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Electrical System Service Manual

Loader

Dealer Copy -- Not for Resale

EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS)

6900881 (1-08) Printed in U.S.A. © Bobcat Company 2008

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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-2003-0903

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.

CORRECT CORRECT CORRECT

B-10731a B-15535 B-15524

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG

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B-15734 B-15732 B-15525
Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an approved attachments not approved by
Avoid exhaust fume leaks which lift arm support device. Replace it Bobcat Company.
can kill without warning. Exhaust if damaged.
system must be tightly sealed.
WRONG WRONG WRONG

B-15733 B-15523 B-6589


B-16102 B-16102
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW07-0805

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ALPHABETICAL INDEX

ACTUATOR TEST HARNESS ............................ 10-01

BOBCAT CONTROLLER .................................... 20-01

CONTROL PANEL SETUP ................................. 20-01

ELECTRICAL HARNESS ................................... 20-01


ELECTRICAL SYSTEM ...................................... 20-01

GENERAL INSTRUCTION ................................. 10-01

INSTRUMENT PANEL IDENTIFICATIONS ........ 20-01

MAINTENANCE CLOCK .................................... 20-01

PASSWORD SETUP .......................................... 20-01

REMOTE START TOOL KIT-MEL1563 .............. 10-01


REMOTE START TOOL (SERIVCE TOOL)
KIT-6689779 ..................................................... 10-01

Dealer Copy -- Not for Resale


SENSOR TESTER.............................................. 10-01
SERVICE PC (LAPTOP COMPUTER) ............... 10-01
SERVICE SOFTWARE
(ENTERING ANALYZER) ................................. 30-01
SERVICE SOFTWARE (MONITOR)................... 30-01
SERVICE SOFTWARE (WARNINGS) ................ 30-01
SERVICE SOFTWARE
(DIAGNOSE/CALIBRATE) ................................ 30-01
SERVICE SOFTWARE
(INSTALLING KITS AND OPTIONS) ................ 30-01
SERVICE SOFTWARE (PROGRAM/UPDATE).. 30-01
SERVICE SOFTWARE (DOWNGRADE)............ 30-01
SERVICE SOFTWARE (OPTIONS).................... 30-01

TEST ADAPTER KIT .......................................... 10-01

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CONTENTS TOOLS

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V GENERAL


INFORMATION
LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . . . . . . IX

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X SERVICE “PC”


SOFTWARE
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI

BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . XIII DIAGNOSTICS


2 CONNECTOR
PRELIMINARY LOADER GLOSSARY OF TERMS . . . . . . . . . . . .XIV

TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
DIAGNOSTICS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 AHC/ACS

SERVICE "PC" SOFTWARE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

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DIAGNOSTICS
AWS / SJC

SERVICE “PC”
SOFTWARE

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FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, Starting procedure, daily checks, etc.

A general inspection of the following items must be made after the loader has had service or repair:
1. Check lift arm support device, 9. The parking brake must
replace if damaged. (Stored function correctly.
Position)

2. Check that ROPS mounting 10. Enclosure door latches must


hardware is tightened and is open and close freely.
Bobcat approved.

3. The seat belt must be 11. Bob-Tach wedges and


correctly installed, functional linkages must function
and in good condition. correctly and be in good

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condition.

4. The seat bar must be 12. Safety treads must be in good


correctly adjusted, clean and condition.
lubricated.

5. Check lift arm support device; 13. Check for correct function of
replace if damaged. indicator lamps (Optional on
some models).

6. Machine signs must be 14. Check hydraulic fluid level,


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

7. Steering levers and foot 15. Inspect for fuel, oil or


pedals must return to neutral. hydraulic fluid leaks.

8. Check for correct function of 16. Lubricate the loader.


the work lights

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17. Check the condition of the 22. Operate the loader and check
battery and cables. all functions.

18. Inspect the air cleaner for 23. Check for any field
damage or leaks. Check the modification not completed.
condition of the element.

19. Check the electrical charging 24. Check for correct function of
system. the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.
20. Check tires for wear and Recommend to the owner that all
pressure. necessary corrections be made
before the machine is returned to

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service.

21. Inspect for loose or broken


parts or connections.

CALIFORNIA PROPOSITION 65 WARNING

Diesel engine exhaust and some of its constituents are known to the
state of California to cause cancer, birth defects and other
reproductive harm.

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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 instructions • An Operator’s Handbook fastened to the operator
can cause injury or death. cab. It’s brief instructions are convenient to the

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W-2003-0903 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.
WARNING • The AEM Safety Manual delivered with the machine
gives general safety information.
Warnings on the machine and in the manuals are for
your safety. Failure to obey warnings can cause • The Service Manual and Parts Manual are available
injury or death. from your dealer for use by mechanics to do shop-
W-2044-1285 type service and repair work.

• The Skid-Steer Loader Operator Training Course is


available through your local dealer or at
IMPORTANT www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
of correct operation of the Skid-Steer Loader. The
This notice identifies procedures which must be
course is available in English and Spanish versions.
followed to avoid damage to the machine.
I-2019-0284
• Service Safety Training Courses are available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com. They provide information for
safe and correct service procedures.

• The Skid-Steer Loader Safety Video is available from


your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.

SI SSL-1007 SM

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SAFETY INSTRUCTIONS (CONT’D)

The dealer and owner / operator review the


recommended uses of the product when delivered. If the
owner / operator will be using the machine for a different
application(s) he or she must ask the dealer for
recommendations on the new use.

Cutting or drilling concrete containing sand or rock


containing quartz may result in exposure to silica dust.
Do not exceed Permissible Exposure Limits (PEL) to
silica dust as determined by OSHA or other job site Rules
and Regulations. Use a respirator, water spray or other
means to control dust. Silica dust can cause lung disease
and is known to the state of California to cause cancer.

Call Before You Dig


Dial 811 (USA Only)

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1-888-258-0808 (USA & Canada)
When you call, you will be directed to a location in your
state / province, or city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.).

SI SSL-1007 SM

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FIRE PREVENTION Hydraulic System

Check hydraulic tubes, hoses and fittings for damage


and leakage. Never use open flame or bare skin to check
for leaks. Hydraulic tubes and hoses must be properly
routed and have adequate support and secure clamps.
Tighten or replace any parts that show leakage.

Maintenance Always clean fluid spills. Do not use gasoline or diesel


fuel for cleaning parts. Use commercial nonflammable
The machine and some attachments have components
solvents.
that are at high temperatures under normal operating
conditions. The primary source of high temperatures is
Fueling
the engine and exhaust system. The electrical system, if
damaged or incorrectly maintained, can be a source of
arcs or sparks.

Flammable debris (leaves, straw, etc.) must be removed


regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard. Stop the engine and let it cool before adding fuel. No
smoking! Do not refuel a machine near open flames or
The operator’s area, engine compartment and engine sparks. Fill the fuel tank outdoors.

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cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Starting

All fuels, most lubricants and some coolants mixtures are Do not use ether or starting fluids on any engine that has
flammable. Flammable fluids that are leaking or spilled glow plugs. These starting aids can cause explosion and
onto hot surfaces or onto electrical components can injure you or bystanders.
cause a fire.
Use the procedure in the Operation & Maintenance
Operation Manual for connecting the battery and for jump starting.

Do not use the machine where exhaust, arcs, sparks or


hot components can contact flammable material, Spark Arrestor Exhaust System
explosive dust or gases. The spark arrestor exhaust system is designed to control
the emission of hot particles from the engine and exhaust
Electrical 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).
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 staring. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.

SI SSL-1007 SM

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FIRE PREVENTION (CONT’D)

Welding And Grinding

Always clean the machine and attachment, disconnect


the battery, and disconnect the wiring from the Bobcat
controllers before welding. Cover rubber hoses, battery
and all other flammable parts. Keep a fire extinguisher
near the machine when welding.

Have good ventilation when grinding or welding painted


parts. Wear dust mask when grinding painted parts.
Toxic dust or gas can be produced.

Dust generated from repairing nonmetallic parts such as


hoods, fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away
from open flames or sparks.

Fire Extinguishers

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Know where fire extinguishers and first aid kits are
located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.

SI SSL-1007 SM

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LIFTING AND BLOCKING THE LOADER Figure 2

Procedure

Figure 1

P-31849

Put floor jack under the rear of the loader [Figure 2].

Lift the rear of the loader and install jackstands [Figure


2].

B-7023 Figure 3

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WARNING
AVOID INJURY OR DEATH
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions N-18877

can cause injury or death.


W-2003-0807
Put the floor jack under the front of the loader [Figure 3].

Always park the loader on a level surface. Lift the front of the loader and put jackstands under the
axle tubes [Figure 3].

NOTE: Make sure the jackstands do not touch the


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

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LIFT ARM SUPPORT DEVICE Start the engine, and raise the lift arms all the way up.
Figure 5
Installing Lift Arm Support Device

WARNING
Never work on a machine with the attachment raised P-31854B
unless secured by an approved support device.
Failure to use an approved support device can cause Have a second person install the lift arm support device
the lift arms, boom or attachment to fall and cause (Item 1) [Figure 5] over the rod of one of the lift cylinders.
serious injury or death.
W-2059-1007 The lift arm support device must be tight against the
cylinder rod. The tabs of the lift arm support device must
be under the cylinder as shown (Inset) [Figure 5].

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Figure 6

WARNING
Repair the support device if damaged or if parts are
missing. Using a damaged support device or with 1
missing parts can cause lift arms or boom to fall
causing serious injury or death.
W-2271-1007

Figure 4

P-31854

Lower the lift arms slowly until the lift arm support device
1 (Item 1) [Figure 6] is held between the lift arms and lift
cylinder .
Removing Lift Arm Support Device
The operator must be in the operator's seat, with the seat
belt fastened and seat bar lowered, until the lift arm
support device is removed and the lift arms are lowered
all the way.
Start the engine, raise the lift arms all the way up.
N-18488B
Have a second person remove the lift arm support
Put jackstands under the rear corners of the loader frame device.
(Inset) [Figure 4].
Lower the lift arms all the way and stop the engine.
Remove the lift arm support device (Item 1) [Figure 4]
from storage position. Return the lift arm support device to storage position and
The operator must be in the operator's seat, with the seat secure with clamping knobs.
belt fastened and seat bar lowered, until the lift arm Remove the jackstands.
support device is installed.

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OPERATOR CAB Figure 8

Description

The Bobcat loader has an operator cab (ROPS and


FOPS) as standard equipment to protect the operator
from rollover and falling objects. Check with your dealer if
the operator cab has been damaged. 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, Level I. Level II
is available.

Level I - Protection from falling bricks, small concrete P-10564B


blocks, and hand tools encountered in operations such
as highway maintenance, landscaping, and other
construction site services. Loosen the nut (both sides) at the front corners of the
operator cab [Figure 8].
Level II - Protection from falling trees, rocks; for
machines involved in site clearing, overhead demolition Remove the nuts and plates [Figure 8] (both sides).
or forestry.

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Raising The Operator Cab

Always stop the engine before raising or lowering the


cab.

Stop the loader on a level surface. Lower the lift arms. If


the lift arms must be up while raising the operator cab,
install the lift arm support device. (See Installing Lift Arm
Support Device on Page X.)

Figure 7

P-31849

Install jackstands under the rear of the loader frame


[Figure 7].

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OPERATOR CAB (CONT’D) Lowering The Operator Cab

Raising The Operator Cab (Cont’d) Always stop the engine before raising or lowering the
cab.
Figure 9
NOTE: Make sure the seat bar is fully raised or
lowered when lowering the cab. Always use
the grab handles to lower the cab.

Figure 10

P-31858A

Lift on the grab handle and bottom of the operator cab


slowly until the cab is all the way up and the latching
mechanism engages [Figure 9].

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Advanced Hand Controls Only P-31859B

Pull down on the bottom of the operator cab until it stops


at the latching mechanism [Figure 10].

Release the latching mechanism (Inset) [Figure 10] and


pull the cab all the way down.

Figure 11

WARNING P-10564B

Never modify operator cab by welding, grinding,


Install the plates and nuts [Figure 11] (both sides).
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to
Tighten the nuts to 40-50 ft.-lb. (54-68 N•m) torque.
the cab can cause loss of operator protection from
rollover and falling objects, and result in injury or
death.
W-2069-0200

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BOBCAT LOADER IDENTIFICATION

Always use the serial number of the loader when


requesting service information or when ordering parts.
Different model loaders may use a different procedure in
doing a specific service operation.

Loader Serial Number

Figure 12

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S N PLATE

Refer to your model loader's Operation & Maintenance


Manual or Service Manual for the location of the serial
number plate [Figure 12].

Explanation of loader Serial Number:

1. The four digit Model/Engine Combination Module


number identifies the model number and engine
combination.

2. The five digit Production Sequence Number identifies


the order which the loader is produced.

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PRELIMINARY LOADER GLOSSARY OF TERMS

Master Password Password set at factory and cannot be changed. Allows for full use of the loader and set
up of owner and user passwords. Available with deluxe instrumentation only.
Owner Password Allows for full use of the loader. Can change user password and set up operator
password(s). Can not change master password. Available with deluxe instrumentation
only.
User Password Allows starting and operating the loader. Can not change any passwords. Available with
deluxe instrumentation only.
BICS Bobcat Interlock Control System. A system that monitors safety related inputs and
enables or disables use of lift, tilt and traction.
Service Code Four digit code displayed on the left instrument panel by the Bobcat controller. Bobcat
controller continuously monitors for service or problem conditions and displays associated
condition in the form of service codes.
Standard Instrumentation Key switch and icons in right side panel.
Deluxe Instrumentation Numeric pad keyless ignition, icons and multi-use display in right side panel.
Bobcat Controller Solid state module which communicates with instrument panels and optional attachment
controllers. Receives sensor information, provides outputs to operator, machine solenoids
and relays as programmed.
Service PC Computer connected to the Bobcat remote start tool. Provides ability to initialize
replacement Bobcat controller, monitor sensors for troubleshooting and displaying stored

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machine service codes.
Bobcat Remote Start Tool Service tool for remote starting the loader and other functions normally operated from
operator cab. Provides interconnection to a service PC.
Service Software Software required when using service PC to allow communication with Bobcat controller.
Service Upgrade Software Software program used by the service PC to check the version of software loaded in
controllers and for upgrading controllers to latest software version.
Service Analyzer Software Software program for service PC. Used to monitor sensors and display historic machine
conditions.
Controller Solid state device which receives inputs and provides outputs as designed.
AHC Advanced Hand Controls. Machine option which provides control of lift and tilt functions
with the steering handles electronically.
ACD Attachment Control Device. A module that receives inputs from the machine and provides
outputs to control attachment functions.
RACD Remote Attachment Control Device. A type of ACD that also allows starting and stopping
the loader's engine and operating an attachment outside of the loader's operator cab.
Icon Symbol representation of a condition or event.
Fault Tree A graphic flow chart used to simplify troubleshooting procedures.
Fuse/Relay Panel Panel which contains multiple fuses and relays. Located on the front of the steering panel
below the operator seat.
Display Service Code Operator selection that when activated displays current service codes.
Short When a wire or other electric component contacts another wire or other electric
component when it should not.

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PRELIMINARY LOADER GLOSSARY OF TERMS (CONT'D)

Open A condition when a wire or other electric current carrying component no longer makes
electrical contact. (examples; broken wire, loose connector).
Continuity A completed electrical circuit. When all connections in an electrical circuit are making
complete contact and allow full designed current to flow. No opens.
Multi-Meter A tool used to measure volts, ohms and electric current. The types of measurements
available and ranges vary by model.
Electric Schematic A drawing using standardized graphic symbols to indicate the function and
interconnection of an electrical circuit. The schematic allows tracing the circuit and its
functions without regard to the actual physical size, shape, or location of components or
parts.
Auxiliary Bleed Valve A valve located in the auxiliary circuit that, when activated, bleeds the auxiliary circuit to
the reservoir.
Pressure Sensor Tester A tool used to monitor and troubleshoot the engine oil pressure and hydraulic charge
Special Tool pressure sensors.
Sensor Tester Special Tool A tool used to monitor and troubleshoot the seat bar sensor.
Seat Bar Sensor Adapter A cable used to adapt the sensor tester for use with the new seat bar sensor used on the
Cable `G' series loaders.
Error ON The Bobcat controller sensed an ON condition (voltage) when it should have been OFF.
Such a condition would exist if a power wire shorted to a sensor wire in the harness.

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Error OFF The Bobcat controller sensed an OFF condition (no voltage) when it should have been
ON. Such a condition would exist if a wire from a sensor was broken or disconnected in
the harness.

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TOOLS TOOLS

ACTUATOR TEST HARNESS (DEUTSCH) - MEL1554 . . . . . 10-60-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1


Digital Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
Resistance Test (Ohms). . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

REMOTE START TOOL KIT-MEL1563. . . . . . . . . . . . . . . . . . 10-20-1


Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-4
Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Service Bar Sensor Adapters-MEL1567 . . . . . . . . . . . . . . 10-20-6
Service Tool Harness Communicator - MEL1566 . . . . . . . 10-20-3
Service Tool Harness Control - MEL1565 . . . . . . . . . . . . . 10-20-2

REMOTE START TOOL (SERVICE TOOL) KIT - 6689779 . . 10-21-1


Computer Service Tool Harness - 6689746 . . . . . . . . . . . . 10-21-3
Loader Service Tool Harness - 6689747 . . . . . . . . . . . . . . 10-21-2
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21-4

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Remote Start Tool (Service Tool) - 6689778 . . . . . . . . . . . 10-21-1
Service Bar Sensor Adapters-MEL1567 . . . . . . . . . . . . . . 10-21-7

SENSOR TESTER - MEL1428 . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . 10-40-1


Connecting Remote Start Tool (Service Tool) . . . . . . . . . . 10-40-2
Connecting The Service PC. . . . . . . . . . . . . . . . . . . . . . . . 10-40-2
Installing Service Software. . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Minimum Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

TEST ADAPTER KIT - MEL1568 . . . . . . . . . . . . . . . . . . . . . . 10-50-1


10 Foot Extension Lead- MEL1568-3 . . . . . . . . . . . . . . . . 10-50-1
Advanced Hand Control "T" Harness-MEL1568-2. . . . . . . 10-50-2
Pressure Sender Tester - MEL1568-1 . . . . . . . . . . . . . . . . 10-50-1

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Dealer Copy -- Not for Resale

24 of 118 10-02 Loader Electrical System Service Manual


GENERAL INSTRUCTIONS Resistance Test (Ohms)

Digital Multimeter Figure 10-10-2

We recommend using a digital multimeter when testing


voltage, resistance and continuity of a circuit. Follow the
applicable instruction manual provided with the
multimeter to become familiar with its operation.

Voltage Test

Figure 10-10-1

N-20271

Install the test probes into the correct connections on the


multimeter for taking resistance measurements [Figure
10-10-2].

Dealer Copy -- Not for Resale


Select resistance test (Ohm meter) and select the
desired scale or range.
N-20270
Before connecting the probes to take a measurement,
always disconnect the battery power from the circuit to be
Install the test probes into the correct connections on the tested. Any battery voltage will give an incorrect
multimeter for taking DC voltage readings [Figure 10-10- resistance measurement.
1].
Connect the negative (Black) and positive (Red) probes
across the location you wish to measure.
Select voltage test and desired scale or range.
The meter will display the resistance in Ohms between
Connect the negative (Black) and positive (Red) probes the negative test point and the positive test point.
across the location you wish to measure.
Related Notes:
The meter will display the voltage difference between the
negative test point and the positive test point. The ohmmeter actually measures the current which flows
from the negative to positive test probes. The current
source is the battery in the multimeter. This is important
to know when checking diodes. A diode will show a very
small or zero resistance when connected in one direction
and a very high or infinite resistance when connected in
the other direction. If the resistance is the same in both
directions, the diode is defective.

When using an ohmmeter for checking the continuity of a


wire harness, connect one probe to one end and the
other probe to the other end. The meter should display a
very small amount of resistance, usually less than one
ohm. If the wire is broken or has a bad contact to a
connector or splice, the resistance reading will be much
higher or infinite. If the wire passes this test, but you think
it may be shorted to another wire or ground, place one of
the probes to each of other connector pins in the harness
and check that the resistance is infinite to each of the
other wires. Any lower resistance value indicates a short
or other contact between the wires.

25 of 118 10-10-1 Loader Electrical System Service Manual


Dealer Copy -- Not for Resale

26 of 118 10-10-2 Loader Electrical System Service Manual


REMOTE START TOOL KIT-MEL1563 Figure 10-20-2

Remote Start Tool - MEL1563

Tools that will be needed to complete the following steps


are:
2
MEL1563 - Remote Start Tool 3
MEL1565 - Service Tool Harness Control 1
MEL1566 - Service Tool Harness Communicator
(Computer Interface)

Figure 10-20-1

P16117
1

The traction lock switch (Item 1) [Figure 10-20-2] is used


to turn traction lock ON or OFF. Push the switch to the
override postion. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the wheels are
able to turn.

Dealer Copy -- Not for Resale


The maximum flow/variable flow switch (Item 2) [Figure
10-20-2] is used to activate the auxiliary hydraulics.
Pressing the switch once will activate maximum flow.
P16114 Pressing the switch again will activate variable flow. The
switch will illuminate to indicate which flow rate is active.
Pressing the switch a third time will turn the flow OFF.
The remote start tool (Item 1) [Figure 10-20-1] is The switch is used when checking pressures and flow
required when the service technician is checking the rate.
hydraulic/hydrostatic system or adjusting the steering
linkage. The auxiliary pressure release (Item 3) [Figure 10-20-2]
is used to release hydraulic pressure to the front and/or
rear auxiliary couplers. To release pressure; push and
hold the switch for a few seconds.

NOTE: With the engine running; pushing and holding


the pressure release switch will cause the
engine to stop. To relieve the pressure; press
the switch until the engine stops.

27 of 118 10-20-1 Loader Electrical System Service Manual


REMOTE START TOOL-MEL1563 (CONT'D) Service Tool Harness Control - MEL1565

Remote Start Tool - MEL1563 (Cont’d) Figure 10-20-5

Figure 10-20-3
2

1 1

P16114

P16116
The service tool harness control (Item 1) [Figure 10-20-
5] is used to connect the remote start tool (Item 2)
Figure 10-20-4 [Figure 10-20-5] to the electrical system on the loader.

Dealer Copy -- Not for Resale


1 Figure 10-20-6

P16120

N-19561
The 10-pin rectangular connector (Item 1) [Figure 10-20-
3] is used to update software in the Deluxe
Instrumentation Panel (Item 1) [Figure 10-20-4]. Remove the plug (Item 1) [Figure 10-20-6] from the
loader harness connector.
NOTE: The Service PC must be connected to the
remote start tool to update the deluxe panel Connect the service tool harness control to the loader
software. harness connector.

The panel must be removed from inside the operator cab


and plugged into this connector [Figure 10-20-3].

28 of 118 10-20-2 Loader Electrical System Service Manual


REMOTE START TOOL-MEL1563 (CONT'D) Service Tool Harness Communicator - MEL1566

Service Tool Harness Control - MEL1565 (Cont’d) Figure 10-20-8

Figure 10-20-7 2

2
1

1
P16119

N-19631
The service tool harness communicator (Item 1) [Figure
10-20-8] is required to connect remote start tool to the
Loaders equipped with an attachment harness (Item 1) Service PC (Item 2) [Figure 10-20-8].
[Figure 10-20-7] must disconnect the attachment

Dealer Copy -- Not for Resale


harness from the loader harness (Item 2) [Figure 10-20-
7].

Connect the service tool harness to the ACD connector


and the loader harness connector.

NOTE: To monitor, diagnose or load new software


the Service PC must be connected to the
Remote Start Tool Switch.

29 of 118 10-20-3 Loader Electrical System Service Manual


REMOTE START TOOL KIT-MEL1563 (CONT’D) Figure 10-20-11

Remote Start Procedure

The tool listed will be needed to do the following


procedure:

MEL1563: Remote Start Tool Kit


1
Figure 10-20-9

1
N-19150

Remove the plug (Item 1) [Figure 10-20-10] or


disconnect the attachment control harness (Item 1)
[Figure 10-20-11] if connected.

Figure 10-20-12

Dealer Copy -- Not for Resale


P16115

The remote start tool (Item 1) [Figure 10-20-9] is


required when the operator cab is in the raised position
for service and the service technician needs to turn the
key switch on or start the engine. Example: adjusting the
steering linkage.

Lift and block the loader. (See LIFTING AND BLOCKING


THE LOADER on Page IX.)

Raise the lift arms (if required by the procedure) and


install an approved lift arm support device. (See LIFT
ARM SUPPORT DEVICE on Page X.)
P13861
Raise the operator cab (if required by the procedure).
(See Raising The Operator Cab on Page XI.)
Connect the remote start tool to the engine harness
Open the rear door of the loader. connector [Figure 10-20-12].

Figure 10-20-10 NOTE: The key switch on the right-hand side


operator panel must be in the off position or
the Remote Start Kit will not operate.

WARNING
1 AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
the Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
service technician will be working in the engine area
N-19151
it is important to remove the operator panel keys.
W-2357-0899

30 of 118 10-20-4 Loader Electrical System Service Manual


REMOTE START TOOL KIT-MEL1563 (CONT'D) Figure 10-20-14

Remote Start Procedure (Cont'd)

Figure 10-20-13

2
3 1

P16118

The traction lock switch (Item 1) [Figure 10-20-14] is


P16116 used to turn traction lock on or off. Push the switch to the
override position. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the wheels are
The remote start tool (Item 1) [Figure 10-20-13] has able to turn.
three rocker switches.

Dealer Copy -- Not for Resale


The maximum flow/variable flow switch (Item 2) [Figure
10-20-14] is used to activate the auxiliary hydraulics.
Pressing the switch once will activate variable flow.
Pressing the switch again will activate maximum flow.
The switch will illuminate to indicate which flow rate is
active. Pressing the switch a third time will turn the flow
OFF. The switch is used when checking pressures and
flow rate.

The auxiliary pressure release (Item 3) [Figure 10-20-14]


is used to release hydraulic pressure to the front and/or
rear auxiliary couplers. To release pressure; push and
hold the switch for three seconds.

NOTE: With the engine running; pushing and holding


the pressure release switch will cause the
engine to stop in three seconds. To relieve the
pressure; continue to press the switch after
the engine has stopped.

31 of 118 10-20-5 Loader Electrical System Service Manual


REMOTE START TOOL-MEL1563 (CONT'D) Figure 10-20-17

Service Bar Sensor Adapters-MEL1567

Figure 10-20-15
1

N-19558

1
The seat bar sensor adapters (Item 1) [Figure 10-20-15]
N-19553 are required to connect the Sensor Tester (MEL1428)
(Item 1) [Figure 10-20-16] to the seat bar sensor (Item 1)
[Figure 10-20-17].
Figure 10-20-16

Dealer Copy -- Not for Resale


1

P-4698

32 of 118 10-20-6 Loader Electrical System Service Manual


REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-21-2
6689779
2
Remote Start Tool (Service Tool) - 6689778

Tools that will be needed to complete the following steps


5 3
are:

Order from Bobcat Parts P/N: 6689779 - Remote Start 6 4


Tool (Service Tool) Kit

Kit Includes:
6689778 - Remote Start Tool (Service Tool) 1
6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness
6689745 - BOSS® Service Tool Harness
P-76439
Figure 10-21-1
The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
21-2] has five buttons.

The STOP button (Item 2) [Figure 10-21-2] is used to


stop the Remote Start Tool (Service Tool) from
communicating and stop the loader engine.

Dealer Copy -- Not for Resale


The RUN button (Item 3) [Figure 10-21-2] is used to turn
the Remote Start Tool (Service Tool) on and activates the
1 loader ignition power. The button will illuminate to
indicate the service tool is active.

The START button (Item 4) [Figure 10-21-2] is used to


start the loader engine.
P-76678

The traction lock button (Item 5) [Figure 10-21-2] is used


to turn traction lock ON or OFF. Push the button and the
The remote start tool (Item 1) [Figure 10-21-1] is button will illuminate indicating the traction lock is
required when the service technician is checking the disabled in which the wheels or tracks are able to turn.
hydraulic / hydrostatic system or adjusting the steering
linkage. Loader S/N: xxxx60000 & Below

The auxiliary button (Item 6) [Figure 10-21-2] is used to


activate the auxiliary hydraulics. The button will illuminate
to indicate the auxiliary hydraulics are active. Pressing
the button once will activate maximum flow. Pressing the
button again will activate variable flow. Pressing the
button a third time will turn the flow OFF. The button is
used when checking pressures and flow rate.

Loader S/N: xxxx60001 & Above

The auxiliary button (Item 6) [Figure 10-21-2] is used to


activate the auxiliary hydraulics. The button will illuminate
to indicate the auxiliary hydraulics are active. Pressing
the button a second time will turn the flow OFF. The
button is used when checking pressures and flow rate.

33 of 118 10-21-1 Loader Electrical System Service Manual


REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-21-5
6689779 (CONT'D)

Loader Service Tool Harness - 6689747 2

Figure 10-21-3

P-76452
2

Loaders with an attachment control harness (7 pin or 14


pin), the attachment harness (Item 1) must be
P-76678 disconnected from the loader harness (Item 2) [Figure
10-21-5].

The loader service tool harness (Item 1) [Figure 10-21-3] When the remote start procedure is completed, replace

Dealer Copy -- Not for Resale


is used to connect the remote start tool (service tool) the loader connector cap (Item 1) [Figure 10-21-4] or
(Item 2) [Figure 10-21-3] to the electrical system on the reconnect the attachment control harness to the loader
loader. harness [Figure 10-21-5].

Figure 10-21-4

P-76451

Loaders without an attachment control harness, remove


the loader harness cap (Item 1) [Figure 10-21-4] and
connect the Loader Service Tool Harness from the
Remote Start Tool (Service Tool).

34 of 118 10-21-2 Loader Electrical System Service Manual


REMOTE START TOOL (SERVICE TOOL) KIT - Computer Service Tool Harness - 6689746
6689779 (CONT'D)
Figure 10-21-7
Loader Service Tool Harness - 6689747 (Cont’d)

Figure 10-21-6

2 1

3 2
1 P-76450

P-76453 The computer service tool harness (Item 1) [Figure 10-


21-7] is required to connect remote start tool (service
NOTE: The Remote Start Tool (Service Tool) tool) to the Service PC (Item 2) [Figure 10-21-7].
connection harness has two connectors (Item

Dealer Copy -- Not for Resale


1) and (Item 3). The main connector (Item 1)
[Figure 10-21-6] is always used for connection
to the loader harness.

The second connector (Item 3) [Figure 10-21-


6] is used for attachment ACD upgrades or
attachment operational diagnostics only. This
connector has a cap attached to it to prevent
damage or corrosion when not in use.

Connect the Remote Start Tool (Service Tool) connector


(Item 1) to the loader harness connector (Item 2) and the
other Remote Start Tool (Service Tool) connector to the
ACD harness connector (Item 3) [Figure 10-21-6].

NOTE: The right instrument panel (Key Switch or


Keyless) must be in the off position or the
Remote Start Tool (Service Tool) will not
operate.

P-76454

35 of 118 10-21-3 Loader Electrical System Service Manual


REMOTE START TOOL (SERVICE TOOL) KIT - Raise the operator cab (if required by the procedure).
6689779 (CONT'D) (See Raising The Operator Cab on Page XI.)

Remote Start Procedure Open the rear door of the loader.

Figure 10-21-9

WARNING 1
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
Remote Start Tool RUN button is not illuminated, the
loader can still be started from the operator panel
inside the cab.

Pressing the RUN button on the Remote Start Tool


disconnects the operator panel from the start circuit.
If the service technician will be working in the engine
area it is important to remove the operator panel key P-76451
or lock the keypad with a unique password.
W-2647-0707
Loaders without an attachment control harness, remove
The tool listed will be needed to do the following the loader harness cap (Item 1) [Figure 10-21-9] and

Dealer Copy -- Not for Resale


procedure: connect the Loader Service Tool Harness from the
Remote Start Tool (Service Tool).
6689779: Remote Start Tool (Service Tool) Kit
Figure 10-21-10
Figure 10-21-8
2

P-76452

P-76450

Loaders with an attachment control harness (7 pin or 14


The Remote Start Tool (Service Tool) (Item 1) [Figure 10- pin), the attachment harness (Item 1) must be
21-8] is required when the operator cab is in the raised disconnected from the loader harness (Item 2) [Figure
position for service and the service technician needs to 10-21-10].
turn on the loader or start the engine. Example: adjusting
the steering linkage. When the remote start procedure is completed, replace
the loader connector cap (Item 1) [Figure 10-21-10] or
Lift and block the loader. (See LIFTING AND BLOCKING reconnect the attachment control harness to the loader
THE LOADER on Page IX.) harness [Figure 10-21-10].

Raise the lift arms (if required by the procedure) and


install an approved lift arm support device. (See LIFT
ARM SUPPORT DEVICE on Page X.)

36 of 118 10-21-4 Loader Electrical System Service Manual


REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-21-12
6689779 (CONT'D)
2
Remote Start Procedure (Cont'd)

Figure 10-21-11
5 3
2
6 4
1

P-76439

3
1 The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
21-12] has five buttons.
P-76453
The STOP button (Item 2) [Figure 10-21-12] is used to
stop the Remote Start Tool (Service Tool) from
NOTE: The Remote Start Tool (Service Tool)
connection harness has two connectors (Item communicating and stop the loader engine.

Dealer Copy -- Not for Resale


1) and (Item 3). The main connector (Item 1)
[Figure 10-21-11] is always used for The RUN button (Item 3) [Figure 10-21-12] is used to
connection to the loader harness. turn the Remote Start Tool (Service Tool) on and
activates the loader ignition power. The button will
The second connector (Item 3) [Figure 10-21- illuminate to indicate the service tool is active.
11] is used for attachment ACD upgrades or
attachment operational diagnostics only. This The START button (Item 4) [Figure 10-21-12] is used to
connector has a cap attached to it to prevent start the loader engine.
damage or corrosion when not in use.
The traction lock button (Item 5) [Figure 10-21-12] is
Connect the Remote Start Tool (Service Tool) connector used to turn traction lock ON or OFF. Push the button and
(Item 1) to the loader harness connector (Item 2) and the the button will illuminate indicating the traction lock is
other Remote Start Tool (Service Tool) connector to the disabled in which the wheels or tracks are able to turn.
ACD harness connector (Item 3) [Figure 10-21-11].
Loader S/N: xxxx60000 & Below
NOTE: The right instrument panel (Key Switch or
Keyless) must be in the off position or the The auxiliary button (Item 6) [Figure 10-21-12] is used to
Remote Start Tool (Service Tool) will not activate the auxiliary hydraulics. The button will illuminate
operate. to indicate the auxiliary hydraulics are active. Pressing
the button once will activate maximum flow. Pressing the
button again will activate variable flow. Pressing the
button a third time will turn the flow OFF. The button is
used when checking pressures and flow rate.

Loader S/N: xxxx60001 & Above

The auxiliary button (Item 6) [Figure 10-21-12] is used to


activate the auxiliary hydraulics. The button will illuminate
to indicate the auxiliary hydraulics are active. Pressing
the button a second time will turn the flow OFF. The
button is used when checking pressures and flow rate.

P-76454

37 of 118 10-21-5 Loader Electrical System Service Manual


REMOTE START TOOL (SERVICE TOOL) KIT -
6689779 (CONT'D)

Remote Start Procedure (Cont'd)

Figure 10-21-13

1 2

P-76441

The gear icon with the left facing arrows (Item 1) [Figure
10-21-13] will illuminate and blink when the RUN key is

Dealer Copy -- Not for Resale


pressed and the loader is communicating with the service
tool.

The computer icon with the right facing arrows (Item 2)


[Figure 10-21-13] will illuminate and blink when the
Remote Start Tool (Service Tool) is transmitting data to
and from the computer.

Loader S/N: xxxx60000 & Below

NOTE: To relieve the pressure at the rear or


secondary front auxiliary, (if equipped) press
and hold the AUXILIARY PRESSURE
RELEASE button on the left instrument panel
for three seconds after the engine has
stopped.

Loader S/N: xxxx60001 & Above

NOTE: To relieve the pressure at the rear or


secondary front auxiliary, (if equipped) press
the RUN button on the remote start tool. Then
press the auxiliary (AUX) hydraulics button on
the remote start tool and move the AUXILIARY
Hydraulic Switch on the to the right and left
several times.

38 of 118 10-21-6 Loader Electrical System Service Manual


REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-21-16
6689779 (CONT'D)

Service Bar Sensor Adapters-MEL1567

Figure 10-21-14 1

N-19558

1
The seat bar sensor adapters (Item 1) [Figure 10-21-14]
are required to connect the Sensor Tester (MEL1428)
N-19553 (Item 1) [Figure 10-21-15] to the seat bar sensor (Item 1)
[Figure 10-21-16].

Figure 10-21-15

Dealer Copy -- Not for Resale


1

P-4698

39 of 118 10-21-7 Loader Electrical System Service Manual


Dealer Copy -- Not for Resale

40 of 118 10-21-8 Loader Electrical System Service Manual


SENSOR TESTER - MEL1428 Figure 10-30-3

Figure 10-30-1

2
1

N-18409

N-19554
The sensor tester is also used to check the BICS Circuit
and the seat bar indicator light (Item 1) [Figure 10-30-3].
Figure 10-30-2

Dealer Copy -- Not for Resale


1

N-19558

The sensor tester (Item 1) [Figure 10-30-1] and seat bar


sensor adapters MEL1567 (Item 2) [Figure 10-30-1] are
required to test the seat bar sensor (Item 1) [Figure 10-
30-2].

41 of 118 10-30-1 Loader Electrical System Service Manual


Dealer Copy -- Not for Resale

42 of 118 10-30-2 Loader Electrical System Service Manual


SERVICE PC (LAPTOP COMPUTER) Installing Service Software

Minimum Requirements Figure 10-40-2

Figure 10-40-1

DIAGRAM
2

DIAGRAM
1
Download the Service Software from the BobcatNet
www.bobcatnet.com to your computer [Figure 10-40-
To service the loader electronics, Bobcat Company 2]. Download by following the screen instructions.
recommends that your dealership designate a portable

Dealer Copy -- Not for Resale


computer as the "Service PC" [Figure 10-40-1]. Although
a Desktop computer on a mobile cart is adequate, a
Laptop will be much more durable and convenient in a
service environment. Your Service PC should meet the
following minimum requirements to operate the Service
Software and to allow for future upgrades and features.

Minimum System Requirements:

Windows® 95/98, NT 4.0, 2000, XP operating system


Pentium® processor, 200MHz or higher
Internet Explorer 4.0 or higher
32 MB of Memory
20 MB of Free Hard Drive Space
24X CD-ROM
Serial Port

Recommended System Requirements:

Windows® 2000 / XP operating system


Pentium® Class III or higher
Internet Explorer 4.0 or higher
64 MB of Memory
20 MB of Free Hard Drive Space
24X CD-ROM
Serial Port

Newer laptops may require a USB to Serial Adapter


Cable. (Not all cables will work with the Bobcat system,
see the recommended cables and suppliers on
BobcatNET for up to date information.)

43 of 118 10-40-1 Loader Electrical System Service Manual


SERVICE PC (LAPTOP COMPUTER) (CONT’D) Connecting Remote Start Tool (Service Tool)

Connecting The Service PC Figure 10-40-4

Figure 10-40-3

1 2
2

3
1
P-76450

P16119
The tools listed will be needed to do the following
procedure:
Tools that will be needed to complete the following steps
are: Order from Bobcat Parts P/N: 6689779 - Remote Start

Dealer Copy -- Not for Resale


Tool (Service Tool) Kit
MEL1563 - Remote Start Tool
Kit Includes:
MEL1565 - Service Tool Harness Control
6689778 - Remote Start Tool (Service Tool)
MEL1566 - Service Tool Harness Communicator
6689747 - Loader Service Tool Harness
(Computer Interface)
6689746 - Computer Service Tool Harness
6689745 - BOSS® Service Tool Harness
NOTE: Make all connections with the key in the OFF
position.
NOTE: Make all connections with the key in the OFF
position.
The Service PC (Item 1) [Figure 10-40-3] with the
remote start tool (Item 2) [Figure 10-40-3]. When
The Service PC (Item 1) with the Remote Start Tool
connected to the loader, the Service PC is used to
(Service Tool) (Item 2) [Figure 10-40-4]. When
monitor, conduct diagnostic and load software.
connected to the loader, the Service PC is used to
monitor, conduct diagnostics, and upgrade software.
Connect the Service Tool Harness Communicator
(MEL1566) (Item 3) [Figure 10-40-3] to the designated
Connect the Remote Start Tool (Service Tool) Computer
serial port on the Service PC.
Service Tool Harness (Item 3) [Figure 10-40-4] to the
designated serial port on the Service PC.
NOTE: The recommended serial cable length should
not exceed 15 feet. A serial cable longer than
NOTE: The recommended serial cable length should
15 feet will create a degraded signal causing
not exceed 15 feet. A serial cable longer than
communication errors.
15 feet will create a degraded signal causing
communication errors.
Connect the other end to the connector on the remote
start tool.
Connect the other end to the connector on the Remote
Start Tool (Service Tool).
Connect the remote start tool to the loader. (See Remote
Start Procedure on Page 10-20-4.)
Connect the Remote Start Tool (Service Tool) to the
loader. (See Remote Start Procedure on Page 10-20-4.)

44 of 118 10-40-2 Loader Electrical System Service Manual


TEST ADAPTER KIT - MEL1568 10 Foot Extension Lead- MEL1568-3

Pressure Sender Tester - MEL1568-1 Figure 10-50-3

Figure 10-50-1

1
2

N-19301

N-19632A
Figure 10-50-4

The Pressure Sender Tester (Item 1) [Figure 10-50-1] is


used to test engine oil pressure sender and the hydraulic

Dealer Copy -- Not for Resale


charge pressure sender.

The tester plugs in-line between the harness and the


sender. The tester has three probe sockets. The sockets
are labeled A, B, and C.

Sockets A (positive) and B (negative) are used to check


voltage.

Socket C (positive) is signal voltage from the sender to


the Bobcat controller.
1
N-19392
Figure 10-50-2

The 10 foot extension lead (Item 2) [Figure 10-50-1] is


used when taking test readings on the electrical harness.
1
The extension lead can be used when testing between
sensor/sender connectors on the engine and the J1, J2,
J3 and J4 harness connectors of the controller. The
extension lead is also used with tester (Item 1) [Figure
10-50-3] and a multi-meter (Item 1) [Figure 10-50-4] to
conduct checks.

N-19774

The tester uses a toggle switch (Item 1) [Figure 10-50-2]


to connect or disconnect socket C from the loader
harness.

45 of 118 10-50-1 Loader Electrical System Service Manual


TEST ADAPTER KIT-MEL1568 (CONT’D) Figure 10-50-7

Advanced Hand Control "T" Harness-MEL1568-2

The Advanced Hand Control "T" harness.

Figure 10-50-5 1

P13860

Disconnect the handle three-pin connector (Item 1)


[Figure 10-50-7].

P13863 Figure 10-50-8

Figure 10-50-6

Dealer Copy -- Not for Resale


1

P13857

N-17783
Connect the Advanced Hand Control "T" harness (Item
1) [Figure 10-50-8] to the handle three-pin connector.
The Advanced Hand Control "T" harness (MEL1568-2)
(Item 1) [Figure 10-50-5], is required when taking
voltage readings from the handle control unit [Figure 10-
50-6] on the loaders.

The loaders have a three-pin connector as compared to


the eight-pin connector used on previous models.

Right Switch Handle

Three-Pin Connector
A-Terminal - Pink/Red - Power
B-Terminal - Pink/Black - Ground
C-Terminal - Pink/Lt. Green - Signal
Left Switch Handle

Three-Pin Connector
A-Terminal - Brown/Red - Power
B-Terminal - Brown/Black - Ground
C-Terminal - Brown/Lt. Green - Signal

46 of 118 10-50-2 Loader Electrical System Service Manual


ACTUATOR TEST HARNESS (DEUTSCH) - MEL1554 Figure 10-60-3

Description

Figure 10-60-1

1
P13859

Disconnect the eight-pin connector (Item 1) [Figure 10-


P13864 60-3] of the actuator(s).

Figure 10-60-4
The actuator test harness (Item 1) [Figure 10-60-1] and
a digital multimeter are required when taking voltage

Dealer Copy -- Not for Resale


readings from the actuator(s). 1

Figure 10-60-2

P13858

Connect the actuator test harness (Item 1) [Figure 10-


60-4] to the loader and actuator eight-pin connectors.
N-18882

Remove the right front side panel (Item 1) [Figure 10-60-


2] from the loader.

47 of 118 10-60-1 Loader Electrical System Service Manual


Dealer Copy -- Not for Resale

48 of 118 10-60-2 Loader Electrical System Service Manual


GENERAL INFORMATION

BOBCAT CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1


Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
GENERAL
CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11-1 INFORMATION
Attachment Control Information (Keyless) . . . . . . . . . . . . . . . . . . . 20-11-2
Right Panel Setup (Keyless) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11-1

ELECTRICAL HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1


21-Pin Octal Style Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6
Connector Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Deutsch Connector Disassembly And Assembly (Flat Faced) . . . 20-40-5
Deutsch Connector Disassembly And Assembly (Flush Faced) . . 20-40-5
Metri-Pac Connector Disassembly And Assembly. . . . . . . . . . . . . 20-40-2
Seven-Pin Octal Metri-Pac Connector Disassembly And Assembly20-40-3

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . 20-20-1

Dealer Copy -- Not for Resale


INSTRUMENT PANEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Left Panel (System Identification With Shut-down Option) . . . . . . 20-10-3
Left Panel (System Identification Without Shut-down Option) . . . . 20-10-2
Right Panel (Key Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-4
Right Panel (Keyless) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
Right Panel Downgrade (Deluxe To Standard) . . . . . . . . . . . . . . . 20-10-7
Right Panel Upgrade (Standard to Deluxe) . . . . . . . . . . . . . . . . . . 20-10-7
Side And Front Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-8

MAINTENANCE CLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13-1
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13-1
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13-1

PASSWORD SETUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12-1


Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12-1
Changing The User Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12-2
Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12-1
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12-2

49 of 118 20-01 Loader Electrical System Service Manual


Dealer Copy -- Not for Resale

50 of 118 20-02 Loader Electrical System Service Manual


INSTRUMENT PANEL IDENTIFICATION The left instrument panel [Figure 20-10-1] is the same
for both Key Switch and Keyless equipped machines.
Left Panel
The table below shows the DESCRIPTION and
Figure 20-10-1 FUNCTION / OPERATION for each of the components of
the left panel.
2
1
3

4 5 6 7 8

11 12
13 9 10

14
B-15551

Dealer Copy -- Not for Resale


REF.
DESCRIPTION FUNCTION / OPERATION
NO
1 TEMPERATURE GAUGE Shows the engine coolant temperature.
2 HOURMETER / CODE DISPLAY / HOURMETER - Records operating hours of loader. CODE DISPLAY - Display numeric SERVICE CODES*
ENGINE PREHEAT COUNTDOWN relating to the loader monitoring system. ENGINE PREHEAT COUNTDOWN - Preheat time remaining.
3 FUEL GAUGE Shows the amount of fuel in the tank.
4 LIGHTS / HOLD FOR CODES LIGHTS - Press once for FRONT LIGHTS. Press a second time for FRONT AND REAR lights. Press a third time
to turn all lights off. HOLD FOR CODES - Press and hold two seconds for display of SERVICE CODES (Item 2).
(CODES* show only when there is an error found by loader monitoring system.)
5 BUCKET POSITIONING (Option) Press to engage the BUCKET POSITIONING function. Press again to disengage. Press and hold two seconds
to view [SHTDN] and Operational Code Number in HOURMETER / CODE DISPLAY.
ATTACHMENT AUXILIARY HYDRAULICS
6 HIGH FLOW (Option) Press to engage the HIGH-FLOW auxiliary hydraulics. Press again to disengage.
7 MAXIMUM FLOW / VARIABLE FLOW Press once to engage the VARIABLE FLOW auxiliary hydraulics. Press a second time to engage MAXIMUM
FLOW. Press a third time to disengage all auxiliary hydraulics. [VARIABLE FLOW allows for slow-to-fast
movement of auxiliary functions (The farther you move the switch, the faster the movement of auxiliary
functions.) MAXIMUM FLOW allows for only fast movement.]
8 AUXILIARY PRESSURE RELEASE Rear Auxiliary Only - With key ON and engine running, press to shut down engine and relieve rear auxiliary
hydraulic pressure. (See Relieve Hydraulic Pressure - Loader and Attachment in the Operation & Maintenance
Manual for front auxiliary pressure release.)
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)

(See SYSTEM SETUP & ANALYSIS, in the Operation & Maintenance Manual for more information)
9 PRESS TO OPERATE LOADER Press to activate BICS when the Seat Bar is down and operator is seated in operating position.
Press and hold three seconds to engage Steering Drift Compensation. (See STEERING DRIFT
COMPENSATION in the Operation & Maintenace Manual.)
10 SEAT BAR The light comes ON when the seat bar is down.
11 LIFT & TILT VALVE The light comes ON when the seat bar is down and the PRESS TO OPERATE button is pressed. The lift and tilt
functions can be operated when the light is ON.
12 TRACTION The light comes ON when the seat bar is down, engine is running, and parking brake is released. The loader can
be moved forward or backward when the light is ON.
13 TRACTION LOCK OVERRIDE (Functions Only When Seat Bar Is Raised And The Engine Is Running) Press to unlock the brakes. Allows you to
use the steering levers to move the loader forward or backward when using the backhoe attachment or for loader
service. (See TRACTION LOCK OVERRIDE in the Operation & Maintenace Manual). Press a second time to
lock the brakes.
14 ALARM The ALARM beeps when there is an Error, WARNING or SHUTDOWN condition.

* See SYSTEM SETUP & ANALYSIS, See Diagnostic Service Codes in the Operation & Maintenace Manual for further description
of SERVICE CODES.

51 of 118 20-10-1 Loader Electrical System Service Manual


INSTRUMENT PANEL IDENTIFICATION (CONT’D) Figure 20-10-3

Left Panel (System Identification Without Shut-down 1


Option)

Figure 20-10-2

B-15551D

Dealer Copy -- Not for Resale


Standard loaders NOT equipped with the shut-down
option will display the word BASE (Item 1) [Figure 20-10-
B-15551 3].

Figure 20-10-4
The left instrument panel is the same for both the
Standard and Deluxe Instrumentation [Figure 20-10-2]. 1

Press and hold BUCKET POSITIONING Button (Item 1)


[Figure 20-10-2] for two seconds to view CONTROLLER
SOFTWARE VERSION in the HOURMETER/CODE
DISPLAY (Item 2) [Figure 20-10-2].

B-15551E

The display will then alternate between the word BASE


and the current version of software loaded on the
controller. An example of a version is P02.0 (Item 1)
[Figure 20-10-4].

52 of 118 20-10-2 Loader Electrical System Service Manual


INSTRUMENT PANEL IDENTIFICATION (CONT’D) Figure 20-10-6

Left Panel (System Identification With Shut-down 1


Option)

Figure 20-10-5

B-15551F

Dealer Copy -- Not for Resale


Standard loaders equipped with the shut-down option will
display the word Shtdn (Item 1) [Figure 20-10-6].
B-15551
Figure 20-10-7

Press and hold BUCKET POSITIONING Button (Item 1) 1


[Figure 20-10-5] for two seconds to view CONTROLLER
SOFTWARE VERSION in the HOURMETER/CODE
DISPLAY (Item 2) [Figure 20-10-5].

B-15551E

The display will then alternate between the word Shtdn


and the current version of software loaded on the
controller. An example of a version is P02.0 (Item 1)
[Figure 20-10-7].

53 of 118 20-10-3 Loader Electrical System Service Manual


INSTRUMENT PANEL IDENTIFICATION (CONT’D) The right instrument panel shown [Figure 20-10-8] is the
Key Switch Panel.
Right Panel (Key Switch)
The table below shows the icons and other components
Figure 20-10-8 of the Right Key Switch Panel.
15 17 19 21 23 25 27

16 18 20 22 24 26 28

29
B-15552G

ICON/
REF. FUNCTION ALARM CODE CONDITION DESCRIPTION
LIGHT
Advanced Control ON 3 Beeps * Error Error with Advanced Control System (ACS)
15 System (ACS) or Selectable Joystick Control (SJC)

Dealer Copy -- Not for Resale


(Opt.)
Attachment ON --- --- --- Electrical controlled attachment is present.
16 Control FLASHING 3 Beeps
* Error Error with Attachment Control Device (ACD)
Device (ACD)
General ON 3 Beeps * Error Error with one or more engine or hydraulic functions.
Warning ON 3 Beeps * WARNING Engine speed high or in shutdown.
17
FLASHING Continuous * SHUTDOWN Engine speed very high. Engine will stop in 10 seconds.
Two-Speed ON --- - --- High range selected. (Fasten shoulder belt.)
18 (Opt.) FLASHING 3 Beeps * Error Two-speed electrical error.
FLASHING - - - - --- Hydraulic fluid temperature below limit for two-speed operation. (See Warming
SLOWLY The Hydraulic / Hydrostatic System on Page OI-36.)
Fuel ON 3 Beeps * Error Fuel level sender system fault.
Level FLASHING 3 Beeps * WARNING Fuel level low.
19
Engine Preheat ON --- --- --- Glow plugs are energized.
FLASHING 3 Beeps * Error Error with glow plugs
20
System Voltage ON 3 Beeps * WARNING Voltage low, high or very high.
21
Seat Belt ON --- --- --- Light stays on for 45 seconds to remind operator to fasten seat belt.
22
Engine ON 3 Beeps * Error Engine oil pressure sender out of range.
Oil Pressure ON 3 Beeps * WARNING Engine oil level low.
23
FLASHING Continuous * SHUTDOWN Engine oil pressure very low. Engine will shutdown in 10 seconds.
Hydrostatic ON 3 Beeps * Error Hydraulic oil pressure sender out of range.
Charge ON 3 Beeps * WARNING Hydraulic oil pressure low.
24
Pressure FLASHING Continuous * SHUTDOWN Hydraulic charge pressure very low. Engine will stop in 10 seconds.
Engine ON 3 Beeps * Error Engine coolant sender out of range
Coolant ON 3 Beeps * WARNING Engine coolant temperature high.
25
Temperature FLASHING Continuous * SHUTDOWN Engine coolant temperature very high. Engine will stop in 10 seconds.
Hydraulic ON 3 Beeps * Error Hydraulic oil temperature out of range.
Oil ON 3 Beeps * WARNING Hydraulic oil temperature high.
26
Temperature FLASHING Continuous SHUTDOWN Hydraulic oil temperature very high. Engine will stop in 10 seconds.
Engine ON 3 Beeps * Error Air filter with high restriction.
27 Air Filter FLASHING 3 Beeps
* WARNING Air filter switch not connected.

Hydraulic ON 3 Beeps * Error Hydraulic filter with high restriction.


Filter FLASHING 3 Beeps * WARNING Hydraulic filter switch not connected.
28
29 Key Switch --- --- --- --- Used to start and stop the engine.
* These functions are monitored and have associated SERVICE CODES. See SYSTEM SETUP AND ANALYSIS for description of SERVICE CODES.

54 of 118 20-10-4 Loader Electrical System Service Manual


INSTRUMENT PANEL IDENTIFICATION (CONT'D) Figure 20-10-10

Right Panel (Keyless)

Figure 20-10-9
5 6

ENTER PASSWORD

1 3
LANGUAGES

2
B-16165

The first screen you will see on your new loader will be as
shown in [Figure 20-10-10].

4 When this screen is on the display you can enter the


password and start the engine or change the Display
Panel setup features.

Dealer Copy -- Not for Resale


NOTE: Your new loader (with Keyless Instrument
Panel) will have an Owner Password. Your
8 7 B-15553H dealer will provide you with this password.
Change the password to one that you will
easily remember to prevent unauthorized use
The right instrument panel shown [Figure 20-10-9] is the of your loader. (See Changing The User
Keyless Panel. Passwords on Page 20-12-2.) Keep your
password in a safe place for future needs.
1. Display Screen: The Display Screen is where all
system setup, monitoring, troubleshooting, and error
Start Engine: Use the Keypad to enter the numbers
conditions are displayed.
(letters) of your password and press the RUN / ENTER
2. Function Icons: The lower left area of the Display key (Item 7) [Figure 20-10-9].
Screen contains the same icons as the Key Switch
Panel. These icons are only visible when the Press and hold the START button (Item 8) [Figure 20-10-
monitoring system has detected the associated 9] until the engine starts.
condition.
Change Language: Press the Selection button at the end
3. Selection Buttons: The four Selection Buttons allow
you to select items from the Display Screen and scroll of the arrow [Figure 20-10-10] to go to the next screen.
through screens.

4. Keypad: The numeric keypad has two functions:


- To enter a number code (password) to allow starting
the engine (Keyless Start).
- To enter a number as directed for further use of the
Display Screen.

5. Bobcat Controller / Display Icon: Indicates


communication error between Bobcat controller and
instrument panel. (Refer to the Operation &
Maintenance Manual for DIAGNOSTIC SERVICE
CODES.)

6. BobCARE PMSM Icon: Indicates planned


maintenance is due. (See MAINTENANCE CLOCK
on Page 20-13-1.)

55 of 118 20-10-5 Loader Electrical System Service Manual


INSTRUMENT PANEL IDENTIFICATION (CONT'D)

Right Panel (Keyless) (Cont’d)

Figure 20-10-11

B-16655

Use the Keypad to select the number of the language


[Figure 20-10-11]

Dealer Copy -- Not for Resale


Press EXIT. The screen will return to [Figure 20-10-10].
You can then enter the password and start the engine.

See DISPLAY CONTROLLER PANEL SETUP for further


description of screens to setup the system for your use.
(See CONTROL PANEL SETUP on Page 20-11-1.)

NOTE: Pressing the EXIT key will go to the pervious


screen and you can continue pressing until
you get to the initial (home) screen.
SHORTCUT: Press the “0” (zero) key to get to
the home screen immediately.

56 of 118 20-10-6 Loader Electrical System Service Manual


INSTRUMENT PANEL IDENTIFICATION (CONT’D) Right Panel Downgrade (Deluxe To Standard)

Right Panel Upgrade (Standard to Deluxe) To downgrade from deluxe instrumentation to standard
instrumentation requires a keystroke sequence on the
Figure 20-10-12 deluxe panel. This downgrade procedure was added for
theft prevention and security reasons.
15 17 19 21 23 25 27
That sequence is as follows:

With Engine OFF/Press Run Enter Button


Select: Tools
16 18 20 22 24 26 28 Select: Owner Utilities
Enter Password
Select: Lock-Out Features
Select: Downgrade Feature
The panel will ask, Do You Wish To Downgrade? Yes/No
Select: Yes, system automatically downgrades.
If the deluxe panel was inoperative, there is another
method to downgrade. See Service PC, Page 10-01.
29

B-15552

Dealer Copy -- Not for Resale


Figure 20-10-13

1 3

6 5 B-15553

To upgrade from standard instrumentation [Figure 20-10-


12] to deluxe instrumentation [Figure 20-10-13] simply
requires that the standard panel be removed and the
deluxe panel plugged in.

57 of 118 20-10-7 Loader Electrical System Service Manual


INSTRUMENT PANEL IDENTIFICATION (CONT’D) Side Panel [Figure 20-10-14].

Side And Front Panels REF.


DESCRIPTION FUNCTION / OPERATION
NO.
Figure 20-10-14 1 POWER PLUG Provides a 12V receptacle for
accessories.
SIDE PANEL
2 NOT USED ---
3 FRONT WIPER Press the top of the switch to start
the front wiper (press and hold for
washer fluid). Press the bottom of
the switch to stop the wiper.
4 REAR WIPER Press the bottom of the switch to
start the rear wiper. Press the top
of the switch to provide washer
fluid to clean the rear window.
2 3 4 5 6 7 8 9
1 5 NOT USED ---
6 NOT USED ---
7 FAN MOTOR Turn clockwise to increase fan
speed; counterclockwise to
decrease. There are four positions;
P16000
OFF-1-2-3.
8 AIR CONDITIONER Press top of switch to start; bottom
Figure 20-10-15 SWITCH to stop. Fan Motor (Item 7) must be
ON for A/C to operate.
FRONT PANEL 9 TEMPERATURE Turn clockwise to increase the

Dealer Copy -- Not for Resale


CONTROL temperature; counterclockwise to
1 2 3 4 5 6 7 8
decrease.

Front Panel [Figure 20-10-15]

REF.
9 OR DESCRIPTION FUNCTION / OPERATION
NO.
1 ADVANCED Press the top to select Hand
CONTROL Controls; bottom to select Foot
SYSTEM (ACS) Controls.
2 NOT USED ---
B-15993N 3 POWER Press and hold the up arrow to
BOB-TACH disengage the the Bob-Tach
B-15993M
wedges. Press and hold the down
arrow to engage the wedges into
NOTE: Parking Brake (Item 4) [Figure 20-10-15] is the mounting frame holes.
Standard on all loaders. 4 PARKING BRAKE Press the top to engage the
(Standard on all PARKING BRAKE; bottom to
Loaders) disengage.
5 TURN SIGNAL Indicates left or right TURN
INDICATORS SIGNALS are ON.
6 HAZARD LIGHTS Press the top to turn the HAZARD
LIGHTS ON; bottom to turn OFF.
7 ROTATING Press the top to turn the
BEACON ROTATING BEACON ON; bottom
to turn OFF.
8 NOT USED ---
9 SELECTABLE Press the top to select ‘ISO’ Control
JOYSTICK Pattern; bottom to select ‘H’ Control
CONTROL (SJC) Pattern.

58 of 118 20-10-8 Loader Electrical System Service Manual


CONTROL PANEL SETUP Examples
Right Panel Setup (Keyless)
Figure 20-11-2
Icon Identification
Figure 20-11-1
Press
TOOL/SETUP

SELECTION
EXAMPLE
BUTTONS

Press
LOADER FEATURES
B-16162

Make selection by pressing the SELECTION BUTTON


adjacent to the icon [Figure 20-11-1].

Dealer Copy -- Not for Resale


ICON DESCRIPTION Press
LOCK/UNLOCK: Allows machine to be DISPLAY OPTIONS
locked/unlocked. You must lock machine to
activate security system.
When system is unlocked, the user can press
RUN/ENTER then press START to begin
operation.
A valid password will need to be entered at
startup to run a locked machine.
TOOL/SETUP: Access system options.
Use to set clock, check system warnings, Press
select language, set passwords, etc. ADJUST CONTRAST
? HELP: Access help on current menu item.

EXIT EXIT returns you to previous level menu.


11:23 CLOCK/JOB CLOCK: Press to clear or lock
0.0 job clock; TOOL/SETUP to set time.
UP ARROW: Goes backward one screen.
Press
DOWN ARROW: Goes forward one screen. UP OR DOWN
Arrow to
OUTLINE ARROWS: No screen available
change contrast.
(backward/forward).

SELECTION ARROW: Use to select menu Press EXIT to


item. return to
previous level
NEXT Goes to the NEXT screen in series. menu.
EXAMPLE: the next Active Warning screen.
B-16163/B-24288/B-16161A/B-16166/B-16167
INFO Goes to more information about attachments.
YES/NO Answer yes/no to current setup question.
CLEAR Removes previously installed password.
SET Set accepts current installed password.

59 of 118 20-11-1 Loader Electrical System Service Manual


CONTROL PANEL SETUP (CONT’D) Attachment Control Information (Keyless)

Right Panel Setup (Keyless) (Cont’d) The Keyless Right Panel allows the user to view
information concerning the operation of Bobcat
More Examples attachments.

Clocks Figure 20-11-3

Press . . .
TOOL/SETUP Press
LOADER FEATURES
DISPLAY OPTIONS TOOL/SETUP
CLOCKS

SET CLOCK
Use the keypad to set time.
Press RUN/ENTER to set clock.
Press EXIT to return to previous level menu.
Press
RESET JOB CLOCK (Password required) LOADER FEATURES
(Job Clock keeps a running total for job hours)
Press CLEAR to reset Job Clock to zero.
Press LOCK/UNLOCK to unlock.
Enter Password and press RUN/ENTER.

Languages

Dealer Copy -- Not for Resale


Press . . . Press
TOOL/SETUP ATTACHMENTS
LOADER FEATURES
DISPLAY OPTIONS

LANGUAGES
Select the language, press RUN/ENTER.
Press EXIT to return to previous level menu.

Vitals (Monitor the engine, hydraulic/hydrostatic, Press


electrical functions when engine is running.) RUN / ENTER BUTTON
on keypad
Press . . .
TOOL/SETUP
LOADER FEATURES.
Press
VITALS UP OR DOWN
Press SELECTION ARROW to select METRIC or Arrow to
ENGLISH (M/E) readouts scroll through
attachments
You can monitor real-time readouts of:
Engine Oil Pressure
Engine Coolant Temperature
Hydraulic Charge Pressure
Hydraulic Oil Temperature Press
System Voltage the keypad number
Engine Speed
of a switch to view
a description of the
The Keyless Right Panel is easy to use. Continue to set attachment function
your own preferences for running / monitoring your of the switch
Bobcat Loader.

B-16163/B-24288/B-16161A/B-15753A/B-15754A/B-15755A

Attachments are listed alphabetically. Press the exit


button to return one screen or press the “0” (zero) key to
return to the home screen immediately [Figure 20-11-3].

60 of 118 20-11-2 Loader Electrical System Service Manual


PASSWORD SETUP Changing The Owner Password

Password Setup is available on Keyless Start machines. Figure 20-12-1

Password Description
Press TOOL / SETUP
All new machines with keyless start arrive at Bobcat
dealerships with the keypad in locked mode. This means
that a password must be used to start the engine.
Press OWNER UTILITIES
For security purposes, your dealer may change the
password and also set it in the locked mode. Your dealer
will provide you with the password.

Master Password:

A permanent, randomly selected password set at the Enter PASSWORD (owner or master)
factory which cannot be changed. This password is on Keypad
used for service by the Bobcat dealer if the owner then press ENTER
password is not known; or to change the owner to Continue
password.
Press PASSWORD UTILITIES
Owner Password:

Dealer Copy -- Not for Resale


Allows for full use of the loader and to setup the
Keyless Right Panel. There is only one owner
password. It must be used to change the owner or
user passwords. Owner should change the password Press MODIFY OWNER
as soon as possible for security of the loader.

User Password:

Allows starting and operating the loader; cannot


change password or any of the other setup features.
Enter new OWNER
For the procedures to change passwords (See Changing PASSWORD on Keypad
The Owner Password on Page 20-12-1) and (See then press ENTER
to Continue.
Changing The User Passwords on Page 20-12-2).

Re-Enter new OWNER


PASSWORD on Keypad
then press ENTER
to Continue.

OWNER PASSWORD procedure


is now complete.

B-16163/B-24288/B-24290/B-24291/B-16171/B-24292/B-24293/B-24294

61 of 118 20-12-1 Loader Electrical System Service Manual


PASSWORD SETUP (CONT’D) Password Lockout Feature

Changing The User Passwords This feature allows the owner to unlock the password
feature so that a password does not need to be used
Figure 20-12-2 every time the engine is started.

Figure 20-12-3
Press TOOL / SETUP
Press
LOCK/UNLOCK

Press OWNER UTILITIES

Enter PASSWORD (owner or master)


on Keypad Enter OWNER
then press ENTER PASSWORD
to Continue on Keypad
then press ENTER
to Continue.
Press PASSWORD UTILITIES

Dealer Copy -- Not for Resale


Press MODIFY USER Press
UNLOCK MACHINE

Enter USER number


on Keypad (There can be up to 8
different Users, each with their
own password.)
then press ENTER to Continue.

Press
Enter USER PASSWORD EXIT
on Keypad
then press ENTER to Continue.

USER PASSWORD procedure Machine is now


is now complete. Enter UNLOCKED and
another USER number can be started
without using a
OR password.
Press EXIT.

B-16163/B-24288/B-24290/B-24291/B-16171/B-24295/B-24296/B-24297A
B-16163/P-76075/P-76076/P-76076A/P-76077

62 of 118 20-12-2 Loader Electrical System Service Manual


MAINTENANCE CLOCK Figure 20-13-3

Description

The Maintenance Clock alerts the operator when the next


service interval is due. EXAMPLE: The Maintenance
Clock can be set to a 250 hour interval as a reminder for
the next 250 hour planned maintenance.

Figure 20-13-1

1
3
B-16163A

The Keyless Right Panel, if equipped, will display a


1 wrench icon (Item 1) [Figure 20-13-3] alerting the
operator to service the machine. This icon will remain on
the display until the maintenance clock is reset.

2 NOTE: Key Switch machines will not display the


BobCARESM PM message or wrench icon on
the right panel.

Dealer Copy -- Not for Resale


B-15551
B-15551-3A Setup
B-15551-3B

See your Bobcat dealer about installation of this feature.


During machine operation, a two beep alarm will sound
when there are less than 10 hours until the next planned Reset
maintenance. The hour interval (Item 1) and [SEr] (Item
2) will alternate in the display screen (Item 3) [Figure 20- Figure 20-13-4
13-1] for 10 seconds. The display will then revert back to
the previous display and will appear for 10 seconds every
time the machine is started until the maintenance clock is 3
reset.

Figure 20-13-2

2
B-15551

Place the key switch in the OFF position (Key Switch) or


press the STOP button (Keyless).
1
Press the LIGHTS button (Item 1) [Figure 20-13-4] to
P-76122
turn the panel ON.

The Keyless Right Panel, if equipped, will display a Press and hold the HIGH FLOW and AUXILIARY
message (Item 1) [Figure 20-13-2] alerting the operator PRESSURE RELEASE buttons (Item 2) simultaneously,
to service the machine. This message will remain for 10 until [rEsET] appears in the display screen (Item 3)
seconds before reverting back to the previous screen [Figure 20-13-4].
and will appear for 10 seconds every time the machine is
started until the maintenance clock is reset.

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ELECTRICAL SYSTEM Figure 20-20-3

Description 9 11
1 13 15 17
5
Figure 20-20-1
2 6 18

3 7 19

4 8 14 16 20
10 12
7117407

P-13849 P-24651

The loader has a 12 volt, negative ground alternator


charging system. The electrical system is protected by

Dealer Copy -- Not for Resale


fuses located in the cab on the steering control panel and
a 100 amp master fuse [Figure 20-20-1] in the engine N-19660
compartment on the left side of the engine. The fuses will
protect the electrical system when there is an electrical
overload. The reason for the overload must be found The location and sizes are shown below and [Figure 20-
before starting the engine again. 20-3].

REF DESCRIPTION AMP REF DESCRIPTION AMP


1 Traction 30 11 Front & Marker R
Fuse And Relay Location / Identification Lights
2 Fuel Shutoff 30 12 Fuel Shutoff R
Figure 20-20-2
3 Power Plug -- 13 Rear Lights R
4 ACS/AWS/SJC -- 14 Traction R
5 Heater 25 15 Switch Power R
1
6 Front & Marker 15 16 Starter R
Lights
7 Rear Lights 15 17 Unswitched 25
Attach.
8 Bobcat Controller 25 18 Switched Attach. 25
9 Heater & Air -- 19 Alternator & 25
Conditioning Accessories
10 Glow Plugs R 20 Accessory Plug 25

P-26323

The electrical system is protected from overload by fuses


and relays under the fuse panel cover (Item 1) [Figure
20-20-2]. A decal is inside the cover to show location and
amp ratings.

Remove the cover to check or replace the fuses.

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BOBCAT CONTROLLER

Identification Chart

4 CONNECTOR CONTROLLER

Dealer Copy -- Not for Resale


J1 J2 J3 J4
BLACK 18 PIN CONNECTOR WHITE 18 PIN CONNECTOR BLACK 30 PIN CONNECTOR WHITE 30 PIN CONNECTOR
(ALL BLUE WIRES) (MOSTLY BLUE AND PURPLE WIRES) (MULTI COLOR WIRES) (MOSTLY GREEN WIRES)

VIEWED FROM MATING END VIEWED FROM MATING END


X = NO CONNECTION X = NO CONNECTION
VIEWED FROM MATING END VIEWED FROM MATING END
X = NO CONNECTION X = NO CONNECTION

V-171/V-172

67 of 118 20-30-1 Loader Electrical System Service Manual


BOBCAT CONTROLLER (CONT’D)

Identification Chart (Cont’d)

2 CONNECTOR CONTROLLER

41 50 41 50
31 J2 40 31
J1 40

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21 30 21 30
11 20 11 20

1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10

ACS CONTROLLER

A B C D E
J3
J3
F G H J K

A B C D E
A B C D
J2
J1 F G H J K
H G F E

J1 J2

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BOBCAT CONTROLLER (CONT’D)

Identification Chart (Cont’d)

SJC CONTROLLER

41 50
31
J1 40
21 30
J1
11 20

1 2 3 4 5 6 7 8 9 10

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AWS CONTROLLER

41 50
31
J1 40
21 30
J1
11 20

1 2 3 4 5 6 7 8 9 10

J2

41 50
31 J2 40
21 30
11 20

1 2 3 4 5 6 7 8 9 10

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ELECTRICAL HARNESS Figure 20-40-2

Connector Maintenance

When using the service code troubleshooting procedure,


reference is made to connectors J1-J4. Refer to the
connector layout diagram (See Identification Chart on
Page 20-30-1) that explains wire numbers and wire
location on the connector plug.

Figure 20-40-1

N-19275

When cleaning connectors that have corrosion or


moisture problems, use a fast drying, ozone-safe contact
cleaner. For best results, use a cleaning brush with
stainless steel bristles to remove corrosion [Figure 20-
40-2].

Dealer Copy -- Not for Resale


Figure 20-40-3
N-19555

Melroe extension lead (MEL1568-3) is used when taking


ohmmeter or continuity readings between sensors/
senders and Bobcat controller connectors [Figure 20-40-
1]. The small extension lead pin can be inserted into the
sensor/sender connectors or into the Bobcat controller
connectors, whichever is preferred.

NOTE: NEVER ATTEMPT TO INSERT PROBE OF


TEST METER LEAD INTO THE PIN SOCKETS,
RATHER TOUCH PROBE TO FACE OF PIN.
DAMAGE TO THE SOCKET WILL RESULT
AND MAY CAUSE INTERMITTENT OPEN N-19276
CONNECTIONS AND OTHER ALARMS TO
OCCUR.
Flush with contact cleaner until clean [Figure 20-40-3].
Make sure sockets are dry before re-assembly.
Compressed air is acceptable to use if contact cleaner is
not available.

71 of 118 20-40-1 Loader Electrical System Service Manual


ELECTRICAL HARNESS (CONT'D) Figure 20-40-6

Metri-Pac Connector Disassembly And Assembly

The procedure to remove a pin from an electrical


connector depends on the manufacturer of the connector.
The loader harness utilizes both Metri-Pac and Deutsch
connectors.

Figure 20-40-4

N-19247

From the front of the connector, insert a jewelers


screwdriver blade or other small needle-like device into
the small square notch on the face of the pin housing
[Figure 20-40-6].

Figure 20-40-7

Dealer Copy -- Not for Resale


N-19245

Figure 20-40-5

N-19443

Push back gently, to disengage the small metal release


N-19246 tab of the pin, then carefully tug on the wire to remove pin
from connector [Figure 20-40-7].

If a connector pin has to be removed from a Metri-Pac


connector, first remove the jacket from back of connector
[Figure 20-40-4] and [Figure 20-40-5].

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ELECTRICAL HARNESS (CONT'D) Seven-Pin Octal Metri-Pac Connector Disassembly
And Assembly
Metri-Pac Connector Disassembly And Assembly
(Cont'd) NOTE: If you do not physically lift the tab, it is likely
that the pin will push back when the
Figure 20-40-8 connector is plugged back into its mating
plug.

Figure 20-40-10

N-19263

Figure 20-40-9 N-19255

Dealer Copy -- Not for Resale


The seven pin octal connector is also a Metri-Pac item.
Use a screwdriver to release the two retaining tabs on the
back of the connector [Figure 20-40-10].

Figure 20-40-11

N-19264

When re-assembling a pin back into a connector, make


sure to first lift the small metal release tab back into
position [Figure 20-40-8] and [Figure 20-40-9].

When this tab is released during the removal process, it N-19256


has a tendency to get bent out of position.

Slide the back off the connector [Figure 20-40-11].

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ELECTRICAL HARNESS (CONT'D) Figure 20-40-14

Seven-Pin Octal Metri-Pac Connector Disassembly


And Assembly (Cont'd)

Figure 20-40-12

N-19259

The four Metri-Pac connectors that plug into the Bobcat


controller are difficult to service [Figure 20-40-14].
N-19257
Figure 20-40-15

Insert a jewelers screwdriver blade or other small needle-

Dealer Copy -- Not for Resale


like device into the recessed black plastic tab [Figure 20-
40-12].

Figure 20-40-13

N-19258

These pins actually push out from the front of the


connector [Figure 20-40-15].

N-19444 NOTE: Since these pins are a pull-to-seat type, if one


of these pins is found to be pushed back, it is
likely that the plastic connector body is
Lift up on the plastic tab to release the pin from the damaged, and that the harness will have to be
connector body. Pull the pin out the back [Figure 20-40- replaced.
13].

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ELECTRICAL HARNESS (CONT'D) Figure 20-40-18

Deutsch Connector Disassembly And Assembly (Flat


Faced)

Figure 20-40-16

N-19250

Remove the pin from the back [Figure 20-40-18].

N-19248 Deutsch Connector Disassembly And Assembly


(Flush Faced)

Deutsch connectors vary in style. If a connector pin has Figure 20-40-19

Dealer Copy -- Not for Resale


to be removed from a flat-faced Deutsch connector, first
pry the face of the connector up with a flat blade
screwdriver [Figure 20-40-16].

Figure 20-40-17

N-19251

On a flush-faced Deutsch connector, use a needle-nosed


plier to reach in and clasp the notch of the connector face
N-19249 [Figure 20-40-19].

Pull back to remove the face.


Remove the face. Use a jewelers screwdriver or other
small needle-like device to reach in an pry up on the
plastic tab that locks the pin in position [Figure 20-40-
17].

75 of 118 20-40-5 Loader Electrical System Service Manual


ELECTRICAL HARNESS (CONT'D) 21-Pin Octal Style Connector

Deutsch Connector Disassembly And Assembly Figure 20-40-22


(Flush Faced) (Cont'd)

Figure 20-40-20

N-19265

N-19252 On the 21-Pin Octal-Style connector, a special tool is


required for pin removal. The tool has a hollow shaft with
one side cut away, to allow the tool to slip over a
Use a jewelers screwdriver or other small needle-like connector wire. Slip the tool over the wire [Figure 20-40-

Dealer Copy -- Not for Resale


device to reach in and pry up on the plastic tab that locks 22].
the pin in position [Figure 20-40-20].
Figure 20-40-23
Figure 20-40-21

N-19266
N-19253

Push to insert the tool inside the connector body [Figure


Remove the pin from the back [Figure 20-40-21]. 20-40-23].

76 of 118 20-40-6 Loader Electrical System Service Manual


ELECTRICAL HARNESS (CONT'D)

21-Pin Octal Style Connector (Cont’d)

Figure 20-40-24

N-19254

Once inserted in the connector body, pull on the wire to


remove it from the back of the connector [Figure 20-40-

Dealer Copy -- Not for Resale


24].

When troubleshooting, if a Metri-Pac connector pin was


found to be pushed back in a connector, remove the pin
from the connector and re-bend the small release tab.

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78 of 118 20-40-8 Loader Electrical System Service Manual


SERVICE "PC" SOFTWARE

SERVICE SOFTWARE (ENTERING ANALYZER) . . . . . . . . 30-10-1


Bobcat Service Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

SERVICE SOFTWARE (MONITOR) . . . . . . . . . . . . . . . . . . . 30-11-1


Bobcat Service Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . 30-11-1

SERVICE SOFTWARE (WARNINGS) . . . . . . . . . . . . . . . . . 30-12-1


Bobcat Service Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . 30-12-1
SERVICE “PC”
SERVICE SOFTWARE (DIAGNOSE/CALIBRATE) . . . . . . . 30-13-1 SOFTWARE
ACD Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13-2
Actuator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13-5
Bobcat Service Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . 30-13-1
Full Function (ACD - Loader Mounted Or Attachment Mounted
Controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13-2
Remote Mounted ACD. . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13-4
Reduced Function (ACD Mounted On Attachment Only) 30-13-3

SERVICE SOFTWARE (INSTALLING KITS AND OPTIONS)30-14-1

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Bobcat Service Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . 30-14-1

SERVICE SOFTWARE (PROGRAM/UPDATE) . . . . . . . . . . 30-15-1


Bobcat Service Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . 30-15-1

SERVICE SOFTWARE (DOWNGRADE) . . . . . . . . . . . . . . . 30-16-1


Bobcat Service Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . 30-16-1

SERVICE SOFTWARE (OPTIONS) . . . . . . . . . . . . . . . . . . . 30-17-1


Bobcat Service Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . 30-17-1

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SERVICE SOFTWARE (ENTERING ANALYZER) Figure 30-10-3

Bobcat Service Analyzer

Figure 30-10-1

P-69276

This error appears when the computer or the remote start


P-34618 tool is connected to the loader but unable to
communicate with the Bobcat controller.

Click the Analyzer Icon [Figure 30-10-1]. It is very important that the part number chosen is the
correct part number [Figure 30-10-3].

Dealer Copy -- Not for Resale


If this error appears, the computer or the remote start tool
is not connected, the key isn't on, or a fuse is open. The
program can be entered by hitting cancel but will be
unable to communicate with the loader.

Figure 30-10-2

P-69275

If this error appears [Figure 30-10-2], the service


analyzer cannot recognize the controller. Select the
correct machine type and continue.

81 of 118 30-10-1 Loader Electrical System Service Manual


SERVICE SOFTWARE (ENTERING ANALYZER) Figure 30-10-5
(CONT’D)

Bobcat Service Analyzer (Cont’d)

Figure 30-10-4

P-73668

This is the Standard main screen of the analyzer program


[Figure 30-10-5].
P-69274
The Diagnose/Calibrate screen is only used on ACS,
SJC and AWS loaders. When the computer is connected
This is the screen that will appear when the program is to a standard loader the Diagnose/Calibrate icon will not
communicating with the loader [Figure 30-10-4].

Dealer Copy -- Not for Resale


be highlighted.
The NEEDS UPDATING icon will appear when the
program in the loader is a outdated version. The
UPDATE all controllers icon will update the loader with
the latest version in the computer. Updating the program
is recommended but not necessary.

If the IN ERROR icon appears, the controller has a


problem and needs to be updated.

The UNPROGRAMMED icon will appear when a new


controller is installed.

NOTE: If the loader is equipped with ACD, ACS, SJC


or AWS and the message NOT FOUND
appears. Click the RESCAN key and if the NOT
FOUND again appears, check for a wiring
problem. If the loaders is NOT equipped with
ACD, ACS, SJC or AWS and the message NOT
FOUND appears, this is normal.

82 of 118 30-10-2 Loader Electrical System Service Manual


SERVICE SOFTWARE (MONITOR) Figure 30-11-3

Bobcat Service Analyzer

Figure 30-11-1
1
2

4 5

6
7
P-69278

P-73668
The Advanced Monitoring screen will allow the view of
many different individual checks. These diagnostic
Click on the Monitor icon [Figure 30-11-1]. checks are listed below [Figure 30-11-3]

Dealer Copy -- Not for Resale


Figure 30-11-2 Enable logging - Item 1 [Figure 30-11-3]. This will
enable and disable the logging feature. The logging
feature will capture all currently monitored data and write
it to a log file. This file can be opened using Microsoft
Excel® or other spreadsheet programs. By default it will
place the log file into the programs “log” directory under
“Advanced Monitoring” and the file name will be in the
format of “Month.Date.Year Time.csv.

Custom - Item 2 [Figure 30-11-3]. Gives the ability to


add a new item to the list of items available for
monitoring.

Selectable Items - Item 3 [Figure 30-11-3]. These are


the selectable items that can be monitored using the
advanced monitoring screen. You can select more than
one item by holding down the “CTRL” key and making
P-34646 your selections. Any item with a “+” next to it has one or
more sub items. By clicking on the “+” or by double
clicking on the name of the group it will expand the group
The monitor screen allows many diagnostic functions to and show all sub items. An item with an “*” in front of it
be observed at one time. It also allows a split screen so denotes that it was a “Custom” added item. If you Right
the values can to be enlarged for easier viewing. The Click the items with a “*” in front of them it will allow you
different functions can be changed on the split screen by to delete them or edit the properties of the custom item.
clicking on the drop down arrow [Figure 30-11-2].
Current - Item 4 [Figure 30-11-3]. The current column
For more diagnostic checks, click on the Advanced displays the current value being read from a machine.
Some are displayed as values, others are graphical
Monitoring Icon.
representations of what is being monitored.

Min and Max - Item 5 [Figure 30-11-3]. The Min column


shows the lowest value read during the monitoring of a
particular item. The Max column shows the highest value
read during the monitoring of a particular item. If a value
happens to go beyond predefined boundaries it will
change the Min and Max values to “RED”.

83 of 118 30-11-1 Loader Electrical System Service Manual


SERVICE SOFTWARE (MONITOR) (CONT’D)

Bobcat Service Analyzer (Cont’d)

Acceptable Ranges - [Figure 30-11-3]. If the mouse


cursor is held over the Min or Max value of an item it will
popup a box which shows the predefined acceptable
range for that item.

Start/Stop - Item 6 [Figure 30-11-3]. Starts or stops the


monitoring of data.

Clear - Item 7 [Figure 30-11-3]. Stops any monitoring


that is going on and clears all the items in the monitoring
section of the screen.

Dealer Copy -- Not for Resale

84 of 118 30-11-2 Loader Electrical System Service Manual


SERVICE SOFTWARE (WARNINGS) By clicking on the View Warnings and Shutdowns (Item
4) [Figure 30-12-2], this will give different alarms and
Bobcat Service Analyzer information about them.

Figure 30-12-1 Figure 30-12-3

P-73668 P-34649

Click on the Warnings Icon [Figure 30-12-1]. The Stored Vital Warnings and Shutdowns screen
[Figure 30-12-3] will show the number of times a
Figure 30-12-2

Dealer Copy -- Not for Resale


specific alarm has occurred, the hour of the last
occurrence and length in minutes that the last alarm had
been active. This screen is accessed by clicking on the
View Warnings and Shutdowns link on the Service Codes
4 screen
3

The Advanced Monitoring and View Service Codes


screens can accessed by clicking on the Icon [Figure 30-
12-3]

Figure 30-12-4
1 2
2
1

P-69272

3
This screen will show the main controller service codes 4
5 6
listed from newest to oldest. It displays the hour in which
the code appeared, the code number, and a short
description. The Advanced Control System screen can 7
also be accessed by clicking on the Icon [Figure 30-12-
2].

Save/Print - Item1 [Figure 30-12-2]. Saves the codes to


a text file. P-69321

Update Codes - Item 2 [Figure 30-12-2]. Updates the


list of codes. The Maintenance Clock [Figure 30-12-4] is used to
inform the operator when routine servicing is required on
Stored Secondary Service Codes - If the machine is the loader. The Maintenance tab will show only for Skid
equipped with ACS, SJC or AWS, more than one tab will Steer Loaders with Service Analyzer software version 37
appear at the top of the screen (Item 3) [Figure 30-12-2].
or greater. This is not available on main controller part
Clicking on the tab for that controller will allow you to view
the codes for that specific controller. numbers 6672349, 6676553, and 6678068.

85 of 118 30-12-1 Loader Electrical System Service Manual


SERVICE SOFTWARE (WARNINGS) (CONT’D)

Bobcat Service Analyzer (Cont'd)

Maintenance Tab - Item 1 [Figure 30-12-4]. Will show


all the information associated with the maintenance clock
on the connected machine.

Clock On - Item 2 [Figure 30-12-4]. Shows if the


maintenance clock is ON or OFF.

Interval - Item 3 [Figure 30-12-4]. This is the service


interval in hours. You can change this value and press
“Reset Service Clock” button to set the new interval.

Next Service In - Item 4 [Figure 30-12-4]. This shows


the remaining time in hours before the next scheduled
service is due.

Reset Service Clock - Item 5 [Figure 30-12-4]. This will


reset the Service Clock Alarm according to the interval
displayed.

ON/OFF - Item 6 [Figure 30-12-4]. This turns the Service

Dealer Copy -- Not for Resale


Clock ON and OFF

Maintenance Clock Log - Item 7 [Figure 30-12-4]. The


current service clock Length (interval) and Time Reset
will be displayed. This screen will also store the most
recent 20 entries on history. Once an entry is added, it
can not be changed. If an entry is made and the interval
is not correct, make another entry and rest the service
clock.

86 of 118 30-12-2 Loader Electrical System Service Manual


SERVICE SOFTWARE (DIAGNOSE/CALIBRATE) Figure 30-13-3

Bobcat Service Analyzer


1
Figure 30-13-1
3
3

5
4

P-69264

The AWS diagnostic screen will show the joystick


P-73668 position and voltage, actuator position and voltage, wheel
angle and wheel speed. The screen also allows you to
perform the wheel alignment calibration and actuator test
Click on the Diagnose / Calibrate Icon [Figure 30-13-1].
procedures. [Figure 30-13-3].
Figure 30-13-2

Dealer Copy -- Not for Resale


Wheel Alignment - (Item 1) [Figure 30-13-3]. “Enter
Align Mode” starts the wheel alignment procedure and
3 “Set Alignment” ends the wheel alignment procedure.
4
See the loader Service Manual for the wheel alignment
procedure details.

Actuator Test - (Item 2) [Figure 30-13-3]. Tests and


calibrates the lift and tilt actuators.
2
Joysticks - (Item 3) [Figure 30-13-3]. If the joysticks are
in neutral, the “crosshair” (+) should be within the box in
1 5
the center. As the joystick moves the “crosshair” (+) will
follow.

Wheel Speed / Angle - (Item 4) [Figure 30-13-3]. This


P-69261
section displays the wheel speeds and angles for AWS
loaders.
The ACS diagnostic screen will show the position of the
handles, pedals, actuator input, and actuator feedback. Actuators - (Item 5) [Figure 30-13-3]. When the
The corresponding voltage is listed below each bar actuators are in neutral, the lines should be located in the
[Figure 30-13-2]. green band. Actuator Input shows where the controller is
driving the actuator and Actuator Feedback is the actual
Green Band - (Item 1) [Figure 30-13-2]. This indicates position of the actuator.
the neutral window. The line (Item 2) represents the
position of the component. The bars for the pedals will
not be displayed in hand control mode and vice versa. NOTE: Refer to the loader Service Manual for the
setting of the wheel alignment and blocking of
Actuator Input - (Item 3) [Figure 30-13-2]. The the loader.
controller is driving the actuator to this position.

Actuator Feedback - (Item 4) [Figure 30-13-2]. Actual


position of the actuator.

Actuator Test - (Item 5) [Figure 30-13-2] Tests and


Calibrates the Lift and Tilt Actuators.

87 of 118 30-13-1 Loader Electrical System Service Manual


SERVICE SOFTWARE (DIAGNOSE/CALIBRATE) High Flow - (Item 7) [Figure 30-13-4] Status of the high
(CONT’D) flow.

ACD Diagnostics • Default On – High flow is default on (if equipped)


when the auxiliaries are activated, but can be turned
The ACD diagnostic screen can be used to diagnose off by the operator.
problems with an attachment, attachment controller, and
handle switches. Use one of the following procedures • Default Off – High flow is default off when the
depending on the ACD system that is on your loader or auxiliaries are activated, but can be turned on (if
attachment. equipped) by the operator.
Full Function (ACD - Loader Mounted Or Attachment
Mounted Controller) • Always On – High flow is always on (if equipped) and
cannot be turned off.
The Attachment Control diagnostic screen can be used
to troubleshoot issues with the Full Function ACD • Always Off – High flow is always off and cannot be
(equipped with eight ACD outputs - A through H). turned on.

Figure 30-13-4 Continuous Flow - (Item 8) [Figure 30-13-4] Status of


the detent trigger.
1
2 • Operation: Pressing the right trigger will activate
constant hydraulic flow to the loader male coupler.

• Not Allowed: Constant flow is not allowed for this

Dealer Copy -- Not for Resale


attachment. Pressing the detent trigger will have no
effect as the ACD controller will not allow this action
for this attachment.
4
6
5
7
8
P-69343

Group # - (Item 1) [Figure 30-13-4] Indicates what


attachment group the attachment belongs to.

Attachments - (Item 2) [Figure 30-13-4] List of


attachments that may be connected based on the group
number found.

Handles - (Item 3) [Figure 30-13-4] Indicates active


handle switches. Switch will turn green if active. If switch
is gray, that button is not available. The handles may vary
depending upon the type of machine connected.

ACD Outputs - (Item 4) [Figure 30-13-4] Indicates which


outputs are being commanded to turn on.

Paddle Position - (Item 5) [Figure 30-13-4] Indicates


the position of the paddle.

Loader Solenoid Outputs - (Item 6) [Figure 30-13-4]


Indicates which loader solenoid outputs are being
commanded on

88 of 118 30-13-2 Loader Electrical System Service Manual


SERVICE SOFTWARE (DIAGNOSE/CALIBRATE) High Flow - (Item 7) [Figure 30-13-5] Status of the high
(CONT’D) flow.

Reduced Function (ACD Mounted On Attachment • Default On – High flow is default on (if equipped)
Only) when the auxiliaries are activated, but can be turned
off by the operator.
The Attachment Control diagnostic screen can be used
to troubleshoot issues with the Reduced Function ACD • Default Off – High flow is default off when the
(equipped with four ACD outputs - A through D). auxiliaries are activated, but can be turned on (if
equipped) by the operator.
NOTE: If there is no ACD, the screen will appear
similar to the below screen but there will be no • Always On – High flow is always on (if equipped) and
ACD outputs shown and other screen cannot be turned off.
differences.
• Always Off – High flow is always off and cannot be
Figure 30-13-5 turned on.

1 Continuous Flow - (Item 8) [Figure 30-13-5] Status of


2 the detent trigger.

• Operation: Pressing the right trigger will activate


constant hydraulic flow to the loader male coupler.

• Not Allowed: Constant flow is not allowed for this

Dealer Copy -- Not for Resale


3 attachment. Pressing the detent trigger will have no
4
effect as the ACD controller will not allow this action
for this attachment.
6

7 5
8
P-69343A

Group # - (Item 1) [Figure 30-13-5] Indicates what


attachment group the attachment belongs to.

Attachments - (Item 2) [Figure 30-13-5] List of


attachments that may be connected based on the group
number found.

Handles - (Item 3) [Figure 30-13-5] Indicates active


handle switches. Switch will turn green if active. If switch
is gray, that button is not available. The handles may vary
depending upon the type of machine connected.

ACD Outputs - (Item 4) [Figure 30-13-5] Indicates which


outputs are being commanded to turn on.

Paddle Position - (Item 5) [Figure 30-13-5] Indicates


the position of the paddle.

Loader Solenoid Outputs - (Item 6) [Figure 30-13-5]


Indicates which loader solenoid outputs are being
commanded on.

89 of 118 30-13-3 Loader Electrical System Service Manual


SERVICE SOFTWARE (DIAGNOSE/CALIBRATE) Auxiliary Detent - (Item 3) [Figure 30-13-7]. Indicates if
(CONT’D) the switch is depressed. While switch is depressed,
image will turn green depending upon which side is
Remote Mounted ACD pressed. Note: Not all attachments will use the bottom
half of the button.
Figure 30-13-6
Auxiliary Pressure Release - (Item 4) [Figure 30-13-7].
1 Indicates if the switch is depressed. While switch is
depressed, image will turn green.

Key Switch - (Item 5) [Figure 30-13-7]. Indicates the


position of the key switch.

Cab Key Indicator - (Item 6) [Figure 30-13-7]. If the light


is on, the attachment will not operate.

Loader Solenoid Outputs - (Item 7) [Figure 30-13-7].


Status of the loader solenoid on the machine. If green,
loader is commanding solenoid on.

P-24907 Attachment Solenoid Outputs - (Item 8) [Figure 30-13-


7]. Status of the attachment solenoid. If green, RACD is
commanding solenoid on.
The remote mounted ACD screen [Figure 30-13-7] is
viewable only when the Hand Tool RAC (Item 1) [Figure

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High Flow - (Item 9) [Figure 30-13-7]. Indicates if
30-13-6] is connected to the loader or when one of the
attachment is setup as a high flow or low flow
following attachments are connected to the loader:
attachment.
concrete mixer, concrete pump or chipper.

Figure 30-13-7

3 4
5
1
6

2
7

9 8
P-69342

The Remote ACD diagnostic screen [Figure 30-13-7]


can be used to troubleshoot issues with a remote ACD.

Loader Type - (Item 1) [Figure 30-13-7]. Indicatesthe


type of loader the RACD is connected to.

Engine Stop - (Item 2) [Figure 30-13-7]. Red when


active (pressed), green when not active.

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SERVICE SOFTWARE (DIAGNOSE/CALIBRATE)
(CONT’D)

Actuator Test

Figure 30-13-8

P-69261

The actuator test button (Item 1) [Figure 30-13-8] is


accessible within the ACS, AWS, and SJC Diagnostics

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Screens. This will test the function of the actuators and
calibrate the system.

While the test is being preformed, various screens may


appear describing what is happening; (examples: in
progress, communications error, actuator failed, no
problem detected or time out occurred).

Follow the instructions on the diagnostic screen to


complete the actuator test.

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SERVICE SOFTWARE (INSTALLING KITS AND Figure 30-14-3
OPTIONS)

Bobcat Service Analyzer

Figure 30-14-1

P-76712

The Install Options / Kits screen on a ACS loader will


show the ACS as an option [Figure 30-14-3].
P-73668

Click on the Install Icon [Figure 30-14-1].

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Figure 30-14-2

P-34650

The Install Options / Kits screen is for updating and


removing options. When installing a new option or kit the
option box must be checked on the “Installed Options /
Kits Screen” and then sent to the machine. If the loader is
equipped with an option and it isn't checked on the
screen, the controller will not allow this option to work
[Figure 30-14-2].

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94 of 118 30-14-2 Loader Electrical System Servcie Manual


SERVICE SOFTWARE (PROGRAM/UPDATE) Figure 30-15-3

Bobcat Service Analyzer

Figure 30-15-1
2

P-69274A

Select the Main Controller (Item 3) [Figure 30-15-2].


P-73668
The main controller update screen [Figure 30-15-3]
displays the model number, serial number, machine
Click on the Program / Update Icon [Figure 30-15-1]. hours, currently loaded options, and parts upgrade

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performed per bulletins. This screen can be used to add
Figure 30-15-2
or remove options for a machine, to update the controller
software, to initialize a new controller or select the parts
3 installed per a bulletin.

If the service tool and laptop are connected, the machine


S/N, hours and options should be filled in. If the
information is not there or the s/n reads 50000001, the
program is not communicating, the controller is not
working or there is a new controller installed in the loader.
If this is a new controller, you must type in the loader
information (Item 1) [Figure 30-15-3].

The options that are on the loader must be checked or


the options will not work (Item 2) [Figure 30-15-3].

1 2 P-76702

The screen shows what controllers are “FOUND” on the


machine and if they have the latest software installed
[Figure 30-15-2].

If some of the controllers need to be updated to the latest


software, press the “UPDATE all controllers” icon (Item 1)
[Figure 30-15-2]. All controllers showing “NEEDS
UPDATING” will be updated.

If a controller is marked “NOT FOUND” and is on the


machine, check the communication and laptop
connections, then press the “RESCAN” icon (Item 2)
[Figure 30-15-2] and the Service Analyzer will recheck
for the installed controllers.

95 of 118 30-15-1 Loader Electrical System Service Manual


SERVICE SOFTWARE (PROGRAM/UPDATE)
(CONT'D)

Bobcat Service Analyzer (Cont'd)

Figure 30-15-4

1
3
5
4
2

P-76702

If you select the Service Tool (Item 1), Attachment


Controller (ACD) (Item 2), Advanced Control System

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Controller (ACS) (Item 3), Drive Controller (SJC) (Item 4),
or the Drive+ Controller (AWS) (Item 5) [Figure 30-15-4]
from this page, the Service Analyzer will allow you to
update the controller that is selected.

The controller will update to the latest version of the


Service Analyzer. If the version is already updated it will
ask if you still want to update. This may be necessary if
the data in the controller is suspected to be corrupt and
the user decides to force an update.

96 of 118 30-15-2 Loader Electrical System Service Manual


SERVICE SOFTWARE (DOWNGRADE) Figure 30-16-3

Bobcat Service Analyzer

Figure 30-16-1

1
P-76709

Select the Downgrade Deluxe Panel Icon (Item 1)


P-73668 [Figure 30-16-3].

Figure 30-16-4
Select the Diagnostics Icon (Item 1) [Figure 30-16-1].

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Figure 30-16-2

P-76713

P-76584 The downgrade option should only be used when


removing a deluxe panel and installing a standard panel
[Figure 30-16-4].
Select the Panels Icon (Item 1) [Figure 30-16-2].
NOTE: Remove the deluxe panel from the loader
before performing the downgrade. This
procedure should only be used if the deluxe
panel will not allow the downgrade.

97 of 118 30-16-1 Loader Electrical System Service Manual


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98 of 118 30-16-2 Loader Electrical System Service Manual


SERVICE SOFTWARE (OPTIONS) Figure 30-17-2

Bobcat Service Analyzer

Figure 30-17-1

1 P-34628

The COM port (Item 1) [Figure 30-17-2] should only


need to be changed when the Laptop is using COM port
P-73668 1 for another application / device.

Click on the Options Icon (Item 1) [Figure 30-17-1] NOTE: If the communication alarm occurs when
trying to enter the Service Analyzer program
and all connections, the service tool key and

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The options screen allows you to change the language,
communications port, the default units (Metric or the fuse check good, select each available
English), and the diagnostic display mode. COM port and retry the Service Analyzer
program.

The Diagnostic Mode should never be changed from


voltage to engineering unless requested by Bobcat
Service Personnel.

99 of 118 30-17-1 Loader Electrical System Service Manual


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ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: ELEC-1


Date: 21 April 2000
Product: Bobcat Loader
Model: Electrical System
Manual No: 6900881 (2-00)
The following pages are a revision to the above Service Manual.

Take out existing pages and put in the new pages as listed below:

TAKE OUT PUT IN REVISION DECRIPTION

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Cartoon Cartoon Updated

Alpha Index Added

Contents i-xii Contents i-xii Revised G Series S/N list, updated Safety Warnings

10-40-3 thru 10-40-6 Replaced by Section 40

All Section 40 Revised All PC Software procedures

Printed in U.S.A.
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SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: ELEC-2

Date: 12 December 2000


Product: Bobcat Loader
Model: Electrical System
Manual No: 6900881 (2-00)

The following pages are a revision to the above Service Manual.

Take out existing pages and put in the new pages as listed below:

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TAKE OUT PUT IN REVISION DECRIPTION
Cover Cover

Cartoon Cartoon Updated

v, vi v, vi Revised

10-10-1 thru 10-10-2 10-10-1 thru 10-10-2 Revised Text


10-20-1 thru 10-20-6 10-20-1 thru 10-20-6 Revised Text and Photos
10-40-1 thru 10-40-2 10-40-1 thru 10-40-2 Revised Text and Photos
10-50-1 thru 10-50-2 10-50-1 thru 10-50-2 Revised Text

Section 30 Section 30 Many resistance and voltage updates and added Hall-
Effect

103 of 118
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SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: ELEC-3


Date: 23 April 2002
Product: Bobcat Loader
Model: Electrical System
Manual No: 6900881 (2-00)

The following pages are a revision to the above Service Manual.

Take out existing pages and put in the new pages as listed below:

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TAKE OUT PUT IN REVISION DECRIPTION

Alpha Index Alpha Index


i, ii i, ii Revised
Section 31 Added 2 Connector Bobcat Controller Troubleshooting
Info.

105 of 118
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PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: ELEC-4


Date: 12 June 2002
Product: Bobcat Loader
Model: Electrical System
Manual No: 6900881 (2-00)

The following pages are a revision to the above Service Manual.

Take out existing pages and put in the new pages as listed below:

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TAKE OUT PUT IN REVISION DECRIPTION

Section 40 Section 40 Revised

107 of 118
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PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: ELEC-5


Date: 8 July 2002
Product: Bobcat Loader
Model: Electrical System
Manual No: 6900881 (2-00)

The following pages are a revision to the above Service Manual.

Take out existing pages and put in the new pages as listed below:

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TAKE OUT PUT IN REVISION DECRIPTION

Alpha Index Alpha Index Revised

30-01 thru 30-06 30-01 thru 30-06 Revised

30-330-1 thru 30-330-28 30-330-1 thru 30-330-54 Added ACS codes and revised the AHC codes

109 of 118
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REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: ELEC-6

Date: 11 April 2003


Product: Bobcat Loader
Model: Electrical System
Manual No: 6900881 (2-00)

Please discard your old Electrical System Service Manual (P/N 6900881) dated 2-00 and replace it
with the revised Electrical System Service Manual (P/N 6900881) Dated 4-03.

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This Service Manual is in a new format with added updates.

Printed in U.S.A.
111 of 118
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REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: ELEC-7

Date: 11 July 2006


Product: Bobcat Loader
Model: Electrical System
Manual No: 6900881 (4-03)

Please discard your old Electrical System Service Manual (P/N 6900881) dated 4-03 and replace it
with the revised Electrical System Service Manual (P/N 6900881) Dated 7-06

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Printed in U.S.A.
113 of 118
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REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: ELEC-8


Date: 16 November 2007
Product: Bobcat Loader
Model: Electrical System
Manual No: 6900881 (4-03)

The following Sections are a revision to the above Electrical Service Manual.

Front Cover

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Alphabetical Index

Contents

Foreword

10-01
10-20
10-21
10-40
20-01
20-20
30-01
30-10
30-11
30-12
30-13
30-14
30-15
30-16
30-17
30-18

Remove Section 40

Printed in U.S.A.
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PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: ELEC-9


Date: 14 January 2008
Product: Bobcat Loader
Model: Electrical System
Manual No: 6900881 (1-08)

The following Sections are a revision to the above Electrical Service Manual.

COVER

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ALPHABETICAL INDEX

30-01
30-14
30-15
Remove 30-18

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