTENTS

SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

MAINFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

ELECTRICAL SYSTEM & ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01

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

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

Dealer Copy -- Not for Resale

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6 of 1040 1-4 T35100(S)(L), T35120(S)L Service Manual


FOREWORD

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5


Before Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Safe Operation Is The Operator’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Safe Operation Needs A Qualified Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Avoid Silica Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7


Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Spark Arrester Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Dealer Copy -- Not for Resale


SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Telescopic Handler Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Other Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

BOBCAT TELESCOPIC HANDLER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

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FOREWORD
This manual is for the Bobcat telescopic handler mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat telescopic handler 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 telescopic handler has had service or repair:
1. Check that ROPS/FOPS 9. Enclosure door latches must
(Including right side window) open and close freely.
is in good condition and is not
modified.

2. Check that ROPS mounting 10. Attachment locking pins must


hardware is tightened and is function correctly and be in
Bobcat approved. good condition.

3. The seat belt must be 11. Safety treads must be in good


correctly installed, functional condition.
and in good condition.

Dealer Copy -- Not for Resale


4. Check boom support device, 12. Check for correct function of
replace if damaged. indicator lamps and gauges.

5. Machine signs must be 13. Check hydraulic fluid level,


legible and in the correct engine oil level and fuel
location. supply.

6. Check tires for wear and 14. Inspect for fuel, oil or
pressure. Use only approved hydraulic fluid leaks.
tires.

7. Check for correct function of 15. Lubricate the Telescopic SPECIFICATIONS


the work lights. Handler.

8. The parking brake must 16. Check the condition of the


function correctly. battery and cables.

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17. Inspect the air cleaner for 20. Operate the Telescopic
damage or leaks. Check the Handler and check all
condition of the element. functions.

18. Check the electrical charging 21. Check for any field
system. modification not completed.

19. Inspect for loose or broken 22. Recommend to the owner


parts or connections. that all necessary corrections
be made before the machine
is returned to service.

Dealer Copy -- Not for Resale

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SAFETY INSTRUCTIONS The following publications provide information on the safe
use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or
service. Untrained operators and failure to follow • An Operator’s Handbook fastened to the operator
instructions can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0807

Dealer Copy -- Not for Resale


operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
IMPORTANT
• The AEM Safety Manual delivered with the machine
This notice identifies procedures which must be gives general safety information.
followed to avoid damage to the machine.
I-2019-0284 • The Service Manual and Parts Manual are available
from your dealer for use by mechanics to do shop-
type service and repair work.

• The Telescopic Handler Operator Training Course is

DANGER available through your local dealer or at


www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
The signal word DANGER on the machine and in the of correct operation of the Telescopic Handler.
manuals indicates a hazardous situation which, if not
avoided, will result in death or serious injury. • The Telescopic Handler Safety Video is available from
D-1002-1107 your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.

The dealer and owner / operator review the

WARNING 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
The signal word WARNING on the machine and in the recommendations on the new use.
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107

SI VH EMEA-0409 SM

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SAFETY INSTRUCTIONS (CONT’D) FIRE PREVENTION

Maintenance

The machine and some attachments have components


that are at high temperatures under normal operating
Cutting or drilling concrete containing sand or rock conditions. The primary source of high temperatures is
containing quartz may result in exposure to silica dust. the engine and exhaust system. The electrical system, if
Use a respirator, water spray or other means to control damaged or incorrectly maintained, can be a source of
dust. 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

Dealer Copy -- Not for Resale


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.

SI VH EMEA-0409 SM

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FIRE PREVENTION (CONT’D) Welding And Grinding

Hydraulic System Always clean the machine and attachment, disconnect


the battery, and disconnect the wiring from the Bobcat
Check hydraulic tubes, hoses and fittings for damage controllers before welding. Cover rubber hoses, battery
and leakage. Never use open flame or bare skin to check and all other flammable parts. Keep a fire extinguisher
for leaks. Hydraulic tubes and hoses must be properly near the machine when welding.
routed and have adequate support and secure clamps.
Tighten or replace any parts that show leakage. Have good ventilation when grinding or welding painted
parts. Wear dust mask when grinding painted parts.
Always clean fluid spills. Do not use gasoline or diesel Toxic dust or gas can be produced.
fuel for cleaning parts. Use commercial nonflammable
solvents. Dust generated from repairing nonmetallic parts such as
hoods, fenders or covers can be flammable or explosive.
Fueling Repair such components in a well ventilated area away
from open flames or sparks.

Fire Extinguishers

Stop the engine and let it cool before adding fuel. No


smoking! Do not refuel a machine near open flames or

Dealer Copy -- Not for Resale


sparks. Fill the fuel tank outdoors.

Starting

Do not use ether or starting fluids on any engine that has


glow plugs. These starting aids can cause explosion and Know where fire extinguishers and first aid kits are
injure you or bystanders. located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Use the procedure in the Operation & Maintenance Obey the recommendations on the instructions plate.
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 VH EMEA-0409 SM

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SERIAL NUMBER LOCATION Engine Serial Number

Always use the serial number of the telescopic handler Figure 2


when requesting service information or when ordering
parts.

Telescopic Handler Serial Number

Figure 1

S6813

P-24121

Dealer Copy -- Not for Resale


The front, on the right side of the frame [Figure 1].

S6801

The engine serial number can be found on the water


pump [Figure 2] in front of you when opening the engine
cover. Always use the full number when ordering
replacement parts.

Other Serial Numbers

Some components can also have serial numbers. Always


use these serial numbers when requesting parts.

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DELIVERY REPORT

Figure 3

B-16315

The Delivery Report must be completed by the dealer


and signed by the owner or operator when the telescopic
handler is delivered. An explanation of the form must be
given to the owner. Make sure it is complete [Figure 3].

Dealer Copy -- Not for Resale

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BOBCAT TELESCOPIC HANDLER IDENTIFICATION
OPERATOR HANDBOOK AND
LOAD CAPACITY CHARTS

BOOM MIRROR

OPERATOR
CAB
(ROPS/FOPS)
TELESCOPING
BOOM

BOOM
STOP

SEAT
BELT

PARKING BRAKE
(Right Instrument Panel)
TIRES (use only approved tires
PALLET FORK at correct pressure)
ATTACHMENT
SAFETY TREAD MIRROR

Dealer Copy -- Not for Resale


LIGHTS
(under boom, on top of frame)

LIGHT

ENGINE
COVER

S6921
S3505

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SAFETY AND MAINTENANCE

LIFTING AND BLOCKING THE TELESCOPIC HANDLER . . . . . . . . . . . . . . . . . . . . . . 10-10-1


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

OPERATOR CAB (ROPS / FOPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1


Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Cab Door Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2

TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER . . . . . . . . . . . . . . . . 10-30-1


Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

TOWING THE TELESCOPIC HANDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1


Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1


Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1


Replacing Filter Element(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Dealer Copy -- Not for Resale


ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Removing And Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-3

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1


Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-2
Secondary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-2
Primary Fuel Filter (Pre-Filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-3
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-4

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1


Checking And Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Engine Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Removing And Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2

HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1


Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . 10-100-3
Hydraulic Tank Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3

AXLES (FRONT AND REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1


Checking And Adding Oil (Planetary Carrier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Removing And Replacing Oil (Planetary Carrier) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

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Checking And Adding Oil (Rear Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2
Removing And Replacing Oil (Rear Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2
Checking And Adding Oil (Front Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-3
Removing And Replacing Oil (Front Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-4
Checking And Adding Oil (Front Drop Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-5
Removing And Replacing Oil (Front Drop Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-5

LUBRICATING THE TELESCOPIC HANDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1


Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1

ATTACHMENT CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1


Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1


Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1


Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Dealer Copy -- Not for Resale


CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Checking And Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Extend / Retract Chain Wear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-2

TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . 10-180-1


Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER . . . . . . . . . 10-190-1


Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1


Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

18 of 1040 10-02 T35100(S)(L), T35120(S)L Service Manual


LIFTING AND BLOCKING THE TELESCOPIC Figure 10-10-2
HANDLER

Procedure

Always park the machine on a level surface.

WARNING
The seat bar system must deactivate the lift, and tilt
control functions when the seat bar is up. See your
Bobcat dealer for service if joysticks do not
deactivate.
S7423
W-2461-1210

Figure 10-10-1 Put the floor jack under the center of the rear axle. Lift the
telescopic handler and install jackstands [Figure 10-10-
2].

Dealer Copy -- Not for Resale


P-23829

STOP the engine. Put the floor jack under the center of
the front axle. Lift the telescopic handler and install
jackstands [Figure 10-10-1].

19 of 1040 10-10-1 T35100(S)(L), T35120(S)L Service Manual


Dealer Copy -- Not for Resale

20 of 1040 10-10-2 T35100(S)(L), T35120(S)L Service Manual


OPERATOR CAB (ROPS / FOPS)

Figure 10-20-1

S3527

The telescopic handler has an operator cab (ROPS and


FOPS) (Item 1) [Figure 10-20-1] to protect the operator
from rollover and falling objects. Check with your dealer if
the operator cab has been damaged. Never operate

Dealer Copy -- Not for Resale


without right window. The seat belt must be worn for roll
over protection.

ROPS / FOPS - Roll Over Protective Structure per SAE


J1040 and ISO 3471, and Falling Object Protective
Structure per SAE J1043 and ISO 3449 (FOPS Level II).

WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Do not
operate without right window. Changes to the cab
can cause loss of operator protection from rollover
and falling objects, and result in serious injury or
death.
W-2906-0211

21 of 1040 10-20-1 T35100(S)(L), T35120(S)L Service Manual


OPERATOR CAB (ROPS / FOPS) (CONT’D)

Cab Door Cab Door Window

Figure 10-20-2 Figure 10-20-4

1
2

P-47350 P-47202

Figure 10-20-3 Turn the handle (Item 1) [Figure 10-20-4]. Push open the
window fully until it latches against the cab.

Dealer Copy -- Not for Resale


Figure 10-20-5

1
1

P-47201

The cab door can be opened from the outside of the cab P-47203
using the latch (Item 1) [Figure 10-20-2] and open from
the inside of the cab when you squeeze the latch (Item 1)
[Figure 10-20-3]. Pull the lever (Item 1) [Figure 10-20-5] inside the cab to
disengage the latch and close the window.
The cab door can be locked (Item 2) [Figure 10-20-2]
with the start key.

22 of 1040 10-20-2 T35100(S)(L), T35120(S)L Service Manual


TRANSPORTING THE TELESCOPIC HANDLER ON A
TRAILER
Fastening
Loading And Unloading
Figure 10-30-2
Figure 10-30-1

3
2
4

1 1
1 S3519
P-97038

Fasten the telescopic handler to the transport vehicle to


The telescopic handler must be loaded backward on the prevent if from moving during sudden stops or when

Dealer Copy -- Not for Resale


trailer. going up or down slopes.

The rear of the trailer must be blocked or supported (Item • Block the wheels (Item 1) [Figure 10-30-2].
1) [Figure 10-30-1] when loading or unloading the
telescopic handler to prevent the front end of the trailer • Fasten the machine frame to the transport vehicle
from raising up. (Items 2 and 3) [Figure 10-30-2].

Be sure the transport and towing vehicles are of • Attach the forks or bucket attachment to the transport
adequate size and capacity. For the weight of the vehicle (Item 4) [Figure 10-30-2].
telescopic handler (See Performance Specifications on
Page SPEC-10-2.)

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

23 of 1040 10-30-1 T35100(S)(L), T35120(S)L Service Manual


Dealer Copy -- Not for Resale

24 of 1040 10-30-2 T35100(S)(L), T35120(S)L Service Manual


TOWING THE TELESCOPIC HANDLER Figure 10-40-2

Procedure DEACTIVATE - ACTIVATE

The telescopic handler can be towed a short distance


such as removing it from mud or loading onto a transport
vehicle.
1

WARNING
UNEXPECTED MACHINE MOVEMENT CAN CAUSE
SERIOUS INJURY OR DEATH
S1394
• Block wheels to prevent roll away before
adjusting screws to bypass the park brake
At each end of the central part of the front axle are two
system.
bolts (see (Item 1) [Figure 10-40-1] and (Item 1) [Figure
• Return adjustment screws to the operating
10-40-2]). When screwed in, these bolts will remove the
position before operating the machine.
W-2808-0909
spring pressure that engages the brake discs.
[Figure 10-40-2] shows the function of such a bolt inside
Block the wheels to prevent the machine from rolling. the axle.
The work will first be carried out on the two bolts on one
Releasing The Parking Brake Discs side of the front axle then the two bolts on the other side:

Dealer Copy -- Not for Resale


The brakes are engaged by spring pressure and released Loosen the locking nuts (Item 2) [Figure 10-40-1] of the
by hydraulic pressure. The park brake must be released bolts and create some clearance for the bolts.
manually before towing. Only the front axle has brakes. Turn the two bolts (Item 1) [Figure 10-40-1] IN, 90° at a
The following procedure describes how to release the time, alternating between the two bolts until the bolts are
brakes: firmly seated.

Figure 10-40-1 Repeat this on the two opposite side bolts on the front
axle.
2 The brakes are now released for towing the machine.
2
Please note that the machine will not be able to brake
until the bolts are returned to their original position.

1
1

S2722

25 of 1040 10-40-1 T35100(S)(L), T35120(S)L Service Manual


TOWING THE TELESCOPIC HANDLER (CONT’D) Engaging Brake Discs

Procedure (Cont’d)

Releasing The Parking Brake Discs (Cont’d)


WARNING
Figure 10-40-3
UNEXPECTED MACHINE MOVEMENT CAN CAUSE
SERIOUS INJURY OR DEATH
• Block wheels to prevent roll away before
1 adjusting screws to bypass the park brake
Operating system.
Position
• Return adjustment screws to the operating
position before operating the machine.
W-2808-0909

Block the wheels to prevent the machine from rolling.


Towing
After towing is completed, turn the tow valve (Item 1)
Position
[Figure 10-40-3] clockwise 90° to the OPERATING
POSITION.
S6802 Figure 10-40-4

Raise the engine cover. 2

Dealer Copy -- Not for Resale


2
Turn the tow valve (Item 1) [Figure 10-40-3]
counterclockwise 90° to TOWING POSITION.
Tow the telescopic handler at a slow speed.

1
1

S2722

To reactivate the park brake, release the 4 bolts (see


(Item 1) [Figure 10-40-4] on the front axle to their
original position (turn the two bolts out, 90° turn at a time,
until no resistance can be felt. Repeat this procedure for
the opposite side two bolts).

Make sure that all 4 bolts have been turned out until they
can easily be loosened by hand. Tighten the locking nuts
(Item 2) [Figure 10-40-4].
This will allow the park brake piston to be active again.

26 of 1040 10-40-2 T35100(S)(L), T35120(S)L 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 telescopic handler.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual and signs (decals) on machine.
Follow warnings and instructions in the manuals when making repairs, adjustments
WARNING 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-EN-0903

SERVICE SCHEDULE HOURS


[5]
ITEM SERVICE REQUIRED 10 50 100 250 500 1000
Engine Oil Check the oil level and add oil as needed.
Hydraulic Fluid Check fluid level and add as needed.
Articulation Pins Lubricate with lithium based multipurpose grease.
Safety Signs, Safety Tread and Check for damaged signs (decals), safety tread and mirrors. Replace if
Mirrors damaged or worn.
Fuel Filter Clean the sediment bowl / water trap.
Nuts and Bolts Check for loose nuts and bolts. Tighten as needed.
Seat Belt Check the condition of the seat belt.
Brakes Check for function. Service as necessary.

Dealer Copy -- Not for Resale


Back-up Alarm (if equipped) Check for function. Replace as necessary.
Tires Check for wear or damage. Inflate to correct pressure. Be sure all tires are
inflated to the same pressure. Use only approved tires.
Engine Air Filter And Air System Check condition indicator, replace element when required and empty dust cup
as needed. Check air system for leaks.
Engine Cooling System Clean debris from oil cooler, radiator and air conditioner condenser. check
coolant level cold in reservoir. Add premixed coolant as needed. (See
ENGINE COOLING SYSTEM.) Check cooling system for leaks.
King Pins, Axle Oscillation (Front/ Lubricate with lithium based multipurpose grease.
Rear), Attach. Frame Pivot(s), Tilt /
Lift Cyl., Boom Pivot, Leveling Cyl.
Telescopic Boom Slide Lubricate with lithium based multipurpose grease. Check wear blocks for
adjustment or replacement.
Hydraulic Hoses, Tubelines and Check condition of hoses, tubelines and connectors. Repair or replace as
Connections needed.
Battery Check electrolyte level. Add distilled water as needed.
Wheel Nuts Check wheel nut torque. Tighten as needed (300 N•m [221 ft-lb]). [1]
Boom Chain Check and apply chain lubricant as needed. Check chain tension and wear.
Adjust or replace as necessary.
Alt. and Air Cond. Belt (if equipped) Check belt tension and adjust as needed. [2]
Door hinges Lubricate door hinges with lithium based multipurpose grease.
Engine Oil and Filter Replace the engine oil and filter. See SPECIFICATIONS for correct capacity.
Use a genuine Bobcat filter. [2]
Engine Air Filter Replace the outer filter element. Use a genuine Bobcat filter. [2]
Fuel Filter, secondary Replace the secondary fuel filter element. Use a genuine Bobcat filter. [2]
Fuel Filter, primary Replace the primary fuel filter (pre-filter) element. Use a genuine Bobcat filter. [2]
Hydraulic Fluid Filter Replace the hydraulic filter element. Use a genuine Bobcat filter. [2]
Hydraulic Tank Breather Replace the hydraulic tank breather.
Hydraulic Fluid and Filter Replace the hydraulic fluid and filter element. See SPECIFICATIONS.
Front and Rear Axle Fluid Replace the axle fluid. See SPECIFICATIONS. [3] [4]
Telescopic Boom Wear Blocks Check for wear and adjust as needed. Replace as necessary.
Pivot Pins and Bushings Check for wear on the pivot pins and bushings.
Engine valve lash Check and adjust as needed.
Stabilizers (If Equipped): Cylinders Lubricate with lithium based multipurpose grease.
and pivots
Engine Coolant Check freeze protection of antifreeze -30°C (-34°F). Flush cooling system and
replace with premixed coolant Every 2 years

[1]Check wheel nut torque every 8 hours for the first 24 hours.
[2]Perform service first time, then as indicated in chart.
[3]Check level.
[4]Replace fluid first time, then as indicated in chart.
[5]Or every 12 months.

27 of 1040 10-50-1 T35100(S)(L), T35120(S)L Service Manual


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28 of 1040 10-50-2 T35100(S)(L), T35120(S)L Service Manual


AIR CLEANER SERVICE Outer Filter

Replacing Filter Element(s) Figure 10-60-2

Figure 10-60-1
1

1
2 1 S6803

S3571
Loosen the filter housing clamps (Item 1) [Figure 10-60-
2].
Replace the large (outer) filter element only when the red
ring shows in the window of the condition indicator Release the fastener and remove the cover (Item 2)

Dealer Copy -- Not for Resale


(Item 1) [Figure 10-60-1]. [Figure 10-60-2].

NOTE: Before replacing the filter element, push the Figure 10-60-3
button on the condition indicator (Item 2)
[Figure 10-60-1]. Start the engine. If the red
ring does not show, do not replace the filter
element.

Replace the inner filter every third time the outer filter is
replaced or when the red ring still shows in the indicator
window after the outer filter has been replaced.

S6804

Pull the element straight out [Figure 10-60-3].

NOTE: Make sure all sealing surfaces are free of dirt


and debris.

Install a new outer element.

Install the dust cover and fasten [Figure 10-60-2].

Connect the filter housing clamps.

29 of 1040 10-60-1 T35100(S)(L), T35120(S)L Service Manual


AIR CLEANER SERVICE (CONT’D)

Replacing Filter Element (Cont’d)

Inner Filter

Remove the outer element.

NOTE: Make sure all sealing surfaces are free of dirt


and debris.

Figure 10-60-4

Dealer Copy -- Not for Resale


S6805

Remove the inner filter (Item 1) [Figure 10-60-4] and


install a new element.

Install the outer element.

Install the dust cover and fasten [Figure 10-60-2].

Connect the filter housing clamp (Item 1) [Figure 10-60-


2].

30 of 1040 10-60-2 T35100(S)(L), T35120(S)L Service Manual


ENGINE COOLING SYSTEM Removing And Replacing The Coolant

Check the cooling system every day to prevent over-


heating, loss of performance or engine damage.
WARNING
WARNING AVOID BURNS
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
AVOID INJURY OR DEATH W-2070-1203
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure. Open the engine cover.
• Flying debris or loose material is present.
• Engine is running. Figure 10-70-3
• Tools are being used.
W-2019-0907
1
Cleaning

Figure 10-70-1

2
MAX

Dealer Copy -- Not for Resale


MIN

S3528

Remove the cap (Item 1) [Figure 10-70-3] from the


coolant reservoir.

Remove the fan shield.


S3527

Open the engine cover (Item 1) [Figure 10-70-1].

Figure 10-70-2

S6815

Use low air pressure or water pressure to clean the


radiator, oil cooler and intercooler [Figure 10-70-2].

31 of 1040 10-70-1 T35100(S)(L), T35120(S)L Service Manual


ENGINE COOLING SYSTEM (CONT’D) Run the engine until it is at operating temperature.

Removing And Replacing The Coolant (Cont’d) Stop the engine.

Figure 10-70-4 Check the coolant level (COLD) in the reservoir when
cool.

Add coolant to the reservoir as needed.

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

Too much antifreeze reduces cooling system


2 efficiency and may cause serious premature engine
S6817 damage.

Too little antifreeze reduces the additives which


Remove the engine block drain plug (Item 1) [Figure 10- protect the internal engine components; reduces the
70-4]. boiling point and freeze protection of the system.

Dealer Copy -- Not for Resale


Open the drain valve (Item 2) [Figure 10-70-4] and drain Always add a premixed solution. Adding full strength
all of the coolant into a container. Dispose of used concentrated coolant can cause serious premature
coolant in an environmentally safe manner. engine damage.
I-2124-0497
Close the drain valves.

NOTE: The cooling system is factory filled with


ethylene glycol (EG) coolant. DO NOT mix
ethylene glycol with propylene glycol.

Add premixed coolant to the reservoir if the coolant level


is low.

Use a refractometer to check the condition of ethylene


glycol in your cooling system.

Fill the radiator with the premixed coolant. Install the


radiator cap.

Add coolant to the reservoir. The coolant level must be


between the MIN and MAX marks (Item 2) [Figure 10-
70-3] on the coolant reservoir.

Follow the following steps when using concentrated


coolant instead of a ready-to-use premix:

• mix the coolant in a separate container: 4,3 L (one


gallon and one pint) of ethylene glycol mixed with 3,8
L (one gallon) of water is the correct mixture of
coolant to provide a -37°C (-34°F) freeze protection.

• Add premixed coolant, 47% water and 53% ethylene


glycol to the coolant tank until the coolant level
reaches the MIN marker on the tank (Item 1) [Figure
10-70-3].

32 of 1040 10-70-2 T35100(S)(L), T35120(S)L Service Manual


ENGINE COOLING SYSTEM (CONT’D)

Checking Level

Open the engine cover.

Check the coolant level in the coolant reservoir.

Figure 10-70-5

1
MAX

MIN

S3528

Dealer Copy -- Not for Resale


The coolant level must be between the MIN and MAX
marks (Item 1) [Figure 10-70-5] on the coolant reservoir
when the engine is cold.

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

33 of 1040 10-70-3 T35100(S)(L), T35120(S)L Service Manual


Dealer Copy -- Not for Resale

34 of 1040 10-70-4 T35100(S)(L), T35120(S)L Service Manual


FUEL SYSTEM Biodiesel Blend Fuel

Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
The following is one suggested blending guideline which
should prevent fuel gelling problems in cold • Biodiesel blend fuel is an excellent medium for
temperatures: microbial growth and contamination which can cause
corrosion and plugging of fuel system components.
TEMPERATURE NO. 2 NO. 1 • Use of biodiesel blend fuel may result in premature
failure of fuel system components, such as plugged
-9°C (+15°F) 100% 0%
fuel filters and deteriorated fuel lines.
Down to -29°C (-20°F) 50% 50%
• Shorter maintenance intervals may be required, such
Below -29°C (-20°F) 0% 100%
as cleaning the fuel system and replacing fuel filters
and fuel lines.
At a minimum, Low Sulfur (500 ppm sulfur) Diesel Fuel
must be used in this machine: • Using biodiesel blended fuels containing more than
five percent biodiesel can affect engine life and cause
The following fuels may also be used in this machine: deterioration of hoses, tubelines, injectors, injector
pump and seals.
• Ultra Low Sulfur (15 ppm sulfur) Diesel Fuel.
Apply the following guidelines if biodiesel blend fuel is

Dealer Copy -- Not for Resale


used:
• Biodiesel Blend Fuel - Must contain no more than five
percent biodiesel mixed with low sulfur or ultra low
• Ensure the fuel tank is as full as possible at all times
sulfur petroleum based diesel. This is commonly
to prevent moisture from collecting in the fuel tank.
marketed as B5 blended diesel fuel. B5 blended
diesel fuel must meet ASTM D975 (US Standard) or • Ensure that the fuel tank cap is securely tightened.
EN590 (EU Standard) specifications.
• Biodiesel blend fuel can damage painted surfaces,
remove all spilled fuel from painted surfaces
immediately.
• Drain all water from the fuel filter daily before
operating the machine.
• Do not exceed engine oil change interval. Extended
oil change intervals can cause engine damage.
• Before machine storage; drain the fuel tank, refill with
100% petroleum diesel fuel, add fuel stabilizer and
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 3 months.

35 of 1040 10-80-1 T35100(S)(L), T35120(S)L Service Manual


FUEL SYSTEM (CONT’D) Secondary Fuel Filter

Filling The Fuel Tank See the SERVICE SCHEDULE for the service interval
when to replace the secondary fuel filter. (See SERVICE
SCHEDULE on Page 10-50-1.)

Figure 10-80-2
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
1
Figure 10-80-1

S6824

Dealer Copy -- Not for Resale


Remove the filter element (Item 1) [Figure 10-80-2].

Clean the area around the filter housing.

Install the new filter element with a new seal, and hand
tighten.

S3524 Remove air from the fuel system. (See Removing Air
From The Fuel System on Page 10-80-4.)

Remove the fuel fill cap (Item 1) [Figure 10-80-1].

Use a clean, approved safety container to add fuel of the


correct specifications. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
WARNING
SMOKING!
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
Install and tighten the fuel fill cap [Figure 10-80-1].
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

36 of 1040 10-80-2 T35100(S)(L), T35120(S)L Service Manual


FUEL SYSTEM (CONT’D) Figure 10-80-5

Primary Fuel Filter (Pre-Filter)


1
See the SERVICE SCHEDULE for the service interval
when to replace the fuel filter. (See SERVICE
SCHEDULE on Page 10-50-1.)
2
Replacing Element

Figure 10-80-3

S36232

Remove the filter element (Item 1), bowl (Item 2) and


bottom cover (Item 3) [Figure 10-80-5] from the filter
housing.

Clean the area around the filter housing and reinstall


1 using a new filter element (Item 1) [Figure 10-80-5].

Dealer Copy -- Not for Resale


S36232 Remove air from the fuel system. (See Removing Air
From The Fuel System on Page 10-80-4.)
Open the drain valve (Item 1) [Figure 10-80-3] on the Removing Water
bottom cover of the fuel primary filter and allow the fluid
to drain into a container. Figure 10-80-6
Tighten the drain valve (Item 1) [Figure 10-80-3] by hand
pressure.

Figure 10-80-4

1
1 S36232

Open the drain valve (Item 1) [Figure 10-80-6] on the


fuel pre-filter bottom cover to remove water from the filter.
S36233

When clean fuel drains from the water separator, tighten


the drain valve (Item 1) [Figure 10-80-6] by hand
Hold the filter assembly (Item 1) and remove the screw pressure.
(Item 2) [Figure 10-80-4].

37 of 1040 10-80-3 T35100(S)(L), T35120(S)L Service Manual


FUEL SYSTEM (CONT’D)

Removing Air From The Fuel System

Figure 10-80-7

2
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
1
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

WARNING
S36409
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
After replacing the filter element or when the fuel tank penetrate skin or eyes, causing serious injury or
has run out of fuel, the air must be removed from the fuel death. Fluid leaks under pressure may not be visible.

Dealer Copy -- Not for Resale


system before starting the engine. Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
Turn the Start key to the Preheat position (Item 1) enters skin or eyes, get immediate medical attention
[Figure 10-80-7] (this will activate the electrical pump from a physician familiar with this injury.
relay). W-2072-0807

Leave the Start key in the Run position (Item 2) [Figure


10-80-7] for 3 minutes.

Crank the engine with the accelerator pedal released


(low idle position) until the engine starts.

Run the engine at low idle for approximately 5 seconds


then cycle the accelerator pedal rapidly from the low idle
position to the high idle position three times. The time
taken to cycle the accelerator pedal to be typically one to
3 seconds. This will assist in displacing any residual
trapped air in the fuel injection pump.

Check for fuel leaks in the fuel system.

38 of 1040 10-80-4 T35100(S)(L), T35120(S)L Service Manual


ENGINE LUBRICATION SYSTEM Engine Oil Chart

Checking And Adding Engine Oil Figure 10-90-2

Check the engine oil level every day before starting the ENGINE OIL
engine for the work shift. RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE
Figure 10-90-1 CRANKCASE)

S6807

Dealer Copy -- Not for Resale


Open the engine cover and remove the dipstick (Item 1) TEMPERATURE RANGE ANTICIPATED BEFORE
[Figure 10-90-1]. NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
CLASSIFICATION CI-4 OR BETTER)
Keep the oil level between the marks on the dipstick [1] Synthetic Oil - Use recommendation from Synthetic
(Inset) [Figure 10-90-1]. Oil Manufacturer.

Use a good quality motor oil that meets API Service Use good quality engine oil that meets API Service
Classification of CI-4 or better. (See Oil Chart, [Figure Classification of CI-4 or better. (See Oil Chart, [Figure
10-90-2].) 10-90-2].)

39 of 1040 10-90-1 T35100(S)(L), T35120(S)L Service Manual


ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-90-4

Removing And Replacing Oil And Filter

See the SERVICE SCHEDULE for the service interval for


replacing the engine oil and filter. (See SERVICE
SCHEDULE on Page 10-50-1.)

Run the engine until it is at operating temperature. Stop


1
the engine.

Figure 10-90-3

S6814
1

Open the engine cover. (See Opening And Closing on


Page 10-160-1.)

Remove the oil filter (Item 1) [Figure 10-90-4].

Clean the filter housing surface.

Dealer Copy -- Not for Resale


Put clean oil on the new oil filter gasket. Install the filter
and hand tighten.
S3525
Figure 10-90-5

Remove the access panel at the rear of the engine


compartment. Route the hose (Item 1) [Figure 10-90-3] 1
out through the access hole. Remove the cap.

Drain the oil into a container and recycle or dispose of 2


used oil in an environmentally safe manner.

Install cap and put the drain hose into the engine
compartment, install the access cover.

WARNING S6809

AVOID INJURY OR DEATH


Always clean up spilled fuel or oil. Keep heat, flames, Remove the filler cap (Item 1) [Figure 10-90-5].
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause Put oil in the engine. For capacity, (See Fluid Capacities
explosion or fire. on Page SPEC-10-4.)
W-2103-0508
Install fill cap, start the engine and let it run for several
minutes.

Stop the engine, and check for leaks at the oil filter.

Remove the dipstick (Item 2) [Figure 10-90-5] and check


the oil level. Add oil as needed if it is not at the top mark
on the dipstick.

40 of 1040 10-90-2 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart

Checking And Adding Fluid Figure 10-100-3

Use only recommended fluid in the hydraulic system. HYDRAULIC / HYDROSTATIC FLUID
(See Hydraulic / Hydrostatic Fluid Chart on Page 10-100- RECOMMENDED ISO VISCOSITY GRADE (VG)
1.) AND VISCOSITY INDEX (VI)

Stop the machine on a level surface. Lower the boom all


the way.

Stop the engine.

Figure 10-100-1

TEMPERATURE RANGE ANTICIPATED


DURING MACHINE USE
[1] VG 100; Minimum VI 120

Dealer Copy -- Not for Resale


[2] VG 46; Minimum VI 140
[3] Synthetic Fluid; VG 46; Minimum VI 150
1 [4] BOBCAT Hydraulic / Hydrostatic Fluid
P-97034
Use only recommended fluid in the hydraulic system
[Figure 10-100-3]. (See Specifications on Page SPEC-
Check the fluid level at the sight gauge (Item 1) [Figure 50-1.)
10-100-1].

Figure 10-100-2

P-97033

Remove the fill / breather cap (Item 1) [Figure 10-100-2]


and add hydraulic fluid.

41 of 1040 10-100-1 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-100-5

Removing And Replacing Hydraulic Fluid

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 P-52179
from a physician familiar with this injury.
W-2072-0807
Remove the reservoir drain plug (Item 1) [Figure 10-100-
5] behind the right front wheel and drain the fluid into a
container. Recycle or dispose of the fluid in an
environmentally safe manner. Reinstall the drain plug and

WARNING tighten.

Dealer Copy -- Not for Resale


Add fluid until it is at the center of the sight gauge (Item 1)
AVOID INJURY OR DEATH [Figure 10-100-5].
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil. Install the fill cap.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

Figure 10-100-4

P-97033

Remove the fill / breather cap (Item 1) [Figure 10-100-4].

42 of 1040 10-100-2 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Hydraulic Tank Breather

Removing And Replacing Hydraulic / Hydrostatic See the SERVICE SCHEDULE for the correct
Filter replacement interval. (See SERVICE SCHEDULE on
Page 10-50-1.)
See the SERVICE SCHEDULE for the correct service
intervals. (See SERVICE SCHEDULE on Page 10-50-1.) Open the engine cover. (See Opening And Closing on
Page 10-160-1.)
Figure 10-100-6
Figure 10-100-8
1

P-97034

Dealer Copy -- Not for Resale


P-97033

Unscrew the plug (Item 1) [Figure 10-100-6] by hand.


Remove and discard the breather (Item 1) [Figure 10-
Figure 10-100-7 100-8].

Install the new breather.

1
S6819

Remove the cartridge (Item 1) [Figure 10-100-7] from


the oil filter.

NOTE: Be careful to keep impurities from getting into


the hydraulic / hydrostatic system.

Put the new cartridge in the oil filter.


Top up the oil if necessary.
Inspect the seal and replace if necessary.
Replace the plug.

43 of 1040 10-100-3 T35100(S)(L), T35120(S)L Service Manual


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44 of 1040 10-100-4 T35100(S)(L), T35120(S)L Service Manual


AXLES (FRONT AND REAR) Removing And Replacing Oil (Planetary Carrier)

Checking And Adding Oil (Planetary Carrier) See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-50-1.)
Figure 10-110-1
Figure 10-110-2

S3297
S3296

Put the machine on a level surface with the plugs (Item 1)


[Figure 10-110-1] positioned as shown.
Put the machine on a level surface with the plug (Item 1)
[Figure 10-110-2] positioned as shown.

Dealer Copy -- Not for Resale


Remove the plugs (Item 1) [Figure 10-110-1]. The oil
level should be at the bottom edge of the plug hole.
Remove the plug (Item 1) [Figure 10-110-2] and drain
into a container. Recycle or dispose of the used lubricant
Add gear lube through the hole if the oil level is below the
in an environmentally safe manner.
hole. For capacity, (See Fluid Capacities on Page SPEC-
10-4.) For type, (See Specifications on Page SPEC-50-
Reposition the plug hole and add gear lube until the lube
1.)
level is at the bottom edge of the plug hole (Item 1)
[Figure 10-110-1]. For capacity, (See Fluid Capacities on
Install and tighten the plug.
Page SPEC-10-4.) For type, (See Specifications on Page
SPEC-50-1.)
Repeat the procedure for the other side.
Install and tighten the plug.

Repeat the procedure for the other side.

45 of 1040 10-110-1 T35100(S)(L), T35120(S)L Service Manual


AXLES (FRONT AND REAR) (CONT’D)

Checking And Adding Oil (Rear Differential) Removing And Replacing Oil (Rear Differential)

See the SERVICE SCHEDULE for the correct service See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-50-1.) interval. (See SERVICE SCHEDULE on Page 10-50-1.)

Figure 10-110-3 Figure 10-110-4

S1841
S1842

Dealer Copy -- Not for Resale


Put the machine on a level surface.
With the machine on a level surface remove the plug
Remove the plug (Item 1) [Figure 10-110-3]. The oil level (item 1) [Figure 10-110-4] and drain into a container.
should be at the bottom edge of the plug hole. Recycle or dispose of the used lubricant in an
environmentally safe manner.
Add oil through the hole if the oil level is below the hole.
For capacity, (See Fluid Capacities on Page SPEC-10-4.) Add oil through the hole (Item 1) [Figure 10-110-3] if the
For type, (See Specifications on Page SPEC-50-1.) oil level is below the hole. For capacity, (See Fluid
Capacities on Page SPEC-10-4.) For type, (See
Install and tighten the plug. Specifications on Page SPEC-50-1.)

Install and tighten the plug.

46 of 1040 10-110-2 T35100(S)(L), T35120(S)L Service Manual


AXLES (FRONT AND REAR) (CONT’D)

Checking And Adding Oil (Front Differential)

See the SERVICE SCHEDULE for the correct service


interval. (See SERVICE SCHEDULE on Page 10-50-1.)

Figure 10-110-5

S1843

Dealer Copy -- Not for Resale


Figure 10-110-6

S1851

Remove the plugs (Item 1) [Figure 10-110-5] and


[Figure 10-110-6]. The oil level should be at the bottom
edge of the plug hole.

Add oil through the hole if the oil level is below the hole.
For capacity, (See Fluid Capacities on Page SPEC-10-4.)
For type, (See Specifications on Page SPEC-50-1.)

Install and tighten the plug.

47 of 1040 10-110-3 T35100(S)(L), T35120(S)L Service Manual


AXLES (FRONT AND REAR) (CONT’D)

Removing And Replacing Oil (Front Differential) Figure 10-110-8

Figure 10-110-7 V723

V723

1
1
1

S1842
S1844
1
S1842
S1845
V723

V723

Dealer Copy -- Not for Resale


1

1
1
S1842
S1843

1
S1842
S1846
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-50-1.)

With the machine on a level surface remove the plug(s)


(Item 1) [Figure 10-110-7] and [Figure 10-110-8] and
drain into a container. Recycle or dispose of the used
lubricant in an environmentally safe manner.

Add oil through the hole (Item 1) [Figure 10-110-5] and


[Figure 10-110-6] if the oil level is below the hole. For
capacity, (See Fluid Capacities on Page SPEC-10-4.) For
type, (See Specifications on Page SPEC-50-1.)

Install and tighten the plug.

48 of 1040 10-110-4 T35100(S)(L), T35120(S)L Service Manual


AXLES (FRONT AND REAR) (CONT’D)

Checking And Adding Oil (Front Drop Box) Removing And Replacing Oil (Front Drop Box)

Figure 10-110-9 Figure 10-110-10

S1851 S1844

Remove the plug (Item 1) [Figure 10-110-9]. The oil level With the machine on a level surface, remove the plug
should be at the bottom edge of the plug hole. (item 1) [Figure 10-110-10] and drain into a container.

Dealer Copy -- Not for Resale


Recycle or dispose of the used lubricant in an
Add oil through the hole if the oil level is below the hole environmentally safe manner.
(Item 1) [Figure 10-110-9]. For capacity, (See Fluid
Capacities on Page SPEC-10-4.) For type, (See Add oil through the hole if the oil level is below the hole
Specifications on Page SPEC-50-1.) (Item 1) [Figure 10-110-9]. For capacity, (See Fluid
Capacities on Page SPEC-10-4.) For type, (See
Install and tighten the plug. Specifications on Page SPEC-50-1.)

Install and tighten the plug.

49 of 1040 10-110-5 T35100(S)(L), T35120(S)L Service Manual


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50 of 1040 10-110-6 T35100(S)(L), T35120(S)L Service Manual


LUBRICATING THE TELESCOPIC HANDLER Figure 10-120-3

Lubrication Locations

Lubricate as specified, to obtain the best performance of


the machine. (See SERVICE SCHEDULE on Page 10-
50-1.)

Record the operating hours each time you lubricate so


that it is performed at the correct interval.

Always use a good quality lithium based multipurpose


grease. Apply lubricant until extra grease shows.

Lubricate the following locations on the telescopic 1


handler: S3538

Figure 10-120-1
3. Axle Oscillation - Front Axle (Item 1) [Figure 10-120-
3].

Figure 10-120-4

Dealer Copy -- Not for Resale


1

P-24167

1. Axle Pivots - Top and bottom (Item 1) [Figure 10-120-


1] all four wheels. S2003

Figure 10-120-2
4. Frame Leveling Cylinder - Rod End (Item 1) [Figure
10-120-4].

1 1

S2000 S1998

2. Axle Oscillation - Rear Axle (Item 1) [Figure 10-120-


2].

51 of 1040 10-120-1 T35100(S)(L), T35120(S)L Service Manual


LUBRICATING THE TELESCOPIC HANDLER Figure 10-120-7
(CONT’D)

Lubrication Locations (Cont’d)

Figure 10-120-5

1 1
1

S3542

7. Tilt Cylinder Rod End (Item 1) [Figure 10-120-7].

S3539 Figure 10-120-8

5. Attachment Frame Pivot (Item 1) [Figure 10-120-5]

Dealer Copy -- Not for Resale


(Both Sides).

Figure 10-120-6

1
1

S3541

8. Tilt Cylinder pivot (Item 1) [Figure 10-120-8] (both


sides).

S3540

6. Tilt Cylinder Base End (Item 1) [Figure 10-120-6].

52 of 1040 10-120-2 T35100(S)(L), T35120(S)L Service Manual


LUBRICATING THE TELESCOPIC HANDLER Figure 10-120-10
(CONT’D)

Lubrication Locations (Cont’d)


2
Figure 10-120-9

S3522

NOTE: Raise the boom and install the approved

Dealer Copy -- Not for Resale


Boom Stop before lubricating the Boom and
Slave Cylinders. (See Installing The Approved
Boom Stop on Page 10-150-1.)

9. Lift Cylinder Rod End (Item 1) and Pivot (Item 2)


1
[Figure 10-120-9].
3
S3543

10. Lift Cylinder Base End (Item 1), Slave Cylinder Rod
End (Item 2), Slave Cylinder Base End (Item 3)
[Figure 10-120-10].

Figure 10-120-11

1 1

S3544

11. Boom Pivot (Item 1) [Figure 10-120-11] (Four


Places).

53 of 1040 10-120-3 T35100(S)(L), T35120(S)L Service Manual


LUBRICATING THE TELESCOPIC HANDLER Figure 10-120-14
(CONT’D)

Lubrication Locations (Cont’d)

Figure 10-120-12

S3546
1
14. Boom Slide [Figure 10-120-14] (Eight Places), Front
Chain Pulley Pivot (Item 1) [Figure 10-120-14].
P-52183
Figure 10-120-15

12. Cab Door Hinges (Item 1) [Figure 10-120-12]

Dealer Copy -- Not for Resale


(Upper).

Figure 10-120-13

1
1 1

1 S3572

15. Rear Chain Pulley Pivot (Item1) [Figure 10-120-15].

S3545

13. Cab Door Hinges (Item 1) [Figure 10-120-13]


(Lower).

54 of 1040 10-120-4 T35100(S)(L), T35120(S)L Service Manual


ATTACHMENT CARRIER Figure 10-130-3

Inspection And Maintenance

Figure 10-130-1

P-23856

The telescopic handler attachment locking pins (Item 1)


P-23854 [Figure 10-130-3] must move freely. The pins must not
be bent or the ends deformed.

The telescopic handler mounting hooks (Item 1) [Figure Figure 10-130-4


10-130-1] must not be damaged. Check for cracked or

Dealer Copy -- Not for Resale


broken hooks.

Figure 10-130-2

S3547
1

The pins must extend through the holes in the


P-23858 attachment mounting frame (Item 1) [Figure 10-130-4].

Lubricate the attachment carrier. (See SERVICE


The stop blocks (Item 1) [Figure 10-130-2] must not be SCHEDULE on Page 10-50-1.)
damaged. Check for bent or broken stop blocks.

55 of 1040 10-130-1 T35100(S)(L), T35120(S)L Service Manual


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56 of 1040 10-130-2 T35100(S)(L), T35120(S)L Service Manual


TIRE MAINTENANCE Mounting

Wheel Nuts

Figure 10-140-1
WARNING
When the engine is running during service, the Travel
Direction Lever must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
death.
W-2397-0301

Tires are to be repaired only by an authorized person


using the correct procedures and type of 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
S2004 bead and rim flange must be lubricated with a rubber
lubricant before mounting the tire.

(See SERVICE SCHEDULE on Page 10-50-1.) [Figure Avoid excessive pressure which can rupture the tire and
10-140-1] for the service interval to check the wheel nuts. cause serious injury or death.

Dealer Copy -- Not for Resale


The correct torque is 360 N•m (266 ft-lb) torque.
During inflation of the tire, check the tire pressure
Rotating frequently to avoid over inflation.

Check the tires regularly for wear, damage and pressure.


(See Traction on Page SPEC-10-3.) for the correct tire
pressure.)

Rear tires usually wear faster than front tires. To keep the
wear even, move the front tires to the rear and rear tires
to the front.

It is important to keep the same size tires on each side of


the telescopic handler. 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
capacity. Check for the correct pressure before operating
the telescopic handler.

57 of 1040 10-140-1 T35100(S)(L), T35120(S)L Service Manual


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58 of 1040 10-140-2 T35100(S)(L), T35120(S)L Service Manual


APPROVED BOOM STOP Removing The Approved Boom Stop

If the boom is raised for service or maintenance, use the • Start the engine and raise the boom. Stop the engine.
following procedure to install and remove the approved
boom stop. • Remove the fasteners, pins and boom stop.

Installing The Approved Boom Stop

• Put the telescopic handler on a flat, solid and level


surface.

• With the operator in the seat, the seat belt fastened,


Travel Direction Control in neutral and the parking
brake engaged, start the engine and raise the boom
and stop the engine.

Figure 10-150-1

Dealer Copy -- Not for Resale


1

S3521

• Remove the boom stop (Item 1) [Figure 10-150-1]


from the storage position.

Figure 10-150-2

S3522

• Install the pins and secure with fasteners [Figure 10-


150-2].

• Start the engine and lower the boom slowly [Figure


10-150-2] so that the boom stop is held securely.

59 of 1040 10-150-1 T35100(S)(L), T35120(S)L Service Manual


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60 of 1040 10-150-2 T35100(S)(L), T35120(S)L Service Manual


ENGINE COVER

Opening And Closing

Figure 10-160-1

P-52162

Pull the latch handle (Item 1) [Figure 10-160-1] out and


rotate counterclockwise. Raise the engine cover to

Dealer Copy -- Not for Resale


provide access for maintenance.

61 of 1040 10-160-1 T35100(S)(L), T35120(S)L Service Manual


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62 of 1040 10-160-2 T35100(S)(L), T35120(S)L Service Manual


CHAIN

Checking And Adjustment Procedure Extend Chains Tightness

Retract Chains Tightness Figure 10-170-2

Figure 10-170-1 1

2 3
1
4
2
3

S3574
4
S3573
Loosen the two lock nuts (Item 1) [Figure 10-170-2].

Dealer Copy -- Not for Resale


Loosen the lock nuts (Item 1) [Figure 10-170-1]. Check the tightness of the adjustment nuts (located
behind the lock nuts). The correct torque value is 18 N•m
Check the tightness of the adjustment screw (Item 2) (13.5 ft-lb).
[Figure 10-170-1]. The correct torque value is 30 N•m
(22.1 ft-lb). Tighten the adjustment nuts as required.

Tighten the adjustment screws as required. Tighten the adjustment nuts alternately and evenly as
required to achieve the desired torque value. Distance
The chain anchor (Item 3) must be perpendicular to the between the mounting surface on the top of the outer
bottom of the intermediate boom section. Re-position the boom section (Item 2) and the chain anchors (Item 3)
chain anchor as required using screw (Item 4) [Figure MUST be even. DO NOT tighten one chain (Item 4)
10-170-1] and lock nut to position the anchor correctly. [Figure 10-170-2] more than the other.

Re-tighten the lock-nuts. Re-tighten the lock-nuts.

Start the engine and operate the extend / retract function


through several cycles to check for proper operation.
Repair as required.

63 of 1040 10-170-1 T35100(S)(L), T35120(S)L Service Manual


CHAIN (CONT’D)

Extend / Retract Chain Wear Check

Figure 10-170-3

S0581

Start the engine.

Dealer Copy -- Not for Resale


Extend the boom completely in the horizontal position.
Shut off the engine. Use a Vernier caliper to measure the
length “L” of 11 links of the extend chain. Measure from
the outside edge of link pin 1 to outside edge of link pin
11 [Figure 10-170-3].

The wear is considered normal as long as “L” is less than


169,50 mm (6.68 in).

If “L” is equal to or longer than 169,50 mm (6.68 in), the


chains, pins, rollers, tension rods and attachment screws
MUST be replaced.

Each time the chain wear is checked, record the date,


machines hours and measurement “L” for future
reference.

64 of 1040 10-170-2 T35100(S)(L), T35120(S)L Service Manual


TELESCOPIC HANDLER STORAGE AND RETURN TO
SERVICE
Return To Service
Storage
After the Bobcat telescopic handler has been in storage,
Sometimes it may be necessary to store your Bobcat it is necessary to follow a list of items to return the
telescopic handler for an extend period of time. Below is telescopic handler to service.
a list of items to perform before storage.
• Check the engine and hydraulic fluid levels; check
• Thoroughly clean the telescopic handler including the coolant level.
engine compartment.
• Install a fully charged battery.
• Lubricate the telescopic handler.
• Remove grease from exposed cylinder rods.
• Replace worn or damaged parts.
• Check all belt tensions.
• Park the telescopic handler in a dry protected shelter.
• Be sure all shields and guards are in place.
• Lower the boom all the way and put the attachment (if
equipped) flat on the ground. • Lubricate the telescopic handler.
• Put grease on any exposed cylinder rods. • Check tire inflation and remove blocks from under
frame.
• Put fuel stabilizer in the fuel tank and run the engine

Dealer Copy -- Not for Resale


a few minutes to circulate the stabilizer to the pump • Remove cover from exhaust pipe opening.
and fuel injectors.
• Start the engine and let run for a few minutes while
If biodiesel blend fuel has been used, perform the observing the instrument panels and systems for
following: correct operation.
Drain the fuel tank, refill with 100% petroleum diesel • Operate machine, check for correct function.
fuel, add fuel stabilizer and run the engine for at least
30 minutes. • Stop the engine and check for leaks. Repair as
needed.
• 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.

65 of 1040 10-180-1 T35100(S)(L), T35120(S)L Service Manual


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66 of 1040 10-180-2 T35100(S)(L), T35120(S)L Service Manual


STOPPING THE ENGINE AND LEAVING THE
TELESCOPIC HANDLER

Procedure

• Stop the telescopic handler on solid, flat and level


ground.

• Put the Travel Direction Control Lever and Joystick in


neutral.

• Engage the parking brake. (See Operation &


Maintenance Manual for correct procedure.)

Figure 10-190-1

Dealer Copy -- Not for Resale


S3518

• Retract and lower the boom and attachment flat on


the ground [Figure 10-190-1].

• Turn the key switch to STOP and unfasten the seat


belt.

• Use grab handles, safety tread and steps when


getting off.

DO NOT JUMP

WARNING
Before you leave the operator’s position:
• Put the travel Direction Control Lever and the
Joystick in neutral.
• Engage the parking brake.
• Retract and lower the boom and attachment flat
on the ground.
• Stop the engine. Raise the restraint bar (if
equipped).
SEE THE MACHINE OPERATION & MAINTENANCE
MANUAL FOR MORE INFORMATION.
W-2637-0607

67 of 1040 10-190-1 T35100(S)(L), T35120(S)L Service Manual


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68 of 1040 10-190-2 T35100(S)(L), T35120(S)L Service Manual


EMERGENCY EXIT

Rear Window

Figure 10-200-1

S3520

Turn the handle (see picture inset) [Figure 10-200-1] and


push the rear window open. Exit through the rear window

Dealer Copy -- Not for Resale


opening.

69 of 1040 10-200-1 T35100(S)(L), T35120(S)L Service Manual


Dealer Copy -- Not for Resale

70 of 1040 10-200-2 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC SYSTEM

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


Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-4
Tightening Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5

LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-10

BUCKET POSITIONING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-9

EXTENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1


Cylinder Group Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Dealer Copy -- Not for Resale


Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-9

TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-9

STEERING CYLINDER (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1


Removing The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Installing The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-3
Disassembling The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-5
Assembling The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-7

STEERING CYLINDER (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1


Removing The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Installing The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-3
Disassembling The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-5
Assembling The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-6

DRIVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1


Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-9

MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

71 of 1040 20-01 T35100(S)(L), T35120(S)L Service Manual


Testing And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-2

QUICK-TACH CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-7

FRAME LEVELING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-9

STEERING MODE VALVE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-4
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-6

Dealer Copy -- Not for Resale


BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-2

GEAR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-4
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-5

FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-5
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-6

HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-6

HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1


Troubleshooting Chart (Controllers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1
Telescoping Valve Section Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-2
Auxiliary Valve Section Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-6

72 of 1040 20-02 T35100(S)(L), T35120(S)L Service Manual


Troubleshooting Chart (Control Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-10
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-11
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-15
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-16
End Housing Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-17
Lifting Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . 20-170-18
Tilting Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . 20-170-23
Telescoping Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . 20-170-28
Auxiliary / Frame Leveling Valve Section Disassembly And Assembly . . . . . . . . . 20-170-40
Inlet-Outlet Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . 20-170-50

PORT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-1


Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-1

FLOW CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-190-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-190-1

JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-1

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-1

Dealer Copy -- Not for Resale


Pressure Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-1
Pressure Switch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-3
Parking Brake Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-4
Parking Brake Valve Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-5
Parking Brake Valve Disassembly And Assembly (Cont’d) . . . . . . . . . . . . . . . . . . . 20-210-6

PRESSURE REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-1


Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-3

ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230-1

TOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-240-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-240-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-240-2

STABILIZER CYLINDER (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-250-1


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-250-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-250-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-250-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-250-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-250-9

STABILIZER CONTROL VALVE (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-260-1


Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-260-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-260-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-260-3

73 of 1040 20-03 T35100(S)(L), T35120(S)L Service Manual


Dealer Copy -- Not for Resale

74 of 1040 20-04 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC SCHEMATIC
TL35100 (S/N A8HD11001 - A8HD12025)
TL35100L (S/N A8GW11001 - A8GW12044)
TL35100SL (S/N A8GT11001 - A8GT12063)
Printable Version Click Here
(Printed FEBRUARY 2012)
6927503-legend
LEGEND
1 RESERVOIR: 19 CHECK VALVE 38 MOTOR DISPLACEMENT CONTROL 57 TELESCOPIC CYLINDER LOAD HOLDING
Reservoir Capacity 76 L (20 U.S. U.S. gal) SPOOL VALVE – rod end: 25000 kPa (250 bar) (3625 psi)
System Capacity 120 L (31.7 U.S. U.S. gal) 20 ANTICAVITATION/WORK PORT RELIEF 58 SOLENOID ACTIVATED DIRECTIONAL
39 SHUTTLE VALVE - Drain
2 FILTER - Hydraulic VALVE – Boom: 21000 kPa (210 bar) (3045 psi) CONTROL VALVE – LLMC Over Ride
21 ANTICAVITATION/WORK PORT RELIEF 40 VARIABLE CAPACITY DISPLACEMENT 59 PROPORTIONAL REDUCER VALVE –
3 SPRING LOADED FILTER BYPASS BIDIRECTIONAL HYDROSTATIC MOTOR
VALVE: 250 kPa (2,5 bar) (36 psi) VALVE – Boom: 27500 kPa (275 bar) (3988 psi) LLMC Valve
41 SERVO PISTON - Swash Plate 60
4 CHECK VALVE CHECK VALVE – LLMC (3)
22 ANTICAVITATION/WORK PORT RELIEF
VALVE – Tilt: 21000 kPa (210 bar) (3045 psi) 42 FLUSHING VALVE: 16 L/min (4.2 U.S. gpm)
5 CHECK VALVE - With 50 kPa (0,5 bar) 61 ANTICAVITATION/WORK PORT RELIEF
(7 psi) Spring 43
43 TOW VALVE VALVE: 25000 kPa (250 bar) (3626 psi)
23 ANTICAVITATION/WORK PORT RELIEF
6 BOOM CYLINDER LOCK VALVE - Lock VALVE – Tilt: 25000 kPa (250 bar) (3625 psi) 44 NOT ANTICAVITATION/WORK PORT RELIEF
NOT USED
USED FOR
FOR THIS
THIS MODEL
MODEL 62
Pressure: 37500 kPa (375 bar) (5439 psi) VALVE: 25000 kPa (250 bar) (3626 psi)
24 COMPENSATOR
45 AUXILIARY PRESSURE RELEASE VALVE
7 ACCUMULATOR (If Equipped): 0,75 L 63 NOT USED FOR THIS MODEL
(0.2 U.S. gal.) 5000 kPa (50 bar) (725 psi) 25 RELIEF VALVE: 1900 kPa (19 bar) (275 psi) 46 NOT USED FOR THIS MODEL
8 TILT CYLINDER LOCK VALVE: 64 LOCK VALVES- Stabilser Cylinder:
26 RELIEF VALVE: 24500 kPa (245 bar) (3553 psi)
28000 kPa (280 bar) (4061 psi) 28000 kPa (280 bar) (4061 psi)
CopyCHECK
Dealer 47 -- NotVALVE - With 350 kPa (3,5 bar)
for Resale
9 SOLENOID - Reverse Drive 27 BLEED CARTRIDGE (50 psi) Spring 65 LOCK VALVES- Stabilser Cylinder:
21000 kPa (210 bar) (3045 psi)
10 SOLENOID - Forward Drive 28 SELF LEVELING CYLINDER LOCK 48 PRIORITY VALVE: 400 kPa (4,0 bar) (58 psi)
VALVE: 25000 kPa (250 bar) (3625 psi) 66 CHECK VALVE with Orifice
11 RELIEF VALVE – Charge 49 RELIEF VALVE: 20000 kPa (200 bar) (2900 psi)
30000 kPa (30 bar) (435 psi) 29 JOYSTICK LOCKOUT VALVE 67
SOLENOID ACTIVATED DIRECTIONAL SOLENOID ACTIVATED DIRECTIONAL
50
12 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - FRAME LEVEL - CONTROL VALVE – Stabiliser Cylinder)
30 SOLENOID ACTIVATED DIRECTIONAL
PRESSURE (2): 45000 kPa (450 bar) (6527 psi) REDUCED SPEED
CONTROL VALVE – Boom Lift Stop 68 SOLENOID ACTIVATED DIRECTIONAL
51 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – Stabiliser Cylinder)
13 VARIABLE CAPACITY DISPLACEMENT 31 ACCUMULATOR: 1.4 L (0.37 U.S. gal.) CONTROL VALVE - FRAME LEVEL -
BIDIRECTIONAL HYDROSTATIC PUMP
1500 kPa (15 bar) (217 psi) LEFT/RIGHT DIRECTION CONTROL 69 ORIFICE: 1,0 mm (0.039 in)
14 CHARGE PUMP: 32 L/min (8.5 U.S. gpm) @ 32 PRESSURE SWITCH- Brake:
52 SHUTTLE VALVE 70 SOLENOID ACTIVATED DIRECTIONAL CONTROL
High Engine Idle 1600 kPa (16 bar) 232 psi
VALVE – Two Speed Fan Motor (OPTIONAL)
53 LOCK VALVES- FRAME LEVELING:
15 SERVO PISTON - Swash Plate 33 PARK BRAKE VALVE – Lever Actuated
21000 kPa (210 bar) (3045 psi) 71 SOLENOID ACTIVATED DIRECTIONAL CONTROL
34 VALVE – FAN Inverter Block (OPTIONAL)
16 HYDRAULIC PUMP - Gear type BRAKE VALVE: 6000 kPa (60 bar) (870 psi) 54 RELIEF VALVE: 17500 kPa (175 bar) (2538 psi)
96 L/min (25.4 U.S. gpm) @ High Engine Idle 72
35 RELIEF VALVE: 17500 kPa (175 bar) (2538 psi) RELIEF VALVE (OPTIONAL):
55 CHECK VALVE - Anti-cavitation 20000 kPa (200 bar) (2900 psi)
17 HYDRAULIC PUMP - Gear Type
37 L/min (9.8 U.S. gpm) @ High Engine Idle 36 RELIEF VALVE (2): 22000 kPa (220 bar) (3190 psi) 56 TELESCOPIC CYLINDER LOAD HOLDING
18 PRIORITY VALVE VALVE – base end: 25000 kPa (250 bar) (3625 psi) NOTE: Unless otherwise specified, springs have
37 SHUTTLE VALVE - Drive Pressure NO significant pressure value.

6927503 (1-23-12)
Printed in Belgium

75 of 1040
MALE HYDRAULIC
COUPLER QUICKTACH
7 EV51
FEMALE
COUPLER

10 FORWARD

BOOM CYLINDER HYDRAULIC CONTROL VALVE HYDROSTATIC PUMP

2ND AUX
24 VALVE M2 M5 M4 M1

20 FLOW
OUT A
28
A
C2
2 13
A1
COOLER 15
B 9 REVERSE
21 EV74 3 CW

B1

B2 S
V2 A
17 cc 11
B1
a1
BOOM LIFT 30 55 WITH 2 SPEED FAN
STOP VALVE MOTOR (OPTIONAL) 14 M3
b1 B C
19 22 5
24 EV58 T

SELF LEVELLING CYLINDER 4 HYDRAULIC


L1
FILTER
A 1
A2
71
FAN MOTOR 70 L2
23 HYDRAULIC
B2 B A 54 RESERVOIR
47
8 12
EV52 B A

a2 FAN INVERSION
BLOCK
(OPTIONAL)
18 GEAR PUMP
b2 C1 C2 C3 C4 16
19
C9 C10
CF
24 IN

EF
C8 C7 C6 C5 T P
TILT CYLINDER
A3
61 DRAIN 72 IN
BLOCK
B3
EVP3
OUT LS
57 17
62

19
44 24
M2 M4 L1 L2
56 A4 B
44 M3
B4
EVP4 FRONT AXLE REAR AXLE

40 41
EXTENSION CYLINDER
EV8
pst Vg min 42 38
19
Y Dealer Copy -- Not for Resale TOW
VALVE
STEERING MODE
VALVE

26 37 EV7
66

P2
T1 43 A

39

P1
P

XB XA

P1
T
A
27 M1 B

P2
EV6
TRAVEL MOTOR

P LS M 25 T

65 64

STABILIZER CYLINDER

58
M2 M1 M
66
P 67 69 T LS
EV14

B T

STEERING UNIT
A

EV21 EV22
60 36
P2 P1 P
59 R L

AMA VALVE

B
64
65 A
4 3 2 1
EV18 EV17
B
EV85
STABILIZER CYLINDER SERVICE
BRAKE
68 STABILISERS BLOCK VALVE
34
F A

45 AUX RELEASE
VALVE

V T P
FRAME LEVELLING CYLINDER

T P
32 P T T LS P
JOYSTICK
50 53
53 PARK BRAKE
VALVE
35

48 EV73 C 29
T
JOYSTICK
EV3
LOCK
49 VALVE X 31
P
P T
EV71 EV72
33

51
Printable Version Click Here
CHARGE C6 C1
B A BLOCK C2

FRAME LEVELLING
C5
HYDRAULIC SCHEMATIC
BLOCK 52
C4 C3
C7
TL35100 (S/N A8HD11001 - A8HD12025)
TL35100L (S/N A8GW11001 - A8GW12044)
TL35100SL (S/N A8GT11001 - A8GT12063)
76 of 1040
(PRINTED FEBRUARY 2011)
Printed in Belgium 6927503

375 b
Printable Version Click Here

HYDRAULIC SCHEMATIC
TL35100 (S/N A8HD12026 AND ABOVE)
TL35100L (S/N A8GW12045 AND ABOVE)
TL35100SL (S/N A8GT12064 AND ABOVE)
TL35100L (S/N A8GZ11001 AND ABOVE)
TL35100SL (S/N A8GU11001 AND ABOVE)
(Printed FEBRUARY 2012)
6927503-A-legend
LEGEND
1 RESERVOIR: 19 CHECK VALVE 38 MOTOR DISPLACEMENT CONTROL 57 TELESCOPIC CYLINDER LOAD HOLDING
Reservoir Capacity 76 L (20 U.S. U.S. gal) SPOOL VALVE – rod end: 25000 kPa (250 bar) (3625 psi)
System Capacity 120 L (31.7 U.S. U.S. gal) 20 ANTICAVITATION/WORK PORT RELIEF 58 SOLENOID ACTIVATED DIRECTIONAL
39 SHUTTLE VALVE - Drain
2 FILTER - Hydraulic VALVE – Boom: 21000 kPa (210 bar) (3045 psi) CONTROL VALVE – LLMC Over Ride
21 ANTICAVITATION/WORK PORT RELIEF 40 VARIABLE CAPACITY DISPLACEMENT 59 PROPORTIONAL REDUCER VALVE –
3 SPRING LOADED FILTER BYPASS BIDIRECTIONAL HYDROSTATIC MOTOR
VALVE: 250 kPa (2,5 bar) (36 psi) VALVE – Boom: 27500 kPa (275 bar) (3988 psi) LLMC Valve
41 SERVO PISTON - Swash Plate 60
4 CHECK VALVE CHECK VALVE – LLMC (3)
22 ANTICAVITATION/WORK PORT RELIEF
VALVE – Tilt: 21000 kPa (210 bar) (3045 psi) 42 FLUSHING VALVE: 16 L/min (4.2 U.S. gpm)
5 CHECK VALVE - With 50 kPa (0,5 bar) 61 ANTICAVITATION/WORK PORT RELIEF
(7 psi) Spring 43 TOW VALVE VALVE: 25000 kPa (250 bar) (3626 psi)
23 ANTICAVITATION/WORK PORT RELIEF
6 BOOM CYLINDER LOCK VALVE - Lock VALVE – Tilt: 25000 kPa (250 bar) (3625 psi) 44 NOT USED FOR THIS MODEL 62 ANTICAVITATION/WORK PORT RELIEF
Pressure: 37500 kPa (375 bar) (5439 psi) VALVE: 25000 kPa (250 bar) (3626 psi)
24 COMPENSATOR
45 AUXILIARY PRESSURE RELEASE VALVE 63 PRESSURE SWITCH- Brake:
7 ACCUMULATOR (If Equipped): 0,75 L
(0.2 U.S. gal.) 5000 kPa (50 bar) (725 psi) 25 RELIEF VALVE: 1900 kPa (19 bar) (275 psi) 10000 kPa (100 bar) 1450 psi
46 ACCUMULATOR: 0,5 L (0.13 U.S. gal)
8 TILT CYLINDER LOCK VALVE: (7200 kPa (72 bar) (1044 psi) 64 LOCK VALVES- Stabilser Cylinder:
26 RELIEF VALVE: 24500 kPa (245 bar) (3553 psi)
28000 kPa (280 bar) (4061 psi) 28000 kPa (280 bar) (4061 psi)
CopyCHECK
Dealer 47 -- NotVALVE - With 350 kPa (3,5 bar)
for Resale
9 SOLENOID - Reverse Drive 27 BLEED CARTRIDGE (50 psi) Spring 65 LOCK VALVES- Stabilser Cylinder:
21000 kPa (210 bar) (3045 psi)
10 SOLENOID - Forward Drive 28 SELF LEVELING CYLINDER LOCK 48 PRIORITY VALVE: 400 kPa (4,0 bar) (58 psi)
VALVE: 25000 kPa (250 bar) (3625 psi) 66 CHECK VALVE with Orifice
11 RELIEF VALVE – Charge 49 RELIEF VALVE: 20000 kPa (200 bar) (2900 psi)
30000 kPa (30 bar) (435 psi) 29 JOYSTICK LOCKOUT VALVE 67
SOLENOID ACTIVATED DIRECTIONAL SOLENOID ACTIVATED DIRECTIONAL
50
12 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - FRAME LEVEL - CONTROL VALVE – Stabiliser Cylinder)
30 SOLENOID ACTIVATED DIRECTIONAL
PRESSURE (2): 45000 kPa (450 bar) (6527 psi) REDUCED SPEED
CONTROL VALVE – Boom Lift Stop 68 SOLENOID ACTIVATED DIRECTIONAL
51 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – Stabiliser Cylinder)
13 VARIABLE CAPACITY DISPLACEMENT 31 ACCUMULATOR: 1.4 L (0.37 U.S. gal.) CONTROL VALVE - FRAME LEVEL -
BIDIRECTIONAL HYDROSTATIC PUMP
1500 kPa (15 bar) (217 psi) LEFT/RIGHT DIRECTION CONTROL 69 ORIFICE: 1,0 mm (0.039 in)
14 CHARGE PUMP: 32 L/min (8.5 U.S. gpm) @ 32 PRESSURE SWITCH- Brake:
52 SHUTTLE VALVE 70 SOLENOID ACTIVATED DIRECTIONAL CONTROL
High Engine Idle 1600 kPa (16 bar) 232 psi
VALVE – Two Speed Fan Motor (OPTIONAL)
53 LOCK VALVES- FRAME LEVELING:
15 SERVO PISTON - Swash Plate 33 PARK BRAKE VALVE – Lever Actuated
21000 kPa (210 bar) (3045 psi) 71 SOLENOID ACTIVATED DIRECTIONAL CONTROL
34 VALVE – FAN Inverter Block (OPTIONAL)
16 HYDRAULIC PUMP - Gear type BRAKE VALVE: 6000 kPa (60 bar) (870 psi) 54 RELIEF VALVE: 17500 kPa (175 bar) (2538 psi)
96 L/min (25.4 U.S. gpm) @ High Engine Idle 72 RELIEF VALVE (OPTIONAL):
35 RELIEF VALVE: 17500 kPa (175 bar) (2538 psi) 55 CHECK VALVE - Anti-cavitation 20000 kPa (200 bar) (2900 psi)
17 HYDRAULIC PUMP - Gear Type
37 L/min (9.8 U.S. gpm) @ High Engine Idle 36 RELIEF VALVE (2): 22000 kPa (220 bar) (3190 psi) 56 TELESCOPIC CYLINDER LOAD HOLDING
18 PRIORITY VALVE VALVE – base end: 25000 kPa (250 bar) (3625 psi) NOTE: Unless otherwise specified, springs have
37 SHUTTLE VALVE - Drive Pressure NO significant pressure value.

6927503-A (1-19-12)
Printed in Belgium

77 of 1040
MALE HYDRAULIC
COUPLER QUICKTACH
EV51
7 FEMALE
COUPLER

ENGINE
6

10 FORWARD

HYDROSTATIC
BOOM CYLINDER HYDRAULIC CONTROL VALVE PUMP
2ND AUX VALVE
M2 M5 M4 M1
(OPTIONAL)
24 HYDRAULIC FLOW
20 FILTER OUT A

28 A 2
13
C2
A1
COOLER 15 9 REVERSE
3 CW
21
PIL B1
BOOM LIFT
B2 S
STOP VALVE 11
V2 55 WITH 2 SPEED FAN
B1
MOTOR (OPTIONAL)
a1
A B
B C 14 M3

b1 EV58
5
19 22
T
24 4 L1
A
SELF LEVELLING CYLINDER EV74
1
71 FAN MOTOR
A2
54 70 HYDRAULIC L2
B A RESERVOIR
23 30
B2
EV52 47 12
8 FAN B A
INVERSION
BLOCK
a2 DRAIN (OPTIONAL) GEAR
BLOCK 16 18 PUMP
b2 C1 C2 C3 C4

19 C9 C10 IN
CF

T P
24 EF

C8 C7 C6 C5
TILT CYLINDER
A3
72 IN

61
B3 OUT LS
EVP3
17
57
62
44
44
19
24 M2 M4 L1 L2
B
A4
56 M3

FRONT AXLE
B4
EVP4 40 41

EV8
EXTENSION CYLINDER 42
38
pst

Y
Dealer Copy -- Not for Resale T3
TOW
VALVE

19 37
26

P2
43
66 T1 39

P1
REAR AXLE
XB XA

P1
65 A
M1
STEERING
27

P2
64 TRAVEL MOTOR MODE VALVE

EV7
P LS M 25 T
A

STABILIZER CYLINDER B
EV6

B4 B3 B1
66 69 58
P 67 T LS LS

EV16
EV20
65 B
STEERING UNIT
T
A B
64
EV21 EV22 36 EV85
R L

60 59
B A4 A3 A2 A

LLMC VALVE 45 AUX


A
RELEASE
EV18 EV17 VALVE

STABILIZER CYLINDER SERVICE


4 3 2 1 BRAKE
68 VALVE 34
ACCUMULATOR
F
CHARGING VALVE
P LS T 63
FRAME LEVELLING CYLINDER
V T P

S
53 53 P T T LS P

50 P T
32 MA
A
16 b 35
JOYSTICK PARK
BRAKE 1.4 l 46
15 b
VALVE
48 EV73

49 C 29 T

C6 C1 EV3 31
EV71 EV71 C2
X
P Printable Version Click Here
C5 JOYSTICK
P T LOCK VALVE 33
51
C4 C3
C7
HYDRAULIC SCHEMATIC
B A
CHARGE TL35100 (S/N A8HD12026 AND ABOVE)
BLOCK
FRAME
LEVELLING WORKING CIRCUITS TL35100L (S/N A8GW12045 AND ABOVE)
PILOT CIRCUITS
BLOCK
DRAIN CIRCUITS TL35100SL (S/N A8GT12064 AND ABOVE)
COMPONENTS
52 TL35100L (S/N A8GZ11001 AND ABOVE)
78 of 1040 TL35100SL (S/N A8GU11001 AND ABOVE)
(PRINTED FEBRUARY 2011)
Printed in Belgium 6927503-A
HYDRAULIC SCHEMATIC
T35120SL (S/N A8GJ11001 - A8GJ12029)
T35120L (S/N A8GV11001 - A8GV12111)
Printable Version Click Here

(Printed FEBRUARY 2012)


6927503-legend
LEGEND
1 RESERVOIR: 19 CHECK VALVE 38 MOTOR DISPLACEMENT CONTROL 57 TELESCOPIC CYLINDER LOAD HOLDING
Reservoir Capacity 76 L (20 U.S. U.S. gal) SPOOL VALVE – rod end: 25000 kPa (250 bar) (3625 psi)
System Capacity 120 L (31.7 U.S. U.S. gal) 20 ANTICAVITATION/WORK PORT RELIEF 58 SOLENOID ACTIVATED DIRECTIONAL
39 SHUTTLE VALVE - Drain
2 FILTER - Hydraulic VALVE – Boom: 21000 kPa (210 bar) (3045 psi) CONTROL VALVE – LLMC Over Ride
21 ANTICAVITATION/WORK PORT RELIEF 40 VARIABLE CAPACITY DISPLACEMENT 59 PROPORTIONAL REDUCER VALVE –
3 SPRING LOADED FILTER BYPASS BIDIRECTIONAL HYDROSTATIC MOTOR
VALVE: 250 kPa (2,5 bar) (36 psi) VALVE – Boom: 27500 kPa (275 bar) (3988 psi) LLMC Valve
41 SERVO PISTON - Swash Plate 60
4 CHECK VALVE CHECK VALVE – LLMC (3)
22 ANTICAVITATION/WORK PORT RELIEF
VALVE – Tilt: 21000 kPa (210 bar) (3045 psi) 42 FLUSHING VALVE: 16 L/min (4.2 U.S. gpm)
5 CHECK VALVE - With 50 kPa (0,5 bar) 61 ANTICAVITATION/WORK PORT RELIEF
(7 psi) Spring 43 TOW VALVE VALVE: 25000 kPa (250 bar) (3626 psi)
23 ANTICAVITATION/WORK PORT RELIEF
6 BOOM CYLINDER LOCK VALVE - Lock VALVE – Tilt: 25000 kPa (250 bar) (3625 psi) 44 NOT USED FOR THIS MODEL 62 ANTICAVITATION/WORK PORT RELIEF
Pressure: 37500 kPa (375 bar) (5439 psi) VALVE: 25000 kPa (250 bar) (3626 psi)
24 COMPENSATOR
45 AUXILIARY PRESSURE RELEASE VALVE
7 ACCUMULATOR (If Equipped): 0,75 L 63 NOT USED FOR THIS MODEL
(0.2 U.S. gal.) 5000 kPa (50 bar) (725 psi) 25 RELIEF VALVE: 1900 kPa (19 bar) (275 psi) 46 NOT USED FOR THIS MODEL
8 TILT CYLINDER LOCK VALVE: 64 LOCK VALVES- Stabilser Cylinder:
26 RELIEF VALVE: 24500 kPa (245 bar) (3553 psi)
28000 kPa (280 bar) (4061 psi) 28000 kPa (280 bar) (4061 psi)
CopyCHECK
Dealer 47 -- NotVALVE - With 350 kPa (3,5 bar)
for Resale
9 SOLENOID - Reverse Drive 27 BLEED CARTRIDGE (50 psi) Spring 65 LOCK VALVES- Stabilser Cylinder:
21000 kPa (210 bar) (3045 psi)
10 SOLENOID - Forward Drive 28 SELF LEVELING CYLINDER LOCK 48 PRIORITY VALVE: 400 kPa (4,0 bar) (58 psi)
VALVE: 25000 kPa (250 bar) (3625 psi) 66 CHECK VALVE with Orifice
11 RELIEF VALVE – Charge 49 RELIEF VALVE: 20000 kPa (200 bar) (2900 psi)
30000 kPa (30 bar) (435 psi) 29 JOYSTICK LOCKOUT VALVE 67
SOLENOID ACTIVATED DIRECTIONAL SOLENOID ACTIVATED DIRECTIONAL
50
12 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - FRAME LEVEL - CONTROL VALVE – Stabiliser Cylinder)
30 SOLENOID ACTIVATED DIRECTIONAL
PRESSURE (2): 45000 kPa (450 bar) (6527 psi) REDUCED SPEED
CONTROL VALVE – Boom Lift Stop 68 SOLENOID ACTIVATED DIRECTIONAL
51 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – Stabiliser Cylinder)
13 VARIABLE CAPACITY DISPLACEMENT 31 ACCUMULATOR: 1.4 L (0.37 U.S. gal.) CONTROL VALVE - FRAME LEVEL -
BIDIRECTIONAL HYDROSTATIC PUMP
1500 kPa (15 bar) (217 psi) LEFT/RIGHT DIRECTION CONTROL 69 ORIFICE: 1,0 mm (0.039 in)
14 CHARGE PUMP: 32 L/min (8.5 U.S. gpm) @ 32 PRESSURE SWITCH- Brake:
52 SHUTTLE VALVE 70 SOLENOID ACTIVATED DIRECTIONAL CONTROL
High Engine Idle 1600 kPa (16 bar) 232 psi
VALVE – Two Speed Fan Motor (OPTIONAL)
53 LOCK VALVES- FRAME LEVELING:
15 SERVO PISTON - Swash Plate 33 PARK BRAKE VALVE – Lever Actuated
21000 kPa (210 bar) (3045 psi) 71 SOLENOID ACTIVATED DIRECTIONAL CONTROL
34 VALVE – FAN Inverter Block (OPTIONAL)
16 HYDRAULIC PUMP - Gear type BRAKE VALVE: 6000 kPa (60 bar) (870 psi) 54 RELIEF VALVE: 17500 kPa (175 bar) (2538 psi)
96 L/min (25.4 U.S. gpm) @ High Engine Idle 72
35 RELIEF VALVE: 17500 kPa (175 bar) (2538 psi) RELIEF VALVE (OPTIONAL):
55 CHECK VALVE - Anti-cavitation 20000 kPa (200 bar) (2900 psi)
17 HYDRAULIC PUMP - Gear Type
37 L/min (9.8 U.S. gpm) @ High Engine Idle 36 RELIEF VALVE (2): 22000 kPa (220 bar) (3190 psi) 56 TELESCOPIC CYLINDER LOAD HOLDING
18 PRIORITY VALVE VALVE – base end: 25000 kPa (250 bar) (3625 psi) NOTE: Unless otherwise specified, springs have
37 SHUTTLE VALVE - Drive Pressure NO significant pressure value.

6927503 (1-23-12)
Printed in Belgium

79 of 1040
MALE HYDRAULIC
COUPLER QUICKTACH
7 EV51
FEMALE
COUPLER

10 FORWARD

BOOM CYLINDER HYDRAULIC CONTROL VALVE HYDROSTATIC PUMP

2ND AUX
24 VALVE M2 M5 M4 M1

20 FLOW
OUT A
28
A
C2
2 13
A1
COOLER 15
B 9 REVERSE
21 EV74 3 CW

B1

B2 S
V2 A
17 cc 11
B1
a1
BOOM LIFT 30 55 WITH 2 SPEED FAN
STOP VALVE MOTOR (OPTIONAL) 14 M3
b1 B C
19 22 5
24 EV58 T

SELF LEVELLING CYLINDER 4 HYDRAULIC


L1
FILTER
A 1
A2
71
FAN MOTOR 70 L2
23 HYDRAULIC
B2 B A 54 RESERVOIR
47
8 12
EV52 B A

a2 FAN INVERSION
BLOCK
(OPTIONAL)
18 GEAR PUMP
b2 C1 C2 C3 C4 16
19
C9 C10
CF
24 IN

EF
C8 C7 C6 C5 T P
TILT CYLINDER
A3
61 DRAIN 72 IN
BLOCK
B3
EVP3
OUT LS
57 17
62

19
44 24
M2 M4 L1 L2
56 A4 B
44 M3
B4
EVP4 FRONT AXLE REAR AXLE

40 41
EXTENSION CYLINDER
EV8
pst Vg min 42 38 TOW STEERING MODE

19
Y
Dealer Copy -- Not for Resale VALVE VALVE

26 37 EV7
66

P2
T1 43 A

39

P1
P

XB XA

P1
T
A
27 M1 B

P2
EV6
TRAVEL MOTOR

P LS M 25 T

65 64

STABILIZER CYLINDER

58
M2 M1 M
66
P 67 69 T LS
EV14

B T

STEERING UNIT
A

EV21 EV22
60 36
P2 P1 P
59 R L

AMA VALVE

B
64
65 A
4 3 2 1
EV18 EV17
B
EV85
STABILIZER CYLINDER SERVICE
BRAKE
68 STABILISERS BLOCK VALVE
34
F A

45 AUX RELEASE
VALVE

V T P
FRAME LEVELLING CYLINDER

T P
32 P T T LS P
JOYSTICK
50 53
53 PARK BRAKE
VALVE
35

48 EV73 C 29
T
JOYSTICK
EV3
LOCK
49 VALVE X 31
P
P T
EV71 EV72
33

51
B A
CHARGE
BLOCK
C6 C1
C2
Printable Version Click Here
C5
FRAME LEVELLING
BLOCK 52 C7
HYDRAULIC SCHEMATIC
C4 C3
T35120SL (S/N A8GJ11001 - A8GJ12029)
T35120L (S/N A8GV11001 - A8GV12111)
80 of 1040
(PRINTED FEBRUARY 2011)
Printed in Belgium 6927503
Printable Version Click Here

HYDRAULIC SCHEMATIC
T35120SL (S/N A8GJ12030 AND ABOVE)
T35120L (S/N A8GV12112 AND ABOVE)
T35120SL (S/N A8GE11001 AND ABOVE)
T35120L (S/N A8GG11001 AND ABOVE)
(Printed FEBRUARY 2012)
6927503-A-legend
LEGEND
1 RESERVOIR: 19 CHECK VALVE 38 MOTOR DISPLACEMENT CONTROL 57 TELESCOPIC CYLINDER LOAD HOLDING
Reservoir Capacity 76 L (20 U.S. U.S. gal) SPOOL VALVE – rod end: 25000 kPa (250 bar) (3625 psi)
System Capacity 120 L (31.7 U.S. U.S. gal) 20 ANTICAVITATION/WORK PORT RELIEF 58 SOLENOID ACTIVATED DIRECTIONAL
39 SHUTTLE VALVE - Drain
2 FILTER - Hydraulic VALVE – Boom: 21000 kPa (210 bar) (3045 psi) CONTROL VALVE – LLMC Over Ride
21 ANTICAVITATION/WORK PORT RELIEF 40 VARIABLE CAPACITY DISPLACEMENT 59 PROPORTIONAL REDUCER VALVE –
3 SPRING LOADED FILTER BYPASS BIDIRECTIONAL HYDROSTATIC MOTOR
VALVE: 250 kPa (2,5 bar) (36 psi) VALVE – Boom: 27500 kPa (275 bar) (3988 psi) LLMC Valve
41 SERVO PISTON - Swash Plate 60
4 CHECK VALVE CHECK VALVE – LLMC (3)
22 ANTICAVITATION/WORK PORT RELIEF
VALVE – Tilt: 21000 kPa (210 bar) (3045 psi) 42 FLUSHING VALVE: 16 L/min (4.2 U.S. gpm)
5 CHECK VALVE - With 50 kPa (0,5 bar) 61 ANTICAVITATION/WORK PORT RELIEF
(7 psi) Spring 43 TOW VALVE VALVE: 25000 kPa (250 bar) (3626 psi)
23 ANTICAVITATION/WORK PORT RELIEF
6 BOOM CYLINDER LOCK VALVE - Lock VALVE – Tilt: 25000 kPa (250 bar) (3625 psi) 44 NOT USED FOR THIS MODEL 62 ANTICAVITATION/WORK PORT RELIEF
Pressure: 37500 kPa (375 bar) (5439 psi) VALVE: 25000 kPa (250 bar) (3626 psi)
24 COMPENSATOR
45 AUXILIARY PRESSURE RELEASE VALVE 63 PRESSURE SWITCH- Brake:
7 ACCUMULATOR (If Equipped): 0,75 L
(0.2 U.S. gal.) 5000 kPa (50 bar) (725 psi) 25 RELIEF VALVE: 1900 kPa (19 bar) (275 psi) 10000 kPa (100 bar) 1450 psi
46 ACCUMULATOR: 0,5 L (0.13 U.S. gal)
8 TILT CYLINDER LOCK VALVE: (7200 kPa (72 bar) (1044 psi) 64 LOCK VALVES- Stabilser Cylinder:
26 RELIEF VALVE: 24500 kPa (245 bar) (3553 psi)
28000 kPa (280 bar) (4061 psi) 28000 kPa (280 bar) (4061 psi)
CopyCHECK
Dealer 47 -- NotVALVE - With 350 kPa (3,5 bar)
for Resale
9 SOLENOID - Reverse Drive 27 BLEED CARTRIDGE (50 psi) Spring 65 LOCK VALVES- Stabilser Cylinder:
21000 kPa (210 bar) (3045 psi)
10 SOLENOID - Forward Drive 28 SELF LEVELING CYLINDER LOCK 48 PRIORITY VALVE: 400 kPa (4,0 bar) (58 psi)
VALVE: 25000 kPa (250 bar) (3625 psi) 66 CHECK VALVE with Orifice
11 RELIEF VALVE – Charge 49 RELIEF VALVE: 20000 kPa (200 bar) (2900 psi)
30000 kPa (30 bar) (435 psi) 29 JOYSTICK LOCKOUT VALVE 67
SOLENOID ACTIVATED DIRECTIONAL SOLENOID ACTIVATED DIRECTIONAL
50
12 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - FRAME LEVEL - CONTROL VALVE – Stabiliser Cylinder)
30 SOLENOID ACTIVATED DIRECTIONAL
PRESSURE (2): 45000 kPa (450 bar) (6527 psi) REDUCED SPEED
CONTROL VALVE – Boom Lift Stop 68 SOLENOID ACTIVATED DIRECTIONAL
51 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – Stabiliser Cylinder)
13 VARIABLE CAPACITY DISPLACEMENT 31 ACCUMULATOR: 1.4 L (0.37 U.S. gal.) CONTROL VALVE - FRAME LEVEL -
BIDIRECTIONAL HYDROSTATIC PUMP
1500 kPa (15 bar) (217 psi) LEFT/RIGHT DIRECTION CONTROL 69 ORIFICE: 1,0 mm (0.039 in)
14 CHARGE PUMP: 32 L/min (8.5 U.S. gpm) @ 32 PRESSURE SWITCH- Brake:
52 SHUTTLE VALVE 70 SOLENOID ACTIVATED DIRECTIONAL CONTROL
High Engine Idle 1600 kPa (16 bar) 232 psi
VALVE – Two Speed Fan Motor (OPTIONAL)
53 LOCK VALVES- FRAME LEVELING:
15 SERVO PISTON - Swash Plate 33 PARK BRAKE VALVE – Lever Actuated
21000 kPa (210 bar) (3045 psi) 71 SOLENOID ACTIVATED DIRECTIONAL CONTROL
34 VALVE – FAN Inverter Block (OPTIONAL)
16 HYDRAULIC PUMP - Gear type BRAKE VALVE: 6000 kPa (60 bar) (870 psi) 54 RELIEF VALVE: 17500 kPa (175 bar) (2538 psi)
96 L/min (25.4 U.S. gpm) @ High Engine Idle 72
35 RELIEF VALVE: 17500 kPa (175 bar) (2538 psi) RELIEF VALVE (OPTIONAL):
55 CHECK VALVE - Anti-cavitation 20000 kPa (200 bar) (2900 psi)
17 HYDRAULIC PUMP - Gear Type
37 L/min (9.8 U.S. gpm) @ High Engine Idle 36 RELIEF VALVE (2): 22000 kPa (220 bar) (3190 psi) 56 TELESCOPIC CYLINDER LOAD HOLDING
18 PRIORITY VALVE VALVE – base end: 25000 kPa (250 bar) (3625 psi) NOTE: Unless otherwise specified, springs have
37 SHUTTLE VALVE - Drive Pressure NO significant pressure value.

6927503-A (1-19-12)
Printed in Belgium

81 of 1040
MALE HYDRAULIC
COUPLER QUICKTACH
EV51
7 FEMALE
COUPLER

ENGINE
6

10 FORWARD

HYDROSTATIC
BOOM CYLINDER HYDRAULIC CONTROL VALVE PUMP
2ND AUX VALVE
M2 M5 M4 M1
(OPTIONAL)
24 HYDRAULIC FLOW
20 FILTER OUT A

28 A 2
13
C2
A1
COOLER 15 9 REVERSE
3 CW
21
PIL B1
BOOM LIFT
B2 S
STOP VALVE 11
V2 55 WITH 2 SPEED FAN
B1
MOTOR (OPTIONAL)
a1
A B
B C 14 M3

b1 EV58
5
19 22
T
24 4 L1
A
SELF LEVELLING CYLINDER EV74
1
71 FAN MOTOR
A2
54 70 HYDRAULIC L2
B A RESERVOIR
23 30
B2
EV52 47 12
8 FAN B A
INVERSION
BLOCK
a2 DRAIN (OPTIONAL) GEAR
BLOCK 16 18 PUMP
b2 C1 C2 C3 C4

19 C9 C10 IN
CF

T P
24 EF

C8 C7 C6 C5
TILT CYLINDER
A3
72 IN
61
B3 OUT LS
EVP3
17
57
62
44
44
19
24 M2 M4 L1 L2
B
A4
56 M3

FRONT AXLE
B4
EVP4 40 41

EV8
EXTENSION CYLINDER 42
pst 38 TOW

Y
Dealer Copy -- Not for Resale T3 VALVE

19 37
26

P2
43
66 T1 39

P1
REAR AXLE
XB XA

P1
65 A
M1
STEERING
27

P2
64 TRAVEL MOTOR MODE VALVE

EV7
P LS M 25 T
A

STABILIZER CYLINDER B
EV6

B4 B3 B1
66 69 58
P 67 T LS LS

EV16
EV20
65 B
STEERING UNIT
T
A B
64
EV21 EV22 36 EV85
R L

60 59
B A4 A3 A2 A

LLMC VALVE 45 AUX


A
RELEASE
EV18 EV17 VALVE

STABILIZER CYLINDER SERVICE


4 3 2 1 BRAKE
68 VALVE 34
ACCUMULATOR
F
CHARGING VALVE
P LS T 63
FRAME LEVELLING CYLINDER
V T P

S
53 53 P T T LS P

50 P T
32 MA
A
16 b 35
JOYSTICK PARK
BRAKE 1.4 l 46
15 b
VALVE
48 EV73

49 C 29 T

C6 C1 EV3
X
31
EV71 EV71
C5
C2
JOYSTICK
P
Printable Version Click Here
P T LOCK VALVE 33
51 C7

B A
C4 C3
HYDRAULIC SCHEMATIC
CHARGE
FRAME
BLOCK T35120SL (S/N A8GJ12030 AND ABOVE)
LEVELLING
BLOCK
WORKING CIRCUITS
PILOT CIRCUITS T35120L (S/N A8GV12112 AND ABOVE)
DRAIN CIRCUITS
52 COMPONENTS T35120SL (S/N A8GE11001 AND ABOVE)
T35120L (S/N A8GG11001 AND ABOVE)
82 of 1040
(PRINTED FEBRUARY 2011)
Printed in Belgium 6927503-A
HYDRAULIC SYSTEM INFORMATION

Glossary Of Hydraulic / Hydrostatic Symbols

Dealer Copy -- Not for Resale

mc-2340

83 of 1040 20-10-1 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC SYSTEM INFORMATION (CONT’D)

Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

Dealer Copy -- Not for Resale

mc-2340
2

84 of 1040 20-10-2 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC SYSTEM INFORMATION (CONT’D)

Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

Dealer Copy -- Not for Resale

mc-2340-3

85 of 1040 20-10-3 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC SYSTEM INFORMATION (CONT’D)

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

PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 6
The hydraulic fluid temperature warning light comes ON when hydraulics are 1, 2
operating.
Slow hydraulic system action. 1, 2, 4, 8
Hydraulic action is not smooth. 1, 3, 4, 5
Boom goes up slowly at full engine RPM. 1, 2, 4, 5, 6, 7
The boom comes down with the lever in neutral position. 7, 8, 9

KEY TO CORRECT THE CAUSE


1. The fluid level is not correct

Dealer Copy -- Not for Resale


2. The hydraulic pump has damage.
3. Relief valve is not at the correct pressure.
4. Suction leak on the inlet side of the hydraulic pump.
5. Fluid is cold. Wrong viscosity fluid. (See Section SPEC-01.)
6. Using the machine for more than its rated capacity.
7. Internal leak in the lift cylinder.
8. External leak from the cylinder(s).
9. Damaged lift spool.

86 of 1040 20-10-4 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC SYSTEM INFORMATION (CONT’D)

Tightening Procedures

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

To tighten the hydraulic fittings, tubelines etc. (See


HYDRAULIC CONNECTION SPECIFICATIONS on Page
SPEC-40-1.) for the correct procedure and torque.

WARNING

Dealer Copy -- Not for Resale


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

87 of 1040 20-10-5 T35100(S)(L), T35120(S)L Service Manual


Dealer Copy -- Not for Resale

88 of 1040 20-10-6 T35100(S)(L), T35120(S)L Service Manual


LIFT CYLINDER Figure 20-20-3

Removal And Installation

Figure 20-20-1 3

2
2

S3563

1
Support the lift cylinder using a cinch strap (Item 1).
S2885 Remove the upper pivot pin snap ring (Item 2) and the
upper pivot pin washer (Item 3) [Figure 20-20-3] at both
sides of the pivot.
Raise the boom and install on adequate stands (Item 1)
[Figure 20-20-1]. Figure 20-20-4

Figure 20-20-2

Dealer Copy -- Not for Resale


2

S3622

S3556
Remove the upper pivot pin (Item 1) [Figure 20-20-4].

Remove the bolts (Item 1) and remove the rear cover Using the lifting chain (Item 2) [Figure 20-20-1], lower
(Item 2) [Figure 20-20-2] from the machine. the boom onto 0 degrees. Lower the lift cylinder onto a
block and remove the cinch strap.

89 of 1040 20-20-1 T35100(S)(L), T35120(S)L Service Manual


LIFT CYLINDER (CONT’D) Installation: Tighten the bolt to 345 N•m (255 ft-lb)
torque.
Removal And Installation (Cont’d)
Figure 20-20-7
Figure 20-20-5

P-50975

P-29774
Lift and support the base end of the cylinder [Figure 20-
20-7].
Remove the two hoses (Item 1) [Figure 20-20-5] from
the lift lock on the lift cylinder. Figure 20-20-8

Dealer Copy -- Not for Resale


NOTE: Mark all hoses for correct installation.

IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
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
S3559

Figure 20-20-6
Remove the lower pivot pin snap ring (Item 1) [Figure 20-
20-8] at both sides of the pivot pin.

S3562

Remove the bolt (Item 1) (both sides) and remove the


cross brace (Item 2) [Figure 20-20-6].

90 of 1040 20-20-2 T35100(S)(L), T35120(S)L Service Manual


LIFT CYLINDER (CONT’D) Figure 20-20-11

Removal And Installation (Cont’d)

Figure 20-20-9

1
P-29779A

Lift and remove the cylinder [Figure 20-20-11].


S3560

Remove the lower pivot pin washer (Item 1) [Figure 20-


20-9] at both sides of the pivot pin.

Figure 20-20-10

Dealer Copy -- Not for Resale


1

S3561

Remove the base end pivot pin (Item 1) [Figure 20-20-


10].

91 of 1040 20-20-3 T35100(S)(L), T35120(S)L Service Manual


LIFT CYLINDER (CONT'D)

Parts Identification

1. Housing
2. Bushing
3. Spacer
4. Grease Fitting
5. Wiper
6. Wear Ring
7. Seal
8. O-ring
9. Rod
10. Head
11. Piston
12. Lock Washer
13. Nut

Dealer Copy -- Not for Resale

B-19851

92 of 1040 20-20-4 T35100(S)(L), T35120(S)L Service Manual


LIFT CYLINDER (CONT'D) Figure 20-20-14

Disassembly

Figure 20-20-12

P-29905

Carefully peen the lock ring from the head gland [Figure
P-29903 20-20-14].

Figure 20-20-15
Use the following tools to disassemble the cylinders:

Dealer Copy -- Not for Resale


MEL1354-Spanner Wrench
MEL1076-Cylinder Wrench

Put the cylinder in a vise [Figure 20-20-12].

Figure 20-20-13

1
2

P-29906

Use a spanner wrench to loosen the head gland [Figure


20-20-15].

P-29904

Remove the four bolts (Item 1) and remove the lift lock
(Item 2) [Figure 20-20-13].

93 of 1040 20-20-5 T35100(S)(L), T35120(S)L Service Manual


LIFT CYLINDER (CONT'D) Figure 20-20-18

Disassembly (Cont'd)

Figure 20-20-16

P-29910

Support the cylinder rod on a wood block [Figure 20-20-


P-29907 18].

Figure 20-20-19
Remove the rod assembly (Item 1) [Figure 20-20-16]
from the housing.

Dealer Copy -- Not for Resale


Figure 20-20-17

P-29923

Carefully peen the lock ring tab (Item 1) [Figure 20-20-


P-29909 19] up and out of the lock nut groove.

Put the rod end of the cylinder in a vise [Figure 20-20-


17].

94 of 1040 20-20-6 T35100(S)(L), T35120(S)L Service Manual


LIFT CYLINDER (CONT'D) Figure 20-20-22

Disassembly (Cont'd)

Figure 20-20-20
1

P-29914

Remove the piston (Item 1) [Figure 20-20-22] from the


P-29912 rod.

Figure 20-20-23
Remove the lock nut from the cylinder rod [Figure 20-20-
20] using a cylinder wrench. 1

Dealer Copy -- Not for Resale


Figure 20-20-21

2
P-29915

Remove the two wear rings (Item 1) and seal (Item 2)


P-29913 [Figure 20-20-23] from the piston.

Remove the lock ring (Item 1) [Figure 20-20-21].

95 of 1040 20-20-7 T35100(S)(L), T35120(S)L Service Manual


LIFT CYLINDER (CONT'D) Figure 20-20-26

Disassembly (Cont'd)

Figure 20-20-24 1

P-29918

1
Remove the head gland (Item 1) [Figure 20-20-26] from
P-29916 the rod.

Figure 20-20-27
Remove the O-ring (Item 1) [Figure 20-20-24].

Dealer Copy -- Not for Resale


Figure 20-20-25

P-29919

P-29917 Remove the two O-rings (Item 1) [Figure 20-20-27] from


the head gland.

Remove the O-ring (Item 1) [Figure 20-20-25] from the


piston.

96 of 1040 20-20-8 T35100(S)(L), T35120(S)L Service Manual


LIFT CYLINDER (CONT'D)

Disassembly (Cont'd)

Figure 20-20-28

P-29920

Remove the wear ring (Item 1) [Figure 20-20-28].

Dealer Copy -- Not for Resale


Figure 20-20-29

2 3

P-29921

Remove seal (Item 1), wear ring (Item 2) and wiper (Item
3) [Figure 20-20-29] from the head gland.

97 of 1040 20-20-9 T35100(S)(L), T35120(S)L Service Manual


LIFT CYLINDER (CONT'D) Figure 20-20-32

Assembly

Use the following tools to assemble the cylinders:

MEL1354-Spanner Wrench 1
MEL1076-Cylinder Wrench
MEL1033-Rod Seal Installation Tool

Wash the cylinder parts in solvent and dry with


compressed air.

Inspect the cylinder parts for nicks, scratches or other


damage. Replace any damaged parts.
P-29885
Lubricate all O-rings and seals with hydraulic fluid during
installation. Always use new O-rings and seals.
Install the center seal (Item 1) [Figure 20-20-32].
Figure 20-20-30
NOTE: The groove in the seal must point away from
the wiper seal (Item 1) [Figure 20-20-30].
1
Figure 20-20-33

Dealer Copy -- Not for Resale


1
2

P-29884

Install the wiper (Item 1) and wear ring (Item 2) [Figure


20-20-30] in the head gland. P-29919

Figure 20-20-31
Install the two O-rings (Item 1) [Figure 20-20-33].

P-29883

Install the wear ring (Item 1) [Figure 20-20-31].

98 of 1040 20-20-10 T35100(S)(L), T35120(S)L Service Manual


LIFT CYLINDER (CONT'D) Figure 20-20-36

Assembly (Cont'd)

Figure 20-20-34

1
P-29916

Install the expander O-ring (Item 1) [Figure 20-20-36] on


P-29918 the piston.

Figure 20-20-37
Install the head gland (Item 1) [Figure 20-20-34] onto the
rod.
1

Dealer Copy -- Not for Resale


Figure 20-20-35

2
P-29915

Install the two wear rings (Item 1) and seal (Item 2)


P-29917 [Figure 20-20-37] onto the piston.

Install the O-ring (Item 1) [Figure 20-20-35] in the piston.

99 of 1040 20-20-11 T35100(S)(L), T35120(S)L Service Manual


LIFT CYLINDER (CONT'D) Figure 20-20-40

Assembly (Cont'd)

Figure 20-20-38

P-29913

Install the lock ring (Item 1) [Figure 20-20-40].


P-32047
Figure 20-20-41

Clean off any old residue, and apply Loctite® #242 or


equivalent to the threads on the rod [Figure 20-20-38].

Dealer Copy -- Not for Resale


Figure 20-20-39

1
1
P-29922

Use the cylinder wrench to install the lock nut (Item 1)


[Figure 20-20-41] and tighten.
P-29914

Install the piston (Item 1) [Figure 20-20-39] on the rod.

100 of 1040 20-20-12 T35100(S)(L), T35120(S)L Service Manual


LIFT CYLINDER (CONT'D) Figure 20-20-44

Assembly (Cont'd)

Figure 20-20-42

P-29925

Use the spanner wrench to tighten the head gland


P-29924
[Figure 20-20-44].

Figure 20-20-45
Peen the lock ring tab (Item 1) [Figure 20-20-42] into the
groove in the lock nut.

Dealer Copy -- Not for Resale


Figure 20-20-43

P-29926

Peen the lock ring into the groove in the head gland
[Figure 20-20-45].
P-29907

Install the rod assembly (Item 1) [Figure 20-20-43] into


the housing.

101 of 1040 20-20-13 T35100(S)(L), T35120(S)L Service Manual


LIFT CYLINDER (CONT'D)

Assembly (Cont'd)

Figure 20-20-46

2
1

P-29904

Install the lift lock (Item 1) onto the cylinder and tighten
the four bolts (Item 2) [Figure 20-20-46].

Dealer Copy -- Not for Resale

102 of 1040 20-20-14 T35100(S)(L), T35120(S)L Service Manual


BUCKET POSITIONING CYLINDER Figure 20-30-3

Removal And Installation

Figure 20-30-1 3

2
1

P-58090

Remove the upper hose (Item 1), tubeline (Item 2) and


S3211
fitting (Item 3) [Figure 20-30-3] from the cylinder.

Lower the boom onto adequate stands or blocks as NOTE: Mark all hoses for correct installation.
shown (Item 1) [Figure 20-30-1].

Figure 20-30-2

Dealer Copy -- Not for Resale


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
1 damage the system.
I-2003-0888

Figure 20-30-4

S3556

Remove the rear cover (Item 1) [Figure 20-30-2] from


the machine.
2

P-58091

Remove the lower hose (Item 1), tubeline (Item 2) and


load lock (Item 3) [Figure 20-30-4] from the cylinder.

103 of 1040 20-30-1 T35100(S)(L), T35120(S)L Service Manual


BUCKET POSITIONING CYLINDER (CONT’D) Figure 20-30-7

Removal And Installation (Cont’d)

Figure 20-30-5 2

1
1

S3562

Remove the bolt (Item 1) (both sides) and remove the


cross brace (Item 2) [Figure 20-30-7].
S3557

Installation: Tighten the bolt to 345 N•m (255 ft-lb)


Remove the nut (Item 1) [Figure 20-30-5] from the upper torque.
retainer bolt.
Figure 20-30-8
Figure 20-30-6

Dealer Copy -- Not for Resale


1

S3559
S3558

Remove the lower pivot pin snap ring (Item 1) [Figure 20-
Remove the upper pivot pin using a pin removal tool 30-8] at both sides of the pivot pin.
[Figure 20-30-6].

NOTE: Secure the top of the cylinder from falling


forward and causing damage to the cylinder
rod when the pivot pin is removed.

104 of 1040 20-30-2 T35100(S)(L), T35120(S)L Service Manual


BUCKET POSITIONING CYLINDER (CONT’D) Figure 20-30-11

Removal And Installation (Cont’d)

Figure 20-30-9

1
P-29762A

Have an assistant tilt the cylinder forward while removing


the cylinder out the back [Figure 20-30-11].
S3560

Remove the lower pivot pin washer (Item 1) [Figure 20-


30-9] at both sides of the pivot pin.

Figure 20-30-10

Dealer Copy -- Not for Resale


1

S3561

Remove the base end pivot pin (Item 1) [Figure 20-30-


10].

105 of 1040 20-30-3 T35100(S)(L), T35120(S)L Service Manual


BUCKET POSITIONING CYLINDER (CONT’D)

Parts Identification

1. Bushing
2. Housing
3. Wear Ring
4. Seal
5. O-ring
6. Set Screw
7. Piston
8. Rod
9. Head Gland
10. Wiper
11. Grease Fitting

Dealer Copy -- Not for Resale

B-19852

106 of 1040 20-30-4 T35100(S)(L), T35120(S)L Service Manual


BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-14

Disassembly

Use the following tools to disassemble the cylinder:

MEL1354-Spanner Wrench

Figure 20-30-12

P-29869

Use a spanner wrench to remove the head gland [Figure


20-30-14].

Figure 20-30-15

P-29871

Dealer Copy -- Not for Resale


1
Put the cylinder in a vise [Figure 20-30-12].

Figure 20-30-13

P-29872

Remove the rod assembly (Item 1) [Figure 20-30-15]


from the housing.

P-29868

Carefully peen the lock ring from the head gland [Figure
20-30-13].

107 of 1040 20-30-5 T35100(S)(L), T35120(S)L Service Manual


BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-18

Disassembly (Cont'd)

Figure 20-30-16 1

P-29874

Remove the piston assembly (Item 1) [Figure 20-30-18]


P-29873 from the rod.

Figure 20-30-19
Put the rod end of the cylinder in a vise [Figure 20-30-
16].

Dealer Copy -- Not for Resale


1
Figure 20-30-17

1
P-29877

Remove the two wear rings (Item 1) and seal (Item 2)


P-29875 [Figure 20-30-19] from the piston.

Support the cylinder rod on a wood block and remove the


set screw (Item 1) [Figure 20-30-17] from the piston.

108 of 1040 20-30-6 T35100(S)(L), T35120(S)L Service Manual


BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-22

Disassembly (Cont'd)

Figure 20-30-20

P-29881

1
Remove the head gland (Item 1) [Figure 20-30-22] from
P-29879 the rod.

Figure 20-30-23
Remove the O-ring (Item 1) [Figure 20-30-20].

Dealer Copy -- Not for Resale


Figure 20-30-21

1
1

P-29883

P-29880 Remove the center seal (Item 1) and outer wear ring
(Item 2) [Figure 20-30-23].

Remove the O-ring (Item 1) [Figure 20-30-21] from the


piston.

109 of 1040 20-30-7 T35100(S)(L), T35120(S)L Service Manual


BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-26

Disassembly (Cont'd)

Figure 20-30-24

P-29878

Remove any residue from the threads on the cylinder rod


P-29884 [Figure 20-30-26].

Remove the outer wear ring (Item 1) and wiper (Item 2)


[Figure 20-30-24].

Dealer Copy -- Not for Resale


Figure 20-30-25

P-29882

Remove the two O-rings (Item 1) [Figure 20-30-25].

110 of 1040 20-30-8 T35100(S)(L), T35120(S)L Service Manual


BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-29

Assembly

Use the following tools to assemble the cylinder: 1

MEL1354-Spanner Wrench
MEL1033-Rod Seal Installation Tool

Wash the cylinder parts in solvent and dry with


compressed air.

Inspect the cylinder parts for nicks, scratches or other


damage. Replace any damaged parts.

Lubricate all O-rings and seals with hydraulic fluid during


P-29883
installation.

Always use new O-rings and seals.


Install the wear ring (Item 1) [Figure 20-30-29].
Figure 20-30-27
Figure 20-30-30

Dealer Copy -- Not for Resale


1

P-29882

P-29885
Install the two O-rings (Item 1) [Figure 20-30-27] onto
the head gland.
Install the center seal (Item 1) [Figure 20-30-30].
Figure 20-30-28
NOTE: The groove in the seal must point away from
the wiper seal (Item 1) [Figure 20-30-28].
1

P-29884

Install the wiper (Item 1) and wear ring (Item 2) [Figure


20-30-28].

111 of 1040 20-30-9 T35100(S)(L), T35120(S)L Service Manual


BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-33

Assembly (Cont'd)

Figure 20-30-31

P-29879

Install the O-ring (Item 1) [Figure 20-30-33] onto the


P-29881 piston.

Figure 20-30-34
Install the head gland (Item 1) [Figure 20-30-31] onto the
rod.

Dealer Copy -- Not for Resale


1
Figure 20-30-32
1

P-29877

Install the two wear rings (Item 1) and seal (Item 2)


P-29880 [Figure 20-30-34].

Install the O-ring (Item 1) [Figure 20-30-32] in the piston.

112 of 1040 20-30-10 T35100(S)(L), T35120(S)L Service Manual


BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-37

Assembly (Cont'd)

Figure 20-30-35

P-29888

Align the hole (Item 1) [Figure 20-30-37] in the piston


P-29886 with the hole in the end of the cylinder rod.

Figure 20-30-38
Apply Loctite® #242 or equivalent to the threads on the
rod [Figure 20-30-35].

Dealer Copy -- Not for Resale


Figure 20-30-36

P-29887

Apply Loctite® #242 or equivalent to the set screw (Item


P-29874 1) [Figure 20-30-38].

Install the piston (Item 1) [Figure 20-30-36] onto the rod.

113 of 1040 20-30-11 T35100(S)(L), T35120(S)L Service Manual


BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-41

Assembly (Cont'd)

Figure 20-30-39

1
P-29869

Use the spanner wrench to tighten the head gland


P-29875 [Figure 20-30-41].

Figure 20-30-42
Install the set screw (Item 1) [Figure 20-30-39] into the
piston and tighten.

Dealer Copy -- Not for Resale


Figure 20-30-40

P-29868

Carefully peen the lock ring over and into the nut [Figure
P-29874
20-30-42].

Install the rod assembly (Item 1) [Figure 20-30-40] into


the housing.

114 of 1040 20-30-12 T35100(S)(L), T35120(S)L Service Manual


EXTENSION CYLINDER Figure 20-40-3

Cylinder Group Removal And Installation

Figure 20-40-1

S3565

Remove the attachment screws (Item 1) [Figure 20-40-3]


from both sides of the cylinder head.
S3211

Figure 20-40-4
Start the engine and raise the boom until the boom is in
the horizontal position (Item 1) [Figure 20-40-1]. Make
sure that the booms are retracted.

Dealer Copy -- Not for Resale


Figure 20-40-2

S3566

Remove the support blocks. [Figure 20-40-4].

S3556

Remove the rear cover (Item 1) [Figure 20-40-2] from


the machine.

115 of 1040 20-40-1 T35100(S)(L), T35120(S)L Service Manual


EXTENSION CYLINDER (CONT’D)

Cylinder Group Removal And Installation (Cont’d)


IMPORTANT
Figure 20-40-5
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 20-40-7
1

S3567A
1
Start the engine and move the cylinder (Item 1) [Figure
20-40-5] a few centimeters toward the rear.

Dealer Copy -- Not for Resale


WARNING S3568

AVOID INJURY OR DEATH


Wear safety glasses to prevent eye injury when any Remove the four attachment screws (Item 1) [Figure 20-
of the following conditions exist: 40-7] from the cylinder body.
• When fluids are under pressure.
• Flying debris or loose material is present. Figure 20-40-8
• Engine is running.
• Tools are being used.
W-2019-0907

Figure 20-40-6

1 S3569

Lift and remove the cylinder out of the boom [Figure 20-
40-8].

S3570

Remove the two tubelines (Item 1) [Figure 20-40-6] from


the bulkhead fittings.

NOTE: Mark all hoses for correct installation.

116 of 1040 20-40-2 T35100(S)(L), T35120(S)L Service Manual


EXTENSION CYLINDER (CONT’D)

Cylinder Group Removal And Installation (Cont’d)

Figure 20-40-9

S3571A

Remove the skid that enables the telescoping cylinder


shaft to be held on the caisson by removing the two bolts
(Item 1) [Figure 20-40-9].

Dealer Copy -- Not for Resale

117 of 1040 20-40-3 T35100(S)(L), T35120(S)L Service Manual


EXTENSION CYLINDER (CONT'D)

Parts Identification

Dealer Copy -- Not for Resale

S2886

118 of 1040 20-40-4 T35100(S)(L), T35120(S)L Service Manual


EXTENSION CYLINDER (CONT'D) Figure 20-40-12

Disassembly

Use the following tools to disassemble the cylinder:

Spanner Wrench

Cylinder Wrench

Figure 20-40-10

1 S3650

Use the spanner wrench to loosen the head gland (Item


1) [Figure 20-40-12].

Figure 20-40-13
1

Dealer Copy -- Not for Resale


S3652

Put the cylinder in a vise.

Remove the cylinder lock (Item 1) [Figure 20-40-10].

Figure 20-40-11

1
S3651

Remove the rod assembly (Item 1) [Figure 20-40-13]


from the housing.
1

S3658

Carefully peen the lock ring (Item 1) [Figure 20-40-11]


up and out of the lock groove.

119 of 1040 20-40-5 T35100(S)(L), T35120(S)L Service Manual


EXTENSION CYLINDER (CONT'D) Figure 20-40-16

Disassembly (Cont’d) 2

Figure 20-40-14

1 S3654

1 Remove the two wear rings (Item 1) and seal (Item 2)


[Figure 20-40-16].
S3656

Figure 20-40-17
Remove the lock screws (Item 1) [Figure 20-40-14] from
the piston. 1

Figure 20-40-15

Dealer Copy -- Not for Resale


S3653

2
Remove the two O-rings (Item 1) [Figure 20-40-17] from
1 the piston.
S3657

Put the other side of the rod assembly in a vise. Use the
cylinder wrench to remove the piston (Item 1) from the
rod (Item 2) [Figure 20-40-15].

120 of 1040 20-40-6 T35100(S)(L), T35120(S)L Service Manual


EXTENSION CYLINDER (CONT'D) Figure 20-40-20

Disassembly (Cont'd)
1
Figure 20-40-18

S3660

Remove the three O-rings (Item 1) [Figure 20-40-20]


from the head gland.
S3662

Remove the ring (Item 1) [Figure 20-40-18] from the rod.

Figure 20-40-19

Dealer Copy -- Not for Resale


1

S3661

Remove the stop ring (Item 1) [Figure 20-40-19] from the


rod.

121 of 1040 20-40-7 T35100(S)(L), T35120(S)L Service Manual


EXTENSION CYLINDER (CONT'D)

Disassembly (Cont'd)

Figure 20-40-21

S3659

Remove the head gland (Item 1) [Figure 20-40-21] from


the rod.

Figure 20-40-22

Dealer Copy -- Not for Resale


3 1

P-29921

Remove the wiper seal (Item 1), two wear rings (Item 2),
and seal (Item 3) [Figure 20-40-22] from the head gland.

122 of 1040 20-40-8 T35100(S)(L), T35120(S)L Service Manual


EXTENSION CYLINDER (CONT'D) Figure 20-40-24

Assembly

Use the following tools to disassemble the cylinder:

Spanner Wrench
1
Cylinder Wrench

Rod Seal Installation Tool

Wash the cylinder parts in solvent and dry with


compressed air.
S3659
Inspect the cylinder parts for nicks, scratches or other
damage. Replace any damaged parts.
Install the head gland (Item 1) [Figure 20-40-24] on the
rod.
Lubricate all O-rings and seals with hydraulic fluid during
installation. Always use new O-rings and seals.
Figure 20-40-25
Figure 20-40-23
1

Dealer Copy -- Not for Resale


3 1

S3660

P-29921
Install the three O-rings (Item 1) [Figure 20-40-25] on
Install the wiper seal (Item 1) and two wear rings (Item 2) the head gland.
[Figure 20-40-23] into the head gland.

Install the seal (Item 3) [Figure 20-40-23] using the seal


installation tool.

NOTE: The groove in the seal must point away from


the wiper seal

123 of 1040 20-40-9 T35100(S)(L), T35120(S)L Service Manual


EXTENSION CYLINDER (CONT'D) Figure 20-40-28

Assembly (Cont’d) 1

Figure 20-40-26

1 S3653

Install the two O-rings (Item 1) [Figure 20-40-28] on the


piston.
S3661

Figure 20-40-29
Install the stop ring (Item 1) [Figure 20-40-26] on the rod.
2
Figure 20-40-27

Dealer Copy -- Not for Resale


1

1 S3654

Install the two wear rings (Item 1) and seal (Item 2)


S3662
[Figure 20-40-29] on the piston.

Install the ring (Item 1) [Figure 20-40-27] on the rod.

124 of 1040 20-40-10 T35100(S)(L), T35120(S)L Service Manual


EXTENSION CYLINDER (CONT'D) Figure 20-40-32

Assembly (Cont’d)

Figure 20-40-30

1
S3651
1

Install the rod assembly (Item 1) [Figure 20-40-32] into


the housing.
S3657

Figure 20-40-33
Clean off any old residue, and apply Loctite® 242 or
equivalent to the threads on the piston.

Use the cylinder wrench to install the piston (Item 1)

Dealer Copy -- Not for Resale


[Figure 20-40-30] on the cylinder rod.

Figure 20-40-31

1 S3650

Use the spanner wrench to tighten the head gland (Item


1) [Figure 20-40-33].

1
S3656

Install the lock screws (Item 1) [Figure 20-40-31] on the


piston.

125 of 1040 20-40-11 T35100(S)(L), T35120(S)L Service Manual


EXTENSION CYLINDER (CONT'D)

Assembly (Cont’d)

Figure 20-40-34

S3664

Carefully peen the lock ring into the groove in the head
gland (Item 1) [Figure 20-40-34].

Figure 20-40-35

Dealer Copy -- Not for Resale


1

S3652

Install the cylinder lock (Item 1), install the two fittings
(Item 2) and two relief cartridges (Item 3) [Figure 20-40-
35].

126 of 1040 20-40-12 T35100(S)(L), T35120(S)L Service Manual


TILT CYLINDER Figure 20-50-3

Removal And Installation

Figure 20-50-1
2

1
1
S3625

Install a lifting eye (Item 1) on the top of the tilt cylinder,


then connect the eye with a lifting chain (Item 2) [Figure
S3577
20-50-3].

Disconnect the four hydraulic hoses (Item 1) [Figure 20- Figure 20-50-4
50-1] at the front of the boom.

NOTE: Mark the hoses for correct installation.

Dealer Copy -- Not for Resale


IMPORTANT
1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. S3626
I-2003-0888

Remove the upper pivot pin snap ring (Item 1) [Figure


Figure 20-50-2
20-50-4] at both sides of the pivot pin.
1

S3624

Disconnect the two connectors (Item 1) [Figure 20-50-2]


at the front of the boom (If Equipped).

127 of 1040 20-50-1 T35100(S)(L), T35120(S)L Service Manual


TILT CYLINDER (CONT’D) Figure 20-50-7

Removal And Installation (Cont’d)

Figure 20-50-5

1 1

S3629

Remove the pivot pin retainer bolt (Item 1) [Figure 20-50-


7].
S3627

Figure 20-50-8
Remove the upper pivot pin washer (Item 1) [Figure 20-
50-5] at both sides of the pivot pin.

Figure 20-50-6

Dealer Copy -- Not for Resale


1

S3630

1
Remove the lower pivot pin (Item 1) [Figure 20-50-8].
S3628

Remove the upper pivot pin (Item 1) [Figure 20-50-6].

128 of 1040 20-50-2 T35100(S)(L), T35120(S)L Service Manual


TILT CYLINDER (CONT’D)

Removal And Installation (Cont’d)

Figure 20-50-9

S3631

Carefully lift and remove the tilt cylinder (Item 1) [Figure


20-50-9].

Dealer Copy -- Not for Resale

129 of 1040 20-50-3 T35100(S)(L), T35120(S)L Service Manual


TILT CYLINDER (CONT’D)

Parts Identification

1. Housing
2. Bushing
3. Cartridge
4. Grease Fitting
5. Rod
6. Wiper
7. Wear Ring
8. Seal
9. Head Gland
10. O-ring
11. Piston
12. Set Screw

Dealer Copy -- Not for Resale


7

B-19854

130 of 1040 20-50-4 T35100(S)(L), T35120(S)L Service Manual


TILT CYLINDER (CONT'D) Figure 20-50-12

Disassembly

Use the following tool to disassemble the cylinder:

MEL1075-Adjustable Gland Wrench

Figure 20-50-10

P-32032

Remove the relief cartridge (Item 1) [Figure 20-50-12].

Figure 20-50-13

P-32030

Dealer Copy -- Not for Resale


Put the cylinder in a vise [Figure 20-50-10].
1
Figure 20-50-11

S3632

Loosen the head gland (Item 1) [Figure 20-50-13].

1
1

P-32031

Remove the two hoses (Item 1) [Figure 20-50-11] from


the cylinder.

131 of 1040 20-50-5 T35100(S)(L), T35120(S)L Service Manual


TILT CYLINDER (CONT'D) Figure 20-50-16

Disassembly (Cont’d)

Figure 20-50-14

S3635

1
Support the cylinder rod on a wood block [Figure 20-50-
S3634 16].

Figure 20-50-17
Remove the rod assembly (Item 1) [Figure 20-50-14].

Figure 20-50-15

Dealer Copy -- Not for Resale


1

P-32039

S32036 Remove the lock ring (Item 1) [Figure 20-50-17].

Put the rod end of the cylinder in a vise [Figure 20-50-


15].

132 of 1040 20-50-6 T35100(S)(L), T35120(S)L Service Manual


TILT CYLINDER (CONT'D) Figure 20-50-20

Disassembly (Cont’d)

Figure 20-50-18

1
P-32041

S3635
Remove the O-ring (Item 1) [Figure 20-50-20].

Figure 20-50-21
Remove the piston (Item 1) [Figure 20-50-18] from the
rod.

Figure 20-50-19

Dealer Copy -- Not for Resale


1 1

P-32042

Remove the O-ring (Item 1) [Figure 20-50-21] from the


2 inside of the piston.
P-32040

Remove the two wear rings (Item 1) and seal (Item 2)


[Figure 20-50-19] from the piston.

133 of 1040 20-50-7 T35100(S)(L), T35120(S)L Service Manual


TILT CYLINDER (CONT'D) Figure 20-50-24

Disassembly (Cont’d)

Figure 20-50-22 1
3

S3639

Remove the wiper seal (Item 1), wear rings (Item 2) and
S3637
seal (Item 3) [Figure 20-50-24].

Remove the head gland (Item 1) [Figure 20-50-22] from


the rod.

Figure 20-50-23

Dealer Copy -- Not for Resale


S3638

Remove the O-ring (Item 1) [Figure 20-50-23] from the


head gland.

134 of 1040 20-50-8 T35100(S)(L), T35120(S)L Service Manual


TILT CYLINDER (CONT'D) Figure 20-50-27

Assembly

Use the following tool to assemble the cylinder:

MEL1075-Adjustable Gland Nut Wrench

Wash the cylinder parts in solvent and dry with


compressed air.

Inspect the cylinder parts for damage. Replace any


damaged parts.

Lubricate all O-rings and seals with hydraulic fluid during S3637
installation. Always use new O-rings and seals.
Install the head gland (Item 1) [Figure 20-50-27] onto the
Figure 20-50-25
rod.

Figure 20-50-28
1
3

Dealer Copy -- Not for Resale


2

S3639

Install the wiper seal (Item 1), wear rings (Item 2), and
seal (Item 3) [Figure 20-50-25]. P-32042

NOTE: The groove in the seal must point away from


Install the O-ring (Item 1) [Figure 20-50-28] on the inside
the wiper seal (Item 1) [Figure 20-50-25].
of the piston.
Figure 20-50-26

S3638

Install the O-ring (Item 1) [Figure 20-50-26] onto the


head gland.

135 of 1040 20-50-9 T35100(S)(L), T35120(S)L Service Manual


TILT CYLINDER (CONT'D) Figure 20-50-31

Assembly (Cont'd)

Figure 20-50-29

P-32047

Clean off any old residue, and apply Loctite® #242 or


1 equivalent to the threads on the rod [Figure 20-50-31].
P-32041

Figure 20-50-32
Install the O-ring (Item 1) [Figure 20-50-29] onto the
piston.
1

Dealer Copy -- Not for Resale


Figure 20-50-30

S3635

Install the piston (Item 1) [Figure 20-50-32] onto the rod


1 1 and tighten.
2 P-32040

Install the two wear rings (Item 1) and seal (Item 2)


[Figure 20-50-30].

136 of 1040 20-50-10 T35100(S)(L), T35120(S)L Service Manual


TILT CYLINDER (CONT'D) Figure 20-50-35

Assembly (Cont'd)

Figure 20-50-33

S3632

Tighten the head gland (Item 1) [Figure 20-50-35].


P-32039
Figure 20-50-36

Install the lock ring (Item 1) [Figure 20-50-33].

Figure 20-50-34
1

Dealer Copy -- Not for Resale


1

P-32050

Apply Loctite® #242 or equivalent to the set screw (Item


S3634
1) [Figure 20-50-36].

Install the piston / rod assembly (Item 1) [Figure 20-50-


34] into the housing.

137 of 1040 20-50-11 T35100(S)(L), T35120(S)L Service Manual


TILT CYLINDER (CONT'D)

Assembly (Cont'd)

Figure 20-50-37

P-32032

Screw in the relief cartridge (Item 1) [Figure 20-50-37]

Figure 20-50-38

Dealer Copy -- Not for Resale


1
1

P-32031

Install the two hoses (Item 1) [Figure 20-50-38].

138 of 1040 20-50-12 T35100(S)(L), T35120(S)L Service Manual


STEERING CYLINDER (FRONT) Figure 20-60-3

Removing The Steering Cylinder

Remove the front axle. (See Removal on Page 40-30-1.) 2


Figure 20-60-1 1

2
S2515

3
Remove the bolt (Item 1) for access for removing the nut
(Item 2) [Figure 20-60-3].
1
S2649 Figure 20-60-4

Remove the two bolts (Item 1) and remove the centering

Dealer Copy -- Not for Resale


sensor (Item 2) from the front steering cylinder (Item
3) [Figure 20-60-1]. 1

Figure 20-60-2

S2516

Remove the nut (Item 1) [Figure 20-60-4].

S2515

Remove the cotter pin (Item 1) [Figure 20-60-2].

139 of 1040 20-60-1 T35100(S)(L), T35120(S)L Service Manual


STEERING CYLINDER (FRONT) (CONT’D) Figure 20-60-7

Removing The Steering Cylinder (Cont’d)

Figure 20-60-5
2

S2651

Remove the ball joints (Item 1) from the steering cylinder


S2517 (Item 2) [Figure 20-60-7].

Figure 20-60-8
Remove the tie rod end (Item 1) [Figure 20-60-5] by
means of a puller.

Dealer Copy -- Not for Resale


Figure 20-60-6

1 2

S2652

Extract the cylinder (Item 1) [Figure 20-60-8] using a


S2650 plastic hammer.

NOTE: For cylinder disassembly (See Disassembling


Disconnect the left and right steering bars (Item 1) from The Steering Cylinder on Page 20-60-5.)
the piston (Item 2) [Figure 20-60-6].

140 of 1040 20-60-2 T35100(S)(L), T35120(S)L Service Manual


STEERING CYLINDER (FRONT) (CONT’D) Figure 20-60-11

Installing The Steering Cylinder

Figure 20-60-9

S2650

Apply Loctite® #242 to the thread and connect the


S2653 steering bars by screwing the terminals onto the piston
stem [Figure 20-60-11], apply a torque of 240 - 270 N•m
(177 - 199 ft-Ib).
Lubricate the seats of the seals and install the steering
cylinder (Item 1) [Figure 20-60-9] into its seat. Figure 20-60-12

Dealer Copy -- Not for Resale


Figure 20-60-10

1
1

S2524

S2654
Insert the pins (Item 1) in the steering case (Item 2)
[Figure 20-60-12] and lock into position using a torque
Tighten the bolts (Item 1) [Figure 20-60-10] to 116 - 128 wrench setting of 260 - 290 N•m (192 - 214 ft-Ib).
N•m (85 - 94,6 ft-Ib) torque.
Find the position of the notching in relation to the hole of
the cotter pins and tighten the nut (Item 3) [Figure 20-
60-12] further.

NOTE: Check that the rubber guards [Figure 20-60-


12] are intact.

141 of 1040 20-60-3 T35100(S)(L), T35120(S)L Service Manual


STEERING CYLINDER (FRONT) (CONT’D)

Installing The Steering Cylinder (Cont’d)

Figure 20-60-13

S2525

Insert the cotter pins (Item 1) [Figure 20-60-13] and


bend the safety stems.

Dealer Copy -- Not for Resale


NOTE: Use new cotter pins.

Figure 20-60-14

1
2

S2526

Install the centering sensor (Item 1) for checking piston


centering.

Tighten the bolts (Item 2) [Figure 20-60-14] to 5 - 6 N•m


(44.3 - 53.1 in-Ib) torque.

142 of 1040 20-60-4 T35100(S)(L), T35120(S)L Service Manual


STEERING CYLINDER (FRONT) (CONT’D) Figure 20-60-17

Disassembling The Steering Cylinder

Figure 20-60-15 2

2
S1518

With the help of a drift, apply pressure to the stop ring


S1516
(Item 1) that is placed inside the cylinder
(Item 2) [Figure 20-60-17] and extract the ring using a
screwdriver.
Remove the snap ring (Item 1) from the cylinder head
(Item 2) [Figure 20-60-15]. Figure 20-60-18

Dealer Copy -- Not for Resale


Figure 20-60-16

1
1
3
2
S1519

S1517
Hammer the piston (Item 1) on the rear of the head
(Item 2) [Figure 20-60-18] using a plastic hammer.
With the help of a plastic hammer, push the head
Continue hammering until the head (Item 2) is ejected
(Item 1) inside the cylinder (Item 2) [Figure 20-60-16].
from the cylinder (Item 3) [Figure 20-60-18].
NOTE: The head should line up with the edge of the
cylinder.

143 of 1040 20-60-5 T35100(S)(L), T35120(S)L Service Manual


STEERING CYLINDER (FRONT) (CONT’D)

Disassembling The Steering Cylinder (Cont’d)

Figure 20-60-19

A
S1520

Disassemble the cylinder unit (Item 1) by extracting first


the head then the piston (Item 3) [Figure 20-60-19].

NOTE: Mark the assembly side of the piston (Item 3).

Dealer Copy -- Not for Resale


The bevelled part “A” of the piston is oriented
toward the head (Item 2) [Figure 20-60-19].

Remove all seals, anti-extrusion rings and scraper rings


from head, cylinder and piston.

NOTE: 1) All seals must be replaced every time the


unit is disassembled.
2) Particular attention must be paid not to
damage the seats of both seals and piston
slide.

144 of 1040 20-60-6 T35100(S)(L), T35120(S)L Service Manual


STEERING CYLINDER (FRONT) (CONT’D) Figure 20-60-22

Assembling The Steering Cylinder


1
Figure 20-60-20

1 2 3

S1523

Install the seal (Item 1) [Figure 20-60-22] onto the


S1521
outside of the head.

After applying grease, install the sealing ring (Item 1) on NOTE: In order to facilitate assembly, apply grease to
the shaft, the anti-extrusion ring (Item 2) and the scraper the outer surface of the piston.
ring (Item 3) [Figure 20-60-20] inside the cylinder. Do not roll the seal (Item 1) [Figure 20-60-22]

Dealer Copy -- Not for Resale


NOTE: Thoroughly check that positioning of the anti- Figure 20-60-23
extrusion ring (Item 2) [Figure 20-60-20] is
correct.
5 3 2
Figure 20-60-21
1

3 2 1 4

S1524

Prepare the piston (Item 1) by installing the guide ring


(Item 2), the magnetic ring (Item 3), the O-ring
S1522 (Item 4) and the seal (Item 5) [Figure 20-60-23].

NOTE: In order to facilitate assembly, apply grease.


After applying grease, install the sealing ring (Item 1) on
the shaft, the anti-extrusion ring (Item 2) and the scraper
ring (Item 3) [Figure 20-60-21] in the head.

NOTE: Thoroughly check that positioning of the anti-


extrusion ring (Item 2) [Figure 20-60-21] is
correct.

145 of 1040 20-60-7 T35100(S)(L), T35120(S)L Service Manual


STEERING CYLINDER (FRONT) (CONT’D) Figure 20-60-26

Assembling The Steering Cylinder (Cont’d)

Figure 20-60-24 1
T18

T18
2

1
S1527

Remove tool T18 and apply it to the opposite side of the


S1525 piston (Item 1) [Figure 20-60-26].

Figure 20-60-27
Apply tool T18 to the shaft on the opposite side of the
head and center it on the cylinder (Item 1) so that it fits
into the piston (Item 2) [Figure 20-60-24].

Dealer Copy -- Not for Resale


1
NOTE: Apply a little grease to seals and cylinder.
T18
Figure 20-60-25

1 3
2
S1528

Apply grease to the head seals (Item 1), install the head
onto the piston (Item 2) and push it onto the cylinder
2
(Item 3) [Figure 20-60-27].

S1526

Push the piston (Item 1) into the cylinder (Item 2)


[Figure 20-60-25] for 100 mm (4.00 in) using a plastic
hammer.

146 of 1040 20-60-8 T35100(S)(L), T35120(S)L Service Manual


STEERING CYLINDER (FRONT) (CONT’D) Figure 20-60-30

Assembling The Steering Cylinder (Cont’d) 2

Figure 20-60-28

S1531

2 Install the snap ring (Item 1) on the head (Item 2)


S1529 [Figure 20-60-30].

NOTE: Make sure that the snap ring


Insert the stop ring (Item 1) ensuring that it fits into the (Item 1) [Figure 20-60-30] is securely
seat of the cylinder (Item 2) [Figure 20-60-28]. fastened in its seat.
If necessary, force it into its seat using a drift

Dealer Copy -- Not for Resale


Figure 20-60-29 and a hammer.

S1530

Apply pressure to the head using two screwdrivers or


levers until the head is fastened onto the stop ring
(Item 1) [Figure 20-60-29].

147 of 1040 20-60-9 T35100(S)(L), T35120(S)L Service Manual


Dealer Copy -- Not for Resale

148 of 1040 20-60-10 T35100(S)(L), T35120(S)L Service Manual


STEERING CYLINDER (REAR) Figure 20-61-3

Removing The Steering Cylinder

Remove the rear axle. (See Removal on Page 40-90-1.) 2


1
Figure 20-61-1

2
3
S2515

Remove the bolt (Item 1) for access for removing the nut
(Item 2) [Figure 20-61-3].
1
S2513 Figure 20-61-4

Remove the two bolts (Item 1) and remove the centering

Dealer Copy -- Not for Resale


sensor (Item 2) from the steering cylinder 1
(Item 3) [Figure 20-61-1].

Figure 20-61-2

S2516
1

Remove the nut (Item 1) [Figure 20-61-4].

S2514

Remove the cotter pin (Item 1) [Figure 20-61-2].

149 of 1040 20-61-1 T35100(S)(L), T35120(S)L Service Manual


STEERING CYLINDER (REAR) (CONT’D) Figure 20-61-7

Removing The Steering Cylinder (Cont’d)

Figure 20-61-5 2

1
1

S2519

Remove the bolts (Item 1) from the steering cylinder


S2517 (Item 2) [Figure 20-61-7].

Figure 20-61-8
Remove the tie rod end (Item 1) [Figure 20-61-5] by
means of a puller.

Dealer Copy -- Not for Resale


Figure 20-61-6 1

2
1

S2520

Extract the cylinder (Item 1) [Figure 20-61-8] using a


S2518 plastic hammer.

NOTE: For cylinder disassembly (See Disassembling


Disconnect the left and right steering bars (Item 1) from The Steering Cylinder on Page 20-61-5.).
the piston (Item 2) [Figure 20-61-6].

150 of 1040 20-61-2 T35100(S)(L), T35120(S)L Service Manual


STEERING CYLINDER (REAR) (CONT’D) Figure 20-61-11

Installing The Steering Cylinder

Figure 20-61-9

S2523

Apply Loctite® #242 to the thread and install the two tie
S2521 rods [Figure 20-61-11]. Tighten the tie rods to 240 - 270
N•m (177 - 199 ft-Ib) torque.

Lubricate the seats of the seals and install the steering Figure 20-61-12
cylinder (Item 1) [Figure 20-61-9] into its seat.

Dealer Copy -- Not for Resale


Figure 20-61-10
2
1

S2524

S2522 Insert the tie rods (Item 1) in the steering case


(Item 2) [Figure 20-61-12]. Tighten the nuts to 260 - 290
N•m (192 - 214 ft-Ib) torque.
Tighten the bolts (Item 1) [Figure 20-61-10] to 116 - 128
N•m (85 - 95 ft-lb) torque. Tighten the nut (Item 3) [Figure 20-61-12] until the
cotter pin hole is visible.

NOTE: Check that the rubber guards [Figure 20-61-


12] are intact.

151 of 1040 20-61-3 T35100(S)(L), T35120(S)L Service Manual


STEERING CYLINDER (REAR) (CONT’D)

Installing The Steering Cylinder (Cont’d)

Figure 20-61-13

S2525

Insert the cotter pins (Item 1) [Figure 20-61-13] and


bend the ends.

Dealer Copy -- Not for Resale


NOTE: Use new cotter pins.

Figure 20-61-14

S2526

Install the centering sensor for checking piston centering.

Tighten the bolt (Item 1) [Figure 20-61-14] to 5 - 6 N•m


(44.3 - 53.1 in-Ib) torque.

152 of 1040 20-61-4 T35100(S)(L), T35120(S)L Service Manual


STEERING CYLINDER (REAR) (CONT’D) Figure 20-61-17

Disassembling The Steering Cylinder

Figure 20-61-15 2

2
S1518

With the help of a drift, apply pressure to the stop ring


S1516 (Item 1) that is placed inside the cylinder
(Item 2) [Figure 20-61-17] and extract the ring using a
screwdriver.
Remove the snap ring (Item 1) from the cylinder head
(Item 2) [Figure 20-61-15]. Figure 20-61-18

Dealer Copy -- Not for Resale


Figure 20-61-16

2
S1519

S1517
Push the piston shaft (Item 1) out of the cylinder until the
head (Item 2) [Figure 20-61-18] can be removed.
With the help of a plastic hammer, push the head
(Item 1) inside the cylinder (Item 2) [Figure 20-61-16].

NOTE: The head should line up with the edge of the


cylinder.

153 of 1040 20-61-5 T35100(S)(L), T35120(S)L Service Manual


STEERING CYLINDER (REAR) (CONT’D) Assembling The Steering Cylinder

Disassembling The Steering Cylinder (Cont’d) Figure 20-61-20

Figure 20-61-19

1 2 3
1

S1521

S1520
After applying grease, install the sealing ring (Item 1), the
anti-extrusion ring (Item 2) and the scraper ring
NOTE: Mark the piston (Item 1) and the end of the (Item 3) [Figure 20-61-20] inside the end of the cylinder.
cylinder housing (Item 2) [Figure 20-61-19]
for ease of assembly. NOTE: Make sure the anti-extrusion ring

Dealer Copy -- Not for Resale


(Item 2) [Figure 20-61-20] is installed as
Remove the piston (Item 1) from the cylinder (Item 2) shown.
[Figure 20-61-19].

Remove all seals, anti-extrusion rings and scraper rings


from head, cylinder and piston.

NOTE: 1) All seals must be replaced every time the


unit is disassembled.
2) Particular attention must be paid not to
damage the seats of both seals and piston
slide.

154 of 1040 20-61-6 T35100(S)(L), T35120(S)L Service Manual


STEERING CYLINDER (REAR) (CONT’D) Figure 20-61-23

Assembling The Steering Cylinder (Cont’d)


5 3 2
Figure 20-61-21
1

3 2 1 4

S1524

Prepare the piston (Item 1) by installing the guide ring


(Item 2), the magnetic ring (Item 3), the O-ring
S1522
(Item 4) and the seal (Item 5) [Figure 20-61-23].

NOTE: Apply grease to the outer diameter of the


After applying grease, install the sealing ring (Item 1), the piston.
anti-extrusion ring (Item 2) and the scraper ring
(Item 3) [Figure 20-61-21] in the head.

Dealer Copy -- Not for Resale


NOTE: Make sure the anti-extrusion ring
(Item 2) [Figure 20-61-21] is installed as
shown.

Figure 20-61-22

S1523

Install the seal (Item 1) [Figure 20-61-22] onto the


outside of the head.

NOTE: In order to facilitate assembly, apply grease to


the outer surface of the piston.
Do not roll the seal (Item 1) [Figure 20-61-22].

155 of 1040 20-61-7 T35100(S)(L), T35120(S)L Service Manual


STEERING CYLINDER (REAR) (CONT’D) Figure 20-61-26

Assembling The Steering Cylinder (Cont’d)

Figure 20-61-24 1
T18

T18
2

1
S1527

Remove tool T18 and install it to the opposite side of the


S1525 piston shaft (Item 1) [Figure 20-61-26].

Figure 20-61-27
NOTE: Make sure the piston assembly orientation is
correct per the marks added in [Figure 20-61-
19]

Dealer Copy -- Not for Resale


1
Install tool T18 to the piston shaft (Item 2) and install it in
the cylinder (Item 1) [Figure 20-61-24]. T18
NOTE: Apply a little grease to seals and cylinder.

Figure 20-61-25

3
2
S1528

1
Apply grease to the head seals (Item 1), install the head
onto the piston shaft (Item 2) and push it onto the cylinder
(Item 3) [Figure 20-61-27].

S1526

Push the piston (Item 1) into the cylinder (Item 2)


[Figure 20-61-25] for 100 mm (4.00 in) using a plastic
hammer.

156 of 1040 20-61-8 T35100(S)(L), T35120(S)L Service Manual


STEERING CYLINDER (REAR) (CONT’D) Figure 20-61-30

Assembling The Steering Cylinder (Cont’d) 2

Figure 20-61-28

S1531

2 Install the snap ring (Item 1) on the head (Item 2)


S1529 [Figure 20-61-30].

NOTE: Make sure that the snap ring (Item 1)


Insert the stop ring (Item 1) ensuring that it fits into the [Figure 20-61-30] is securely fastened in its
seat of the cylinder (Item 2) [Figure 20-61-28]. seat.
If necessary, force it into its seat using a drift

Dealer Copy -- Not for Resale


Figure 20-61-29 and a hammer.

S1530

Apply pressure to the head using two screwdrivers or


levers until the head is fastened onto the stop ring
(Item 1) [Figure 20-61-29].

157 of 1040 20-61-9 T35100(S)(L), T35120(S)L Service Manual


Dealer Copy -- Not for Resale

158 of 1040 20-61-10 T35100(S)(L), T35120(S)L Service Manual


DRIVE BOX

Parts Identification

1. Gear
2. Snap ring
3. Ball bearing
4. Snap ring
5. Vent
6. Ring nut
7. Bearing
8. Ring
9. Plug
10. Seal
11. Ball bearing

Dealer Copy -- Not for Resale


12. Gear

13. Snap ring


14. Ball bearing
15. Seal
16. Plug
17. Spring washer
18. Hexagon bolt
19. Magnet plug
20. Dowel
21. Plug
22. Flange
23. O-ring
24. Screw
25. Cover
26. Shim
27. Bearing

S2500

159 of 1040 20-70-1 T35100(S)(L), T35120(S)L Service Manual


DRIVE BOX (CONT’D) Figure 20-70-3

Disassembly 1

Remove the front axle. (See Removal on Page 40-30-1.)

Remove the drive motor. (See Removal And Installation


on Page 30-30-1.)

Figure 20-70-1
1

S2463

Take of the drive side flange cover (Item 1) [Figure 20-


70-3] by alternatively forcing a screwdriver into the
appropriate slots.
1 NOTE: Look out not to damage the surfaces.

Figure 20-70-4
S2603

Dealer Copy -- Not for Resale


Loosen the securing bolts (Item 1) [Figure 20-70-1] only
so that later when you pry the drive side flange cover
loose, it does not fall.

Figure 20-70-2 1

S2463

1 Remove the securing bolts and lift off the cover (Item 1)
[Figure 20-70-4].

S2604

Loosen the drive side flange cover (Item 1) [Figure 20-


70-2] using a plastic hammer.

160 of 1040 20-70-2 T35100(S)(L), T35120(S)L Service Manual


DRIVE BOX (CONT’D) Figure 20-70-7

Disassembly (Cont’d)

Figure 20-70-5
1

S2488

Using a lever, remove the flange sealing ring (Item 1)


S2663 [Figure 20-70-7].

To remove the drive side shaft (Item 1), hook off the snap Figure 20-70-8
ring (Item 2) [Figure 20-70-5].
1
Figure 20-70-6

Dealer Copy -- Not for Resale


1

S2432

S2463 Remove the snap ring (Item 1) [Figure 20-70-8].

Using two levers, remove the drive side shaft (Item 1)


[Figure 20-70-6].

161 of 1040 20-70-3 T35100(S)(L), T35120(S)L Service Manual


DRIVE BOX (CONT’D) Figure 20-70-11

Disassembly (Cont’d)

Figure 20-70-9

2
2

1
S2489

With a puller, remove the bearing (Item 1) from the flange


1
shaft (Item 2) [Figure 20-70-11].
S2433

Figure 20-70-12
With a puller, remove the bearing (Item 1) from the input
shaft (Item 2) [Figure 20-70-9].
1

Dealer Copy -- Not for Resale


Figure 20-70-10

2 S2490

Remove the secondary gear wheel (Item 1) [Figure 20-


70-12].
S2434

Remove the bearing (Item 1) and the snap ring (Item 2)


[Figure 20-70-10].

162 of 1040 20-70-4 T35100(S)(L), T35120(S)L Service Manual


DRIVE BOX (CONT’D) Figure 20-70-15

Disassembly (Cont’d)

Figure 20-70-13

S2492

1
Remove the internal bearing (Item 1) [Figure 20-70-15].

S2435 Figure 20-70-16

Remove the snap ring (Item 1) [Figure 20-70-13].

Figure 20-70-14

Dealer Copy -- Not for Resale


2

S2493

1 Pull out the cup of the sealing ring (Item 1) by using drift
(Item 2) [Figure 20-70-16].
S2491

Remove the flange (Item 1) [Figure 20-70-14] by means


of a plastic hammer.

163 of 1040 20-70-5 T35100(S)(L), T35120(S)L Service Manual


DRIVE BOX (CONT’D) Figure 20-70-19

Assembly

Figure 20-70-17

S2494

T27
Install the flange (Item 1) [Figure 20-70-19] and fasten it.
S2665
For keying the flange (Item 1) [Figure 20-70-19], use a
Insert the sealing ring using tool T27 [Figure 20-70-17]. plastic hammer if necessary.

NOTE: Bring the sealing ring just to the end stop, Figure 20-70-20
apply grease to the sealing lips.

Dealer Copy -- Not for Resale


Figure 20-70-18

1
S2495

Insert the bearing (Item 1) [Figure 20-70-20].


S2436

Insert the sealing ring (Item 1) [Figure 20-70-18] with a


normal tool.

NOTE: Bring the sealing ring just to the end stop,


apply grease to the sealing lips.

164 of 1040 20-70-6 T35100(S)(L), T35120(S)L Service Manual


DRIVE BOX (CONT’D) Figure 20-70-23

Assembly (Cont’d)

Figure 20-70-21

1 S2437 / S2438

Using a normal tool insert the bearing (Item 1) [Figure


20-70-23].
S2496

Figure 20-70-24
Using a normal tool insert the bearing (Item 1) [Figure
20-70-21] and snap ring.

Dealer Copy -- Not for Resale


Figure 20-70-22

2
1

S2439 / S2440

Insert the snap ring (Item 1) and using a normal tool


S2497 insert the bearing (Item 2) [Figure 20-70-24].

Install the secondary gear wheel (Item 1) [Figure 20-70-


22] with a plastic hammer.

165 of 1040 20-70-7 T35100(S)(L), T35120(S)L Service Manual


DRIVE BOX (CONT’D) Figure 20-70-27

Assembly (Cont’d)

Figure 20-70-25
1
1

S2606

Install drive side flange cover (Item 1) [Figure 20-70-27],


apply Loctite® #510 to the short screws.
S2441
Figure 20-70-28

Secure the bearing with the snap ring (Item 1) [Figure


20-70-25].

Dealer Copy -- Not for Resale


Figure 20-70-26

S2666

Tighten the bolts to 80 - 90 N•m torque [Figure 20-70-


28].
S2498

Install the drive side shaft (Item 1) [Figure 20-70-26] with


a plastic hammer.

166 of 1040 20-70-8 T35100(S)(L), T35120(S)L Service Manual


DRIVE BOX (CONT’D)

Special Tools

TOOL IMAGE DESCRIPTION BOBCAT PN


T27 Pinion tail seal 6912202

Dealer Copy -- Not for Resale

167 of 1040 20-70-9 T35100(S)(L), T35120(S)L Service Manual


Dealer Copy -- Not for Resale

168 of 1040 20-70-10 T35100(S)(L), T35120(S)L Service Manual


MAIN RELIEF VALVE Figure 20-80-3
S/N A8HD12999 & BELOW
Testing And Adjustment S/N A8GW12999 & BELOW
S/N A8GT12999 & BELOW
The following tool will be needed to do the following S/N A8GV12999 & BELOW
procedure: S/N A8GJ12999 & BELOW

MEL10003-Hydraulic Tester

Figure 20-80-1

3
4

Dealer Copy -- Not for Resale


1 P-44328 2 1

Connect the inlet hose (Item 1) from the tester (Item 5) to S3507
the front coupler (Item 2) [Figure 20-80-1].

Connect the outlet hose (Item 3) from the tester (Item 5) Start the engine, lower the restraint bar (if equipped) and
to the rear coupler (Item 4) [Figure 20-80-1]. run at low idle RPM. Push the detent rocker switch (Item
1) and front auxiliary rocker switch (Item 2) [Figure 20-
80-2] and [Figure 20-80-3]. Make sure the tester is
connected correctly. If no flow is indicated on the tester,
IMPORTANT the hoses are connected wrong. with the hoses
connected correctly, increase the engine speed to 2200
RPM.
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284 Warm the fluid to 60°C (140°F) by turning the restrictor
control (Item 5) [Figure 20-80-1] on the tester to about
6,9 MPa (69 bar) (1000 psi). DO NOT exceed system
Figure 20-80-2 relief pressure. Open the restrictor control knob and
S/N A8HD13000 & ABOVE record the free flow (U.S. gpm) at 2200 RPM.
S/N A8GW13000 & ABOVE
S/N A8GT13000 & ABOVE There should be 55 L/min (13 U.S. gpm) free flow. Turn
S/N A8GV13000 & ABOVE the restrictor control (Item 5) [Figure 20-80-1] on the
S/N A8GJ13000 & ABOVE
tester until the main relief opens. The correct pressure
should be 26,5 MPa (265 bar) (3844 psi).

If adjustment is needed, (See [Figure 20-80-4].)

2 1

P-97008

169 of 1040 20-80-1 T35100(S)(L), T35120(S)L Service Manual


MAIN RELIEF VALVE (CONT’D) Removal And Installation

Testing And Adjustment (Cont’d)

Remove the rear cover.


IMPORTANT
Figure 20-80-4
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
1 I-2003-0888

Remove the rear cover.

Figure 20-80-6

1
P-50980

Dealer Copy -- Not for Resale


Locate the main relief valve (Item 1) on the front right
side of the control valve [Figure 20-80-4].

Figure 20-80-5

P-50980
1

Locate the main relief valve (Item 1) [Figure 20-80-6] on


the front right side of the control valve.
2
Clean the area around the control valve.

Remove the main relief valve (Item 1) [Figure 20-80-6].

Installation: Tighten the main relief valve to 45 N•m


P-44331 (33 ft-lb) torque.

Loosen the lock nut (Item 1) and turn the adjustment


screw (Item 2) [Figure 20-80-5] clockwise to increase the
pressure or counterclockwise to decrease the pressure.

NOTE: A 90° turn = 1 MPa (10 bar) (150 psi).

Retest the main relief valve after adjustment.

170 of 1040 20-80-2 T35100(S)(L), T35120(S)L Service Manual


QUICK-TACH CYLINDER Figure 20-90-3

Removal And Installation

Figure 20-90-1

S3645

Remove the end bushing (Item 1) [Figure 20-90-3] (Both


sides).
S3643

Figure 20-90-4
Remove the two hoses (Item 1) [Figure 20-90-1] from
the cylinder.

NOTE: Mark the hoses for correct installation.

Dealer Copy -- Not for Resale


IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
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 S3646
damage the system.
I-2003-0888
Remove the roll pin (Item 1) [Figure 20-90-4] (Both
sides).
Figure 20-90-2

S3644

Remove the bolt (Item 1) [Figure 20-90-2] from each


side of the cylinder.

171 of 1040 20-90-1 T35100(S)(L), T35120(S)L Service Manual


QUICK-TACH CYLINDER (CONT'D)

Removal And Installation (Cont'd)

Figure 20-90-5

2 1
S3647

Remove the washer (Item 1) and spring (Item 2)


[Figure 20-90-5] from the cylinder rod extension (Both
sides).

Dealer Copy -- Not for Resale


Figure 20-90-6

S3648

Remove the roll pin (Item 1) and remove the extension


rod (Item 2) [Figure 20-90-6] from the cylinder rod (Both
sides).

Remove the cylinder.

172 of 1040 20-90-2 T35100(S)(L), T35120(S)L Service Manual


QUICK-TACH CYLINDER (CONT'D)

Parts Identification

1. Housing
2. Extension
3. Wiper
4. Seal
5. O-ring
6. Head Gland
7. Rod
8. Piston
9. Wear Ring

Dealer Copy -- Not for Resale

S4890

173 of 1040 20-90-3 T35100(S)(L), T35120(S)L Service Manual


QUICK-TACH CYLINDER (CONT'D) Figure 20-90-9

Disassembly

Use the following tool to disassemble the cylinder:

MEL1076-Cylinder Wrench

Figure 20-90-7

P-32173

Use the cylinder wrench to loosen the head gland


[Figure 20-90-9].

Figure 20-90-10

P-32169

Dealer Copy -- Not for Resale


Place the cylinder in a vise [Figure 20-90-7].

Figure 20-90-8
1

P-32172

1
Remove the rod assembly (Item 1) [Figure 20-90-10]
from the housing.

P-32170

Remove the two fittings (Item 1) [Figure 20-90-8].

174 of 1040 20-90-4 T35100(S)(L), T35120(S)L Service Manual


QUICK-TACH CYLINDER (CONT'D) Figure 20-90-13

Disassembly (Cont'd)
1
Figure 20-90-11

P-32175
1

Remove the head gland (Item 1) [Figure 20-90-13] from


each rod.
P-32173

Figure 20-90-14
Use the cylinder wrench to loosen the second head gland
(Item 1) [Figure 20-90-11] on the opposite side.

Figure 20-90-12

Dealer Copy -- Not for Resale


1
1

P-32176

Remove the O-rings (Item 1) [Figure 20-90-14] from


each head gland.
P-32174

Remove the rod assembly (Item 1) [Figure 20-90-12]


from the housing.

175 of 1040 20-90-5 T35100(S)(L), T35120(S)L Service Manual


QUICK-TACH CYLINDER (CONT'D) Figure 20-90-17

Disassembly (Cont'd)

Figure 20-90-15

1
P-32179
2
Remove the O-ring (Item 1) [Figure 20-90-17] from each
piston.
P-32177

Remove the wiper seal (Item 1) and seal (Item 2)


[Figure 20-90-15] from each head gland.

Figure 20-90-16

Dealer Copy -- Not for Resale


2 1

P-32178

Remove the wear ring (Item 1) and seal (Item 2)


[Figure 20-90-16] from each piston.

176 of 1040 20-90-6 T35100(S)(L), T35120(S)L Service Manual


QUICK-TACH CYLINDER (CONT'D) Figure 20-90-20

Assembly
1
Use the following tool to assemble the cylinder:

MEL1076-Cylinder Wrench

Wash the cylinder parts in solvent and dry with


compressed air.

Inspect the cylinder parts for nicks, scratches or other 2


damage. Replace any damaged parts.

Lubricate all O-rings and seals with hydraulic fluid during P-32177
installation.
Install the wiper (Item 1) and seal (Item 2) [Figure 20-90-
Always use new O-rings and seals.
20] in each head gland.
Figure 20-90-18
NOTE: The groove in the seal must point away from
the wiper seal (Item 1) [Figure 20-90-20].

Figure 20-90-21

Dealer Copy -- Not for Resale


1
P-32179 1

Install a new O-ring (Item 1) [Figure 20-90-18] on each


piston. P-32176

Figure 20-90-19
Install the two O-rings (Item 1) [Figure 20-90-21] on
each head gland.
2 1

P-32178

Install a new wear ring (Item 1) and seal (Item 2)


[Figure 20-90-19] on each piston.

177 of 1040 20-90-7 T35100(S)(L), T35120(S)L Service Manual


QUICK-TACH CYLINDER (CONT'D) Figure 20-90-24

Assembly (Cont'd)

Figure 20-90-22

P-32180

Use the cylinder wrench to tighten both head glands


[Figure 20-90-24].
P-32175

Figure 20-90-25
Install each head gland (Item 1) [Figure 20-90-22] onto
the rod.

Figure 20-90-23

Dealer Copy -- Not for Resale


1

1
1

P-32170

Install the two fittings (Item 1) [Figure 20-90-25].


P-32174

Install each rod assembly (Item 1) [Figure 20-90-23] into


the housing.

178 of 1040 20-90-8 T35100(S)(L), T35120(S)L Service Manual


FRAME LEVELING CYLINDER Figure 20-100-2

Removal And Installation

Figure 20-100-1

1 1

P-40479

Remove the two hoses (Item 1) [Figure 20-100-2].


S2050
Install caps and plugs.

Install jack stands under the frame to prevent the frame Figure 20-100-3
from tilting during cylinder removal [Figure 20-100-1].

Dealer Copy -- Not for Resale


Relieve hydraulic pressure.

WARNING 1

Hydraulic fluid escaping under pressure can have


sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290 S2049

Remove the snap ring (Item 1) and washer (Item 2)


[Figure 20-100-3].
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

NOTE: Mark all hoses for correct installation.

179 of 1040 20-100-1 T35100(S)(L), T35120(S)L Service Manual


FRAME LEVELING CYLINDER (CONT’D)

Removal And Installation (Cont’d)

Figure 20-100-4

S2034

Remove the pivot pin (Item 1) [Figure 20-100-4].

Dealer Copy -- Not for Resale


Figure 20-100-5

1 1

P-40483

Remove the four mounting bolts (Item 1) [Figure 20-100-


5].

Remove the frame leveling cylinder.

180 of 1040 20-100-2 T35100(S)(L), T35120(S)L Service Manual


FRAME LEVELING CYLINDER (CONT’D)

Parts Identification

1. Relief Cartridge
2. Housing
3. Wear Ring
4. Seal
5. Set Screw
6. Piston
7. O-ring
8. Sleeve
9. Head Gland
10. Wiper
11. Bushing
12. Rod
13. Grease Fitting

Dealer Copy -- Not for Resale


4
5

1
3

6
7
1 8

7
4
10
13
7

9
3

11
12

B-19814

181 of 1040 20-100-3 T35100(S)(L), T35120(S)L Service Manual


FRAME LEVELING CYLINDER (CONT’D) Figure 20-100-8

Disassembly
2
Use the following tools to disassemble the cylinder:
1
MEL1353 - Cylinder Gland Nut Wrench

Figure 20-100-6

2
P-40486

1 Remove the two relief cartridges (Item 1) and two fittings


1 (Item 2) [Figure 20-100-8].

Figure 20-100-9

P-40484

Dealer Copy -- Not for Resale


Remove the mounting blocks (Item 1) [Figure 20-100-6].

Figure 20-100-7

P-40487

Put the cylinder in a vise [Figure 20-100-9].

P-40485

Remove the bushing (Item 1) [Figure 20-100-7] from


both mounting blocks.

182 of 1040 20-100-4 T35100(S)(L), T35120(S)L Service Manual


FRAME LEVELING CYLINDER (CONT’D) Figure 20-100-12

Disassembly (Cont’d)

Figure 20-100-10 1

P-40492

Remove the rod assembly (Item 1) [Figure 20-100-12]


P-29868 from the housing.

Figure 20-100-13
Carefully peen the lock ring from the head gland
[Figure 20-100-10].

Dealer Copy -- Not for Resale


Figure 20-100-11

P-40493

Put the rod end of the cylinder in a vise [Figure 20-100-


P-40489 13].

Remove the head gland using a wrench [Figure 20-100-


11].

183 of 1040 20-100-5 T35100(S)(L), T35120(S)L Service Manual


FRAME LEVELING CYLINDER (CONT’D) Figure 20-100-16

Disassembly (Cont’d)

Figure 20-100-14

1
P-29879

Remove the expander O-ring (Item 1) [Figure 20-100-


P-40494 16].

Figure 20-100-17
Remove the set screw (Item 1) [Figure 20-100-14] from
the piston.

Dealer Copy -- Not for Resale


Remove the piston assembly (Item 2) [Figure 20-100-14]
from the rod.

Figure 20-100-15

1
1

1 P-29880

Remove the O-ring (Item 1) [Figure 20-100-17] from the


piston.

2
P-29877

Remove the two wear rings (Item 1) and seal (Item 2)


[Figure 20-100-15] from the piston.

184 of 1040 20-100-6 T35100(S)(L), T35120(S)L Service Manual


FRAME LEVELING CYLINDER (CONT’D) Figure 20-100-20

Disassembly (Cont’d)

Figure 20-100-18 1

P-40497

Remove the head gland (Item 1) [Figure 20-100-20]


P-40496 from the rod.

Figure 20-100-21
Remove the sleeve (Item 1) [Figure 20-100-18] from the
rod.

Dealer Copy -- Not for Resale


Figure 20-100-19

1 2

P-29883

Remove the center seal (Item 1) and outer wear ring


P-40501 (Item 2) [Figure 20-100-21] from the head gland.

Remove the O-ring (Item 1) [Figure 20-100-19] from the


sleeve.

185 of 1040 20-100-7 T35100(S)(L), T35120(S)L Service Manual


FRAME LEVELING CYLINDER (CONT’D) Figure 20-100-24

Disassembly (Cont’d)

Figure 20-100-22

1
P-40509

Remove the bushing (Item 1) [Figure 20-100-24] from


P-29884 the rod end.

Remove the outer wear ring (Item 1) and wiper seal (Item
2) [Figure 20-100-22]

Dealer Copy -- Not for Resale


Figure 20-100-23

P-29882

Remove the two O-rings (Item 1) [Figure 20-100-23].

Remove the rod from the vise.

186 of 1040 20-100-8 T35100(S)(L), T35120(S)L Service Manual


FRAME LEVELING CYLINDER (CONT’D) Figure 20-100-27

Assembly
1
Use the following tools to assemble the cylinder:

MEL1353 - Cylinder Gland Nut Wrench

Wash the cylinder parts in solvent and dry with


compressed air.
2
Inspect the cylinder parts for nicks, scratches or other
damage. Replace any damaged parts.

Always use new O-rings and seals. Lubricate all O-rings


and seals with hydraulic fluid during installation. P-29884

Figure 20-100-25
Install the wiper seal (Item 1) and wear ring (Item 2)
[Figure 20-100-27].
1
Figure 20-100-28

Dealer Copy -- Not for Resale


1

P-40509

Install the bushing (Item 1) [Figure 20-100-25] in the rod


end. P-29883

Figure 20-100-26
Install the wear ring (Item 1) [Figure 20-100-28].

P-29882

Install the two O-rings (Item 1) [Figure 20-100-26] onto


the head gland.

187 of 1040 20-100-9 T35100(S)(L), T35120(S)L Service Manual


FRAME LEVELING CYLINDER (CONT’D) Figure 20-100-31

Assembly (Cont’d)

Figure 20-100-29
1

P-40501

Install the O-ring (Item 1) [Figure 20-100-31] in the


P-29885 sleeve.

Figure 20-100-32
Install the center seal (Item 1) [Figure 20-100-29].

Dealer Copy -- Not for Resale


NOTE: The groove in the seal must point away from
the wiper seal (Item 1) [Figure 20-100-29].
1
Figure 20-100-30

P-40496

Install the sleeve (Item 1) [Figure 20-100-32] on the rod.

P-40497

Put the rod end in a vise. Use care not to damage the
rod.

Install the head gland (Item 1) [Figure 20-100-30] onto


the rod.

188 of 1040 20-100-10 T35100(S)(L), T35120(S)L Service Manual


FRAME LEVELING CYLINDER (CONT’D) Figure 20-100-35

Assembly (Cont’d)

Figure 20-100-33

1 1

1 2
P-29877

Install the two wear rings (Item 1) and seal (Item 2)


P-29880 [Figure 20-100-35].

Figure 20-100-36
Install the O-ring (Item 1) [Figure 20-100-33] in the
piston.

Dealer Copy -- Not for Resale


Figure 20-100-34

P-40508

1
Clean the threads and apply Loctite® #242 or equivalent
P-29879 to the threads on the rod [Figure 20-100-36].

Install the expander O-ring (Item 1) [Figure 20-100-34]


onto the piston.

189 of 1040 20-100-11 T35100(S)(L), T35120(S)L Service Manual


FRAME LEVELING CYLINDER (CONT’D) Figure 20-100-39

Assembly (Cont’d)

Figure 20-100-37

P-29887

Apply Loctite® #242 or equivalent to the set screw (Item


P-40493 1) [Figure 20-100-39].

Figure 20-100-40
Install the piston (Item 1) [Figure 20-100-37] on the rod.

Dealer Copy -- Not for Resale


Figure 20-100-38

1
P-40494

P-29888 Install the set screw (Item 1) [Figure 20-100-40] into the
piston and tighten.

Align the hole (Item 1) [Figure 20-100-38] in the piston


with the hole in the end of the cylinder rod.

190 of 1040 20-100-12 T35100(S)(L), T35120(S)L Service Manual


FRAME LEVELING CYLINDER (CONT’D) Figure 20-100-43

Assembly (Cont’d)

Figure 20-100-41

P-40491

Carefully peen the lock ring over and into the nut (Item 1)
P-40492 [Figure 20-100-43].

Remove the cylinder from the vise.


Put the housing in a vise. Use care not to damage the
housing. Figure 20-100-44

Dealer Copy -- Not for Resale


Install the rod assembly (Item 1) [Figure 20-100-41] into
the housing. 2

Figure 20-100-42 1

2
P-40486

Install the two relief valve cartridges (Item 1) and two


fittings (Item 2) [Figure 20-100-44].
P-40490

Tighten the head gland using a wrench [Figure 20-100-


42].

191 of 1040 20-100-13 T35100(S)(L), T35120(S)L Service Manual


FRAME LEVELING CYLINDER (CONT’D)

Assembly (Cont’d)

Figure 20-100-45

P-40485

Install the bushing (Item 1) [Figure 20-100-45] on both


mounting blocks.

Dealer Copy -- Not for Resale


Figure 20-100-46

P-40484

Install the two mounting blocks (Item 1) [Figure 20-100-


46].

192 of 1040 20-100-14 T35100(S)(L), T35120(S)L Service Manual


STEERING MODE VALVE BLOCK Figure 20-110-2

Removal And Installation


1

WARNING 2

Hydraulic fluid escaping under pressure can have


sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a 1
physician familiar with this injury is not received
immediately.
W-2145-0290
P-50932

Figure 20-110-1
Remove the four mounting bolts (Item 1) [Figure 20-110-
2].

NOTE: Mark the location of the valve on the block.


1
Remove the valve (Item 2) [Figure 20-110-2] from the

Dealer Copy -- Not for Resale


block.

IMPORTANT
1 When repairing hydrostatic and hydraulic systems,
P-50931 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
Relieve hydraulic pressure. damage the system.
I-2003-0888
Remove the retainer screw (Item 1) [Figure 20-110-1]
from the two solenoids.

Remove the wire connectors from the two solenoids.

NOTE: Mark the location of the wire connectors for


correct installation.

193 of 1040 20-110-1 T35100(S)(L), T35120(S)L Service Manual


STEERING MODE VALVE BLOCK (CONT’D)

Removal And Installation (Cont’d)

Figure 20-110-3

1
1

P-50934

Remove the four hoses (Item 1) [Figure 20-110-3].

Dealer Copy -- Not for Resale


NOTE: Mark the location of the hoses.

Figure 20-110-4

P-50936

Remove the four mounting bolts (Item 1) [Figure 20-110-


4] and remove the block.

194 of 1040 20-110-2 T35100(S)(L), T35120(S)L Service Manual


STEERING MODE VALVE BLOCK (CONT’D)

Parts Identification

1
1. Nut
2. O-Ring
3. Solenoid
4. Shaft 2
5. Pin
6. Spring
7. Retainer 3
8. Spool
9. Housing
10. Bolt 4
11. Washer 2
12. Elbow 5
13. Adapter
14. Housing 6
7

Dealer Copy -- Not for Resale


10

11
8

9
3

2
2
1

12 13
*
* 10

* * 12
14
13

* Supplied with fitting. S4891

195 of 1040 20-110-3 T35100(S)(L), T35120(S)L Service Manual


STEERING MODE VALVE BLOCK (CONT'D)

Disassembly
IMPORTANT
Mark the location of the solenoids to the housing for
correct assembly. When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
Figure 20-110-5 parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1
Figure 20-110-7

1 1

P-42291

Dealer Copy -- Not for Resale


Remove the four O-rings (Item 1) [Figure 20-110-5] from
the housing.
P-42294
Figure 20-110-6

Remove the solenoids (Item 1) [Figure 20-110-7] from


the solenoid shafts.

Figure 20-110-8

1
1 1

P-42292

Remove the nut (Item 1) [Figure 20-110-6] from each


solenoid.
P-42295
NOTE: Mark the location of the solenoids.

Remove the O-ring (Item 1) [Figure 20-110-8] from both


shafts.

196 of 1040 20-110-4 T35100(S)(L), T35120(S)L Service Manual


STEERING MODE VALVE BLOCK (CONT'D) Figure 20-110-11

Disassembly (Cont'd)

Figure 20-110-9

1 1

P-42299

Remove the O-ring (Item 1) [Figure 20-110-11] from


P-42296 each shaft.

Figure 20-110-12
Loosen the shafts (Item 1) [Figure 20-110-9].

Dealer Copy -- Not for Resale


Figure 20-110-10

5
1
4
2
1

3
P-42300

P-42297 Carefully remove the spool (Item 1) [Figure 20-110-12]


from the housing.

Remove the shaft (Item 1), pin (Item 2), spring (Item 3)
and spring retainer (Item 4) from the housing (Item 5)
[Figure 20-110-10] (Both Sides).

197 of 1040 20-110-5 T35100(S)(L), T35120(S)L Service Manual


STEERING MODE VALVE BLOCK (CONT'D) Figure 20-110-15

Solenoid Testing

Figure 20-110-13

P-42299

Install a new O-ring (Item 1) [Figure 20-110-15] on each


P-42301 shaft.

Figure 20-110-16
Use a circuit tester, touch one probe to the prong and the
other probe to the other prong [Figure 20-110-13], there

Dealer Copy -- Not for Resale


must be continuity. If there is no continuity, replace the
solenoid. 5
2
Assembly

Clean all components with solvent and dry with


compressed air.

Check all components for wear or damage. Replace any 1


3
worn or damaged components.
4
Always use new O-rings.
P-42297
Lightly oil all parts.

Figure 20-110-14 Install the spring retainer (Item 1), spring (Item 2), pin
(Item 3) and shaft (Item 4) in the housing (Item 5)
[Figure 20-110-16] (Both Sides).

P-42300

Carefully install the spool (Item 1) [Figure 20-110-14].

198 of 1040 20-110-6 T35100(S)(L), T35120(S)L Service Manual


STEERING MODE VALVE BLOCK (CONT'D) Figure 20-110-19

Assembly (Cont'd)

Figure 20-110-17

1 1

P-42293

Install the O-ring (Item 1) [Figure 20-110-19] on the two


P-42296 solenoids.

Figure 20-110-20
Tighten each shaft (Item 1) [Figure 20-110-17].

Dealer Copy -- Not for Resale


Figure 20-110-18 1

2
1 1

P-42294

P-42295 Install the solenoids (Item 1) on the shafts (Item 2)


[Figure 20-110-20].

Install an O-ring (Item 1) [Figure 20-110-18] on each


shaft.

199 of 1040 20-110-7 T35100(S)(L), T35120(S)L Service Manual


STEERING MODE VALVE BLOCK (CONT'D)

Assembly (Cont'd)

Figure 20-110-21

1 1

P-42292

Install the nuts (Item 1) [Figure 20-110-21] on each shaft


and hand tighten.

Dealer Copy -- Not for Resale


NOTE: Do not overtighten the nuts.

Figure 20-110-22

P-42291

Install the four O-rings (Item 1) [Figure 20-110-22] on


the housing.

200 of 1040 20-110-8 T35100(S)(L), T35120(S)L Service Manual


BRAKE VALVE Figure 20-120-3

Removal And Installation

Figure 20-120-1

1 P-25249

Remove the accelerator cable (Item 1) from the pedal


P-52341 and mounting bracket (Item 2) [Figure 20-120-3].

Figure 20-120-4
Remove the dash cover / column cover. (See Removal
And Installation on Page 50-140-1.)

Dealer Copy -- Not for Resale


Disconnect the connector (Item 1) [Figure 20-120-1]
from the brake light switch.

Figure 20-120-2

P-25638

Remove the three hoses (Item 1) [Figure 20-120-4] from


the brake valve.

NOTE: Mark hoses for correct installation.


P-42865

Disconnect the connector (Item 1) [Figure 20-120-2]


from the inching switch. 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

201 of 1040 20-120-1 T35100(S)(L), T35120(S)L Service Manual


BRAKE VALVE (CONT’D) Figure 20-120-7

Removal And Installation (Cont’d)

Figure 20-120-5

1 1

1
P-42870

Remove the roll pin (Item 1) and pedal (Item 2)


1 P-25637 [Figure 20-120-7].

Figure 20-120-8
Remove the mounting bolts (Item 1) [Figure 20-120-5].

Dealer Copy -- Not for Resale


Remove the pedal assembly.

Disassembly And Assembly 2

Figure 20-120-6

1
1 2

P-42871

Assembly: Align the hole (Item 1) in the pedal with the


hole (Item 2) [Figure 20-120-8] in the shaft.

P-42869

Remove the bolt (Item 1) and spring (Item 2) [Figure 20-


120-6].

202 of 1040 20-120-2 T35100(S)(L), T35120(S)L Service Manual


BRAKE VALVE (CONT’D) Figure 20-120-11

Disassembly And Assembly (Cont’d)

Figure 20-120-9

P-42875

Remove the shaft and bearing assembly [Figure 20-120-


P-42872 11].

Figure 20-120-12
Loosen the two set screws (Item 1) [Figure 20-120-9] on
the two bearings. 1

Dealer Copy -- Not for Resale


Figure 20-120-10
1 2

2
1 P-42876

1
Remove the flanges (Item 1) and bearings (Item 2)
P-42874 [Figure 20-120-12].

Remove the three bolts (Item 1) [Figure 20-120-10] from


both bearing flanges.

203 of 1040 20-120-3 T35100(S)(L), T35120(S)L Service Manual


BRAKE VALVE (CONT’D) Figure 20-120-15

Disassembly And Assembly (Cont’d)

Figure 20-120-13

P-42879

Remove the brake valve (Item 1) [Figure 20-120-15]


P-42878

Remove the three fittings (Item 1) [Figure 20-120-13]


from the brake valve.

Dealer Copy -- Not for Resale


Figure 20-120-14

2
P-42877

Remove the four bolts (Item 1), spacers (Item 2)


[Figure 20-120-14] and nuts from the brake valve.

204 of 1040 20-120-4 T35100(S)(L), T35120(S)L Service Manual


GEAR PUMP Figure 20-130-2

Removal And Installation

Raise the boom and install the boom stop. (See Installing
The Approved Boom Stop on Page 10-150-1.)

Stop the engine.

Relieve the hydraulic pressure. Drain the hydraulic 1


reservoir. (See Removing And Replacing Hydraulic Fluid 2
on Page 10-100-2.)

WARNING P-56477

Hydraulic fluid escaping under pressure can have Remove the four bolts (Item 1) and remove the hose
sufficient force to enter a person’s body by (Item 2) [Figure 20-130-2] from the hydrostatic pump.
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a Figure 20-130-3
physician familiar with this injury is not received
immediately.

Dealer Copy -- Not for Resale


W-2145-0290

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-56478

Figure 20-130-1
Remove the hose (Item 1) [Figure 20-130-3] from the
backside of the gear pump.
1

1
1

P-56463

Remove the three hoses (Item 1) [Figure 20-130-1] from


the backside of the pump.

205 of 1040 20-130-1 T35100(S)(L), T35120(S)L Service Manual


GEAR PUMP (CONT'D) Figure 20-130-6

Removal And Installation (Cont'd)

Figure 20-130-4

1 P-56470

Loosen the hose clamp (Item 1) and remove the hose


P-56464 (Item 2) [Figure 20-130-6].

Figure 20-130-7
Remove the hose (Item 1) [Figure 20-130-4].

Dealer Copy -- Not for Resale


Figure 20-130-5
1

1 1
P-56482

P-56468 Install a chain hoist and lifting strap to lift and support the
gear pump [Figure 20-130-7].

Loosen the hose clamp (Item 1) [Figure 20-130-5] and Remove the two mounting bolts (Item 1) [Figure 20-130-
remove the hose. 7] from the gear pump.

Installation: Tighten the mounting bolts to 50 - 80 N•m


(52 - 59 ft-lb) torque.

206 of 1040 20-130-2 T35100(S)(L), T35120(S)L Service Manual


GEAR PUMP (CONT'D)

Removal And Installation (Cont'd)

Figure 20-130-8

P-56483

Remove the gear pump [Figure 20-130-8].

Dealer Copy -- Not for Resale


NOTE: It can be necessary to reposition any hose or
wires.

207 of 1040 20-130-3 T35100(S)(L), T35120(S)L Service Manual


GEAR PUMP (CONT’D)

Parts Identification

1. Fitting
2. O-ring 1
3. Spring
4. Spring Seat 2
5. Spool 3
6. Screen 8
4
7. Orifice Spool
8. Bolt 5
9. Housing 6
10. Plug 7
11. Bolt 14
12. Washer
13. Cover 9 16
14. Seal Ring 17
15. Housing
16. Back-up Ring 18
19
17. Seal Ring

Dealer Copy -- Not for Resale


18. Holder 2 18
10
19. Gear 17
20. Drive Shaft 16
21. Mount Plate
22. Thrust Plate 13
15
23. Mount Plate
24. Seal 14
25. Snap ring 14

12
11
15
14

21 19
22

17
16
20
25 2

24

23
8 17
16
22

S4892

208 of 1040 20-130-4 T35100(S)(L), T35120(S)L Service Manual


GEAR PUMP (CONT'D) Figure 20-130-11

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

P-56449
Figure 20-130-9

Remove the flow divider from the housing [Figure 20-


1 130-11].

Figure 20-130-12
1
6

Dealer Copy -- Not for Resale


1
5 4 3 2

1
1
P-56447

Mark the pump housing for correct assembly and remove


the fittings (Item 1) [Figure 20-130-9].
P-25293
Figure 20-130-10

Remove the fitting (Item 1), O-ring (Item 2), spring (Item
1 1 3), spring seat (Item 4) and spool (Item 5) from the
housing (Item 6) [Figure 20-130-12].

NOTE: Always use new O-rings.

1 1

P-56448

Remove the four bolts (Item 1) [Figure 20-130-10].

Assembly: Tighten the bolts to 33 N•m (25 ft-lb) torque.

209 of 1040 20-130-5 T35100(S)(L), T35120(S)L Service Manual


GEAR PUMP (CONT'D) Figure 20-130-15

Disassembly And Assembly (Cont'd)

Figure 20-130-13

2
1

P-25296

To remove the orifice assembly (Item 1) [Figure 20-130-


P-25294 15] from the spool, make a holding fixture from a 19 mm
thick x 38 mm wide x 50 mm (0.750 in thick x 1.500 in
wide x 2.0 in long) long piece of hardwood. Drill a 14 mm
Remove the plug (Item 1) and O-ring (Item 2) [Figure 20- (0.550 in) hole in the center of the hardwood block. Cut
130-13] from the housing. the block lengthwise [Figure 20-130-14].

Dealer Copy -- Not for Resale


Figure 20-130-14 Place both halves of the hardwood block around the
spool. Clamp the blocks in a vise [Figure 20-130-15].
Cut
NOTE: Do not use anything other than hardwood
blocks to grip the spool, or the spool will be
damaged.

Figure 20-130-16
14 mm
(0.550”) dia. 50 mm (2.0”)

1 2

38 mm (1.500”)

B-14674

P-25295

Remove the screen (Item 1) from the orifice (Item 2)


[Figure 20-130-16] and clean.

210 of 1040 20-130-6 T35100(S)(L), T35120(S)L Service Manual


GEAR PUMP (CONT'D) Figure 20-130-19

Disassembly And Assembly (Cont'd)

Figure 20-130-17 1

2 1 3
1

2
1 1

P-56451

Remove the housing (Item 1) from the gear assembly


P-56450 (Item 2) [Figure 20-130-19].

Assembly: The position of the small opening (Item 3) on


Remove the four bolts (Item 1) and cover (Item 2) the gear holders will point toward the large port (Item 4)
[Figure 20-130-17]. [Figure 20-130-19] on the housing.

Dealer Copy -- Not for Resale


Figure 20-130-18 Figure 20-130-20

1
1

P-56454 P-56452

Remove the housing / gear assembly (Item 1) Remove both O-rings (Item 1) [Figure 20-130-20] from
[Figure 20-130-18] from the main housing. the housing.

211 of 1040 20-130-7 T35100(S)(L), T35120(S)L Service Manual


GEAR PUMP (CONT'D) Figure 20-130-23

Disassembly And Assembly (Cont'd)

Figure 20-130-21 1 1

1 1

2
P-25304
1

Remove the four bolts (Item 1) and drive shaft (Item 2)


P-56453 [Figure 20-130-23].

Assembly: Tighten the bolts to 33 N•m (25 ft-lb) torque.


Remove the back-up ring (Item 1) and seal ring (Item 2)
[Figure 20-130-21] from the gear holder. Figure 20-130-24

Dealer Copy -- Not for Resale


Assembly: The seal ring (Item 2) [Figure 20-130-21] is
installed onto the gear holder first followed by the back-
up ring.

Figure 20-130-22

P-25305

Turn the housing over and remove the mount plate


[Figure 20-130-24].

P-25322

Remove and discard the O-ring (Item 1) [Figure 20-130-


22] from the flange.

212 of 1040 20-130-8 T35100(S)(L), T35120(S)L Service Manual


GEAR PUMP (CONT'D) Figure 20-130-27

Disassembly And Assembly (Cont'd)


2
Figure 20-130-25
1

1
3

4
P-25310

Remove the O-ring (Item 1) and gear assembly (Item 2)


P-25306 [Figure 20-130-27] from the housing.

Assembly: The position of the V portion (Item 3) on the


Remove the snap ring (Item 1) [Figure 20-130-25]. thrust plate must point toward the larger port (Item 4)
[Figure 20-130-27] on the housing.

Dealer Copy -- Not for Resale


Figure 20-130-26
Figure 20-130-28

1 2 2

3 1 3
1
P-25307

P-25313

Remove the shaft seal (Item 1) [Figure 20-130-26].


Remove the two thrust plates (Item 1), seal ring (Item 2)
and back-up ring (Item 3) [Figure 20-130-28] from the
gears.

Assembly: The seal ring (Item 2) will be installed on the


thrust plate (Item 1) first followed by the back-up ring
(Item 3) [Figure 20-130-28].

213 of 1040 20-130-9 T35100(S)(L), T35120(S)L Service Manual


Dealer Copy -- Not for Resale

214 of 1040 20-130-10 T35100(S)(L), T35120(S)L Service Manual


FAN MOTOR Figure 20-140-2

Removal And Installation 4 4

IMPORTANT 5

When repairing hydrostatic and hydraulic systems, 3


clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
2 1
S6837
Drain the radiator. (See Removing And Replacing The
Coolant on Page 10-70-1.)
Remove the mounting bolt (Item 1) and nut (Item 2).
Figure 20-140-1 Remove the radiator support (Item 3) [Figure 20-140-2].

Loosen the two hose clamps (Item 4) and remove the


1 intercooler hose (Item 5) [Figure 20-140-2].
2

Dealer Copy -- Not for Resale


1 Figure 20-140-3

2
S6834

Loosen the two hose clamps (Item 1) and remove the


radiator hose (Item 2) [Figure 20-140-1].
S6835

Mark the location of the hood latch (Item 1). Remove the
two mounting bolts (Item 2) [Figure 20-140-3]. Remove
the hood latch.

215 of 1040 20-140-1 T35100(S)(L), T35120(S)L Service Manual


FAN MOTOR (CONT’D) Figure 20-140-6

Removal And Installation (Cont’d)

Figure 20-140-4 2
1

P-53264

Loosen the screw (Item 1) and disconnect the connector


S6836 (Item 2) [Figure 20-140-6].

Figure 20-140-7
Remove the top hose (Item 1) [Figure 20-140-4] from the
fan motor. 1

Dealer Copy -- Not for Resale


Figure 20-140-5

1 S6845

Remove the two bolts (Item 1) [Figure 20-140-7] (both


S6848 sides) from the fan guard.

Tilt the cooler forward and carefully remove the fan


Remove the three hoses (Item 1) [Figure 20-140-5] from assembly.
the bottom of the fan motor.

216 of 1040 20-140-2 T35100(S)(L), T35120(S)L Service Manual


FAN MOTOR (CONT’D) Figure 20-140-10

Removal And Installation (Cont’d)

Figure 20-140-8 2

1 2

1
1

1
1 P-53270

Remove the four fan guard mount bolts (Item 1) and


P-53269 remove the fan guard (Item 2) [Figure 20-140-10].

Figure 20-140-11
Remove the four bolts (Item 1) and remove the blade
assembly (Item 2) [Figure 20-140-8] from the fan motor.

Dealer Copy -- Not for Resale


NOTE: Mark the direction of the fan for correct
assembly.
1
Figure 20-140-9

1 P-53272

Remove the nut and lock washer (Item 1) [Figure 20-


140-11].

P-53271

Mark the location of the fan motor to the fan guard for
correct assembly (Item 1) [Figure 20-140-9].

217 of 1040 20-140-3 T35100(S)(L), T35120(S)L Service Manual


FAN MOTOR (CONT’D)

Removal And Installation (Cont’d)

Figure 20-140-12

P-53273

Remove the fan blade mounting flange (Item 1) [Figure


20-140-12] from the fan motor.

Dealer Copy -- Not for Resale

218 of 1040 20-140-4 T35100(S)(L), T35120(S)L Service Manual


FAN MOTOR (CONT’D)

Parts Identification

Dealer Copy -- Not for Resale


3

1. Seal

2. Check valve

3. Housing

4. Gear assembly

S2754

219 of 1040 20-140-5 T35100(S)(L), T35120(S)L Service Manual


FAN MOTOR (CONT’D) Figure 20-140-15

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, 4
3
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. 2
I-2003-0888
1
P-53276
Figure 20-140-13

Remove the plug (Item 1), spring (Item 2) and check


2 1 valve (Item 3) from the housing (Item 4) [Figure 20-140-
15].

Figure 20-140-16

Dealer Copy -- Not for Resale


P-53274

1
Remove the nut (Item 1) and solenoid (Item 2) [Figure
20-140-13].

Mark the housing for correct assembly. P-53277

Figure 20-140-14
Remove the O-ring (Item 1) [Figure 20-140-16] from the
plug. Replace as needed.

2
1

P-53275

Remove the solenoid stem (Item 1) and three fittings


(Item 2) [Figure 20-140-14].

220 of 1040 20-140-6 T35100(S)(L), T35120(S)L Service Manual


FAN MOTOR (CONT’D) Figure 20-140-19

Disassembly And Assembly (Cont’d)

Figure 20-140-17

1
1

1 1 P-53281

Remove the quad ring (Item 1) [Figure 20-140-19] from


P-53278 the housing.

Figure 20-140-20
Remove the four bolts (Item 1) [Figure 20-140-17] from
the end. 2

Dealer Copy -- Not for Resale


Assembly: Tighten bolts to 43 - 47 N•m (32 - 35 ft-lb) 1
torque.

Figure 20-140-18

P-53282

Remove the gear assembly (Item 1) from the housing


(Item 2) [Figure 20-140-20].

P-53279

Remove the end cover (Item 1) from the main housing


(Item 2) [Figure 20-140-18].

221 of 1040 20-140-7 T35100(S)(L), T35120(S)L Service Manual


FAN MOTOR (CONT’D) Figure 20-140-23

Disassembly And Assembly (Cont’d)

Figure 20-140-21

P-53285

1
Inspect the gears (Item 1) [Figure 20-140-23] for
P-53283 damage or wear.

Remove the back-up ring / seal (Item 1) [Figure 20-140-


21] from the gear holder.

Dealer Copy -- Not for Resale


Figure 20-140-22

P-53256

Remove the snap ring (Item 1) and remove the seal (Item
2) [Figure 20-140-22].

Assembly: The open part of the seal goes into the


housing first.

222 of 1040 20-140-8 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC FLUID RESERVOIR Figure 20-150-3

Removal And Installation 2

Remove the engine / hydrostat assembly. (See Removal


And Installation on Page 70-90-1.)

Figure 20-150-1

1 S6856

Remove the hose (Item 1) [Figure 20-150-3] from the


tubeline.

Remove the mounting bolt (Item 2) [Figure 20-150-3].


P-56462
Figure 20-150-4

Dealer Copy -- Not for Resale


Remove the two bolts (Item 1) [Figure 20-150-1]. 1

Figure 20-150-2

1
2

S6857

Loosen the nut (Item 1) [Figure 20-150-4] on the


S6855 tubeline.

Remove the tubeline.


Remove the bolt (Item 1) and shield (Item 2) [Figure 20-
150-2]. Remove the two hoses (Item 2) [Figure 20-150-4] from
the filter.

223 of 1040 20-150-1 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC FLUID RESERVOIR (CONT’D) Figure 20-150-6

Removal And Installation (Cont’d)

Figure 20-150-5

P-55220

Figure 20-150-7
P-55217

Remove the hose (Item 1) [Figure 20-150-5] from the


tank.

Dealer Copy -- Not for Resale


1
S6858

Remove the two tank mounting bolts (Item 1) [Figure 20-


150-6] and [Figure 20-150-7].

Remove the hydraulic reservoir.

224 of 1040 20-150-2 T35100(S)(L), T35120(S)L Service Manual


STEERING VALVE

Removal And Installation Figure 20-160-2

S/N A8HD12999 & Below, S/N A8GW12999 & Below,


S/N A8GT12999 & BELOW, S/N A8GV12999 & Below, 1
S/N A8GJ12999 & Below: 1
Remove the dash cover / column cover. (See Removal
And Installation on Page 50-140-1.)

S/N A8HD13000 & Above, S/N A8GW13000 & Above,


S/N A8GT13000 & Above, S/N A8GV13000 & Above, 1
S/N A8GJ13000 & Above:
1
Remove the dash cover / column cover. (See Removal
And Installation on Page 50-141-1.)
P-27156

Figure 20-160-1
Remove the four bolts (Item 1) [Figure 20-160-2] and
remove the steering valve.
1

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1

P-42863

Remove the five hoses (Item 1) [Figure 20-160-1] from


the steering valve.

NOTE: Mark hoses for correct 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

225 of 1040 20-160-1 T35100(S)(L), T35120(S)L Service Manual


STEERING VALVE (CONT'D)

Parts Identification

1. Bolt 13. Drive Pin


2. End Cap 14. Pin
3. Spacer 15. Check Ball (.250”)
4. O-ring 16. Spring
5. Wear Ring 17. Pin
6. Gerotor assembly 18. Check Ball (.187”)
7. Drive Shaft 19. O-ring
8. O-ring 20. Housing
1
2 9. Spacer Plate 21. Thrust Washer
10. Spool 22. Thrust Bearing
3 11. Sleeve 23. Seal
12. Springs 24. Gland Bushing
4 25. Seal
5

7
8

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13
14
15
10

19
11 20

21
22
21
23
24
25
26
16 27
17 12

18

S4721

226 of 1040 20-160-2 T35100(S)(L), T35120(S)L Service Manual


STEERING VALVE (CONT'D) Figure 20-160-5

Disassembly

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
S0200

Remove the hydraulic fittings from the steering valve.


Remove the gerotor assembly (Item 1) [Figure 20-160-5]
Figure 20-160-3
and the O-ring beneath.

Figure 20-160-6

Dealer Copy -- Not for Resale


1

S4962

Remove the seven end cap bolts [Figure 20-160-3]. S0202

Figure 20-160-4
Remove the spacer plate (Item 1) [Figure 20-160-6].

1 2

S0198

Remove the O-ring (Item 1), spacer (Item 2) and wear


ring (Item 3) [Figure 20-160-4].

227 of 1040 20-160-3 T35100(S)(L), T35120(S)L Service Manual


STEERING VALVE (CONT'D) Figure 20-160-9

Disassembly (Cont'd)
1
Figure 20-160-7

1 2

S4728

Tip the housing onto the port face and remove the spool
S0203
and sleeve assembly (Item 1) [Figure 20-160-9].

NOTE: Do not bind spool and sleeve in housing.


Remove the O-ring (Item 1) [Figure 20-160-7]. Rotate spool and sleeve assembly slowly
when removing it from housing.
Remove the drive shaft (Item 2) [Figure 20-160-7], while

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holding the steering valve upright. Figure 20-160-10

Figure 20-160-8

4
3
1

4
2

1 2
S4726

S4722
Remove the two bearing washers (Item 1) and thrust
bearing (Item 2) [Figure 20-160-10].
Carefully remove the two springs (Item 1), two pins (Item
2), pin (Item 3) and balls (Item 4) [Figure 20-160-8] from
each port.

228 of 1040 20-160-4 T35100(S)(L), T35120(S)L Service Manual


STEERING VALVE (CONT'D) Figure 20-160-13

Disassembly (Cont'd)

Figure 20-160-11 1

2 1

S4731

1
The housing valves (Item 1) [Figure 20-160-13] are
factory adjusted and are not to be changed. The housing
S5361
with specified valve pressure settings, the mating spool
and sleeve are not practical replacement parts.
Remove the pin (Item 1), then remove the six springs
(Item 2) by partially sliding out the spool. [Figure 20-160- Figure 20-160-14
11].

Dealer Copy -- Not for Resale


Figure 20-160-12

S4731

2
Remove the seals (Items 1 and 2) [Figure 20-160-14]
S5360
from the gland bushing.

Remove the control spool (Item 1) from the sleeve NOTE: Gland bushing removal requires a special 4-
(Item 2) [Figure 20-160-12]. pin tool. Do not attempt to remove without
this tool as damage to the bushing could
occur.
It is not required to remove the bushing for
seal replacement.

229 of 1040 20-160-5 T35100(S)(L), T35120(S)L Service Manual


STEERING VALVE (CONT'D) Assembly

Inspection Figure 20-160-17

Figure 20-160-15

2
S4738
2
S4738
Assemble the spool (Item 1) and sleeve (Item 2)
[Figure 20-160-17] carefully so that spring slots line up
Inspect the spool (Item 1) and sleeve (Item 2) [Figure 20- at the same end. Rotate the spool while sliding parts
160-15] for any damage or wear. Replace as needed. together.

Dealer Copy -- Not for Resale


Figure 20-160-16 NOTE: Test for free rotation. The spool should rotate
smoothly in the sleeve with fingertip force
applied at splined end.

Figure 20-160-18

S4737
1

Inspect the drive shaft (Item 1) [Figure 20-160-16] for


any damage or wear. Replace as needed.
S5360

Install the six springs (Item 1) [Figure 20-160-18] onto


the spool and sleeve.
Center spring set in spring slots. Seat springs down
evenly and flush with upper surface of spool and sleeve.

NOTE: There are six springs and should be


positioned three per side and back to back.

230 of 1040 20-160-6 T35100(S)(L), T35120(S)L Service Manual


STEERING VALVE (CONT'D) Figure 20-160-21

Assembly (Cont’d)

Figure 20-160-19

S4731

1 Install the seal (Item 1) [Figure 20-160-21] in the gland


bushing, with smooth side of the seal facing toward
S5361
bushing.

Insert pin (Item 1) [Figure 20-160-19] through the spool Figure 20-160-22
and sleeve assembly until the pin is flush at both sides of
the sleeve.

Dealer Copy -- Not for Resale


Figure 20-160-20

1
3

S4731

Install the seal (Item 1) [Figure 20-160-22] in the gland


2 bushing.
S4726

Install the big diameter bearing washer (Item 1)


[Figure 20-160-20] with the chamfered side toward the
sleeve.

Install the thrust bearing (Item 2) [Figure 20-160-20].

Install the small diameter bearing washer (Item 3)


[Figure 20-160-20] with the chamfered side facing the
outside of the bearing assembly.

231 of 1040 20-160-7 T35100(S)(L), T35120(S)L Service Manual


STEERING VALVE (CONT'D) Assembly (Cont’d)

Assembly (Cont’d) Figure 20-160-25

Figure 20-160-23
5

4 6

1
3

S4728

Insert the spool and sleeve assembly (Item 1)


[Figure 20-160-23] so that the splined end of the spool
enters the 14 hole end of the housing first. Mind the

Dealer Copy -- Not for Resale


correct position of the bearing and washers inside the S4732
housing.

NOTE: To prevent the cross pin from dropping into Install the two 4,74 mm (0.187 in) balls (Item 1), 6,35 mm
the discharge groove of the housing, do not (0.250) ball (Item 2), pin (Item 3), two pins (Item 4) and
pull the spool assembly beyond this point. springs (Item 5) [Figure 20-160-25] in the holes as
With the spool assembly in this flush position, shown.
check for free rotation within housing by
turning assembly with fingertip force at the Install the spacer plate (Item 6) [Figure 20-160-25]. Align
splined end. the bolt holes in the spacer plate with tapped holes in the
housing.
Figure 20-160-24
Figure 20-160-26

2
1

S4742
S4733

Install the O-ring (Item 1) [Figure 20-160-24] into the


Rotate the spool and sleeve assembly until the pin (Item
housing.
1) is parallel with the port face (Item 2) [Figure 20-160-
26].
Install the drive (Item 3) [Figure 20-160-26] making sure
the drive is engaged with the pin.
Mark the drive according to the parallel line.

232 of 1040 20-160-8 T35100(S)(L), T35120(S)L Service Manual


STEERING VALVE (CONT'D) Figure 20-160-29

Assembly (Cont’d)

Figure 20-160-27 1
2 3

1 S0198

Install the O-ring (Item 1), spacer (Item 2) and wear ring
S4734 (Item 3) [Figure 20-160-29].

Figure 20-160-30
Install the O-ring (Item 1) [Figure 20-160-27] in the
gerotor (on the spacer plate side).

Dealer Copy -- Not for Resale


Figure 20-160-28

S4962

2 Install the seven end cap bolts [Figure 20-160-30].

Pretighten to 17 N•m (12.5 ft-lb), then tighten screws to


26 - 30 N•m (19.2 - 22.1 ft-lb) torque.

S4735

Align the star valleys (Items 1) (Reference A) to the


marked drive (Item 2) (Reference B) [Figure 20-160-28].
This way the valleys are aligned with the pin.

NOTE: Keep in mind the parallel relationship of


reference lines A, B, C, and D in [Figure 20-
160-28].

233 of 1040 20-160-9 T35100(S)(L), T35120(S)L Service Manual


Dealer Copy -- Not for Resale

234 of 1040 20-160-10 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE

Troubleshooting Chart (Controllers)

The following troubleshooting chart is provided for


WARNING
assistance in locating and correcting problems which are
Check for correct function after adjustments, repairs
most common. Many of the recommended procedures
or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel
adjustments can cause injury or death.
W-2004-1285

PROBLEM CAUSE CORRECTION


None of the controllers work Insufficient power supply Check battery voltage
Insufficient pilot pressure Check pilot pressure
Plugged controller filter Clean filter
Only one controller works No actuation signal Check signal voltage
Unsuitable actuation signal Check signal voltage
Insufficient actuation power supply Check signal voltage
All controllers not working or jerky Plugged controller filter Clean filter
One controller not working or jerky Faulty actuation signal Check signal
Friction or jamming of the plunger Replace controller
One controller not working or jerky Contamination of the proportional Replace controller

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in one direction valve in the controller
Controller creeps Neutral position incorrect Adjust neutral adjustment
Oil leakage between control valve Faulty seals Replace seal
and controller
Oil leakage between controllers Faulty controller couplers Replace controller couplers

235 of 1040 20-170-1 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-2
S/N A8HD13000 & ABOVE
Telescoping Valve Section Troubleshooting
S/N A8GW13000 & ABOVE
S/N A8GT13000 & ABOVE
Record the serial number of the machine, control valve S/N A8GV13000 & ABOVE
and control module. S/N A8GJ13000 & ABOVE

The following procedure must be done with the control


valve in the machine. The control valve is removed for
photo clarity. 1

With the engine OFF, the key switch in the run position,
move the joystick handle to relieve any hydraulic
pressure.

Remove the rear cover from machine. P-97008

Figure 20-170-1
The hydraulic control function switch (Item 1) [Figure 20-
170-1] and [Figure 20-170-2] must be ON (light is on) for
all testing procedures.

1 Figure 20-170-3

Dealer Copy -- Not for Resale


1

P-50943

1. Locate the telescoping valve section (Item 1)


[Figure 20-170-3] on the control valve.
S/N A8HD12999 & BELOW
S/N A8GW12999 & BELOW
S/N A8GT12999 & BELOW
S/N A8GV12999 & BELOW
S/N A8GJ12999 & BELOW P-50797

236 of 1040 20-170-2 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) (Item 1) [Figure 20-170-4] (pin 3, brown wire) is 0.9
volt. If the voltage drops below 0.9 volt the controller
Telescoping Valve Section Troubleshooting (Cont’d) will interpret this as a failure.

Figure 20-170-4 5. With the telescopic function switch (Item 1)


[Figure 20-170-5] in the neutral (middle) position
1 check that the voltage on the controller connector
(Item 1) [Figure 20-170-4] (pin 3, brown wire) is 2.5
volt.

6. With the telescopic function switch (Item 1)


[Figure 20-170-5] in the maximum (forward) position
check that the voltage on the controller connector
(Item 1) [Figure 20-170-4] (pin 3, brown wire) is 4.1
volt.

If one of the three voltage readings in Steps 4, 5 and 6 is


not correct, replace the joystick handle. (See Removal
And Installation on Page 20-200-1.)
P-47793
If all voltage readings in Steps 4, 5 and 6 are correct go
to step 7.
2. With the engine OFF, the key in the run position,
check that the battery voltage on the controller

Dealer Copy -- Not for Resale


connector (Item 1) [Figure 20-170-4] (pin 1, blue
wire) is at least 12 volt or higher.

3. With the engine OFF, the key in the run position,


check the regulated voltage on the controller
connector (Item 1) [Figure 20-170-4] (pin 4, black
wire) is 5 volt. If 5 volt is not seen, replace the
controller.

Figure 20-170-5

m
Maximu
l
Neutra
1
m
Minimu

S7486

4. With the telescopic function switch (Item 1)


[Figure 20-170-5] in the minimum (back) position
check that the voltage on the controller connector

237 of 1040 20-170-3 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Checking Drain Pressure

Telescoping Valve Section Troubleshooting (Cont’d) Figure 20-170-8

Checking Pilot Pressure

Raise the boom and install the boom stop. (See Installing
The Approved Boom Stop on Page 10-150-1.)

Figure 20-170-6

1
1

P-42977

11. Remove the hose (Item 1) [Figure 20-170-8] from the


control valve, and install a tee fitting.

Figure 20-170-9

Dealer Copy -- Not for Resale


P-44343

7. Locate the test fitting (Item 1) [Figure 20-170-6] and


remove the cap.

Figure 20-170-7

P-52913

12. Install a 3,5 MPa (35 bar) (508 psi) gauge on the tee
fitting [Figure 20-170-9].

13. Start the engine, lower the restraint bar (if equipped)
P-44342 and run the engine at 2200 RPM. Record the
pressure. The pressure at the gauge should be 150
kPa (1,5 bar) (22 psi) maximum.
8. Install a 7 MPa (70 bar) (1000 psi) gauge on the test
fitting [Figure 20-170-7]. 14. Remove the gauge.

9. Start the engine, lower the restraint bar (if equipped)


and run the engine at 2200 RPM. Record the
pressure. The pressure at the gauge should be 3,5
MPa (35 bar) (508 psi) maximum.

10. Remove the gauge.

238 of 1040 20-170-4 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-12

Telescoping Valve Section Troubleshooting (Cont’d)

Figure 20-170-10

1 2
P-52901

17. If the telescopic function does not work, remove the


P-52155 two screws (Item 1) and remove the cover (Item 2)
[Figure 20-170-12].

15. With adequate room in front of the machine, start the 18. Start the engine, lower the restraint bar (if equipped)
engine, lower the restraint bar (if equipped) and run and run the engine at 2200 RPM.

Dealer Copy -- Not for Resale


the engine at 2200 RPM. Move the telescopic control
switch (Item 1) [Figure 20-170-10] forward and back Figure 20-170-13
to see if this function works. Stop the engine.

Figure 20-170-11

P-61126

P-47793 19. Manually push and pull the spool (Item 1) [Figure 20-
170-13] to test the movement of the telescopic
function in both directions.
16. If the telescopic function does not work, with the
engine running disconnect the controller connector NOTE: If by manually operating the spool, and the
(Item 1) [Figure 20-170-11] and reconnect it back in. telescopic function is working the controller
must be replaced.

239 of 1040 20-170-5 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-15
S/N A8HD13000 & ABOVE
Auxiliary Valve Section Troubleshooting S/N A8GW13000 & ABOVE
S/N A8GT13000 & ABOVE
Record the serial number of the machine, control valve S/N A8GV13000 & ABOVE
and control module. S/N A8GJ13000 & ABOVE

The following procedure must be done with the control


valve in the machine. The control valve is removed for
photo clarity. 1

With the engine OFF, the key switch in the run position,
move the joystick handle to relieve any hydraulic
pressure. 2

Figure 20-170-14 P-97008

S/N A8HD12999 & BELOW


S/N A8GW12999 & BELOW
S/N A8GT12999 & BELOW
The hydraulic control function switch (Item 1) must be ON
S/N A8GV12999 & BELOW (light is on) and the front auxiliary hydraulics ON/OFF
S/N A8GJ12999 & BELOW 1 switch (Item 2) [Figure 20-170-14] and [Figure 20-170-
15] must be ON (top position).

Figure 20-170-16

Dealer Copy -- Not for Resale


1

P-50943

1. Locate the auxiliary valve section (Item 1) [Figure 20-


170-16] on the control valve.
P-50797

240 of 1040 20-170-6 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-18

Auxiliary Valve Section Troubleshooting (Cont’d)

Figure 20-170-17
m
Maximu
1
l
Neutra
m
Minimu
1

P-47793
P-52155

2. With the engine OFF, the key in the run position,


check that the battery voltage on the controller 4. With the auxiliary function switch (Item 1) [Figure 20-

Dealer Copy -- Not for Resale


connector (Item 1) [Figure 20-170-17] (pin 1, blue 170-18] in the minimum (back) position check that the
wire) is at least 12 volt or higher. voltage on the controller connector (Item 1)
[Figure 20-170-17] (pin 3, brown wire) is 0.9 volt. If
3. With the engine OFF, they key switch in the run the voltage drops below 0.9 volt the controller will
position, check the regulated voltage on the controller interpret this as a failure.
connector (Item 1) [Figure 20-170-17] (pin 4, black
wire) is 5 volt. If 5 volt is not seen, replace the 5. With the auxiliary function switch (Item 1) [Figure 20-
controller. 170-18] in the neutral (middle) position check that the
voltage on the controller connector (Item 1)
[Figure 20-170-17] (pin 3, brown wire) is 2.5 volt.

6. With the auxiliary function switch (Item 1) [Figure 20-


170-18] in the maximum (forward) position check that
the voltage on the controller connector (Item 1)
[Figure 20-170-17] (pin 3, brown wire) is 4.1 volt.

If one of the three voltage readings in Steps 4, 5 and 6 is


not correct, replace the joystick handle. (See Removal
And Installation on Page 20-200-1.)

If all voltage readings in Steps 4, 5 and 6 are correct go


to step 7.

241 of 1040 20-170-7 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Checking Drain Pressure

Auxiliary Valve Section Troubleshooting (Cont’d) Figure 20-170-21

Checking Pilot Pressure

Raise the boom and install the boom stop. (See Installing
The Approved Boom Stop on Page 10-150-1.)

Figure 20-170-19

1
1

P-42977

11. Remove the hose (Item 1) [Figure 20-170-21] from


the control valve, and install a tee fitting.

Figure 20-170-22

Dealer Copy -- Not for Resale


P-44343

7. Locate the test fitting (Item 1) [Figure 20-170-19] and


remove the cap.

Figure 20-170-20

P-52913

12. Install a 3,5 MPa (35 bar) (500 psi) gauge on the tee
fitting [Figure 20-170-22].

13. Start the engine, lower the restraint bar (if equipped)
P-44342 and run the engine at 2200 RPM. Record the
pressure. The pressure at the gauge should be 150
kPa (1,5 bar) (22 psi) maximum.
8. Install a 7 MPa (70 bar) (1000 psi) gauge on the test
fitting [Figure 20-170-20]. 14. Remove the gauge.

9. Start the engine, lower the restraint bar (if equipped)


and run the engine at 2200 RPM. Record the
pressure. The pressure at the gauge should be 3,5
MPa (35 bar) (500 psi) maximum.

10. Remove the gauge.

242 of 1040 20-170-8 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-25

Auxiliary Valve Section Troubleshooting (Cont’d)

Figure 20-170-23

1 2

P-52901

17. If the auxiliary function does not work, remove the two
P-52155 screws (Item 1) and remove the cover (Item 2)
[Figure 20-170-25].

15. With adequate room in front of the machine, start the 18. Start the engine, lower the restraint bar (if equipped)
engine, lower the restraint bar (if equipped) and run and run the engine at 2200 RPM.

Dealer Copy -- Not for Resale


the engine at 2200 RPM. Move the auxiliary control
switch (Item 1) [Figure 20-170-23] forward and back Figure 20-170-26
to see if this function works. Stop the engine.

Figure 20-170-24

P-61228

P-47793 19. Manually push and pull the spool (Item 1) [Figure 20-
170-26] to test the movement of the auxiliary function
in both directions.
16. If the auxiliary function does not work, with the engine
running disconnect the controller connector (Item 1) NOTE: If by manually operating the spool, and the
[Figure 20-170-24] and reconnect it back in. auxiliary function is working the controller
must be replaced.

243 of 1040 20-170-9 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D)

Troubleshooting Chart (Control Valve)


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

PROBLEM CAUSE CORRECTION


Lack of strength at all actuators Load sense relief cartridge defective Replace relief cartridge
Load sense relief cartridge out of Make necessary adjustments
adjustment
Lack of force on one actuator only Secondary relief valve out of adjust- Reset to original pressure
ment
Secondary relief valve blocked open Replace relief valve
Lack of load hold Load check valve failure Replace load check valve
Excessive clearance between housing Replace housing and spool
and spool
Simultaneous movement of con- Blockage of individual compensator Remove and clean orifice
trols orifice

Dealer Copy -- Not for Resale


Individual pressure compensator Replace housing and compensator
blocked
Load sense line leakage Replace load sense regulator
Engine remains under load after Flow regulator blocked Replace flow regulator
spools are returned to neutral Flow regulator filter clogged Replace filter
Detent malfunction Controller defective Replace controller
Spool return difficult Tie rod bolts too tight Re-torque tie rod bolts
Spool leaking oil Defective spool seal Replace spool seal
Oil leakage between valve section Defective seals Replace seals

244 of 1040 20-170-10 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-28

Removal And Installation

Relieve hydraulic pressure. Drain the hydraulic reservoir.


(See Removing And Replacing Hydraulic Fluid on Page
10-100-2.)

WARNING 1
Hydraulic fluid escaping under pressure can have 1
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
P-50942
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately. Remove the two tie-straps (Item 1) [Figure 20-170-28]
W-2145-0290
and reposition the harness.

Figure 20-170-29

IMPORTANT

Dealer Copy -- Not for Resale


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

1
Figure 20-170-27

P-50943
1

Remove the two hoses (Item 1) [Figure 20-170-29].

NOTE: Mark all hoses and tubelines for correct


installation.

S7421

Remove the rear cover (Item 1) [Figure 20-170-27].

245 of 1040 20-170-11 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-32

Removal And Installation (Cont’d)


1
1
Figure 20-170-30

P-50946

1 Remove the six hoses (Item 1) [Figure 20-170-32] from


P-50944 the control valve.

Figure 20-170-33
Remove the two hoses (Item 1) [Figure 20-170-30].

Dealer Copy -- Not for Resale


Figure 20-170-31

1
1 P-50947

P-50945 Remove the two hoses (Item 1) [Figure 20-170-33] from


the control valve.

Remove the five hoses (Item 1) [Figure 20-170-31] from


the control valve.

246 of 1040 20-170-12 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-36

Removal And Installation (Cont’d)

Figure 20-170-34

P-50950

Remove the mounting bolt (Item 1) [Figure 20-170-36]


P-50948 from the front of the control valve.

Figure 20-170-37
Disconnect the two wire connectors (Item 1) [Figure 20-
170-34] from the main wire harness.

Dealer Copy -- Not for Resale


NOTE: Mark the location of the connectors for
correct installation.

Figure 20-170-35

1 1
1
1 P-50951

Remove the two mounting bolts (Item 1) [Figure 20-170-


37] from the control valve.

Installation: Tighten the mounting bolts to 24 - 26 N•m


P-50949 (18 - 19 ft-lb) torque.

Remove the two hoses (Item 1) [Figure 20-170-35].

247 of 1040 20-170-13 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D)

Removal And Installation (Cont’d)

Figure 20-170-38

P-50952

Install a hoist and lifting strap (Item 1) [Figure 20-170-


38] on the control valve.

Dealer Copy -- Not for Resale


Remove the hydraulic control valve.

Use care not to damage the tubelines or fittings.

248 of 1040 20-170-14 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D)

Parts Identification

1. End Housing
2. Lifting Valve Section
3. Tilting Valve Section
4. Telescoping Valve Section
5. Auxiliary Valve Section
6. Inlet-Outlet Valve Section

Dealer Copy -- Not for Resale


1

4 5
2 3 6

P-47794

249 of 1040 20-170-15 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-40

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

P-47794
Figure 20-170-39

Remove all hydraulic fittings. Mark the valve sections for


proper assembly [Figure 20-170-40].

Figure 20-170-41

Dealer Copy -- Not for Resale


6 1
5 4 3 2
P-50956

Mark the valve sections for ease of assembly Inlet-Outlet


Valve Section (Item 1), Auxiliary / Frame Leveling Valve 1
Section (Item 2), Telescoping Valve Section (Item 3), P-47795
Tilting Valve Section (Item 4), Lifting Valve Section (Item
5) and End Housing Valve Section (Item 6) [Figure 20-
170-39]. Remove the three nuts (Item 1) [Figure 20-170-41] from
the tie rod bolts.

Assembly: Tighten the nuts to 35 N•m (26 ft-lb) torque.

250 of 1040 20-170-16 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-44

End Housing Disassembly And Assembly

Figure 20-170-42

P-42985

1 Remove the O-ring (Item 1) [Figure 20-170-44] from the


P-47796 plug.

Remove the end housing (Item 1) [Figure 20-170-42].

Dealer Copy -- Not for Resale


Figure 20-170-43

1
2

P-42984

Remove the dust cap (Item 1) and plug (Item 2)


[Figure 20-170-43] from the end housing.

251 of 1040 20-170-17 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-47

Lifting Valve Section Disassembly And Assembly

Figure 20-170-45

1
1

P-42989

Remove the plug (Item 1) [Figure 20-170-47] from the


P-47797 valve section.

Figure 20-170-48
Remove the lifting valve section (Item 1) [Figure 20-170-
45].

Dealer Copy -- Not for Resale


Figure 20-170-46
1
2
1

P-42990

1 Remove the two O-rings (Item 1) and back-up ring (Item


P-42987 2) [Figure 20-170-48] from the plug.

Remove the four O-rings (Item 1) [Figure 20-170-46]


from the valve section.

252 of 1040 20-170-18 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-51

Lifting Valve Section Disassembly And Assembly


(Cont’d)

Figure 20-170-49

P-42993

Remove the O-ring (Item 1) [Figure 20-170-51] from the


1 cover.
P-42991
Figure 20-170-52

Loosen the four screws (Item 1) [Figure 20-170-49].

Dealer Copy -- Not for Resale


Assembly: Tighten the screws to 10 N•m (88.5 in-lb)
torque.

Figure 20-170-50

2 2

1 1
P-42995

Remove the spring (Item 1) and spring retainer (Item 2)


[Figure 20-170-52] from the spool.

P-42992

Remove the four screws (Item 1) and cover (Item 2)


[Figure 20-170-50].

253 of 1040 20-170-19 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-55

Lifting Valve Section Disassembly And Assembly


(Cont’d)

Figure 20-170-53

1
1

P-42997

Loosen the four screws (Item 1) [Figure 20-170-55].

P-42996 Assembly: Tighten the screws to 10 N•m (88.5 in-lb)


torque.

Remove the relief valve (Item 1) [Figure 20-170-53] from Figure 20-170-56

Dealer Copy -- Not for Resale


the valve section.

Assembly: Tighten the relief valve to 45 N•m (33 ft-lb)


torque.

Figure 20-170-54 2

1
2

1
P-42998

Remove the four screws (Item 1) and cover (Item 2)


[Figure 20-170-56] from the valve section.

P-42988

Remove the two O-rings (Item 1) and back-up ring (Item


2) [Figure 20-170-54] from the relief valve.

254 of 1040 20-170-20 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-59

Lifting Valve Section Disassembly And Assembly


(Cont’d)

Figure 20-170-57

P-44000

Remove the spool (Item 1) [Figure 20-170-59] from the


valve section.
P-42993
Figure 20-170-60

Remove the O-ring (Item 1) [Figure 20-170-57] from the

Dealer Copy -- Not for Resale


cover.

Figure 20-170-58

1
2
1

P-44275

Remove the two plugs (Item 1) [Figure 20-170-60] from


the valve section.
P-42999
Assembly: Tighten the plugs to 27 - 33 N•m (20 - 24 ft-
lb) torque.
Remove the spring (Item 1) and spring retainer (Item 2)
[Figure 20-170-58] from the spool.

255 of 1040 20-170-21 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-63

Lifting Valve Section Disassembly And Assembly


(Cont’d)

Figure 20-170-61
1

2
1

P-44278

Loosen the plug (Item 1) [Figure 20-170-63].

P-44276 Assembly: Tighten the plug to 54 - 66 N•m (40 - 49 ft-lb)


torque.

Remove the spring (Item 1) and poppet (Item 2) Figure 20-170-64

Dealer Copy -- Not for Resale


[Figure 20-170-61] from the plugs.

Figure 20-170-62

1
3

P-44279

P-44277 Remove the individual pressure compensator plug (Item


1), poppet (Item 2) and guide (Item 3) [Figure 20-170-
64] from the valve section.
Remove the O-ring (Item 1) [Figure 20-170-62] from the
plugs.

256 of 1040 20-170-22 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Tilting Valve Section Disassembly And Assembly

Lifting Valve Section Disassembly And Assembly Figure 20-170-66


(Cont’d)

Figure 20-170-65 1

P-44001

P-44280 Remove the tilting valve section (Item 1) [Figure 20-170-


66]

Remove the O-ring (Item 1) [Figure 20-170-65] from the Figure 20-170-67

Dealer Copy -- Not for Resale


plug.

P-44002

Remove the four O-rings (Item 1) [Figure 20-170-67]


from the valve section.

257 of 1040 20-170-23 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-70

Tilting Valve Section Disassembly And Assembly


(Cont’d)

Figure 20-170-68

1 1

P-44004

Loosen the four screws (Item 1) [Figure 20-170-70] on


the cover.
P-44003
Assembly: Tighten the screws to 10 N•m (88.5 in-lb)
torque.
Remove the relief valve (Item 1) [Figure 20-170-68] from

Dealer Copy -- Not for Resale


the valve section. Figure 20-170-71

Assembly: Tighten the relief valve to 45 N•m (33 ft-lb)


torque.

Figure 20-170-69

1
1

P-44005

Remove the four screws (Item 1) and cover (Item 2)


[Figure 20-170-71] from the valve section.
P-42988

Remove the two O-rings (Item 1) and back-up ring (Item


2) [Figure 20-170-69] from the relief valve.

258 of 1040 20-170-24 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-74

Tilting Valve Section Disassembly And Assembly


(Cont’d)

Figure 20-170-72
1

P-44007

Remove the relief valve (Item 1) [Figure 20-170-74] from


the valve section.
P-42993
Assembly: Tighten the relief valve to 45 N•m (33 ft-lb)
torque.
Remove the O-ring (Item 1) [Figure 20-170-72] from the

Dealer Copy -- Not for Resale


cover. Figure 20-170-75

Figure 20-170-73

1
2

1
2
1

P-42988

P-44006
Remove the two O-rings (Item 1) and back-up ring (Item
2) [Figure 20-170-75] from the relief valve.
Remove the spring (Item 1) and spring retainer (Item 2)
[Figure 20-170-73] from the spool.

259 of 1040 20-170-25 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-78

Tilting Valve Section Disassembly And Assembly


(Cont’d)

Figure 20-170-76

2
1

P-44010
1

Remove the spring (Item 1) and spring retainer (Item 2)


[Figure 20-170-78] from the spool.
P-44008
Figure 20-170-79

Loosen the four screws (Item 1) [Figure 20-170-76] on

Dealer Copy -- Not for Resale


the cover.

Assembly: Tighten the screws to 10 N•m (88.5 in-lb)


torque.
1
Figure 20-170-77

2
P-44011
1

Remove the spool (Item 1) [Figure 20-170-79] from the


valve section.

P-44009

Remove the four screws (Item 1) and cover (Item 2)


[Figure 20-170-77] from the valve section.

260 of 1040 20-170-26 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-82

Tilting Valve Section Disassembly And Assembly


(Cont’d)

Figure 20-170-80 1

P-44277
1

Remove the O-ring (Item 1) [Figure 20-170-82] from the


plugs.
P-44275
Figure 20-170-83

Remove the two plugs (Item 1) [Figure 20-170-80] from

Dealer Copy -- Not for Resale


the valve section.

Assembly: Tighten the plugs to 27 - 33 N•m (20 - 24 ft-


lb) torque. 1

Figure 20-170-81

2
1

P-44278

Loosen the plug (Item 1) [Figure 20-170-83].

Assembly: Tighten the plug to 54 - 66 N•m (40 - 49 ft-lb)


torque.

P-44276

Remove the spring (Item 1) and poppet (Item 2)


[Figure 20-170-81] from the plugs.

261 of 1040 20-170-27 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Telescoping Valve Section Disassembly And
Assembly
Tilting Valve Section Disassembly And Assembly
(Cont’d) Figure 20-170-86

Figure 20-170-84
1

1 P-47799

P-44279
Remove the telescoping valve section (Item 1)
[Figure 20-170-86].
Remove the individual pressure compensator plug (Item

Dealer Copy -- Not for Resale


1), poppet (Item 2) and guide (Item 3) [Figure 20-170- Figure 20-170-87
84] from the valve section.

Figure 20-170-85

1 1

P-44013

P-44280 Remove the four O-rings (Item 1) [Figure 20-170-87]


from the valve section.

Remove the O-ring (Item 1) [Figure 20-170-85] from the


plug.

262 of 1040 20-170-28 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-90

Telescoping Valve Section Disassembly And


Assembly (Cont’d)

Figure 20-170-88

P-44016

1
Remove the O-ring (Item 1) [Figure 20-170-90] from the
controller assembly.
P-44014
Figure 20-170-91

Remove the two screws (Item 1) [Figure 20-170-88] from

Dealer Copy -- Not for Resale


the controller assembly.

Assembly: Tighten the screws to 14 - 16 N•m (10 - 12 ft-


lb) torque.

Figure 20-170-89
1

P-44017

Remove the two couplers (Item 1) [Figure 20-170-91]


from the controller assembly.

1
P-44015

Remove the controller assembly (Item 1) [Figure 20-170-


89] from the valve section.

263 of 1040 20-170-29 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-94

Telescoping Valve Section Disassembly And


Assembly (Cont’d)

Figure 20-170-92

2
1

P-44020

Remove the four screws (Item 1) and cover (Item 2)


[Figure 20-170-94] from the controller assembly.
P-44018
Figure 20-170-95

Remove the two O-rings (Item 1) [Figure 20-170-92]

Dealer Copy -- Not for Resale


from the couplers.

Figure 20-170-93

1 P-44021

Remove the seal (Item 1) [Figure 20-170-95] from the


cover.
P-44019

Loosen the four screws (Item 1) [Figure 20-170-93] on


the controller assembly.

Assembly: Tighten the screws to 3 - 3,5 N•m (26.6 - 31


in-lb) torque.

264 of 1040 20-170-30 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-98

Telescoping Valve Section Disassembly And


Assembly (Cont’d)

Figure 20-170-96

1
2
P-44024
1

Remove the port block (Item 1) from the controller (Item


2) [Figure 20-170-98].
P-44022
Figure 20-170-99

Remove the plug (Item 1) [Figure 20-170-96] from the

Dealer Copy -- Not for Resale


cover.

Figure 20-170-97
3

1
2
1

4
P-47808

Remove the two valve cartridges (Item 1) and plunger


(Item 2) [Figure 20-170-99] from the controller.
P-44023
NOTE: The upper valve cartridge (Item 3) is for
extending the boom and the lower valve
Remove the O-ring (Item 1) [Figure 20-170-97] from the cartridge (Item 4) [Figure 20-170-99] is for
plug. retracting the boom.

265 of 1040 20-170-31 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-102

Telescoping Valve Section Disassembly And


Assembly (Cont’d)

Figure 20-170-100 1

1
P-44028
2

5
Remove the three O-rings (Item 1) [Figure 20-170-102]
4 from the port valve.
3
P-47810
Figure 20-170-103

Remove the cover (Item 1), poppet (Item 2), spool (Item

Dealer Copy -- Not for Resale


3) and spacer (Item 4) from the valve (Item 5) [Figure 20-
170-100].

Figure 20-170-101

1
2
1

P-47811

Remove the four O-rings (Item 1) [Figure 20-170-103]


from the valve.

P-44027

Remove the spool (Item 1) and spring (Item 2)


[Figure 20-170-101] from the port valve.

Assembly: The port valve, spool and spring must be


thoroughly cleaned before assembly.

266 of 1040 20-170-32 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-106

Telescoping Valve Section Disassembly And


Assembly (Cont’d)

Figure 20-170-104

1 1

P-44037

Loosen the screw (Item 1) [Figure 20-170-106] on the


piston.
P-44036
Assembly: Tighten the screw to 10 N•m (88.5 in-lb)
torque.
Remove the relief valve (Item 1) [Figure 20-170-104]

Dealer Copy -- Not for Resale


from the valve section. Figure 20-170-107

Assembly: Tighten the valve to 45 N•m (33 ft-lb) torque.

Figure 20-170-105

1
2
1

2
1

P-44038

Remove the screw (Item 1) and piston (Item 2)


P-42988 [Figure 20-170-107] from the adapter.

Remove the two O-rings (Item 1) and back-up ring (Item


2) [Figure 20-170-105] from the relief valve.

267 of 1040 20-170-33 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-110

Telescoping Valve Section Disassembly And


Assembly (Cont’d)
1
Figure 20-170-108

P-42990

1 Remove the two O-rings (Item 1) and back-up ring (Item


2) [Figure 20-170-110] from the plug.
P-44039
Figure 20-170-111

Remove the two O-rings (Item 1) [Figure 20-170-108]

Dealer Copy -- Not for Resale


from the piston.

Figure 20-170-109

1
1

P-44041

Loosen the two screws (Item 1) [Figure 20-170-111] on


the cover.
P-44040
Assembly: Tighten the screws to 10 N•m (88.5 in-lb)
torque.
Remove the plug (Item 1) [Figure 20-170-109] from the
valve section.

268 of 1040 20-170-34 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-114

Telescoping Valve Section Disassembly And


Assembly (Cont’d)

Figure 20-170-112

1
P-44045

Loosen the adapter (Item 1) [Figure 20-170-114].

P-44042 Assembly: Tighten the adapter to 9 - 11 N•m (79.7 - 97.4


in-lb) torque.

Remove the two screws (Item 1) and cover (Item 2) Figure 20-170-115

Dealer Copy -- Not for Resale


[Figure 20-170-112] from the valve section.

Figure 20-170-113

P-44046

1
P-44044 Remove the adapter (Item 1) [Figure 20-170-115] from
the spool.

Install a hex wrench in the screw (Item 1) [Figure 20-


170-113] on the end of the spool.

269 of 1040 20-170-35 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-118

Telescoping Valve Section Disassembly And


Assembly (Cont’d)

Figure 20-170-116

P-44049

Assembly: Install the countersunk side of the washer


(Item 1) [Figure 20-170-118] into the valve section.
P-44047
Figure 20-170-119

Remove the O-ring (Item 1) [Figure 20-170-116] from

Dealer Copy -- Not for Resale


the adapter.

Figure 20-170-117

P-44050

Remove the spool (Item 1) [Figure 20-170-119] from the


valve section.
P-44048
NOTE: When the spool is removed, use care not to
scratch the spool surface and do not
Remove the washer (Item 1) [Figure 20-170-117] from interchange spools and valve blocks.
the valve section.

270 of 1040 20-170-36 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-122

Telescoping Valve Section Disassembly And


Cut
Assembly (Cont’d)

Figure 20-170-120

3 18 mm 51 mm (2.0”)
2 (0.710”)

38 mm
(1.500”) 19 mm (0.750”)
B-14674

To remove the spring assembly from the spool, make a


holding fixture from a 19 mm thick x 38 mm wide x 51 mm
P-44051 long (0.750 in thick x 1.500 in wide x 2.0 in long) piece of
hardwood. Drill a 18 mm (0.710 in) hole in the center of
the hardwood block. Cut the block lengthwise [Figure 20-
Remove the O-ring (Item 1) seal (Item 2) and retainer 170-122].

Dealer Copy -- Not for Resale


(Item 3) [Figure 20-170-120] from the spool.
Figure 20-170-123
Figure 20-170-121

P-33886
P-44053

Using the wood blocks clamp the spool (Item 1)


Assembly: The lip on the seal (Item 1) [Figure 20-170- [Figure 20-170-123] in a vise.
121] fits inside the retainer (Item 3) [Figure 20-170-120].
NOTE: Do not use anything other than hardwood
blocks to grip the spool, or the spool will be
damaged.

Loosen the screw (Item 2) [Figure 20-170-123].

Assembly: Tighten the screw to 10 N•m (88.5 in-lb)


torque.

271 of 1040 20-170-37 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-126

Telescoping Valve Section Disassembly And


Assembly (Cont’d)
2
Figure 20-170-124
1

1 P-44276
4

3
Remove the spring (Item 1) and poppet (Item 2)
2 [Figure 20-170-126] from the plugs.
P-44052
Figure 20-170-127

Remove the screw (Item 1), spring retainer (Item 2),

Dealer Copy -- Not for Resale


spring (Item 3) and spring retainer (Item 4) [Figure 20-
170-124] from the spool.
1
Figure 20-170-125

P-44277

1
Remove the O-ring (Item 1) [Figure 20-170-127] from
the plugs.

P-44275

Remove the two plugs (Item 1) [Figure 20-170-125] from


the valve section.

Assembly: Tighten the plugs to 27 - 33 N•m (20 - 24 ft-


lb) torque.

272 of 1040 20-170-38 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-130

Telescoping Valve Section Disassembly And


Assembly (Cont’d)

Figure 20-170-128

P-44280

Remove the O-ring (Item 1) [Figure 20-170-130] from


the plug.
P-44278

Loosen the plug (Item 1) [Figure 20-170-128].

Dealer Copy -- Not for Resale


Assembly: Tighten the plug to 54 - 66 N•m (40 - 49 ft-lb)
torque.

Figure 20-170-129

1
P-44279

Remove the individual pressure compensator plug (Item


1), poppet (Item 2) and guide (Item 3) [Figure 20-170-
129] from the valve section.

273 of 1040 20-170-39 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-133

Auxiliary / Frame Leveling Valve Section


Disassembly And Assembly

Figure 20-170-131

P-44081

Remove the two screws (Item 1) [Figure 20-170-133]


from the controller assembly.
P-44079
Assembly: Tighten the screws to 14 - 16 N•m (10 - 12 ft-
lb) torque.
Remove the frame leveling valve section (Item 1)

Dealer Copy -- Not for Resale


[Figure 20-170-131]. Figure 20-170-134

Figure 20-170-132

1 1
P-44082

P-44080
Remove the controller assembly (Item 1) [Figure 20-170-
134] from the valve section.
Remove the four O-rings (Item 1) [Figure 20-170-132]
from the valve section.

274 of 1040 20-170-40 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-137

Auxiliary / Frame Leveling Valve Section


Disassembly And Assembly (Cont’d)

Figure 20-170-135

2
1

P-44085

1 Remove the four screws (Item 1) and cover (Item 2)


[Figure 20-170-137] from the controller assembly.
P-44083
Figure 20-170-138

Remove the O-ring (Item 1) [Figure 20-170-135] from

Dealer Copy -- Not for Resale


the controller assembly.
1
Figure 20-170-136

P-44021

1 Remove the seal (Item 1) [Figure 20-170-138] from the


cover.
P-44084

Loosen the four screws (Item 1) [Figure 20-170-136].

Assembly: Tighten the screws to 3 - 3,5 N•m (26.6 - 31


in-lb) torque.

275 of 1040 20-170-41 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-141

Auxiliary / Frame Leveling Valve Section


Disassembly And Assembly (Cont’d)

Figure 20-170-139

2
1
P-44086
1

Remove the controller (Item 1) from the port block (Item


2) [Figure 20-170-141].
P-44022
Figure 20-170-142

Remove the plug (Item 1) [Figure 20-170-139] from the

Dealer Copy -- Not for Resale


cover.

Figure 20-170-140

1
P-47808

Remove the two valve cartridges (Item 1) and plunger


(Item 2) [Figure 20-170-142] from the controller.
P-44023

Remove the O-ring (Item 1) [Figure 20-170-140] from


the plug.

276 of 1040 20-170-42 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-145

Auxiliary / Frame Leveling Valve Section


Disassembly And Assembly (Cont’d)

Figure 20-170-143 1

2
5

3
4 P-44028

Remove the three O-rings (Item 1) [Figure 20-170-145]


from the port valve.
P-47810
Figure 20-170-146

Remove the cover (Item 1), poppet (Item 2), spool (Item

Dealer Copy -- Not for Resale


3) and spacer (Item 4) from the valves (Item 5)
[Figure 20-170-143].

Figure 20-170-144

1
2
1

P-47811

Remove the four O-rings (Item 1) [Figure 20-170-146]


from the valve.

P-44027

Remove the spool (Item 1) and spring (Item 2)


[Figure 20-170-144] from the port valve.

Assembly: The port valve, spool and spring must be


thoroughly cleaned before assembly.

277 of 1040 20-170-43 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-149

Auxiliary / Frame Leveling Valve Section


Disassembly And Assembly (Cont’d)

Figure 20-170-147

1 2 P-44093

Remove the two O-rings (Item 1) [Figure 20-170-149]


from the connecting flange.
P-44091

Loosen the two screws (Item 1) [Figure 20-170-147] on

Dealer Copy -- Not for Resale


the connecting flange.

Assembly: Tighten the screws to 9 - 11 N•m (79.7 - 97.4


in-lb) torque.

Controller Filter Removal And Installation

Remove the filter (Item 2) [Figure 20-170-147] from the


port.

NOTE: The valve assembly does not have to be


removed for this procedure.

Figure 20-170-148

P-44092

Remove the two screws (Item 1) and connecting flange


(Item 2) [Figure 20-170-148].

278 of 1040 20-170-44 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-152

Auxiliary / Frame Leveling Valve Section


Disassembly And Assembly (Cont’d)

Figure 20-170-150

P-44097

1
Loosen the two screws (Item 1) [Figure 20-170-152] on
the cover.
P-44094
Assembly: Tighten the screws to 10 N•m (88.5 in-lb)
torque.
Loosen the screw (Item 1) [Figure 20-170-150] on the

Dealer Copy -- Not for Resale


piston. Figure 20-170-153

Assembly: Tighten the screw to 10 N•m (88.5 in-lb)


torque.

Figure 20-170-151

2
1
P-44098

Remove the two screws (Item 1) and cover (Item 2)


[Figure 20-170-153] from the valve section.
P-44096

Remove the screw (Item 1) and piston (Item 2)


[Figure 20-170-151] from the adapter.

279 of 1040 20-170-45 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-156

Auxiliary / Frame Leveling Valve Section


Disassembly And Assembly (Cont’d)

Figure 20-170-154

P-44101

1 Remove the adapter (Item 1) [Figure 20-170-156] from


the spool.
P-44099
Figure 20-170-157

Install a hex wrench in the screw (Item 1) [Figure 20-

Dealer Copy -- Not for Resale


170-154].

Figure 20-170-155
1

P-44047

Remove the O-ring (Item 1) [Figure 20-170-157] from


the adapter.
P-44100

Loosen the adapter (Item 1) [Figure 20-170-155].

Assembly: Tighten the adapter to 9 - 11 N•m (79.7 - 97.4


in-lb) torque.

280 of 1040 20-170-46 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-160

Auxiliary / Frame Leveling Valve Section


Disassembly And Assembly (Cont’d)

Figure 20-170-158

P-44103

Remove the spool (Item 1) [Figure 20-170-160] from the


valve section.
P-44102
NOTE: When the spool is removed, use care not to
scratch the spool surface and do not
Remove the washer (Item 1) [Figure 20-170-158] from interchange spools and valve blocks.

Dealer Copy -- Not for Resale


the valve section.
Figure 20-170-161
Figure 20-170-159

3
2

P-44051
P-44049

Remove the O-ring (Item 1), seal (Item 2) and retainer


Assembly: Install the countersunk side of the washer (Item 3) [Figure 20-170-161] from the spool.
(Item 1) [Figure 20-170-159] into the valve section.

281 of 1040 20-170-47 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-164

Auxiliary / Frame Leveling Valve Section


Disassembly And Assembly (Cont’d)

Figure 20-170-162

1
2

P-33886

Using the wood blocks clamp the spool (Item 1)


[Figure 20-170-164] in a vise.
P-44053
NOTE: Do not use anything other than hardwood
blocks to grip the spool, or the spool will be
Assembly: The lip on the seal (Item 1) [Figure 20-170- damaged.

Dealer Copy -- Not for Resale


162] fits inside the retainer.
Loosen the screw (Item 2) [Figure 20-170-164].
Figure 20-170-163
Assembly: Tighten the screw to 10 N•m (88.5 ft-lb)
Cut torque.

Figure 20-170-165

18 mm 51 mm (2.0”)
(0.710”)

38 mm
(1.500”) 19 mm (0.750”)
4
B-14674 1
3

To remove the spring assembly from the spool, make a 2


holding fixture from a 19 mm thick x 38 mm wide x 51 mm
P-44052
long (0.750 in thick x 1.500 in wide x 2.0 in long) piece of
hardwood. Drill a 18 mm (0.710 in) hole in the center of
the hardwood block. Cut the block lengthwise [Figure 20- Remove the screw (Item 1), spring retainer (Item 2),
170-163]. spring (Item 3) and spring retainer (Item 4) [Figure 20-
170-165] from the spool.

282 of 1040 20-170-48 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-168

Auxiliary / Frame Leveling Valve Section


Disassembly And Assembly (Cont’d)

Figure 20-170-166
1

P-44277

1
Remove the O-ring (Item 1) [Figure 20-170-168] from
the plugs.
P-44281
Figure 20-170-169

Remove the two plugs (Item 1) [Figure 20-170-166] from

Dealer Copy -- Not for Resale


the valve section.
1
Assembly: Tighten the plugs to 27 - 33 N•m (20 - 24 ft-
lb) torque.

Figure 20-170-167

2
1

P-44282

Loosen the plug (Item 1) [Figure 20-170-169].

Assembly: Tighten the plug to 54 - 66 N•m (40 - 49 ft-lb)


torque.

P-44276

Remove the spring (Item 1) and poppet (Item 2)


[Figure 20-170-167] from the plugs.

283 of 1040 20-170-49 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Inlet-Outlet Valve Section Disassembly And
Assembly
Auxiliary / Frame Leveling Valve Section
Disassembly And Assembly (Cont’d) Figure 20-170-172

Figure 20-170-170

3
2
P-44104
1
P-44283
Remove the four O-rings (Item 1) [Figure 20-170-172]
from the valve section.
Remove the individual pressure compensator plug (Item

Dealer Copy -- Not for Resale


1), poppet (Item 2) and guide (Item 3) [Figure 20-170- Figure 20-170-173
170] from the valve section.

Figure 20-170-171

P-44105

P-44280 Remove the flushing valve plug (Item 1) [Figure 20-170-


173] from the valve section.

Remove the O-ring (Item 1) [Figure 20-170-171] from Assembly: Tighten the plug to 100 N•m (74 ft-lb) torque.
the plug.

284 of 1040 20-170-50 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-176

Inlet-Outlet Valve Section Disassembly And


Assembly (Cont’d)

Figure 20-170-174 1

P-44108

Remove the plug (Item 1) [Figure 20-170-176] from the


valve section.
P-44106
Assembly: Tighten the plug to 20 N•m (15 ft-lb) torque.

Remove the O-ring (Item 1) [Figure 20-170-174] from Figure 20-170-177

Dealer Copy -- Not for Resale


the plug.

Figure 20-170-175

P-44109

P-44107 Remove the O-ring (Item 1) [Figure 20-170-177] from


the plug.

Remove the spring, shims and piston (Item 1)


[Figure 20-170-175] from the valve section.

285 of 1040 20-170-51 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-180

Inlet-Outlet Valve Section Disassembly And


Assembly (Cont’d)

Figure 20-170-178

1
1

P-44112

Remove the flow regulator valve (Item 1) [Figure 20-170-


180] from the valve section.
P-44110
Assembly: Tighten the flow regulator valve to 20 N•m
(15 ft-lb) torque.
Remove the relief valve (Item 1) [Figure 20-170-178]

Dealer Copy -- Not for Resale


from the valve section. Figure 20-170-181

Assembly: Tighten the relief valve to 45 N•m (33 ft-lb)


torque.

Figure 20-170-179
4
3
2 1

2
1

P-44265

1 Remove the plug (Item 1), shim (Item 2), spring (Item 3)
and spool (Item 4) [Figure 20-170-181] from the valve.
P-44111

Remove the two O-rings (Item 1) and back-up ring (Item


2) [Figure 20-170-179] from the relief valve.

286 of 1040 20-170-52 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-184

Inlet-Outlet Valve Section Disassembly And


Assembly (Cont’d)

Figure 20-170-182 1

1
1 2

P-44267

Remove the two O-rings (Item 1) and back-up ring (Item


2) [Figure 20-170-184] from the flow regulator valve.
P-44268
Figure 20-170-185

Remove the O-ring (Item 1) [Figure 20-170-182] from

Dealer Copy -- Not for Resale


the plug.

Figure 20-170-183
1

P-44114

Remove the test fitting (Item 1) [Figure 20-170-185] from


the valve section.
P-44269

Remove the screen (Item 1) [Figure 20-170-183] from


the valve.

287 of 1040 20-170-53 T35100(S)(L), T35120(S)L Service Manual


HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-188

Inlet-Outlet Valve Section Disassembly And


Assembly (Cont’d)

Figure 20-170-186
1

P-44117

Remove the O-ring (Item 1) [Figure 20-170-188] from


the test fitting.
P-44115

Remove the O-ring (Item 1) [Figure 20-170-186] from

Dealer Copy -- Not for Resale


the test fitting.

Figure 20-170-187

P-44116

Remove the cap (Item 1) [Figure 20-170-187] from the


test fitting.

288 of 1040 20-170-54 T35100(S)(L), T35120(S)L Service Manual


PORT RELIEF VALVES Figure 20-180-2

Adjustment Procedure

IMPORTANT 1

When repairing hydrostatic and hydraulic systems,


clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 2
damage the system.
I-2003-0888

P-50958
A portable hydraulic hand pump will be used to test the
work port relief valves. The hand pump must have clean
hydraulic fluid that is compatible with the Bobcat Loosen the lock nut (Item 1) [Figure 20-180-2].
hydraulic fluid.
Turn the adjusting screw (Item 2) [Figure 20-180-2]
NOTE: The valve is shown removed from the clockwise to increase the pressure and counterclockwise
machine for photo clarity. to reduce the pressure.

Dealer Copy -- Not for Resale


Figure 20-180-1 NOTE: A 90° turn is approximately 2758 kPa (27,58
bar) (400 psi). When the correct pressure
setting is obtained, tighten the locknut while
holding the adjustment screw from turning.

Adjust the port relief valve until the correct setting is


obtained.

P-50955

Install the hand pump, hose and a pressure gauge


(minimum of 34,4 MPa [344 bar] [5000 psi]) into the valve
section work port in which the port relief valve is located
[Figure 20-180-1]. Pressurize this section with the hand
pump until the port relief valve opens and record the
pressure reading.

If the port relief pressure setting needs to be adjusted,


release the hand pump pressure valve.

289 of 1040 20-180-1 T35100(S)(L), T35120(S)L Service Manual


Dealer Copy -- Not for Resale

290 of 1040 20-180-2 T35100(S)(L), T35120(S)L Service Manual


FLOW CONTROL VALVE Figure 20-190-3

Removal And Installation

Figure 20-190-1

1
1

P-44263

Remove and clean the filter (Item 1) [Figure 20-190-3].


S7421
NOTE: Check the filter for any damage. Replace the
filter if required.
Remove the rear cover (Item 1) [Figure 20-190-1].

Dealer Copy -- Not for Resale


Figure 20-190-2

P-44331

Remove the flow control valve (Item 1) [Figure 20-190-2]


from the right front of the hydraulic control valve.

Installation: Tighten the flow control valve to 20 N•m (15


ft-lb) torque.

291 of 1040 20-190-1 T35100(S)(L), T35120(S)L Service Manual


Dealer Copy -- Not for Resale

292 of 1040 20-190-2 T35100(S)(L), T35120(S)L Service Manual


JOYSTICK Remove the joystick panel. (See Removal And
Installation on Page 50-131-1.)
Removal And Installation
Figure 20-200-3
S/N A8HD12999 & Below, S/N A8GW12999 & Below,
S/N A8GT12999 & Below, S/N A8GV12999 & Below,
S/N A8GJ12999 & Below:

Remove the dash cover / steering column cover. (See


Removal And Installation on Page 50-140-1.)

Remove the joystick panel. (See Removal And


Installation on Page 50-130-1.)

Figure 20-200-1
1

S36357

Disconnect the electrical connector (Item 1) [Figure 20-


200-3].

Dealer Copy -- Not for Resale


For All Models:
1
NOTE: The joystick is not serviceable and must be
replaced as a complete unit.

P-61622 Figure 20-200-4

Disconnect the electrical connector (Item 1) [Figure 20-


200-1].

S/N A8HD13000 & Above, S/N A8GW13000 & Above,


S/N A8GT13000 & Above, S/N A8GV13000 & Above,
S/N A8GJ13000 & Above: 1

Figure 20-200-2

1
P-61623

Raise the dust boot (Item 1) [Figure 20-200-4].

P-97028

Remove the fuse box cover (Item 1) [Figure 20-200-2].

293 of 1040 20-200-1 T35100(S)(L), T35120(S)L Service Manual


JOYSTICK (CONT’D) Figure 20-200-6

Removal And Installation (Cont’d)

Figure 20-200-5

2
1

1
1

2 P-61624

Remove the six hoses (Item 1) [Figure 20-200-6] from


P-61640 the joystick.

Mark the hoses for correct assembly.


Remove the four mounting bolts and spacers (Item 1)
[Figure 20-200-5]. Figure 20-200-7

Dealer Copy -- Not for Resale


Installation: The joystick harness (Item 2) [Figure 20-
200-5] must be positioned around the swivel joint as
shown.

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
P-61623
immediately.
W-2145-0290

Remove the joystick assembly (Item 1) [Figure 20-200-


7].

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

294 of 1040 20-200-2 T35100(S)(L), T35120(S)L Service Manual


PARKING BRAKE Figure 20-210-2

Parking Brake Valve Removal And Installation

Figure 20-210-1

2
2
1
S4519

Remove the three hoses (Item 1). Unplug the electrical


P-50821
connector (Item 2) [Figure 20-210-2].

Relieve the hydraulic pressure. Figure 20-210-3

Dealer Copy -- Not for Resale


Remove the three screws (Item 1) from the access panel
1
(Item 2) [Figure 20-210-1].

Remove the access panel (Item 2) [Figure 20-210-1].

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
S4519
physician familiar with this injury is not received
immediately.
W-2145-0290 Remove the two screws (Item 1) [Figure 20-210-3] in
order to loosen the parking brake lever.

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 all hoses and electrical connectors for correct


installation.

295 of 1040 20-210-1 T35100(S)(L), T35120(S)L Service Manual


PARKING BRAKE (CONT’D) Parking Brake Valve Disassembly And Assembly

Parking Brake Valve Removal And Installation Figure 20-210-5


(Cont’d)

Figure 20-210-4

1
S2756

S4519 Remove the fittings (Item 1) [Figure 20-210-5].

Figure 20-210-6
Lift the parking brake lever and valve (Item 1) [Figure 20-

Dealer Copy -- Not for Resale


210-4] out the frame.

P-44439

Loosen the collar (Item 1) [Figure 20-210-6].

NOTE: Use care removing the collar. The collar is


under spring pressure.

296 of 1040 20-210-2 T35100(S)(L), T35120(S)L Service Manual


PARKING BRAKE (CONT’D) Figure 20-210-9

Parking Brake Valve Disassembly And Assembly


(Cont’d)

Figure 20-210-7

1
P-44442

Remove the electrical connector (Item 1) [Figure 20-210-


9] from the housing.
P-44440

Remove the collar (Item 1), spring (Item 2) and shaft

Dealer Copy -- Not for Resale


(Item 3) [Figure 20-210-7] from the housing.

Figure 20-210-8

P-44441

Remove the washer (Item 1) [Figure 20-210-8] from the


housing

297 of 1040 20-210-3 T35100(S)(L), T35120(S)L Service Manual


Dealer Copy -- Not for Resale

298 of 1040 20-210-4 T35100(S)(L), T35120(S)L Service Manual


PRESSURE REDUCING VALVE Figure 20-220-3

Testing

Raise the boom and install the boom stop. (See Installing
The Approved Boom Stop on Page 10-150-1.)

Figure 20-220-1

1
P-50928

Install a 7 MPa (70 bar) (1000 psi) gauge on the test


fitting [Figure 20-220-3].

Start the engine, lower the restraint bar (if equipped) and
S7421 run engine at 2200 RPM.

Dealer Copy -- Not for Resale


Record the pressure. The pressure at the gauge should
Remove the rear cover (Item 1) [Figure 20-220-1]. be 3,31 MPa (33,10 bar) (480 psi).

Figure 20-220-2 The pressure reducing valve is not adjustable. If the


pressure is incorrect, replace the pressure reducing
valve. (See Removal And Installation on Page 20-220-2.)

P-50930

Locate the test fitting (Item 1) [Figure 20-220-2] below


the control valve and remove the cap.

299 of 1040 20-220-1 T35100(S)(L), T35120(S)L Service Manual


PRESSURE REDUCING VALVE (CONT’D)

Removal And Installation


WARNING
Relieve hydraulic pressure. Drain the hydraulic reservoir.
(See Removing And Replacing Hydraulic Fluid on Page Hydraulic fluid escaping under pressure can have
10-100-2.) sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
Figure 20-220-4 and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290

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
S7421

Dealer Copy -- Not for Resale


Figure 20-220-6
Remove the rear cover (Item 1) [Figure 20-220-4].

Mark the hoses and electrical connectors for correct


installation.

Figure 20-220-5

2 1

P-50938

1
Remove the top hose (Item 1) [Figure 20-220-6].

P-50937

Remove the screw (Item 1) and disconnect the electrical


connector (Item 2) [Figure 20-220-5].

300 of 1040 20-220-2 T35100(S)(L), T35120(S)L Service Manual


PRESSURE REDUCING VALVE (CONT’D) Disassembly And Assembly

Removal And Installation (Cont’d) Figure 20-220-9

Figure 20-220-7

1
P-44338
1
P-50939
Remove the nut (Item 1) and coil (Item 2) [Figure 20-
220-9] from the spool.
Remove the two hoses (Item 1) [Figure 20-220-7].
Figure 20-220-10

Dealer Copy -- Not for Resale


Figure 20-220-8

1
1

P-44337
P-50940

Remove the spool (Item 1) [Figure 20-220-10].


Remove the two mounting bolts (Item 1) and remove the
pressure reducing valve (Item 2) [Figure 20-220-8].

301 of 1040 20-220-3 T35100(S)(L), T35120(S)L Service Manual


PRESSURE REDUCING VALVE (CONT’D) Figure 20-220-12

Disassembly And Assembly (Cont’d)

Figure 20-220-11

2 1

1
P-44341
1 2
1
2 Remove the fittings (Item 1) [Figure 20-220-12].
P-44340
Wash the valve in clean solvent and dry with compressed
air. Check the components for wear or damage. Replace
Remove the three O-rings (Item 1) and four back-up rings any worn or damaged components. Always use new O-
(Item 2) [Figure 20-220-11] from the spool. rings and back-up rings.

Dealer Copy -- Not for Resale


Apply clean hydraulic fluid to the components during
assembly.

302 of 1040 20-220-4 T35100(S)(L), T35120(S)L Service Manual


ACCUMULATOR Figure 20-230-2
S/N A8HD12999 & BELOW
Removal And Installation
S/N A8GW12999 & BELOW
S/N A8GT12999 & BELOW
The accumulator is located below the control valve, and S/N A8GV12999 & BELOW
can be seen through an access hole on the bottom of the S/N A8GJ12999 & BELOW
machine.

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

WARNING

Dealer Copy -- Not for Resale


Load, unload and turn on flat level ground. Do not
exceed Rated Operating Capacity (ROC) shown on P-50796
sign (decal) in cab. Failure to obey warnings can
cause the machine to tip or roll over and cause injury
or death. With the engine off, relieve the hydraulic pressure by
W-2056-0903
pressing the bottom of the button (Item 1) [Figure 20-
230-1] and [Figure 20-230-2].
Figure 20-230-1
Figure 20-230-3
S/N A8HD13000 & ABOVE
S/N A8GW13000 & ABOVE
S/N A8GT13000 & ABOVE
S/N A8GV13000 & ABOVE
S/N A8GJ13000 & ABOVE

2 1
1
P-97008
P-50941

Remove the accumulator (Item 1) from the manifold (Item


2) [Figure 20-230-3].

303 of 1040 20-230-1 T35100(S)(L), T35120(S)L Service Manual


Dealer Copy -- Not for Resale

304 of 1040 20-230-2 T35100(S)(L), T35120(S)L Service Manual


TOW VALVE Figure 20-240-2

Removal And Installation

Open the engine cover. (See Opening And Closing on


Page 10-160-1.)

Figure 20-240-1
1

S6839

Mark the hoses for correct installation. Remove the two


hoses (Item 1) [Figure 20-240-2].

Figure 20-240-3
S6838

Dealer Copy -- Not for Resale


Position the tow valve to towing position to relieve
hydraulic pressure [Figure 20-240-1].
2

WARNING 3

Hydraulic fluid escaping under pressure can have 1


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
S6892
physician familiar with this injury is not received
immediately.
W-2145-0290
Remove the two bolts, nuts (Item 1) and strap (Item 2).
Remove the tow valve (Item 3) [Figure 20-240-3].

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

305 of 1040 20-240-1 T35100(S)(L), T35120(S)L Service Manual


TOW VALVE (CONT’D) Figure 20-240-6

Disassembly And Assembly

Clean the outside of the tow valve before disassembly.

Mark the outside of the tow valve for ease of assembly.

Figure 20-240-4
1

P-46750

Remove the retainer (Item 1) and stop plate (Item 2)


2 [Figure 20-240-6].

NOTE: Record the position of the stop plate for


1 proper assembly.
P-46747

Dealer Copy -- Not for Resale


Figure 20-240-7

Remove the screw (Item 1) and washer (Item 2) [Figure


20-240-4].

Figure 20-240-5

1
1 1

P-46752

Remove the two fittings (Item 1) [Figure 20-240-7].

P-46749

Remove the handle (Item 1) [Figure 20-240-5].

306 of 1040 20-240-2 T35100(S)(L), T35120(S)L Service Manual


TOW VALVE (CONT’D) Figure 20-240-10

Disassembly And Assembly (Cont’d)

Figure 20-240-8 1

P-46755
1

Remove the O-ring (Item 1) [Figure 20-240-10] from the


P-46753 adapters.

Remove the O-ring (Item 1) [Figure 20-240-8] from the


fittings.

Dealer Copy -- Not for Resale


Figure 20-240-9

1 1

P-46754

Remove the two adapters (Item 1) [Figure 20-240-9].

307 of 1040 20-240-3 T35100(S)(L), T35120(S)L Service Manual


TOW VALVE (CONT’D) Figure 20-240-13

Disassembly And Assembly (Cont’d)

Figure 20-240-11
1

P-46759

Figure 20-240-14
P-46756

Figure 20-240-12
1

Dealer Copy -- Not for Resale


2

1
P-46760

Assembly: Align the slot (Item 1) [Figure 20-240-13]


P-46758 with the notch (Item 1) [Figure 20-240-14] in the shaft.

Remove the seal (Item 1) [Figure 20-240-11] from the


valve (Both sides).

Assembly: The concave side of the seal (Item 1) [Figure


20-240-11] fits over the ball (Item 2) [Figure 20-240-12].

Turn the shaft (Item 1) until the shaft and ball (Item 2)
[Figure 20-240-12] are in the position shown. Remove
the ball.

Assembly: Record the position of the shaft and ball for


proper assembly.

308 of 1040 20-240-4 T35100(S)(L), T35120(S)L Service Manual


TOW VALVE (CONT’D) Figure 20-240-17

Disassembly And Assembly (Cont’d)

Figure 20-240-15

1
1

P-46762

Remove the seal (Item 1) [Figure 20-240-17] from the


P-46763 housing.

Clean all parts in solvent and dry with compressed air.


Remove the shaft (Item 1) [Figure 20-240-15] by
pressing the shaft into the housing. Inspect all parts for wear or damage. Replace any worn

Dealer Copy -- Not for Resale


or damaged parts.
Figure 20-240-16
Always install new seals and O-rings. Lubricate all seals
and O-rings with clean hydraulic fluid before installation.

P-46761

Remove the O-ring (Item 1) [Figure 20-240-16] from the


shaft.

309 of 1040 20-240-5 T35100(S)(L), T35120(S)L Service Manual


Dealer Copy -- Not for Resale

310 of 1040 20-240-6 T35100(S)(L), T35120(S)L Service Manual


STABILIZER CYLINDER (IF EQUIPPED) Figure 20-250-3

Removal

Figure 20-250-1

1 1
S3220

Disconnect both hoses (Item 1) [Figure 20-250-3] and


S3217 put caps on the connections to prevent bleeding the
hydraulic tank.

Extend and support the boom on adequate stands Figure 20-250-4


[Figure 20-250-1].

Dealer Copy -- Not for Resale


Figure 20-250-2

S3218

S3215 Remove the bolt and washer (Item 1) [Figure 20-250-4]


on one side of the rod end articulation pin.

Position the stabilizer horizontally and place blocks to


support the stabilizer when being disassembled [Figure
20-250-2].

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

311 of 1040 20-250-1 T35100(S)(L), T35120(S)L Service Manual


STABILIZER CYLINDER (IF EQUIPPED) (CONT’D) Figure 20-250-7

Removal (Cont’d)

Figure 20-250-5 1

S3221

1
Remove the pivot pin retainer bolt (Item 1) [Figure 20-
S3224 250-7].

Figure 20-250-8
Remove the pin (Item 1) [Figure 20-250-5].

Figure 20-250-6

Dealer Copy -- Not for Resale


1

S3227

S3226 Remove the pivot pin (Item 1) [Figure 20-250-8] and


remove the cylinder using the lifting strap.

Support the cylinder by using a lifting strap (Item 1)


[Figure 20-250-6].

312 of 1040 20-250-2 T35100(S)(L), T35120(S)L Service Manual


STABILIZER CYLINDER (IF EQUIPPED) (CONT’D)

Parts Identification

Figure 20-250-9

1 7

10
12
5
8
1. Cylinder Ref. 2 to 14
2. Rod
3. Piston Torque: 900 ± 180 N•m
(664 ± 133 ft-lb)
4. Screw Torque: 20 N•m (14.7 ft-lb)

Dealer Copy -- Not for Resale


5. Bushing
6. Grease nipple
7. Cap
8. Inner ring
9. Cylinder 9
13
10. Grease nipple 8
11. Cylinder head Torque: 450 - 500 N•m 5
(332 - 369 ft-lb)
12. Valve Torque: 45 - 50 N•m
(33 - 37 ft-lb)
13. Valve
14. Seal kit
3

14
7

6
11

5
8 4

8
5
S2821

313 of 1040 20-250-3 T35100(S)(L), T35120(S)L Service Manual


STABILIZER CYLINDER (IF EQUIPPED) (CONT’D) Figure 20-250-12

Disassembly

Figure 20-250-10
1

S3230

Carefully peen the lock ring (Item 1) [Figure 20-250-12]


S3229 from the head gland.

Figure 20-250-13
Put the cylinder (Item 1) [Figure 20-250-10] in a vise.

Figure 20-250-11

Dealer Copy -- Not for Resale


1

1 S2819

S3222 Loosen the head gland using a wrench (Item 1) [Figure


20-250-13].

Remove both relief cartridges (Item 1) [Figure 20-250-


11] from the cylinder.

314 of 1040 20-250-4 T35100(S)(L), T35120(S)L Service Manual


STABILIZER CYLINDER (IF EQUIPPED) (CONT’D) Figure 20-250-16

Disassembly (Cont’d)

Figure 20-250-14

S3235

Remove the piston assembly (Item 1) [Figure 20-250-16]


S2820
from the rod.

Figure 20-250-17
Remove the rod assembly (Item 1) [Figure 20-250-14]
from the housing.

Dealer Copy -- Not for Resale


Figure 20-250-15 2

4 3
1

1 3
2

S3228

Remove the seal (Item 1), two wear rings (Item 2), two
S3234 rings (Item 3) and the O-ring (Item 4) [Figure 20-250-17]
from the piston.

Remove the set screw (Item 1) [Figure 20-250-15] from


the piston.

315 of 1040 20-250-5 T35100(S)(L), T35120(S)L Service Manual


STABILIZER CYLINDER (IF EQUIPPED) (CONT’D) Figure 20-250-20

Disassembly (Cont’d)

Figure 20-250-18

1
S2839

Remove the seal (Item 1) [Figure 20-250-20] from the


S2836 inside of the head gland.

Remove the head gland (Item 1) [Figure 20-250-18]


from the rod.

Dealer Copy -- Not for Resale


Figure 20-250-19

S2837

Remove the O-ring (Item 1) and wiper seal (Item 2)


[Figure 20-250-19] from the head gland.

316 of 1040 20-250-6 T35100(S)(L), T35120(S)L Service Manual


STABILIZER CYLINDER (IF EQUIPPED) (CONT’D) Figure 20-250-23

Assembly

Use the following tool to assemble the cylinder:


MEL1075-Adjustable Gland Nut Wrench

Wash the cylinder parts in solvent and dry with


compressed air.
1
Inspect the cylinder parts for damage. Replace any
damaged parts.

Lubricate all O-rings and seals with hydraulic fluid during


installation. Always use new O-rings and seals. S2836

Figure 20-250-21
Install the head gland (Item 1) [Figure 20-250-23] onto
the rod.
2
Figure 20-250-24

Dealer Copy -- Not for Resale


2

4 3

1 1

3
S2837
2

Install the O-ring (Item 1) and wiper seal (Item 2) [Figure


20-250-21] onto the head gland. S3228

Figure 20-250-22
Install the seal (Item 1), two wear rings (Item 2), two rings
(Item 3) and the O-ring (Item 4) [Figure 20-250-24] onto
the piston.

S2839

Install the seal (Item 1) [Figure 20-250-22] into the head


gland.

317 of 1040 20-250-7 T35100(S)(L), T35120(S)L Service Manual


STABILIZER CYLINDER (IF EQUIPPED) (CONT’D) Figure 20-250-27

Assembly (Cont’d)

Figure 20-250-25

2
S2820

1
Install the rod assembly (Item 1) [Figure 20-250-27] onto
S3235
the housing.

Figure 20-250-28
Clean off any old residue, and apply Loctite® #242 or
equivalent to the threads on the rod (Item 1). Install the
piston (Item 2) [Figure 20-250-25] onto the rod and

Dealer Copy -- Not for Resale


tighten.

Figure 20-250-26
1

S2819

Tighten the head gland (Item 1) using a wrench [Figure


20-250-28].
S3234

Apply Loctite® #242 or equivalent to the set screw


(Item 1) [Figure 20-250-26]. Install the set screw into the
piston and tighten.

318 of 1040 20-250-8 T35100(S)(L), T35120(S)L Service Manual


STABILIZER CYLINDER (IF EQUIPPED) (CONT’D) Installation

Assembly (Cont’d) Figure 20-250-31

Figure 20-250-29

1 1

S3226

S3230
Install the pivot pin (Item 1) [Figure 20-250-31].

Using a punch, seat the lock ring to keep the head gland Figure 20-250-32
from turning [Figure 20-250-29].

Dealer Copy -- Not for Resale


Figure 20-250-30
1

1 S3221

S3222 Install the pivot pin retainer bolt (Item 1) [Figure 20-250-
32].

Install both relief cartridges (Item 1) [Figure 20-250-30]


onto the cylinder.

319 of 1040 20-250-9 T35100(S)(L), T35120(S)L Service Manual


STABILIZER CYLINDER (IF EQUIPPED) (CONT’D)

Installation (Cont’d)

Figure 20-250-33

S3218

Install the rod end pivot pin and secure with the bolt and
washer (Item 1) [Figure 20-250-33].

Dealer Copy -- Not for Resale


Figure 20-250-34

1 1
S3220

Remove caps and connect the two hoses (Item 1)


[Figure 20-250-34].

320 of 1040 20-250-10 T35100(S)(L), T35120(S)L Service Manual


STABILIZER CONTROL VALVE (IF EQUIPPED)

Parts Identification

Figure 20-260-1

1. Hydraulic block
2. Set of plugs 6
3. Screw
4. Washer
5. Nut 1
6. Control valve
7. Adapter
8. Adapter 7
9. Fitting
3
10. Elbow fitting
11. Adapter 1
12. No return valve
13. Elbow fitting
14. Hose

Dealer Copy -- Not for Resale


15. Adapter 4
2
16. Pipe 5
17. Pipe
18. Support
19. Elbow fitting
20. Screw
21. Washer
22. Nut
14

10

12
11 8
9
10

22

17 13
21
20
13 11
14
12
19 15

16

18

S3214

321 of 1040 20-260-1 T35100(S)(L), T35120(S)L Service Manual


STABILIZER CONTROL VALVE (IF EQUIPPED) Figure 20-260-4
(CONT’D)

Removal

Figure 20-260-2
2 2 2 2

2 1

1
1 S3247
2

Pull the connections plate forward, mark the tube


positions, disconnect the four hoses / tubes (Item 2) and
S3217 remove the plate (Item 1) [Figure 20-260-4].

Figure 20-260-5
Remove the nuts and bolts (Item 1) and the two hoses for
oil flow from and to the machine (Item 2) [Figure 20-260-
2].

Dealer Copy -- Not for Resale


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. S2818
I-2003-0888

Figure 20-260-3 Mark and remove the remaining hoses (Item 1) [Figure
20-260-5] from the block.

2 2

1 1

S3220

Mark and disconnect the four hoses (Item 1) and remove


both bolts (Item 2) [Figure 20-260-3].

322 of 1040 20-260-2 T35100(S)(L), T35120(S)L Service Manual


STABILIZER CONTROL VALVE (IF EQUIPPED) Installation
(CONT’D)
Figure 20-260-8
Removal (Cont’d)

Figure 20-260-6 1
1

1
1
3 3

2 2 2

2
2

3 S3249
3
1
S3248 Install the bolts (Item 1) to install the valve (Item 2)
[Figure 20-260-8].

Carefully remove the stabilizer control valve block Figure 20-260-9


(Item 1) [Figure 20-260-6] and put it on a stand, without
damaging the electric cables.

Dealer Copy -- Not for Resale


Mark and remove the four nuts (Item 2) and coils (Item 3) 2
[Figure 20-260-6] from the spools. 2

Figure 20-260-7 3 3

3
1 3
1
2
1 2
1
1
S3248

2
Put the stabilizer control valve block (Item 1) on a stand
in such a way that the electrical coils can be connected to
the spools. Install the coils (Item 2) and the four nuts
(Item 3) [Figure 20-260-9] on the spools.
S3249

Remove the bolts (Item 1) to uninstall the valve (Item 2)


[Figure 20-260-7].

323 of 1040 20-260-3 T35100(S)(L), T35120(S)L Service Manual


STABILIZER CONTROL VALVE (IF EQUIPPED) Figure 20-260-12
(CONT’D)

Installation (Cont’d)
1 1
Figure 20-260-10

2 2
1

S3220

Install both bolts (Item 1) and connect the four hoses


(Item 2) [Figure 20-260-12].
S2818
Figure 20-260-13

Place the valve block in its position in the stabilizer frame,


but do not yet secure the valve block to the frame.
2 1

Dealer Copy -- Not for Resale


Install the hoses (Item 1) [Figure 20-260-10].

Figure 20-260-11

1
2

2 2 2 2
S3217

Secure the valve block to the frame with two bolts


(Item 1) and connect the hoses (Item 2) [Figure 20-260-
1 13].

S3247

Pull the valve block a bit forward in order to be able to


connect the four hoses / tubes (Item 2) [Figure 20-260-
11].

324 of 1040 20-260-4 T35100(S)(L), T35120(S)L Service Manual


HYDROSTATIC SYSTEM

HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1


Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2

OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-22

HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-21

Dealer Copy -- Not for Resale


Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-25

325 of 1040 30-01 T35100(S)(L), T35120(S)L Service Manual


Dealer Copy -- Not for Resale

326 of 1040 30-02 T35100(S)(L), T35120(S)L Service Manual


HYDROSTATIC SYSTEM INFORMATION

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

PROBLEM CAUSE
The telescopic handler does not move 1, 2
The telescopic handler does not move in a straight line. 3, 4
The hydrostatic system is overheating. 5, 6, 7, 8
Warning light comes ON. 5, 8, 9, 10, 11

KEY TO CORRECT THE CAUSE


1. The hydrostatic pump has damage.
2. The hydrostatic motor has damage.
3. The tires do not have the correct tire pressure.

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4. The tires are not the same size.
5. The hydrostatic fluid is not at the correct level.
6. The oil cooler has a restriction.
7. The temperature sending switch is not operating correctly.
8. The telescopic handler is not being operated at the correct RPM.
9. The sender is defective.
10. Pump is defective or worn hydrostatics
11. Hydraulic filter is plugged.

327 of 1040 30-10-1 T35100(S)(L), T35120(S)L Service Manual


HYDROSTATIC SYSTEM INFORMATION (CONT’D)

Replenishing Valve Function


IMPORTANT
Figure 30-10-1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

The functions of the replenishing valves are:

1. 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
Valve Moves For
Function 1 flow to the oil cooler for cooling; Function 1
Charge Oil [Figure 30-10-1].
Replacement
2. To keep high pressure fluid out of the low pressure
side of the hydrostatic circuitry; Function 2
[Figure 30-10-1].

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Valve Stays on Seat
to Hold High
Pressure for
Drive
Function 2 B-2804

328 of 1040 30-10-2 T35100(S)(L), T35120(S)L Service Manual


OIL COOLER

Description

The oil cooler is a combined radiator / oil cooler. (See OIL


COOLER / RADIATOR on Page 70-50-1.)

Dealer Copy -- Not for Resale

329 of 1040 30-20-1 T35100(S)(L), T35120(S)L Service Manual


Dealer Copy -- Not for Resale

330 of 1040 30-20-2 T35100(S)(L), T35120(S)L Service Manual


HYDROSTATIC DRIVE MOTOR

Removal And Installation

Remove the front axle. (See Removal on Page 40-30-1.)

Figure 30-30-1

1 1

P-22325

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Install a chain hoist and lifting strap to lift and support the
drive motor [Figure 30-30-1].

Remove the four mounting bolts (Item 1) [Figure 30-30-


1] from the drive motor.

Installation: Tighten the mounting bolts to 190 - 210


N•m (140 - 155 ft-lb) torque.

Remove the hydrostatic drive motor from the axle


housing.

331 of 1040 30-30-1 T35100(S)(L), T35120(S)L Service Manual


HYDROSTATIC DRIVE MOTOR (CONT'D)

Parts Identification

1. Bolt
2. End Cap
3. Plug
4. O-ring
5. Seal
6. Servo Piston
7. Feed Back Lug
8. Nut
9. Adjuster
10. Rod
11. Set Screw
12. Spring seat
13. Spring
14. Spool
15. Orifice
16. Housing
17. Solenoid

Dealer Copy -- Not for Resale

B-18528

332 of 1040 30-30-2 T35100(S)(L), T35120(S)L Service Manual


HYDROSTATIC DRIVE MOTOR (CONT'D)

Parts Identification (Cont’d)

1. Valve Segment
2. Plate
3. Pins
4. Bearing
5. Cylinder
6. Pin
7. Synchronizing Shaft
8. Rollers
9. Bolt
10. Nut
11. Cap
12. Plug
13. O-ring
14. Ring
15. Piston
16. Spring Seat
17. Spring

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18. Shaft
19. Bearing
20. Spacer
21. Nut
22. O-ring
23. Seal
24. Housing

B-15937

333 of 1040 30-30-3 T35100(S)(L), T35120(S)L Service Manual


HYDROSTATIC DRIVE MOTOR (CONT'D)

Parts Identification (Cont’d)

Dealer Copy -- Not for Resale


1. Nut
2. Solenoid
3. Solenoid Shaft
4. O-ring
5. Spring
6. Plug
7. Fitting
8. Bolt
9. Orifice
10. Housing
11. Spool
12. Adjustment Spool
13. End Nut
14. Nut
15. Spring Seat
16. Limiter
B-15939

334 of 1040 30-30-4 T35100(S)(L), T35120(S)L Service Manual


HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-4

Disassembly 1

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

P-29653
Figure 30-30-2

Remove the solenoid nut (Item 1) [Figure 30-30-4].

Figure 30-30-5

Dealer Copy -- Not for Resale


P-29652

Place the hydrostatic drive motor on a work surface, mark


the sections for correct assembly [Figure 30-30-2]. P-29654

Figure 30-30-3
Remove the solenoid (Item 1) [Figure 30-30-5] from the
shaft.