863 Service Manual

TURBO
TURBO
Service
Manual
S/N 514440001 & Above
S/N 514540001 & Above
S/N 514640001 & Above
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6900942 (2-06)
Printed in U.S.A.
© Bobcat Company 2006
MAINTENANCE SAFETY
WARNING
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
W-2003-0903
instructions can cause injury or death.
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT
CORRECT
B-10731a
B-15590
Never service the Bobcat SkidSteer Loader without instructions.
Use the correct procedure to lift or
lower operator cab.
CORRECT
B-15591
Cleaning and maintenance are
required daily.
WRONG
WRONG
WRONG
B-15592
B-15593
B-15599
Have good ventilation when
welding or grinding painted
parts.
Wear dust mask when grinding
painted parts. Toxic dust and gas
can be produced.
Avoid exhaust fume leaks which
can kill without warning. Exhaust
system must be tightly sealed.
Disconnecting or loosening any
hydraulic tubeline, hose, fitting,
component or a part failure can
cause lift arms to drop. Do not go
under lift arms when raised
unless
supported
by
an
approved lift arm support device.
Replace it if damaged.
WRONG
WRONG
B-15600
B-15601
Stop, cool and clean engine of
flammable
materials
before
checking fluids.
Never service or adjust loader
with the engine running unless
instructed to do so in the
manual.
Avoid contact with leaking
hydraulic fluid or diesel fuel
under pressure. It can penetrate
the skin or eyes.
Never fill fuel tank with engine
running, while smoking or when
near open flame.
Keep body, jewelry and clothing
away
from
moving
parts,
electrical contact, hot parts and
exhaust.
Wear eye protection to guard
from battery acid, compressed
springs, fluids under pressure
and flying debris when engines
are running or tools are used.
Use eye protection approved for
type of welding.
Keep rear door closed except for
service. Close and latch door
before operating the loader.
Never work on loader with lift
arms up unless lift arms are held
by an approved lift arm support
device. Replace if damaged.
Never modify equipment or add
attachments not approved by
Bobcat Company.
WRONG
B-6589
Lead-acid batteries
produce
flammable and explosive gases.
Keep arcs, sparks, flames and
lighted tobacco away from
batteries.
Batteries contain acid which
burns eyes or skin on contact.
Wear protective clothing. If acid
contacts body, flush well with
water. For eye contact flush well
and get immediate medical
attention.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW08-0805
ALPHABETICAL INDEX
ADVANCED CONTROL SYSTEM
(ACS) ADVANCED HAND CONTROL................. 60-01
ADVANCED CONTROL SYSTEM
(ACS) SELECTABLE HAND/FOOT CONTROL... 60-01
ADVANCED CONTROL SYSTEM (AHC) ............... 60-01
ADVANCED CONTROL SYSTEM
(AHC) (W/PUSH BUTTON FLOAT) ..................... 60-01
AIR CLEANER ........................................................ 70-01
AIR CLEANER SERVICE ....................................... 10-01
AIR CONDITIONG SERVICE ................................. 80-01
AIR CONDITIONING SYSTEM FLOW ................... 80-01
ALTERNATOR (55 AMP) ........................................ 60-01
ALTERNATOR (90 AMP) ........................................ 60-01
ENGINE LUBRICATION SYSTEM .........................10-01
ENGINE SPECIFACATIONS ............................. SPEC-01
ENGINE SPEED CONTROL ...................................70-01
EVAPORATOR ........................................................80-01
EVAPORATOR/HEATER UNIT................................80-01
EXPANSION VALVE ................................................80-01
BASIC TROUBLESHOOTING ................................ 80-01
BATTERY ............................................................... 60-01
BICS™ SYSTEM .................................................... 60-01
BOBCAT CONTROLLER ....................................... 60-01
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™) ............................ 60-01
BOB-TACH................................................... 10-01, 50-01
BRAKE .................................................................... 40-01
BRAKE (TWO-SPEED)........................................... 40-01
BUCKET POSITITON VALVE
20-01
GENERAL AIR CONDITIONING SERVICE
GUIDELINES ........................................................80-01
CHAINCASE ........................................................... 40-01
CHARGE PRESSURE ........................................... 30-01
COOLING FAN ...................................................... 70-01
COMPONENTS ..................................................... 80-01
COMPRESSOR ..................................................... 80-01
CONDENSER ......................................................... 80-01
CONTROL HANDLE (ADVANCED CONTROL SYSTEM)
(ACS) ADVANCED HAND CONTROL................. 20-01
CONTROL HANDLE (ADVANCED HAND CONTROL)
(AHC) .................................................................. 20-01
CONTROL HANDLE (ADVANCED HAND CONTROL)
(AHC) (W/PUSH BUTTON FLOAT) ..................... 20-01
CONTROL HANDLE (ADVANCED CONTROL SYSTEM)
(ACS) SELECTABLE HAND/FOOT CONTROL... 20-01
CONTROL PANEL ..................................................50-01
CONTROL PEDALS ............................................... 50-01
CONTROL PEDALS (ACS) .................................... 50-01
CONVERSIONS ............................................... SPEC-01
CYLINDER (LIFT) ................................................... 20-01
CYLINDER (POWER BOB-TACH).......................... 20-01
CYLINDER (TILT) ................................................... 20-01
DELUXE INSTRUMENTATION SERVICE CODES 60-01
DRIVE BELT ........................................................... 30-01
DRIVE COMPONENTS .......................................... 40-01
FAN GEARBOX .......................................................10-01
FINAL DRIVE TRANSMISSION (CHAINCASE)......10-01
FLYWHEEL AND HOUSING ..................................70-01
FRONT AUXILIARY HYD. COUPLER BLOCK .......20-01
FUEL SYSTEM........................................................10-01
FUEL TANK .............................................................50-01
HEATER COIL .........................................................80-01
HEATER/AC FAN ...................................................80-01
HEATER VALVE ......................................................80-01
HYDRAULIC CONNECTION SPECS ............... SPEC-01
HYDRAULIC CONTROL VALVE
(ADVANCED CONTROL SYSTEM) (ACS) ..........20-01
HYDRAULIC CONTROL VALVE
(FOOT CONTROL)...............................................20-01
HYDRAULIC FLUID RESERVOIR ..........................20-01
HYDRAULIC/HYDROSTATIC FILTER ....................20-01
HYDRAULIC FLUID SPECIFICATIONS............ SPEC-01
HYDRAULIC/HYDROSTATIC SYSTEM.............. 10-01
HYDRAULIC PUMP ................................................20-01
HYDRAULIC SYSTEM INFORMATION ..................20-01
HYDROSTATIC MOTOR .........................................30-01
HYDROSTATIC MOTOR (TWO-SPEED) ................30-01
HYDROSTATIC PUMP ............................................30-01
HYDROSTATIC SYSTEM INFORMATION..............30-01
INSTRUMENT PANEL ............................................60-01
LIFT ARMS ..............................................................50-01
LIFT ARM BY-PASS VALVE ....................................20-01
LIFT ARM SUPPORT DEVICE................................10-01
LIFTING AND BLOCKING THE LOADER...............10-01
LIGHTS....................................................................60-01
LOADER SPECIFICATIONS ............................. SPEC-01
LOADER TORQUE............................................ SPEC-01
LUBRICATING THE LOADER.................................10-01
MAIN RELIEF VALVE (FOOT CONTROL) ..............20-01
MUFFLER................................................................70-01
ELECTRICAL/HYD. CONTROLS REFERENCE .... 60-01
ELECTRICAL SYSTEM INFORMATION ................ 60-01
ENGINE & ENGINE MOUNTS ............................... 70-01
ENGINE COMPONENTS AND TESTS .................. 70-01
ENGINE COOLING SYSTEM ................................. 10-01
863 Bobcat Loader
Service Manual
ALPHABETICAL INDEX (CONT’D)
OIL COOLER...........................................................30-01
OPERATOR CAB..........................................10-01, 50-01
OPERATOR SEAT...................................................50-01
OPERATOR SEAT (SUSPENSION)........................50-01
POWER BOB-TACH (OPTION)....................10-01, 50-01
POWER BOB-TACH BLOCK...................................20-01
PRESSURE RELIEF VALVE ...................................80-01
PRESSURE SWITCH..............................................80-01
RADIATOR...............................................................70-01
REAR AUXILIARY DIVERTER VALVE ....................20-01
REAR DOOR ..........................................................50-01
REAR GRILL ..........................................................50-01
RECEIVER/DRIER..................................................80-01
RECOMMENDED SERVICE TOOLS ......................80-01
RECONDITIONING THE ENGINE ..........................70-01
REMOTE START .....................................................10-01
RPM SENSOR.........................................................70-01
SAFETY...................................................................80-01
SEAT BAR ...............................................................50-01
SEAT BAR SENSOR ...............................................60-01
SELECT VALVE.......................................................20-01
SERVICE SCHEDULE.............................................10-01
STARTER ................................................................60-01
SYSTEM CHARGING AND RECLAMATION ..........80-01
SYSTEM TROOUBLESHOOTING CHART.............80-01
TEMPERATURE/PRESSURE.................................80-01
THERMOSTAT ........................................................80-01
TIRE MAINTENANCE..............................................10-01
TORQUE SPECIFICATIONS FOR BOLTS........ SPEC-01
TOWING THE LOADER ..........................................10-01
TRACTION LOCK....................................................60-01
TRANSPORTING THE LOADER ............................10-01
TROUBLESHOOTING.............................................70-01
863 Bobcat Loader
Service Manual
CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . XI
SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
SAFETY AND
MAINTENANCE
HYDRAULIC
SYSTEM
HYDROSTATIC
SYSTEM
DRIVE
SYSTEM
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 80-01
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
MAIN
s
FRAME
A
ELECTRICAL
SYSTEM &
ANALYSIS
ENGINE
SERVICE
HVAC
SPECIFICATIONS
I
863 Bobcat Loader
Service Manual
FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, Starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS
(Including side screens) is in
good condition and is not
modified.
9. The parking brake
function correctly.
2. Check that ROPS mounting
hardware is tightened and is
Bobcat approved.
10. Enclosure door latches must
open and close freely.
3. The seat belt must be
correctly installed, functional
and in good condition.
11. Bob-Tach
wedges
and
linkages
must
function
correctly and be in good
condition.
4. The seat bar must be
correctly adjusted, clean and
lubricated.
12. Safety treads must be in good
condition.
5. Check lift arm support device,
replace if damaged.
13. Check for correct function of
indicator lamps (Optional on
some models).
6. Machine signs must be
legible and in the correct
location.
14. Check hydraulic fluid level,
engine oil level and fuel
supply.
7. Steering levers and foot
pedals must return to neutral.
15. Inspect for fuel,
hydraulic fluid leaks.
8. Check for correct function of
the work lights
16. Lubricate the loader.
II
must
oil
or
863 Bobcat Loader
Service Manual
17. Check the condition of the
battery and cables.
22. Operate the loader and check
all functions.
18. Inspect the air cleaner for
damage or leaks. Check the
condition of the element.
23. Check
for
any
field
modification not completed.
19. Check the electrical charging
system.
24. Check for correct function of
the Bobcat Interlock Control
System (BICS) before the
machine is returned to the
customer.
20. Check tires for wear and
pressure.
25. Recommend to the owner
that all necessary corrections
be made before the machine
is returned to 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.
III
863 Bobcat Loader
Service Manual
IV
863 Bobcat Loader
Service Manual
SAFETY INSTRUCTIONS
The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
This symbol with a warning statement means:
“Warning, be alert! Your safety is involved!”
Carefully read the message that follows.
•
The Delivery Report is used to assure that complete
instructions have been given to the new owner and
that the machine is in safe operating condition.
•
The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
•
Machine signs (decals) instruct on the safe operation
and care of your Bobcat machine or attachment. The
signs and their locations are shown in the Operation
& Maintenance Manual. Replacement signs are
available from your Bobcat dealer.
•
An Operator’s Handbook fastened to the operator
cab. It’s brief instructions are convenient to the
operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
•
The AEM Safety Manual delivered with the machine
gives general safety information.
•
The Service Manual and Parts Manual are available
from your dealer for use by mechanics to do shoptype service and repair work.
•
The Skid-Steer Loader Operator Training Course is
available through your local dealer or at
www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
of correct operation of the Skid-Steer Loader. The
course is available in English and Spanish versions.
•
Service Safety Training Courses are available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com. They provide information for
safe and correct service procedures.
•
The Skid-Steer Loader Safety Video is available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.
WARNING
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0903
WARNING
Warnings on the machine and in the manuals are for
your safety. Failure to obey warnings can cause
injury or death.
W-2044-1285
IMPORTANT
This notice identifies procedures which must be
followed to avoid damage to the machine.
I-2019-0284
SI SSL-0206 SM
V
863 Bobcat Loader
Service Manual
SAFETY INSTRUCTIONS (CONT’D)
The dealer and owner/operator review the recommended
uses of the product when delivered. If the owner/operator
will be using the machine for a different application(s) he
or she must ask the dealer for recommendations on the
new use.
Call Before You Dig
1-888-258-0808
When you call, you will be directed to a location in
your state/city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.)
SI SSL-0206 SM
VI
863 Bobcat Loader
Service Manual
SAFETY INSTRUCTIONS (CONT’D)
•
Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump
starting.
•
Use the procedure in the Operation & Maintenance
Manual for cleaning the spark arrestor muffler (if
equipped).
Fire Prevention
The machine and attachments have components that are
at high temperature under normal operating conditions.
The primary source of high temperatures is the engine
and exhaust system. The electrical system, if damaged
or incorrectly maintained, can be a source of arcs or
sparks.
Figure 1
Flammable debris (leaves, straw, etc.) must be removed
regularly. If flammable debris is allowed to accumulate, it
will increase fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential hazard.
The spark arrestor muffler is designed to control the
emission of hot particles from the engine and exhaust
system, but the muffler and the exhaust gases are still
hot.
•
Do not use the machine where exhaust, arcs, sparks
or hot components can contact flammable material,
explosive dust or gases.
•
The operator cab, engine compartment, and engine
cooling system must be inspected every day and
cleaned if necessary to prevent fire hazard and
overheating.
•
Check all electrical wiring and connections for
damage. Keep the battery terminals clean and tight.
Repair or replace any damaged part.
•
Check fuel and hydraulic tubes, hoses and fittings for
damage and leakage. Never use open flame or bare
skin to check for leaks. Tighten or replace any parts
that show leakage. Always clean fluid spills. Do not
use gasoline or diesel fuel for cleaning parts. Use
commercial nonflammable solvents.
•
Do not use ether or starting fluids on any engine
which has glow plugs. These starting aids can cause
explosion and injure you or bystanders.
•
Always clean the machine, disconnect the battery,
and disconnect the wiring from the 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 a dust mask
when grinding painted parts. Toxic dust or gas can be
produced.
•
Stop the engine and let it cool before adding fuel. NO
SMOKING!
•
Know where fire extinguishers and first aid kits are
located and how to use them. Fire extinguishers are
available from your Bobcat dealer [Figure 1].
SI SSL-0206 SM
VII
863 Bobcat Loader
Service Manual
VIII
863 Bobcat Loader
Service Manual
SERIAL NUMBER LOCATIONS
Engine Serial Number
Always use the serial number of the loader when
requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Figure 3
Loader Serial Number
Figure 2
P-10443
Figure 4
N-19358
The loader serial number plate is located on the inside of
the operator cab on the right fender and in front of the
seat [Figure 2].
Explanation of loader Serial Number:
XXXX
Model 1.-Model/ Engine
Combination
XXXXX
N-19359
Model 2.-Production
Sequence (Series)
The engine serial number is located on the valve cover at
the right side of the engine [Figure 3]. There is also an
extra S/N tag attached to the engine [Figure 4].
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.
IX
863 Bobcat Loader
Service Manual
DELIVERY REPORT
Figure 5
B-16315
The Delivery Report must be filled out by the dealer and
signed by the owner or operator when the Bobcat loader
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [Figure
5].
X
863 Bobcat Loader
Service Manual
BOBCAT LOADER IDENTIFICATION
OPERATOR
SEAT With
SEAT BELT
◆FRONT LIGHTS
GRAB
HANDLES
◆REAR
AUXILIARY
QUICK
COUPLERS
TILT CYLINDER
◆ FRONT AUXILLIARY
QUICK COUPLERS
†BUCKET
SAFETY TREAD
BUCKET STEPS
LIFT ARM
SUPPORT DEVICE
B-15565
•OPERATOR CAB
(ROPS/FOPS)
REAR GRILL
SEAT BAR
LIFT ARM
LIFT CYLINDER
◆REAR LIGHT
REAR
DOOR
◆TAIL LIGHT
TIRES*
B-15566
◆ OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment)
* TIRES - Flotation tires◆ are shown. The Bobcat loader is factory equipped with standard tires.
† BUCKET - Several different buckets and other attachments are available for the Bobcat loader.
• ROPS, FOPS - Roll-Over Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective Structure per
SAE J1043 and ISO 3449, Level 1. Level II is available. The Bobcat loader is base-equipped with a standard operator cab
as shown. Extra insulated cab is available as an option (Reduced noise level).
XI
863 Bobcat Loader
Service Manual
XII
863 Bobcat Loader
Service Manual
SAFETY AND MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1
SAFETY &
MAINTENANCE
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . 10-90-1
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . 10-110-1
Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
DRIVE
SYSTEM
FAN GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . 10-130-1
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Replacing The Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Lift Pump Strainer . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Air From The Fuel System . . . . . . . . . . . . . . .
10-100-1
10-100-1
10-100-2
10-100-3
10-100-1
10-100-3
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . .
Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . .
Replacing The Hydraulic/Hydrostatic Fluid . . . . . . . . . . .
Replacing Hydraulic Fluid And Case Drain Filters . . . . . .
10-120-1
10-120-4
10-120-1
10-120-2
10-120-2
ELECTRICAL
SYSTEM &
ANALYSIS
ENGINE
SERVICE
SPECIFICATIONS
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Disengaging The Lift Arm Support Device. . . . . . . . . . . . . 10-20-2
Engaging The Lift Arm Support Device . . . . . . . . . . . . . . . 10-20-1
LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
10-01
863 Bobcat Loader
Service Manual
SAFETY AND MAINTENANCE (CONT’D)
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
POWER BOB-TACH (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151-1
REMOTE START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-4
Procedure For Loader With, Attachments Control Harness. . . . . . . . . . . 10-60-2
Procedure For Loader Without, Attachments Control Harness . . . . . . . . 10-60-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Tire Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
Procedure For Non-Two-Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
Procedure (S/N 51451171, 514540173, 514449390 and Above) . . . . . . 10-50-3
Procedure For Two-Speeds (S/N 51464170, 514540172, 514449389 And
Below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-2
TRANSPORTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Adjusting The Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
10-02
863 Bobcat Loader Loader
Service Manual
LIFTING AND BLOCKING THE LOADER
Figure 10-10-2
Procedure
WARNING
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0903
Figure 10-10-1
N-19374
Put a floor jack under the rear of the loader [Figure 1010-2].
Lift the rear of the loader and install jackstands [Figure
10-10-2].
Figure 10-10-3
B-7023A
Read the removal and installation, disassembly and
assembly, etc., completely to become familiar with the
procedure before beginning [Figure 10-10-1].
P-7704
Put the floor jack under the front of the loader [Figure 1010-3].
Always park the loader on a level surface.
Lift the front of the loader and put jackstands under the
axle tubes [Figure 10-10-3].
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
NOTE: Make sure the jackstands do not touch the
tires.
W-2017-0286
10-10-1
863 Bobcat Loader
Service Manual
10-10-2
863 Bobcat Loader
Service Manual
LIFT ARM SUPPORT DEVICE
Figure 10-20-2
Engaging The Lift Arm Support Device
1
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
N-19369
WARNING
Service lift arm support device if damaged or if parts
are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
causing injury or death.
W-2271-1197
Lower the lift arm support device on top of the lift
cylinder. Hook the free end of the spring (Item 1) [Figure
10-20-2] to the lift arm support device so there will be no
interference with the support device engagement.
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine.
Figure 10-20-1
1
2
N-19368
Maintenance and service work can be done with the loft
arms lowered. If the lift arms are raised, use the
following procedures to engage and disengage an
approved lift arm support device:
Install jackstands under the rear of the loader frame.
Disconnect the spring from the lift arm support device
retaining pin (Item 1) [Figure 10-20-1]. support the lift
arm support device (Item 2) [Figure 10-20-1] with your
hand and remove the retaining pin.
10-20-1
863 Bobcat Loader
Service Manual
Figure 10-20-5
LIFT ARM SUPPORT DEVICE (CONT’D)
Engaging The Lift Arm Support Device (Cont’d)
Figure 10-20-3
P-10707
1
N-19372
Raise the lift arms a small amount and the spring will lift
the support device off the lift cylinder rod [Figure 10-205]. Lower the lift arms. Stop the engine.
N-19370
Raise the lift arms, until the lift arm support device drops
onto the lift cylinder rod (Inset) [Figure 10-20-3].
Lower the lift arms slowly until the support device is held
between the lift arm and the lift cylinder. Stop the engine.
Raise the seat bar and move pedals until both pedals
lock.
Install the pin (Item 1) [Figure 10-20-3] into the rear of
the lift arm support device below the cylinder rod.
Disengaging The Lift Arm Support Device
Raise the seat bar and move pedals until both pedals
lock.
Disconnect the spring from the bracket.
Raise the support device into storage position and insert
pin through lift arm support device and bracket. (See
Engaging The Lift Arm Support Device on Page 10-20-1.)
(Item 1) [Figure 10-20-1 on Page 1].]
Connect spring to pin. (See Engaging The Lift Arm
Support Device on Page 10-20-1, [Figure 10-20-1 on
Page 1].)
Figure 10-20-4
1
N-19371
Remove the pin from the lift arm support device.
Connect the spring (Item 1) [Figure 10-20-4] from the lift
arm support device to the bracket below the lift arms.
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine.
10-20-2
863 Bobcat Loader
Service Manual
OPERATOR CAB
Figure 10-30-1
Raising The Operator Cab
WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat. Changes to the cab
can cause loss of operator protection from rollover
and falling objects, and result in injury or death.
W-2069-1299
N-19374
Install jackstands under the rear of the loader frame
[Figure 10-30-1].
Figure 10-30-2
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 1. Level II
is available.
Level 1 - Protection from falling bricks, small concrete
blocks and hand tools encountered in operations such as
highway maintenance, landscaping,
and
other
construction site services.
N-19364
N-19365
Loosen the nut (both sides) at the front corners of the
operator cab [Figure 10-30-2].
Remove the nuts and plates (both sides) [Figure 10-302]
Level II - Protection from falling trees, rocks; for machines
involved in site clearing, overhead demolition or forestry.
Always stop the engine before raising or lowering the
cab.
Stop the loader in 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 Engaging The Lift
Arm Support Device on Page 10-20-1.) (See Engaging
The Lift Arm Support Device on Page 10-20-1.)
10-30-1
863 Bobcat Loader
Service Manual
OPERATOR CAB (CONT’D)
Lowering The Operator Cab
Raising The Operator Cab (Cont’d)
Figure 10-30-4
Figure 10-30-3
N-20120
N-19517
Lift on the grab handles and bottom of the operator cab
slowly until the cab is all the way up and the latching
mechanism engages [Figure 10-30-3].
Advanced Control System (ACS) And Advanced Hand
Control (AHC)
N-19518
Always stop the engine before raising or lowering the
cab.
NOTE: Make sure the seat bar is fully raised or
lowered when lowering the cab. Always use
the grab handles to lower the cab.
Pull down on the bottom of the operator cab until it stops
at the latching mechanism [Figure 10-30-4].
Release the latching mechanism (Inset) [Figure 10-30-4]
and pull the cab all the way down.
10-30-2
863 Bobcat Loader
Service Manual
OPERATOR CAB (CONT’D)
Emergency Exit
Lowering The Operator Cab (Cont’d)
The front opening on the operator cab and rear window
provide exits.
Figure 10-30-5
Rear Window (If Equipped)
Figure 10-30-6
N-19365
N-19364
Install the plates and nuts [Figure 10-30-5] (both sides).
N-19385
Tighten the nuts to 40-50 ft.-lbs. (54-68 Nm) torque.
Pull on the tag on the top of the rear window to remove
the rubber cord [Figure 10-30-5].
Push the rear window out of the rear of the operator cab.
Figure 10-30-7
N-19520
Exit through the rear of the operator cab [Figure 10-307].
10-30-3
863 Bobcat Loader
Service Manual
OPERATOR CAB (CONT’D)
Figure 10-30-9
Emergency Exit (Cont’d)
Front Door (If Equipped)
Figure 10-30-8
X
N-20170
Push the window out with your foot [Figure 10-30-9] at
any corner of the window.
Exit through the front door.
N-20171
NOTE: When an Operator Cab Enclosure Kit is
installed, the window of the front door can be
used as an emergency exit [Figure 10-30-8].
NOTE: When the special applications kit is installed,
the front door cannot be used for an
emergency exit.
Pull the plastic loop at the top of the window in the front
door to remove the rubber cord [Figure 10-30-8].
10-30-4
863 Bobcat Loader
Service Manual
TRANSPORTING THE LOADER
Adjusting The Bumper
Procedure
Figure 10-40-2
WARNING
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0494
N-19048
N-19523
Figure 10-40-1
1
N-19521
A loader with an empty bucket or no attachment must be
loaded backward onto the transport vehicle [Figure 1040-1].
Be sure the transport and towing vehicles are of
adequate size and capacity (See Performance on Page
SPEC-10-2.) for weight of loader.
6707867
P-39472
Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving
during sudden stops or when going up or down slopes
[Figure 10-40-2].
•
Lower the bucket or attachment to the floor.
Stop the engine.
Engage the parking brake.
Install chains at the front and rear loader tie down
positions (Inset) [Figure 10-40-2].
Fasten each end of the chain to the transport vehicle.
10-40-1
863 Bobcat Loader
Service Manual
The rear of the trailer must be blocked or supported (Item
1) [Figure 10-40-1] when loading or unloading the loader
to prevent the front end of the trailer from raising up.
•
•
•
•
10-40-2
863 Bobcat Loader
Service Manual
TOWING THE LOADER
Figure 10-50-2
Procedure For Non-Two-Speeds
IMPORTANT
Do not push or pull the machine at more than 2 MPH
(3,2 km/h) or for a distance of more than 25 feet (7,6
meters) with the towing tool in place.
1
I-2017-0389
Figure 10-50-1
N-18409
•
•
1
Press the TRACTION LOCK OVERRIDE Button
(Item 1) [Figure 10-50-2].
Tow the Bobcat at 2 MPH (3,2) km/hr.) or less for not
more than 25 feet (7,6 meters).
If the electrical system is not functioning, contact your
local Bobcat dealer.
P-28360A
To prevent damage to the loaders hydrostatic system, the
loader must be towed only a short distance at slow speed.
(Example: Moving the loader onto a transport vehicle.)
The towing chain (or cable) must be rated at 1 & 1/2
times the weight of the loader. (See Performance on
Page SPEC-10-2.)
•
Turn the key switch to RUN (Item 1) [Figure 10-50-1]
(Standard Panel) OR press the RUN / ENTER Button
(Deluxe).
10-50-1
863 Bobcat Loader
Service Manual
TOWING THE LOADER (CONT’D)
counterclockwise. The knob will come out to release
the solenoid valve.
Procedure For Two-Speeds (S/N 51464170,
514540172, 514449389 And Below)
Figure 10-50-4
1
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P-16465
Connect a Port-a-Power to the coupler (Item 1) [Figure
10-50-4].
Figure 10-50-5
Figure 10-50-3
P-16467
Operate the Port-a-Power 350-400 PSI (2413-2758 kPa)
to release the brake [Figure 10-50-5].
1
Lower the operator cab and tow the loader.
Before operating the loader again, disconnect the Port-aPower.
P-16466
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Engage the parking brake solenoid valve, by pushing
IN the red Traction Lock By-Pass Knob (Item 1) [Figure
10-50-3] and turning it 1/4 TURN clockwise.
Disengage the parking brake solenoid valve by pushing
IN on the red Traction Lock By-Pass Knob (Item 1)
[Figure 10-50-3] and turning it 1/4 TURN
10-50-2
863 Bobcat Loader
Service Manual
TOWING THE LOADER (CONT’D)
Connect the drain hose (Item 1) [Figure 10-50-6] to the
check valve (Item 2) [Figure 10-50-6].
Procedure (S/N 51451171, 514540173, 514449390 and
Above)
Connect the Tee fitting (Item 3) [Figure 10-50-6], check
valve (Item 2) [Figure 10-50-6], and the coupler (Item 5)
[Figure 10-50-6] to the swivel fitting (Item 4) [Figure 1050-6].
Figure 10-50-7
1
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
P-34088
W-2059-0598
Figure 10-50-6
Disconnect the two hoses (Item 1) [Figure 10-50-7] from
the parking brake solenoid valve that go to the right and
left brake housings on the hydrostatic motors.
7
5
3
Figure 10-50-8
6
2
1
1
2
7
4
1
P-34159
3
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
The parts from the list below are required to complete the
towing tool needed in this procedure [Figure 10-50-6]:
1 - 2 ft. common drain hose (Item 1)
1 - 6678026 - Check relief valve (500 PSI) (Item 2)
1 - 10K5 - Tee fitting (Item 3)
1 - 13K5 - Swivel fitting (Item 4)
1 - 6661753 - Coupler, male (Item 5)
1 - MEL1218 - Coupler, female (Item 6)
2 - 36K5 - Caps (Item 7)
P-34089
Connect the two hoses (Item 1) [Figure 10-50-8] to the
tee fitting of the towing tool.
Connect the Port-a-Power (Item 2) [Figure 10-50-8] (with
an attached pressure gauge 600 PSI (4137 kPa) or
larger) to the quick coupler on the towing tool.
Route the drain hose (Item 3) [Figure 10-50-8] into a
bucket.
10-50-3
863 Bobcat Loader
Service Manual
TOWING THE LOADER (CONT’D)
Procedure (S/N 51451171, 514540173, 514449390 and
Above) (Cont’d)
Figure 10-50-9
P-34090
Operate the Port-a-Power to 350-400 PSI (2413-2758
kPa) to release the brakes [Figure 10-50-9].
Lower the cab and tow the loader.
Release the port-a-power pressure to apply the brakes.
Remove the towing tool from the brake hoses.
Install the two hydraulic hoses to the parking brake
solenoid valve.
10-50-4
863 Bobcat Loader
Service Manual
REMOTE START
Figure 10-60-2
Procedure For Loader Without, Attachments Control
Harness
Figure 10-60-1
1
1
N-19983
Figure 10-60-3
P-13841
The tool listed will be needed to do the following
procedure:
1
MEL1563: Remote Start Tool Kit
The remote start (Item 1) [Figure 10-60-1] 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 10-10-1.)
Raise the lift arms (if required by the procedure) and
install an approved lift arm support device.
(See
Engaging The Lift Arm Support Device on Page 10-20-1.)
2
N-19984
Remove the cap (Item 1) [Figure 10-60-2] from the
loader harness (Item 1) [Figure 10-60-3].
When the remote start procedure is completed, replace
the loader connected cap (Item 2) [Figure 10-60-3].
Raise the operator cab (if required by the procedure).
(See Raising The Operator Cab on Page 10-30-1.)
Open the rear door of the loader.
10-60-1
863 Bocat Loader
Service Manual
REMOTE START (CONT’D)
Procedure For Loader With, Attachments Control
Harness
Procedure For Loader Without, Attachments Control
Harness (Cont’d)
The tool listed will be needed to do the following
procedure:
WARNING
MEL 1563: Remote Start Tool Kit
Figure 10-60-5
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
service technician will be working the engine area it
is important to remove the operator panel keys.
1
W-2357-0899
Figure 10-60-4
P-13841
The remote start (Item 1) [Figure 10-60-5] 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.
1
2
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the lift arms (if required by the procedure) and
install an approved lift arm support device.
(See
Engaging The Lift Arm Support Device on Page 10-20-1.)
N-19985
Connect the remote start tool to the engine harness
connector (Item 1) [Figure 10-60-4].
The connector (Item 2) [Figure 10-60-4] from the remote
start harness is not used in the remote start procedure
and should remain capped.
Raise the operator cab (See Raising The Operator Cab
on Page 10-30-1.)
Open the rear door of the loader.
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.
10-60-2
863 Bobcat Loader
Service Manual
REMOTE START (CONT’D)
Figure 10-60-7
Procedure For Loader With, Attachments Control
Harness (Cont’d)
1
WARNING
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
service technician will be working the engine area it
is important to remove the operator panel keys.
W-2357-0899
Figure 10-60-6
2
N-20079
Disconnect the attachment control harness (Item 1)
[Figure 10-60-6] & [Figure 10-60-7] from the loader
harness (Item 2) [Figure 10-60-7].
Figure 10-60-8
1
1
2
N-19987
N-20080
Connect the remote start tool (Item 1) [Figure 10-60-8]
to the loader harness connector (Item 2) [Figure 10-607].
The connector (Item 2) [Figure 10-60-8] on the remote
start harness is not used in the remote start procedure
and should remain capped.
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.
10-60-3
863 Bocat Loader
Service Manual
REMOTE START (CONT’D)
Figure 10-60-10
Procedure
Figure 10-60-9
2
3
1
1
N-19541
P-13842
The remote start tool (Item 1) [Figure 10-60-9] has three
rocker switches.
The traction lock switch (Item 1) [Figure 10-60-10] is
used to turn traction lock on or off, Push the switch to the
override position. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the wheels are
able to turn.
The maximum flow/variable flow switch (Item 2) [Figure
10-60-10] 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 10-6010] 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 this will cause the
engine to stop in three seconds. To relieve
the pressure; continue to press the switch
after the engine has stopped.
10-60-4
863 Bobcat Loader
Service Manual
SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat loader.
WARNING
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0903
SERVICE SCHEDULE
ITEM
SERVICE REQUIRED
Engine Oil
Check the oil level and add as needed.
Engine Air Filter and Air System
Check display panel. Service only when required. Check for leaks and
damaged components.
Clean debris from oil cooler, radiator & grill.
Lubricate with multi-purpose lithium based grease (14 places).
Engine Cooling System
Lift Arms, Cylinders, Bob-Tach
Pivot Pins and Wedges
Tires
HOURS
8-10
50
100
■
■
▼
■
250 500 1000 3000
Check for damaged tires and correct air pressure.
Seat Bar, Control Interlocks, Seat Check the condition of seat belt. Clean or replace seat beltretractors as
Belt, Seat Belt Retractors
needed. Check the sear bar and control interlocks for correct operation. Clean
dirt and debris from moving parts.
Bobcat Interlock Control Systems Check that four (4) BICS™ indicator lights and functions are activated. See
(BICS™)
details in this Manual.
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or
safety treads that are damaged or worn.
Operator Cab
Check the fastening bolts, washers and nuts. Check the condition of the cab.
Indicators and Lights
Check for correct operation of all indicators and lights.
Fuel Filter
Heater and A/C Filters
Hydraulic Fluid, Hoses and
Tubelines
Final Drive Trans. (Chaincase),
Foot Pedals or Hand Controls,
and Steering Levers
Wheel Nuts
Remove the trapped water.
Clean or replace filters as needed during heating/cooling season.
Check fluid level and add as needed. Check for damage and leaks. Repair or
replace as needed.
Check oil level. Check for correct operation. Repair or adjust as needed.
Parking Brake
❏Check for loose wheel nuts and tighten to 105-115 ft.-lbs. (142-156 Nm)
torque
Check operation.
Battery
Check cables, connections and electrolyte level. Add distilled water as needed.
Engine/Hydro. Drive Belt
Alternator Belt
Air Conditioner Belt
Bobcat Interlock Control System
(BICS™)
Fuel Filter
Steering Shaft
Fan Drive Gearbox
*Check for wear or damage. Check idler arm stop.
Check tension and adjust as needed.
Check belt for wear. Adjust or replace as needed.
Check the function of the lift arm by-pass control.
Replace filter element.
Grease three fittings.
Check gear lube level.
Hydraulic Reservoir Breather Cap
Replace the reservoir breather cap.
Hyd./Hydro. Filter
Engine Oil and Filter
Final Drive Trans. (Chaincase)
● Replace the filter element.
^Replace oil and filter. Use CD or better grade oil and Bobcat filter.
Replace the fluid.
Hydraulic Reservoir
Case Drain Filters
Replace the fluid.
Replace the filters.
Engine Valves
Engine Timing Belt
#Adjust the engine valves.
▼Replace the timing belt and belt tensioner assy.
^
❍
❏ Check wheel nut torque every 8 hours for the first 24 hours.
* Inspect the new belt after first 50 hours.
● Also replace hydraulic/hydrostatic filter element when the transmission warning light comes ON.
^ First oil and filter change must occur at 50 hours; 500 hours thereafter.
❍ When operating under severe conditions, change oil and filter every 250 hours.
# After the first 500 hours on new engine, adjust engine valves; 1000 hours thereafter.
■ Or every 12 months.
▼ Or every 5 years.
10-70-1
863 Bobcat Loader
Service Manual
10-70-2
863 Bobcat Loader
Service Manual
AIR CLEANER SERVICE
OUTER FILTER
Replacing Filter Element
Figure 10-80-3
Figure 10-80-1
2
1
1
B-15553
B-15552
P-24843
It is important to change the air filter element only when
the Air Cleaner Icon in the right panel is ON (Item 1)
[Figure 10-80-1] and you hear three beeps from the
alarm.
Replace the inner filter every third time the outer filter is
replaced or as indicated. ((See Replacing Filter Element
on Page 10-80-1.))
Disengage the clamps (Item 1) [Figure 10-80-3] and
remove the dust cover (Item 2) [Figure 10-80-3].
Figure 10-80-4
Figure 10-80-2
2
1
1
P-24844
B-15551
Press and hold the LIGHT Button (Item 1) [Figure 10-802] for two seconds.
If the filter element needs replacement, the CODE [0117] (Air Filter Plugged) will show in the HOURMETER /
CODE DISPLAY (Item 2) [Figure 10-80-2].
Remove the outer filter element (Item 1) [Figure 10-804].
NOTE: Make sure all sealing surfaces are free of dirt
and debris.
Install a new outer element.
Install the dust cover and fasten the clamps.
10-80-1
863 Bobcat Loader
Service Manual
AIR CLEANER SERVICE (CONT’D)
Figure 10-80-6
Replacing Filter Element (Cont’d)
Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight.
INNER FILTER
Only replace the inner filter element under the following
conditions:
•
•
Replace the inner filter element every third time the
outer filter is replaced.
After the outer element has been replaced, start the
engine and run at full RPM. If the HOURMETER /
CODE DISPLAY shows [01-17] (Air Filter Plugged),
replace the inner filter element.
1
P-24843
Figure 10-80-5
Install the dust cover and fasten the clamps (Item 1)
[Figure 10-80-6].
1
P-24845
Remove the inner filter element (Item 1) [Figure 10-805].
NOTE: Make sure all sealing surfaces are free of dirt
and debris.
Install the new inner element.
10-80-2
863 Bobcat Loader
Service Manual
ENGINE COOLING SYSTEM
Figure 10-90-2
Cleaning The Cooling System
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
1
W-2019-1285
P-28467
Figure 10-90-1
Remove the fasteners (Item 1) [Figure 10-90-2] (both
sides) and raise the oil cooler.
Check the cooling system for leaks.
Figure 10-90-3
1
1
N-19411
Check the cooling system every day to prevent
overheating, loss of performance or engine damage.
Lift the grill [Figure 10-90-1].
N-19416
Use air pressure or water pressure to clean the top of the
oil cooler (Item 1) [Figure 10-90-1].
Use air pressure or water pressure to clean the top of the
engine oil cooler (Item 1) [Figure 10-90-3].
10-90-1
863 Bobcat Loader
Service Manual
ENGINE COOLING SYSTEM (CONT’D)
Cleaning The Cooling System (Cont’d)
Figure 10-90-4
Access
Cover
N-19361
NOTE: The access cover (both sides) must be in place
to ensure correct air flow through the oil
cooler which will ensure cooling for the
engine and hydraulic system [Figure 10-90-4].
10-90-2
863 Bobcat Loader
Service Manual
FUEL SYSTEM
Figure 10-100-2
Fuel Specifications
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1.
The following is a suggested blending guideline which
should prevent fuel gelling during cold temperatures:
Temp.
Down to
Below
F°
(C° )
No. 2
No.1
+15°
-20°
-20°
(9° )
(-29° )
100%
50%
0%
0%
50%
100%
(-29° )
B-15602
Contact your fuel supplier for local recommendations.
Use a clean, approved safety container to add fuel of the
correct specifications. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING! [Figure 10-100-2].
Filling The Fuel Tank
WARNING
Install and tighten the fuel cap (Item 1) [Figure 10-100-1]
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0887
Open the rear door.
Figure 10-100-1
1
N-19408
Remove the fuel fill cap (Item 1) [Figure 10-100-1].
10-100-1
863 Bobcat Loader
Service Manual
FUEL SYSTEM (CONT’D)
Fuel Filter
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Figure 10-100-3
2
1
N-19327
(See SERVICE SCHEDULE on Page 10-70-1.) for the
service interval for removing water from,or replacing the
fuel filter.
Loosen the drain (Item 1) [Figure 10-100-3] at the
bottom of the filter element to remove water from the
filter.
Remove the filter element (Item 2) [Figure 10-100-3].
Clean the area around the filter housing. Put clean oil on
the seal of the new filter element. Install the fuel filter,
and hand tighten.
Remove the air from the fuel system. (See Removing Air
From The Fuel System on Page 10-100-3.)
10-100-2
863 Bobcat Loader
Service Manual
FUEL SYSTEM (CONT’D)
Removing Air From The Fuel System
Fuel Lift Pump Strainer
WARNING
Figure 10-100-4
2
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
1
W-2072-0496
After replacing the filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel
system before starting the engine.
Open the vent (Item 2) [Figure 10-100-4] on the fuel filter
housing.
Squeeze the hand pump (priming bulb) (Item 3) [Figure
10-100-4] until fuel flows from the vent with no air
bubbles.
P-24722
Close the vent (Item 2) [Figure 10-100-4].
3
N-19325
Loosen the bolt and remove the cover and strainer (Item
1) [Figure 10-100-4].
Clean the strainer with clean diesel fuel.
Install the strainer and cover and tighten bolt.
10-100-3
863 Bobcat Loader
Service Manual
10-100-4
863 Bobcat Loader
Service Manual
ENGINE LUBRICATION SYSTEM
Replacing Oil And Filter
Checking Engine Oil
WARNING
Figure 10-110-1
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
2
W-2103-1285
Figure 10-110-2
1
N-19327
Check the engine oil every day.
1
Before restarting the engine for the work shift, open the
rear door. Remove the dipstick (Item 1) [Figure 10-1101]
Keep the oil level between the marks on the dipstick.
N-19328
Use a good quality motor oil that meets API Service
Classification of CD or better. (See oil chart below.)
RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)
C°
(See SERVICE SCHEDULE on Page 10-70-1.) for the
service interval for replacing the engine oil filter.
Run the engine until it its at operating temperature. Stop
the engine.
Open the rear door. Remove the drain plug [Figure 10110-2]. Drain the oil into container. Recycle or dispose
of the used oil in an environmentally safe manner.
F°
TEMPERATURE RANGE ANTICIPATED
BEFORE NEXT OIL CHANGE (DIESEL ENGINES
MUST USE API CLASSIFICATION CD, CF4, CG4)
*Can be used ONLY when available with appropriate
diesel rating.
10-110-1
863 Bobcat Loader
Service Manual
ENGINE LUBRICATION SYSTEM (CONT’D)
Replacing Oil And Filter (Cont’d)
Figure 10-110-3
1
N-19325
Remove the oil filter (Item 1) [Figure 10-110-3].
Clean the filter housing surface. Use genuine Bobcat
filter only. Put clean oil on the new oil filter gasket. Install
the filter and hand tighten only.
Install and tighten the drain plug.
Remove the filler cap (Item 2) [Figure 10-110-1].
Put 10 qts. (9,5 L) of oil in the engine.
Start the engine and let it run for several minutes. Stop
the engine. Check for leaks and check the oil level. Add
oil as needed if it is not at the top mark on the dipstick.
Install dipstick and close the rear door.
10-110-2
863 Bobcat Loader
Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM
Figure 10-120-2
Checking And Adding Fluid
Use only recommended fluid in the hydraulic system.
(See HYDRAULIC FLUID SPECIFICATIONS on Page
SPEC-60-1.) for the correct fluid.
1
Put the loader on a level surface.
Lower the lift arms and tilt the Bob-Tach fully back.
Stop the engine.
Figure 10-120-1
N-19360
CD-12250
Sight Gauge
Remove the fill cap (Item 1) [Figure 10-120-2].
Add fluid as needed to bring the level to the center of the
sight gauge.
NOTE: Before installing the fill breather cap, make
sure the rubber gasket is installed on the cap
(inset ) [Figure 10-120-2].
P-4613
Install the fill cap [Figure 10-120-2].
N-19361
Check the fluid level in the sight gauge (Item 1) [Figure
10-120-1].
10-120-1
863 Bobcat Loader
Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)
WARNING
Replacing The Hydraulic/Hydrostatic Fluid
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496
(See SERVICE SCHEDULE on Page 10-70-1.) for the
correct service interval.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Replacing Hydraulic Fluid And Case Drain Filters
(See SERVICE SCHEDULE on Page 10-70-1.) for the
correct service interval.
Replace the fluid if it becomes contaminated or after
major repair.
Always replace the hydraulic/hydrostatic filter and clean
the hydraulic fill screen and the case drain filters
whenever the hydraulic fluid is replaced.
Remove the fill cap and raise the operator cab. (See
Raising The Operator Cab on Page 10-30-1.)
Figure 10-120-3
Hydraulic Fill Screen
Figure 10-120-4
1
1
N-19516
Remove the filter (Item 1) [Figure 10-120-3].
Clean the surface of the filter housing where the filter seal
contacts the housing. Put clean oil on the seal of the new
filter element.
N-19362
Remove two hose clamps and remove the hose (Item 1)
[Figure 10-120-4]
Install and hand tighten the filter element.
Lower the operator cab.
Start the engine and operate the loader hydraulic
controls.
Stop and check for leaks at the filter.
Check the fluid level in the reservoir and add as needed.
10-120-2
863 Bobcat Loader
Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)
Figure 10-120-6
Replacing The Hydraulic Fluid And Case Drain Filters
(Cont’d)
Hydraulic Fill Screen (Cont’d)
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
N-19496
W-2103-1285
Figure 10-120-5
Drain the reservoir [Figure 10-120-6].
Motor Cover.
Remove Left
Case Drain Filters
Remove the hydrostatic motor covers. (Both Sides.) Pull
the reservoir drain hose [Figure 10-120-6] out the left
motor cover hole. Remove the plug and drain the fluid
into a container.
1
Recycle or dispose of used fluid on an environmentally
safe manner.
N-19363
Remove the hydraulic fill screen (Item 1) [Figure 10-1205] and use clean solvent to remove contamination from
the screen.
Use air pressure to dry the screen.
Install screen, hose and hose clamps.
10-120-3
863 Bobcat Loader
Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)
Breather Cap
Replacing Hydraulic Fluid And Case Drain Filters
(Cont’d)
The fill cap is also a breather for the hydraulic/hydrostatic
reservoir. (See SERVICE SCHEDULE on Page 10-70-1.)
for correct service interval.
Case Drain Filters (Cont’d)
Figure 10-120-9
Figure 10-120-7
RIGHT CASE DRAIN
FILTER
1
1
N-19360
N-19495
Remove the cap (Item 1) [Figure 10-120-9] and use
clean solvent to remove debris. Dry the cap thoroughly.
Install the fill/breather cap.
Figure 10-120-8
LEFT CASE DRAIN
FILTER
1
N-19497
Disconnect the hoses from the hydrostatic motor case
drain filter (Item 1) [Figure 10-120-7] and [Figure 10120-8].
Remove the case drain filters (Item 1) [Figure 10-120-7]
and [Figure 10-120-8] and clean thoroughly with clean
solvent.
Install the case drain filters and tighten hoses.
Install the plug in the reservoir drain hose and tighten.
Install motor covers. (Both Sides.)
Add the correct fluid to the reservoir until the fluid levels
at the center of the sight gauge.
10-120-4
863 Bobcat Loader
Service Manual
FINAL DRIVE TRANSMISSION (CHAINCASE)
Replacing The Oil
Checking And Adding Oil
Figure 10-130-2
Figure 10-130-1
1
1
P-1616
P-10153
The chaincase contains the final drive sprockets and the
chains and uses the same type of fluid as is used in the
hydraulic/hydrostatic system. (See HYDRAULIC FLUID
SPECIFICATIONS on Page SPEC-60-1.)
To drain the oil from the chaincase, remove the cover
(Item 1) [Figure 10-130-2] which is installed over the
drain plug at the rear of the chaincase.
Figure 10-130-3
To check the chaincase oil level, use the following
procedure:
Drive the loader on a level surface. Stop the engine.
Remove the plug (Item 1) [Figure 10-130-1] from the
front of the chaincase housing.
1
If oil can be reached with the tip of your finger through the
hole the oil level is correct.
If the level is low, add oil through the check plug hole until
the oil flows from the hole. Install and tighten the plug.
P-1619
Remove the drain plug (Item 1) [Figure 10-130-3] and
drain the oil into a container. Recycle or dispose of the
used oil in an environmentally safe manner.
Check the drain plug and replace if necessary.
Install and tighten the plug.
10-130-1
863 Bobcat Loader
Service Manual
10-130-2
863 Bobcat Loader
Service Manual
FAN GEAR BOX
Checking And Adding Oil
Figure 10-140-1
Gear Lube
Level
1
P-7616
(See SERVICE SCHEDULE on Page 10-70-1.) for the
correct service interval.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the plug (Item 1) [Figure 10-140-1] to check the
lubricant level.
If the level is low, add SAE 90W gear lubricant through
the check plug hole until lubricant flows from the hole.
10-140-1
863 Bobcat Loader
Service Manual
10-140-2
863 Bobcat Loader
Service Manual
BOB-TACH
Figure 10-150-3
Inspection And Maintenance
Bob-Tach
Wedge
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Levers must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0588
Wedge Must Contact
Lower Edge Of Hole
In The Attachment
Figure 10-150-1
B-15177
If the wedge does not contact the lower edge of the hole
[Figure 10-150-2] and [Figure 10-150-3], the
attachment will be loose and can come off the Bob-Tach.
Figure 10-150-4
1
N-17022
N-17027
Move the Bob-Tach levers to engage the wedges (Item 1)
[Figure 10-150-1]. The levers and wedges must move
freely.
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [Figure 10-150-1].
TS-1062
Figure 10-150-2
Inspect the mounting frame on the attachment and the
Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-150-4]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
Look for cracked welds. Contact your Bobcat dealer for
repair or replacement parts.
Lubricate the wedges. (See
LOADER on Page 10-160-1.)
LUBRICATING
THE
1
N-17023
The spring loaded wedge (Item 1) [Figure 10-150-1]
must contact the lower edge if the hole in the attachment
(Item 1) [Figure 10-150-2] and [Figure 10-150-3].
10-150-1
863 Bobcat Loader
Service Manual
10-150-2
863 Bobcat Loader
Service Manual
POWER BOB-TACH (OPTION)
Figure 10-151-3
Inspection And Maintenance
Figure 10-151-1
1
B-15177
Wedge Must Contact
Lower Edge Of Hole
In The Attachment
N-17043
If the wedge does not contact the lower edge of the hole
[Figure 10-151-3], the attachment will be loose and can
come off the Bob-Tach.
B-15554B
B-15554A
B-15993C
Push and hold the BOB-TACH “WEDGES UP” switch
[Figure 10-151-1] until wedges are fully raised. Push
and hold the BOB-TACH “WEDGES DOWN” switch
[Figure 10-151-1] until the wedges are fully down. The
wedges must move freely.
Figure 10-151-4
Figure 10-151-2
TS-1062
Inspect the mounting frame on the attachment and the
Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-151-4]. Replace any parts including
decals and lever that are damaged, bent, or missing.
Keep all fasteners tight. Inspect the hoses and fittings for
leaks.
1
N-17043
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [Figure 10-151-2]
and must contact the lower edge of the hole in the
attachment [Figure 10-151-2] and (Item 1) [Figure 10151-3].
Look for cracked welds. Contact your Bobcat dealer for
repair or replacement parts.
Lubricate the wedges. (See
LOADER on Page 10-160-1.)
10-151-1
LUBRICATING
THE
863 Bobcat Loader
Service Manual
10-151-2
863 Bobcat Loader
Service Manual
LUBRICATING THE LOADER
Figure 10-160-3
Procedure
Figure 10-160-1
3
1
N-19358
3. Lift Arm Pivot Pin (Both sides) [Figure 10-160-3].
N-19367
Figure 10-160-4
Lubricate the loader for the best performance of the
loader. (See LUBRICATING THE LOADER on Page 10160-1.)
Record the operating hours each time you lubricate the
Bobcat loader.
4
Always use a good quality lithium based multi-purpose
grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Lubricate the following locations on the loader:
1. Rod End Lift Cylinder (Both Sides) [Figure 10-160-1].
Figure 10-160-2
P-7641
4. Base End Tilt Cylinder (Both Sides) [Figure 10-1604].
2
P-10815
2. Base End Lift Cylinder (Both Sides) [Figure 10-1602].
10-160-1
863 Bobcat Loader
Service Manual
LUBRICATING THE LOADER (CONT’D)
Figure 10-160-7
Procedure (Cont’d)
Figure 10-160-5
1
5
N-19502
8. Steering Lever Shaft (Both Sides) [Figure 10-160-7].
N-19501
5. Rod End Tilt Cylinder (Both Sides) [Figure 10-160-5].
Figure 10-160-6
6
7
N-19500
6. Bob-Tach Pivot Pin (Both Sides) [Figure 10-160-6].
7. Bob-Tach Wedge (Both Sides) [Figure 10-160-6].
10-160-2
863 Bobcat Loader
Service Manual
TIRE MAINTENANCE
Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
capability.
Check for the correct pressure before
operating the loader.
Wheel Nuts
Figure 10-170-1
Tire Mounting
WARNING
Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1285
IMPORTANT
P-10142
(See SERVICE SCHEDULE on Page 10-70-1.) for the
service interval to check the wheel nuts. The correct
torque is 105-115 ft.-lbs. (142-156 Nm) torque [Figure
10-170-1].
Tire Rotation
Check the tires regularly for wear, damage and pressure.
(See Tires on Page SPEC-10-4.) for the correct tire
pressure.)
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
I-2057-0794
Tires are to be repaired only by an authorized person
using the proper procedures and safety equipment. Tires
and rims must always be checked for correct size before
mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust. The tire
bead and rim flange must be lubricated with a rubber
lubricant before mounting the tire, avoid excessive
pressure which can rupture the tire and cause serious
injury or death. During inflation of the tire, check the tire
pressure frequently to avoid over inflation
Figure 10-170-2
B-9976
Rear tires usually wear faster than front tires. To keep
tire wear even, move the front tires to the rear and rear
tires to the front [Figure 10-170-2].
It is important to keep the same size tires on each side of
the loader. If different sizes are used, each tire will be
turning at a different rate and cause excessive wear. The
tread bars of all the tires must face the same direction.
10-170-1
863 Bobcat Loader
Service Manual
10-170-2
863 Bobcat Loader
Service Manual
HYDRAULIC SYSTEM
BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-90-1
20-90-4
20-90-1
20-90-2
20-90-2
CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-20-1
20-20-7
20-20-1
20-20-5
20-20-4
20-20-2
CYLINDER (POWER BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-22-1
20-22-5
20-22-1
20-22-4
20-22-3
20-22-2
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rod End Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-21-1
20-21-7
20-21-1
20-21-5
20-21-4
20-21-1
20-21-3
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK. . . . . . . . . . . . . 20-130-1
Disassembly And Assembly (518916011 & Above). . . . . . . . . . . . . 20-130-1
Removal And Installation (514449564 & Above) . . . . . . . . . . . . . . . 20-130-1
SAFETY &
MAINTENANCE
HYDRAULIC
SYSTEM
DRIVE
SYSTEM
ELECTRICAL
SYSTEM &
ANALYSIS
ENGINE
SERVICE
SPECIFICATIONS
Continued On Next Page
20-01
863 Bobcat Loader
Service Manual
HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS). 20-41-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . 20-41-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . 20-41-1
Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-25
Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24
Auxiliary Electric Solenoid Disassembly And Assembly . . . . . . . . . . . . . 20-41-30
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
BICS™ Valve Check Valve Removal And Installation . . . . . . . . . . . . . . . 20-41-16
BICS™ Valve Lift Arm By-Pass Orifice Removal And Installation . . . . . . 20-41-15
BICS™ Valve Lock Valve Removal And Installation . . . . . . . . . . . . . . . . 20-41-17
BICS™ Valve Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-13
BICS™ Valve Removal Solenoid And Installation . . . . . . . . . . . . . . . . . . 20-41-18
BICS™ Valve Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-19
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-32
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-19
Lift And Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . 20-41-28
Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-20
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-26
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-20
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-22
Port-Auxiliary Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-31
Port Relief Valve(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-23
Removal & Installation (S/N 514447863 & Below). . . . . . . . . . . . . . . . . . . 20-41-3
Removal And Installation (S/N 514447864 & Above) . . . . . . . . . . . . . . . . 20-41-7
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-27
Continued On Next Page
20-02
863 Bobcat Loader
Service Manual
HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC CONTROL VALVE (FOOT CONTROL) . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-1
Anti-Cavitation Valve/Port Relief Valve, Tilt Spool . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-20
Anti-Cavitation Valve, Lift Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-20
Auxiliary Electric Solenoid Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-36
Auxiliary Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-35
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-33
BICS™ Valve, Check Valve Disassembly And Assembly (S/N 514450007 & Below)20-40-12
BICS™ Valve, Lift arm By-Pass Orifice Disassembly And Assembly . . . . . . . . . . . . 20-40-11
BICS™ Valve, Lock Valve Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . .20-40-14
BICS™ Valve, Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-10
BICS™ Valve, Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . .20-40-15
BICS™ Valve, Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-16
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-38
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-16
Lift And Tilt Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-21
Lift Spool And Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-22
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-17
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-18
Port Relief-Auxiliary Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-37
Port Relief Valve, Tilt Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-19
Port Relief Valve, Lift Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-19
Removal And Installation (S/N 514447863 & Below). . . . . . . . . . . . . . . . . . . . . . . . . .20-40-1
Removal And Installation (S/N 514447864 & Above) . . . . . . . . . . . . . . . . . . . . . . . . .20-40-4
Rubber Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-21
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-31
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-1
Draining The Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-1
Hydraulic Fluid Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-1
HYDRAULIC/HYDROSTATIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-70-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-70-1
Continued On Next Page
20-03
863 Bobcat Loader
Service Manual
HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 & BELOW) . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking The Output Of The Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-60-1
20-60-7
20-60-1
20-60-4
20-60-6
20-60-3
20-60-2
HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N 514449483 & BELOW) . . . . . . 20-61-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-10
Checking The Output Of The High Flow Pump . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-5
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-9
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-2
HYDRAULIC PUMP (CAST IRON) (S/N 514449260 & ABOVE) . . . . . . . . . . . . . .
Check The Output Of The Hydraulic Pump With Power Bob-Tach . . . . . . . . . .
Check The Output Of The Hydraulic Pump Without Power Bob-Tach . . . . . . . .
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-62-1
20-62-3
20-62-1
20-62-7
20-62-6
20-62-4
HYDRAULIC PUMP (CAST IRON HIGH FLOW) (S/N 514449484-514450945) . .
Check The Output Of The Hydraulic Pump With Power Bob-Tach . . . . . . . . . .
Check The Output Of The Hydraulic Pump Without Power Bob-Tach . . . . . . . .
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-63-1
20-63-2
20-63-1
20-63-6
20-63-7
20-63-4
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Tighten Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
LIFT ARM BY-PASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Inspection For Loaders With ACS. . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-50-1
20-50-1
20-50-2
20-50-1
20-50-1
Continued On Next Page
20-04
863 Bobcat Loader
Service Manual
HYDRAULIC SYSTEM (CONT’D)
MAIN RELIEF VALVE (FOOT CONTROL) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking The Main Relief Valve At Front Auxiliary Hydraulics . . . . . . . . .
Checking The Main Relief Valve Without Front Auxiliaries . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-30-1
20-30-5
20-30-1
20-30-2
20-30-4
POWER BOB-TACH BLOCK (6676547-ALUMINUM) . . . . . . . . . . . . . . . . . 20-120-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
POWER BOB-TACH BLOCK (6678554-CAST IRON) . . . . . . . . . . . . . . . . . 20-121-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-1
REAR AUXILIARY DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-110-1
20-110-2
20-110-2
20-110-2
SELECT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking The High Flow Pump Relief Valve (S/N 514450945 & Below).
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-100-1
20-100-4
20-100-1
20-100-2
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE
SPECIFICATIONS FOR BOLTS, SPEC SECTION) UNLESS OTHERWISE SPECIFIED.
20-05
863 Bobcat Loader
Service Manual
20-06
863 Bobcat Loader
Service Manual
HYDRAULIC/HYDROSTATIC SCHEMATIC
863 (S/N 514440001-41938)
(S/N 514540001-40073)
(PRINTED NOVEMBER 2002)
V-0027legend Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . 18.8 Qts. (17.8 L)
2
FILTER - CASE DRAIN (90 Micron)
3
FILTER - HYDRAULIC (CANISTER)
4
5
6
7
SPRING LOADED FILTER BY-PASS
VALVE: 45-55 PSI (311-379 kPa)
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
FLOW DIVIDER ADJUSTMENT VALVE
8
CHECK VALVE - BUCKET POSITION
VALVE
9
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
11 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
14
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
29
CHARGE PUMP
11.0 GPM (41,6 L/min.) at 2615 Engine RPM
15
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
30
HYDRAULIC PUMP . . . . . . . Gear Type
18.0 GPM (68,1 L/min.) at 2615 Engine RPM
31
DRIVE MOTOR SHUTTLE VALVE
32
SHUTTLE RELIEF VALVE:
200 PSI (1378 kPa)
16 FILTER - BICS CONTROL VALVE
(SCREEN)
17 BOOM DOWN RESTRICTOR
33
18 LIFT AND TILT LOAD CHECK VALVE
19 RELIEF VALVE - MAIN:
2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers
20 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
LOAD SHUTTLE VALVE - BLEED OFF
35
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P2" and "F2")
36
22 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END)
3500 PSI (24132 kPa)
37
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D1" and "P1")
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D2" and "P2")
24
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
25
RELIEF VALVE - PORT: . . . . . (Optional)
3500 PSI (24132 kPa)
38
FILTER - DIVERTER VALVE (SCREEN)
INTEGRATED IN SOLENOID
26
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE: 4712 PSI (32489 kPa)
39
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TO ACTIVATE
REAR AUXILIARY ("SV1")
27
CHARGE PRESSURE SWITCH
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
28
Printed in U.S.A.
34
21 ANTICAVITATION VALVE
23 ONE WAY RESTRICTOR VALVE
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR
AUXILIARY ("SV2")
RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.)Fluid
at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa)
40
*
41
CHECK VALVE - BICS CONTROL VALVE
42
LIFT ARM BY-PASS RESTRICTOR
43
CHECK VALVE - AUXILIARY
44
MUFFLER (If Equipped)
45
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
46
RESTRICTOR - 0.020 inch (0,5 mm)
47
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
48
RELIEF VALVE - 1200 PSI (8268 kPa)
49
RESTRICTOR - 0.090 inch (2,3 mm)
50
RELIEF VALVE - 2000 PSI (13780 kPa)
51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
53 SCREEN
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P1" and "F1")
V-0027legend (11-5-02)
DIVERTER VALVE (OPTIONAL)
HYDRAULIC/HYDROSTATIC SCHEMATIC
863 (S/N 514440001-41938)
(S/N 514540001-40073)
38
39
(PRINTED NOVEMBER 2002)
V-0027
PILOT
Printable Version Click Here
DRIVE MOTOR
40
MALE
31
MALE
36
F1
D1
MALE
2
32
34
(REAR QUICK
COUPLERS)
33
F2
FEMALE
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
37
35
D2
FEMALE
FEMALE
9
DRAIN
P1
P2
HYDRAULIC FILTER
3
HYDROSTATIC PUMPS
BUCKET POSITION VALVE (OPTIONAL)
OIL
COOLER
4
45
D
8
28
26
26
7
6
A
OUTLET
CHARGE INLET
C
52
HYDRAULIC CONTROL VAVLE
29
10
43
26
26
BOB-TACH
CYLINDER
(OPTIONAL)
45
OUTLET
INLET
11
27
HYDRAULIC
POWERED
BOB-TACH
DR (OPTIONAL)
24
25
24
B
A
B
AUXILIARY
SPOOL
53
23
22
30
46
TILT CYLINDER
BICS CONTROL VALVE
47
48
49
A
50
B
DRIVE MOTOR
21
18
9
P1
5
20
P2
LIFT CYLINDERS
17
13
A
31
12
TILT
CYLINDER
SPOOL
51
B
LIFT
CYLINDER
SPOOL
32
42
18
19
*
2
44
16
41
14
16
*
(If Equipped)
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY- PASS VALVE
15
1
Printed in U.S.A.
V-0027 (11-5-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
863 (S/N 514440001-41938)
(S/N 514640001-40147)
(PRINTED NOVEMBER 2002)
V-0028legend Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . 18.8 Qts. (17.8 L)
16 FILTER - BICS CONTROL VALVE
(SCREEN)
32
SHUTTLE RELIEF VALVE:
200 PSI (1378 kPa)
2
FILTER - CASE DRAIN (90 Micron)
17 BOOM DOWN RESTRICTOR
33
REAR AUXILIARY BLEED SHUTTLE VALVE
3
FILTER - HYDRAULIC (CANISTER)
18 LIFT AND TILT LOAD CHECK VALVE
34
4
SPRING LOADED FILTER BY-PASS
VALVE: 45-55 PSI (311-379 kPa)
35
5
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
19 RELIEF VALVE - MAIN:
2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers
LOAD CHECK VALVE - SELECT VALVE
(HIGH FLOW)
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - HIGH FLOW
20 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
36
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - DIVERTER
6
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
21 ANTICAVITATION VALVE
37
22 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END)
3500 PSI (24132 kPa)
38
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
23 ONE WAY RESTRICTOR VALVE
39
PILOT TO OPEN CHECK VALVE
24
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
40
25
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF
RELIEF VALVE - PORT: . . . . . (Optional)
3500 PSI (24132 kPa)
41
CHECK VALVE - BICS CONTROL VALVE
26
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE: 4712 PSI (32489 kPa)
42
LIFT ARM BY-PASS RESTRICTOR
27
CHARGE PRESSURE SWITCH
43
CHECK VALVE - AUXILIARY
28
RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.)Fluid
at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa)
44
MUFFLER (If Equipped)
45
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
46
RESTRICTOR - 0.020 inch (0,5 mm)
47
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
48
RELIEF VALVE - 1200 PSI (8268 kPa)
49
RESTRICTOR - 0.090 inch (2,3 mm)
7
FLOW DIVIDER ADJUSTMENT VALVE
8
CHECK VALVE - BUCKET POSITION
VALVE
9
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
11 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
29
14
30
15
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
31
Printed in U.S.A.
CHARGE PUMP
11.0 GPM (41,6 L/min.) at 2615 Engine RPM
HYDRAULIC PUMP . . . . . . . Gear Type
18.0 GPM (68,1 L/min.) at 2615
Engine RPM
HIGH FLOW CAPACITY: (Includes 53 )
28.0 GPM (106 L/min.) at 2615
Engine RPM
DRIVE MOTOR SHUTTLE VALVE
*
RELIEF VALVE - MAIN (HIGH FLOW)
3000 PSI (20685 kPa)
50 RELIEF VALVE - 2000 PSI (13780 kPa)
51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
53 HYDRAULIC HIGH FLOW PUMP
10.0 GPM (37,8 L/min.) at 2615 Engine RPM
54 SELECT VALVE RESTRICTOR
55 SCREEN
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-0028legend (11-5-02)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
863 (S/N 514440001-41938)
(S/N 514640001-40147)
MALE
SELECT VALVE
C2
C1
(RIGHT SIDE LIFT ARM
QUICK COUPLERS)
39
DRIVE MOTOR
(REAR QUICK COUPLERS)
54
54
31
FEMALE
39
MALE
33
Printable Version Click Here
FEMALE
(PRINTED NOVEMBER 2002)
V-0028
MALE
40
32
*
2
44
34
38
PRESS
FEMALE
PB
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
36
MALE
37
35
9
T
DRAIN
(MALE)
HYDRAULIC FILTER
3
BUCKET POSITION VALVE (OPTIONAL)
HYDROSTATIC PUMPS
OIL
COOLER
4
45
D
8
28
26
26
7
6
A
CHARGE INLET
OUTLET
52
C
10
HYDRAULIC CONTROL VAVLE
29
43
26
BOB-TACH
CYLINDER
(OPTIONAL)
45
HYDRAULIC
POWERED
BOB-TACH
DR (OPTIONAL)
INLET
30
11
27
26
24
25
24
B
A
B
AUXILIARY
SPOOL
55
23
22
OUTLET
46
TILT CYLINDER
BICS CONTROL VALVE
47
48
53
49
50
A
51
DRIVE MOTOR
B
21
18
9
P1
5
20
P2
LIFT CYLINDERS
17
13
A
31
12
TILT
CYLINDER
SPOOL
B
LIFT
CYLINDER
SPOOL
32
42
18
*
2
44
19
16
41
14
16
*
(If Equipped)
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY- PASS VALVE
15
1
Printed in U.S.A.
V-0028 (11-5-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
863 (S/N 514441939 - 514449259)
(S/N 514540074 - 514541068)
(PRINTED NOVEMBER 2002)
V-0019legend Printable Version Click Here
LEGEND
1
2
RESERVOIR:
Capacity . . . . . . .
15
18.8 Qts. (17.8 L)
FILTER - CASE DRAIN (90 Micron)
3
FILTER - HYDRAULIC (CANISTER)
4
SPRING LOADED FILTER BY-PASS
VALVE:
45-55 PSI (311-379 kPa)
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
29 CHARGE PUMP
(S/N 514441939-46864)
(S/N 514540074-41034)
11.0 GPM (41,6 L/min.) at 2615 Engine RPM
(S/N 514446865 AND ABOVE)
(S/N 514541035 AND ABOVE)
14.0 GPM (53,0 L/min.) at 2615 Engine RPM
16 FILTER - BICS CONTROL VALVE
(SCREEN)
17 BOOM DOWN RESTRICTOR
30
18 LIFT AND TILT LOAD CHECK VALVE
5
6
7
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
19 RELIEF VALVE - MAIN:
2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers
20 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
FLOW DIVIDER ADJUSTMENT VALVE
21 ANTICAVITATION VALVE
8
9
CHECK VALVE - BUCKET POSITION
VALVE
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
11 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
22 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END)
3500 PSI (24132 kPa)
23 ONE WAY RESTRICTOR VALVE
24
25
RELIEF VALVE - PORT: . . . . . . . . (Optional)
3500 PSI (24132 kPa)
26
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE:
(S/N 514441939-46864)
(S/N 514540074-41034)
4712 PSI (32489 kPa)
(S/N 514446865 AND ABOVE)
(S/N 514541035 AND ABOVE)
5000 PSI (34475 kPa)
CHARGE PRESSURE SWITCH
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
14
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
Printed in U.S.A.
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
27
28
*
CHECK VALVE - BICS CONTROL VALVE
42
LIFT ARM BY-PASS RESTRICTOR
43
CHECK VALVE - AUXILIARY
44
MUFFLER (If Equipped)
45
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
46
RESTRICTOR - 0.020 inch (0,5 mm)
31
DRIVE MOTOR SHUTTLE VALVE
47
32
SHUTTLE RELIEF VALVE:
200 PSI (1378 kPa)
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
48
RELIEF VALVE - 1200 PSI (8268 kPa)
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR
AUXILIARY ("SV2")
49
RESTRICTOR - 0.090 inch (2,3 mm)
34
LOAD SHUTTLE VALVE - BLEED OFF
50
RELIEF VALVE - 2000 PSI (13780 kPa)
35
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P2" and "F2")
51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
33
36
37
RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.) Fluid
at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa)
HYDRAULIC PUMP . . . . . . . Gear Type
(S/N 514441939-46864)
(S/N 514540074-41034)
18.0 GPM (68,1 L/min.) at 2615 EngineRPM
(S/N 514446865 AND ABOVE)
(S/N 514541035 AND ABOVE)
20.0 GPM (75,7 L/min.) at 2615 Engine RPM
41
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D1" and "P1")
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D2" and "P2")
38
FILTER - DIVERTER VALVE (SCREEN)
INTEGRATED IN SOLENOID
39
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TO ACTIVATE
REAR AUXILIARY ("SV1")
40
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P1" and "F1")
52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
53 SCREEN
54 ACCUMULATOR - FOUND ONLY ON
MACHINES WITH
S/N 514444558 AND ABOVE
S/N 514540126 AND ABOVE
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-0019legend (11-4-02)
DIVERTER VALVE (OPTIONAL)
HYDRAULIC/HYDROSTATIC SCHEMATIC
863 (S/N 514441939 - 514449259)
(S/N 514540074 - 514541068)
38
39
PILOT
(PRINTED NOVEMBER 2002)
V-0019
Printable Version Click Here
DRIVE MOTOR
40
MALE
31
MALE
36
F1
D1
32
34
(REAR QUICK
COUPLERS)
33
F2
FEMALE
MALE
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
37
35
D2
FEMALE
FEMALE
9
DRAIN
P1
P2
HYDRAULIC FILTER
3
HYDROSTATIC PUMPS
BUCKET POSITION VALVE (OPTIONAL)
OIL
COOLER
4
45
D
8
28
26
26
7
6
54
A
OUTLET
CHARGE INLET
C
52
10
HYDRAULIC CONTROL VAVLE
29
43
26
BOB-TACH
CYLINDER
(OPTIONAL)
45
OUTLET
INLET
11
27
26
HYDRAULIC
POWERED
BOB-TACH
DR (OPTIONAL)
24
25
24
B
A
B
AUXILIARY
SPOOL
53
23
22
30
46
TILT CYLINDER
BICS CONTROL VALVE
47
48
49
50
A
51
DRIVE MOTOR
B
21
18
9
P1
5
20
P2
LIFT CYLINDERS
17
13
A
31
12
TILT
CYLINDER
SPOOL
B
LIFT
CYLINDER
SPOOL
32
42
18
19
*
2
44
16
41
14
16
*
(If Equipped)
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY- PASS VALVE
15
1
Printed in U.S.A.
V-0019 (11-4-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE OPTION
863 (S/N 514441939 - 514449259)
(S/N 514540074 - 514541068)
(PRINTED NOVEMBER 2002)
V-0022legend Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . .
18.8 Qts. (17.8 L)
2
FILTER - CASE DRAIN (90 Micron)
3
FILTER - HYDRAULIC (CANISTER)
4
SPRING LOADED FILTER BY-PASS
VALVE:
45-55 PSI (311-379 kPa)
5
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
6
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
7
FLOW DIVIDER ADJUSTMENT VALVE
8
CHECK VALVE - BUCKET POSITION
VALVE
9
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
11 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
19 RELIEF VALVE - MAIN:
2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers
21 ANTICAVITATION VALVE
35
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P2" and "F2")
36
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D1" and "P1")
37
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D2" and "P2")
51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
53 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
54 HYDRAULIC BRAKE - SPRING APPLIED PRESSURE TO RELEASE
22 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END)
3500 PSI (24132 kPa)
23 ONE WAY RESTRICTOR VALVE
55 PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE BRAKE
24
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
25
RELIEF VALVE - PORT: . . . . . . . (Optional)
3500 PSI (24132 kPa)
38
FILTER - DIVERTER VALVE (SCREEN)
INTEGRATED IN SOLENOID
26
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE:
5000 PSI (34475 kPa)
39
57 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
27
CHARGE PRESSURE SWITCH
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TO ACTIVATE
REAR AUXILIARY ("SV1")
40
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P1" and "F1")
59 SCREEN
28
RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.)Fluid
at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa)
29
CHARGE PUMP
14.0 GPM (53,0 L/min.) at 2615 Engine RPM
HYDRAULIC PUMP . . . . . . . . Gear Type
20.0 GPM (75,7 L/min.) at 2615 Engine RPM
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
31
DRIVE MOTOR SHUTTLE VALVE
14
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
32
SHUTTLE RELIEF VALVE:
200 PSI (1378 kPa)
15
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
33
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR
AUXILIARY ("SV2")
Printed in U.S.A.
50 RELIEF VALVE - 2000 PSI (13780 kPa)
3500 PSI (24132 kPa)
30
18 LIFT AND TILT LOAD CHECK VALVE
LOAD SHUTTLE VALVE - BLEED OFF
20 RELIEF VALVE - PORT:
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
16 FILTER - BICS CONTROL VALVE
(SCREEN)
17 BOOM DOWN RESTRICTOR
34
41
CHECK VALVE - BICS CONTROL VALVE
42
LIFT ARM BY-PASS RESTRICTOR
43
CHECK VALVE - AUXILIARY
56 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - MAKE-UP
58 BRAKE DIAGNOSTIC PLUG
60 ACCUMULATOR - FOUND ONLY ON
MACHINES WITH
S/N 514444558 AND ABOVE
S/N 514540126 AND ABOVE
44 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
DRIVE MOTOR
45
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
46
RESTRICTION - 0.020 inch (0,5 mm)
47
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
48
RELIEF VALVE - 1200 PSI (8268 kPa)
49
RESTRICTOR - 0.090 inch (2,3 mm)
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-0022legend (11-5-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE OPTION
863 (S/N 514441939 - 514449259)
(S/N 514540074 - 514541068)
(PRINTED NOVEMBER 2002) Printable Version Click Here
DIVERTER VALVE (OPTIONAL)
38
39
PILOT
V-0022
TWO SPEED DRIVE MOTOR
40
31
MALE
32
36
MALE F1
D1
34
(REAR QUICK
COUPLERS)
54
33
F2
44
FEMALE
MALE
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
37
35
D2
FEMALE
FEMALE
53
DRAIN
9
P1
P2
HYDRAULIC FILTER
3
HYDROSTATIC PUMPS
4
45
26
BUCKET POSITION VALVE (OPTIONAL)
OIL
COOLER
D
8
26
28
7
6
60
A
CHARGE
INLET
52
OUTLET
C
10
HYDRAULIC CONTROL VAVLE
29
43
11
27
BOB-TACH
CYLINDER
(OPTIONAL)
45
26
26
30
INLET
OUTLET
58
TWO SPEED VALVE
HYDRAULIC
POWERED
BOB-TACH
DR (OPTIONAL)
B
B
AUXILIARY
SPOOL
B1
23
22
TWO SPEED DRIVE MOTOR
55
TILT CYLINDER
BICS CONTROL VALVE
47
48
B
49
50
54
A
51
9
56
C
24
A
59
46
P
24
25
B
12
TILT
CYLINDER
SPOOL
21
53
18
44
D
P1
5
P2
20
LIFT CYLINDERS
17
13
A
57
B
LIFT
CYLINDER
SPOOL
A
31
42
18
32
19
16
T
41
14
16
2
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY- PASS VALVE
15
1
Printed in U.S.A.
V-0022 (11-5-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
863 (S/N 514441939 - 514449483)
(S/N 514640148 - 514641170)
(PRINTED NOVEMBER 2002)
V-0023legend Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . . . 18.8 Qts. (17.8 L)
16 FILTER - BICS CONTROL VALVE
(SCREEN)
2
FILTER - CASE DRAIN (90 Micron)
17 BOOM DOWN RESTRICTOR
3
FILTER - HYDRAULIC (CANISTER)
18 LIFT AND TILT LOAD CHECK VALVE
HYDRAULIC PUMP . . . . . . . . Gear Type
(S/N 514441939-46822)
(S/N 514640148-41074)
18.0 GPM (68,1 L/min.) at 2615
Engine RPM
4
SPRING LOADED FILTER BY- PASS
VALVE: . . . 45-55 PSI (311-379 kPa)
5
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
19 RELIEF VALVE - MAIN:
2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers
HIGH FLOW CAPACITY: (Includes 53 )
28.0 GPM (106,0 L/min.) at 2615
Engine RPM
6
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
20 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
7
FLOW DIVIDER ADJUSTMENT VALVE
8
CHECK VALVE - BUCKET POSITION
VALVE
23 ONE WAY RESTRICTOR VALVE
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
24
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
25
RELIEF VALVE - PORT: . . . . . . (Optional)
3500 PSI (24132 kPa)
26
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE:
(S/N 514441939-46822)
(S/N 514640148-41074)
4712 PSI (32489 kPa)
(S/N 514446823 AND ABOVE)
(S/N 514641075 AND ABOVE)
5000 PSI (34475 kPa)
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
11 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
27
CHARGE PRESSURE SWITCH
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
28
RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.)Fluid
at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa)
14
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
15
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY- PASS
Printed in U.S.A.
(S/N 514446823 AND ABOVE)
(S/N 514641075 AND ABOVE)
20.0 GPM (75,7 L/min.) at 2615
Engine RPM
21 ANTICAVITATION VALVE
22 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END)
3500 PSI (24132 kPa)
9
30
29
CHARGE PUMP:
(S/N 514441939-46822)
(S/N 514640148-41074)
11.0 GPM (41,6 L/min.) at 2615 Engine RPM
(S/N 514446823 AND ABOVE)
(S/N 514641075 AND ABOVE)
14.0 GPM (53,0 L/min.) at 2615 Engine RPM
HIGH FLOW CAPACITY: (Includes 53 )
30.0 GPM (113,6 L/min.) at 2615
Engine RPM
31
DRIVE MOTOR SHUTTLE VALVE
32
SHUTTLE RELIEF VALVE:
200 PSI (1378 kPa)
33
REAR AUXILIARY BLEED SHUTTLE VALVE
34
LOAD CHECK VALVE - SELECT VALVE
(HIGH FLOW)
*
42
LIFT ARM BY-PASS RESTRICTOR
43
CHECK VALVE - AUXILIARY
44
MUFFLER (If Equipped)
45
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
46
RESTRICTOR - 0.020 inch (0,5 mm)
47
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
48
RELIEF VALVE - 1200 PSI (8268 kPa)
49
RESTRICTOR - 0.090 inch (2,3 mm)
50 RELIEF VALVE - 2000 PSI (13780 kPa)
51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
HYDRAULIC
HIGH FLOW PUMP
53
10.0 GPM (37,8 L/min.) at 2615 Engine RPM
54
FILTER - CASE DRAIN (ATTACHMENT)
35
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - HIGH FLOW
55
RESTRICTION - SELECT VALVE
36
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - DIVERTER
56
SCREEN
37
RELIEF VALVE - MAIN (HIGH FLOW)
3000 PSI (20685 kPa)
38
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
39
PILOT TO OPEN CHECK VALVE
40
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF
41
CHECK VALVE - BICS CONTROL VALVE
57 ACCUMULATOR - FOUND ONLY ON
MACHINES WITH
S/N 514444558 AND ABOVE
S/N 514640276 AND ABOVE
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-0023legend (11-5-02)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
863 (S/N 514441939 - 514449483)
(S/N 514640148 - 514641170)
C2
C1
(RIGHT SIDE LIFT ARM
QUICK COUPLERS)
39
DRIVE MOTOR
FEMALE
33
39
MALE
Printable Version Click Here
FEMALE
40
MALE
(PRINTED NOVEMBER 2002)
V-0023
MALE
SELECT VALVE
(REAR QUICK COUPLERS)
55
31
*
32
55
44
34
38
FEMALE
PB
PRESS
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
36
MALE
37
35
9
T
DRAIN
(MALE)
HYDRAULIC FILTER
54
3
HYDROSTATIC PUMPS
4
45
28
26
BUCKET POSITION VALVE (OPTIONAL)
OIL
COOLER
D
8
26
7
6
57
A
CHARGE INLET
OUTLET
52
C
10
HYDRAULIC CONTROL VAVLE
29
43
26
BOB-TACH
CYLINDER
(OPTIONAL)
45
HYDRAULIC
POWERED
BOB-TACH
DR (OPTIONAL)
INLET
30
11
27
26
24
25
24
B
A
B
AUXILIARY
SPOOL
56
23
22
OUTLET
46
TILT CYLINDER
BICS CONTROL VALVE
47
48
53
49
A
50
DRIVE MOTOR
12
TILT
CYLINDER
SPOOL
21
18
9
P1
5
20
P2
LIFT CYLINDERS
17
13
A
31
B
51
B
LIFT
CYLINDER
SPOOL
32
42
18
*
2
19
44
16
41
14
16
*
(If Equipped)
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY- PASS VALVE
15
1
Printed in U.S.A.
V-0023 (11-5-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW AND TWO SPEED VALVE OPTION
863 (S/N 514441939 - 514449483)
(S/N 514640148 - 514641170)
(PRINTED NOVEMBER 2002)
V-0024legend Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . . . . 18.8 Qts. (17.8 L)
2
FILTER - CASE DRAIN (90 Micron)
3
FILTER - HYDRAULIC (CANISTER)
4
SPRING LOADED FILTER BY-PASS
VALVE:
45-55 PSI (311-379 kPa)
5
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
19 RELIEF VALVE - MAIN:
2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers
31
DRIVE MOTOR SHUTTLE VALVE
50 RELIEF VALVE - 2000 PSI (13780 kPa)
32
SHUTTLE RELIEF VALVE: 200 PSI (1378 kPa)
20 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
33
REAR AUXILIARY BLEED SHUTTLE VALVE
34
LOAD CHECK VALVE - SELECT VALVE
(HIGH FLOW)
35
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - HIGH FLOW
51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
53 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
54 HYDRAULIC BRAKE - SPRING APPLIED PRESSURE TO RELEASE
21 ANTICAVITATION VALVE
22 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END)
3500 PSI (24132 kPa)
23 ONE WAY RESTRICTOR VALVE
6
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
24
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
7
FLOW DIVIDER ADJUSTMENT VALVE
25
8
CHECK VALVE - BUCKET POSITION
VALVE
RELIEF VALVE - PORT: . . . . .
(Optional)
3500 PSI (24132 kPa)
26
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
27
9
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
11 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
14
15
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
16 FILTER - BICS CONTROL VALVE
(SCREEN)
17 BOOM DOWN RESTRICTOR
18 LIFT AND TILT LOAD CHECK VALVE
Printed in U.S.A.
28
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE:
5000 PSI (34475 kPa)
CHARGE PRESSURE SWITCH
RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.)Fluid
at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa)
29
CHARGE PUMP
14.0 GPM (53,0 L/min.) at 2615 Engine RPM
30
HYDRAULIC PUMP . . . . . . . . Gear Type
(S/N 514441939-46822)
(S/N 514640148-41074)
18.0 GPM (68,1 L/min.) at 2615
Engine RPM
HIGH FLOW CAPACITY: (Includes 60 )
28.0 GPM (106,0 L/min.) at 2615
Engine RPM
(S/N 514446823 AND ABOVE)
(S/N 514641075 AND ABOVE)
20.0 GPM (75,7 L/min.) at 2615
Engine RPM
HIGH FLOW CAPACITY: (Includes 60 )
30.0 GPM (113,6 L/min.) at 2615
Engine RPM
36 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - DIVERTER
37 RELIEF VALVE - MAIN (HIGH FLOW)
3000 PSI (20685 kPa)
38
39
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
PILOT TO OPEN CHECK VALVE
55 PUSH BUTTON SOLENOID ACTIVATED
DIRECTIONAL CONTROL VALVE BRAKE
56 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - MAKE-UP
57 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
58 BRAKE DIAGNOSTIC PLUG
40 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF
41
CHECK VALVE - BICS CONTROL VALVE
42
LIFT ARM BY-PASS RESTRICTOR
43
CHECK VALVE - AUXILIARY
59 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
DRIVE MOTOR
60 HYDRAULIC HIGH FLOW PUMP
10.0 GPM (37,8 L/min.) at 2615 Engine RPM
44 FILTER - CASE DRAIN (Attachment)
61 RESTRICTION - SELECT VALVE
45
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
62
46
RESTRICTOR - 0.020 inch (0,5 mm)
47
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
63 ACCUMULATOR - FOUND ONLY ON
MACHINES WITH
S/N 514444558 AND ABOVE
S/N 514640276 AND ABOVE
48
RELIEF VALVE - 1200 PSI (8268 kPa)
49
RESTRICTOR - 0.090 inch (2,3 mm)
SCREEN
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-0024legend (3-25-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW AND TWO SPEED VALVE OPTION
863 (S/N 514441939 - 514449483)
(S/N 514640148 - 514641170)
(PRINTED NOVEMBER 2002)
Printable Version Click Here
SELECT VALVE
C2
C1
(RIGHT SIDE LIFT ARM
QUICK COUPLERS)
39
FEMALE
33
39
MALE
TWO SPEED DRIVE MOTOR
MALE
V-0024
FEMALE
40
(REAR QUICK COUPLERS)
31
32
61
61
34
38
FEMALE
PB
PRESS
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
36
MALE
59
54
37
35
53
T
9
DRAIN
(MALE)
HYDRAULIC FILTER
44
3
HYDROSTATIC PUMPS
4
45
26
BUCKET POSITION VALVE (OPTIONAL)
OIL
COOLER
D
8
26
28
7
6
63
A
CHARGE
INLET
52
OUTLET
C
10
HYDRAULIC CONTROL VAVLE
29
43
11
27
BOB-TACH
CYLINDER
(OPTIONAL)
45
26
26
30
INLET
OUTLET
58
TWO SPEED VALVE
HYDRAULIC
POWERED
BOB-TACH
DR (OPTIONAL)
B
B
AUXILIARY
SPOOL
62
23
22
46
60
TWO SPEED DRIVE MOTOR
TILT CYLINDER
BICS CONTROL VALVE
47
48
B
49
50
54
A
51
9
56
C
24
A
B1
55
B
12
TILT
CYLINDER
SPOOL
21
53
18
59
D
P
24
25
P1
5
P2
20
LIFT CYLINDERS
17
13
A
57
B
LIFT
CYLINDER
SPOOL
A
31
42
18
32
19
16
T
41
14
16
2
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY- PASS VALVE
15
1
Printed in U.S.A.
V-0024 (11-5-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
863 (S/N 514449260 - 514449563)
(S/N 514541069 - 514541072)
(PRINTED NOVEMBER 2002)
V-0161legend Printable Version Click Here
LEGEND
1
2
RESERVOIR:
Capacity . . . . . . .
15
FILTER - HYDRAULIC (CANISTER)
4
SPRING LOADED FILTER BY-PASS
VALVE:
45-55 PSI (311-379 kPa)
6
7
41
CHECK VALVE - BICS CONTROL VALVE
30
42
LIFT ARM BY-PASS RESTRICTOR
16 FILTER - BICS CONTROL VALVE
(SCREEN)
HYDRAULIC PUMP . . . . . . . Gear Type
20.7 GPM (78,4 L/min.) at 2450 Engine RPM
31
DRIVE MOTOR SHUTTLE VALVE
43
CHECK VALVE - AUXILIARY
17 BOOM DOWN RESTRICTOR
32
SHUTTLE RELIEF VALVE:
200 PSI (1378 kPa)
44
MUFFLER (If Equipped)
18 LIFT AND TILT LOAD CHECK VALVE
33
45
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
19 RELIEF VALVE - MAIN:
2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR
AUXILIARY ("SV2")
34
LOAD SHUTTLE VALVE - BLEED OFF
46
35
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P2" and "F2")
TWO STAGE RELIEF VALVE 1000 PSI/
2000 PSI (6894 kPA/ 13788 kPA)
47
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
48
RELIEF VALVE - 1200 PSI (8268 kPa)
49
PRESSURE COMPENSATED FLOW
CONTROL
50
CHECK VALVE WITH .015 (0,38mm)
ORIFICE
FILTER - CASE DRAIN (90 Micron)
3
5
29 CHARGE PUMP
14.0 GPM (53,0 L/min.) at 2450 Engine RPM
18.8 Qts. (17.8 L)
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
20 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
FLOW DIVIDER ADJUSTMENT VALVE
21 ANTICAVITATION VALVE
8
9
CHECK VALVE - BUCKET POSITION
VALVE
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
11 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
14
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
Printed in U.S.A.
22 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END)
3500 PSI (24132 kPa)
36
37
23 ONE WAY RESTRICTOR VALVE
24
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
25
RELIEF VALVE - PORT: . . . . . . . . (Optional)
3500 PSI (24132 kPa)
26
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE:
5000 PSI (34475 kPa)
27
CHARGE PRESSURE SWITCH
28
RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.) Fluid
at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa)
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D1" and "P1")
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D2" and "P2")
38
FILTER - DIVERTER VALVE (SCREEN)
INTEGRATED IN SOLENOID
39
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TO ACTIVATE
REAR AUXILIARY ("SV1")
40
*
51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
53 ACCUMULATOR
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P1" and "F1")
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-0161legend (11-5-02)
DIVERTER VALVE (OPTIONAL)
HYDRAULIC/HYDROSTATIC SCHEMATIC
863 (S/N 514449260 - 514449563)
(S/N 514541069 - 514541072)
38
39
PILOT
(PRINTED NOVEMBER 2002)
V-0161
Printable Version Click Here
DRIVE MOTOR
40
MALE
31
MALE
36
F1
D1
32
34
(REAR QUICK
COUPLERS)
33
F2
FEMALE
MALE
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
37
35
D2
FEMALE
FEMALE
9
DRAIN
P1
P2
HYDRAULIC FILTER
3
BUCKET POSITION VALVE (OPTIONAL)
HYDROSTATIC PUMPS
OIL
COOLER
4
45
D
8
28
26
26
7
6
53
A
OUTLET
CHARGE INLET
C
52
10
HYDRAULIC CONTROL VAVLE
29
43
26
11
27
26
45
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
24
25
BOB-TACH
CYLINDER
(OPTIONAL)
24
B
A
B
AUXILIARY
SPOOL
DR
OUTLET
INLET
23
22
48
46
47
A
51
B
50
21
18
9
20
P1
LIFT CYLINDERS
17
13
P2
5
A
PP
31
12
TILT
CYLINDER
SPOOL
49
DRIVE MOTOR
TILT CYLINDER
BICS CONTROL VALVE
30
B
LIFT
CYLINDER
SPOOL
32
42
18
19
*
2
44
16
41
14
16
*
(If Equipped)
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY- PASS VALVE
15
1
Printed in U.S.A.
V-0161 (11-5-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE OPTION
863 (S/N 514449260 - 514449563)
(S/N 514541069 - 514541072)
(PRINTED NOVEMBER 2002)
V-0162legend Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . .
18.8 Qts. (17.8 L)
2
FILTER - CASE DRAIN (90 Micron)
3
FILTER - HYDRAULIC (CANISTER)
4
SPRING LOADED FILTER BY-PASS
VALVE:
45-55 PSI (311-379 kPa)
5
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
6
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
7
FLOW DIVIDER ADJUSTMENT VALVE
8
CHECK VALVE - BUCKET POSITION
VALVE
9
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
11 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
14
15
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
16 FILTER - BICS CONTROL VALVE
(SCREEN)
17 BOOM DOWN RESTRICTOR
18 LIFT AND TILT LOAD CHECK VALVE
Printed in U.S.A.
19 RELIEF VALVE - MAIN:
2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers
34
LOAD SHUTTLE VALVE - BLEED OFF
47
35
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P2" and "F2")
48
RELIEF VALVE - 1200 PSI (8268 kPa)
49
PRESSURE COMPENSATED FLOW
CONTROL
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D1" and "P1")
50 CHECK VALVE WITH .015 (0,38mm)
ORIFICE
20 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
21 ANTICAVITATION VALVE
36
22 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END)
3500 PSI (24132 kPa)
23 ONE WAY RESTRICTOR VALVE
37
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D2" and "P2")
24
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
25
RELIEF VALVE - PORT: . . . . . . . (Optional)
3500 PSI (24132 kPa)
38
FILTER - DIVERTER VALVE (SCREEN)
INTEGRATED IN SOLENOID
26
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE:
5000 PSI (34475 kPa)
39
27
CHARGE PRESSURE SWITCH
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TO ACTIVATE
REAR AUXILIARY ("SV1")
28
RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.)Fluid
at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa)
29
CHARGE PUMP
14.0 GPM (53,0 L/min.) at 2450 Engine RPM
30 HYDRAULIC PUMP . . . . . . . Gear Type
20.7 GPM (78,4 L/min.) at 2450
Engine RPM
40
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P1" and "F1")
51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
53 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
54 HYDRAULIC BRAKE - SPRING APPLIED PRESSURE TO RELEASE
55 PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE BRAKE
56 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - MAKE-UP
41
CHECK VALVE - BICS CONTROL VALVE
57 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
42
LIFT ARM BY-PASS RESTRICTOR
58 BRAKE DIAGNOSTIC PLUG
43
CHECK VALVE - AUXILIARY
31
DRIVE MOTOR SHUTTLE VALVE
44 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
DRIVE MOTOR
32
SHUTTLE RELIEF VALVE:
200 PSI (1378 kPa)
45
33
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR
AUXILIARY ("SV2")
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
46
TWO STAGE RELIEF VALVE 1000 PSI/
2000 PSI (6894 kPa/ 13788 kPa)
59 ACCUMULATOR
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-0162legend (11-5-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE OPTION
863 (S/N 514449260 - 514449563)
(S/N 514541069 - 514541072)
(PRINTED NOVEMBER 2002)
V-0162
DIVERTER VALVE (OPTIONAL)
38
39
PILOT
Printable Version Click Here
TWO SPEED DRIVE MOTOR
40
31
MALE
32
36
MALE F1
D1
34
(REAR QUICK
COUPLERS)
54
33
F2
44
FEMALE
MALE
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
37
35
D2
FEMALE
FEMALE
53
DRAIN
9
P1
P2
HYDRAULIC FILTER
3
BUCKET POSITION VALVE (OPTIONAL)
HYDROSTATIC PUMPS
4
45
26
OIL
COOLER
D
8
26
28
7
6
60
A
CHARGE
INLET
52
OUTLET
C
10
HYDRAULIC CONTROL VAVLE
29
43
11
27
45
26
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
26
30
INLET
BOB-TACH
CYLINDER
(OPTIONAL)
24
25
24
B
A
B
DR
OUTLET
AUXILIARY
SPOOL
58
TWO SPEED VALVE
B1
23
22
TILT CYLINDER
BICS CONTROL VALVE
TWO SPEED DRIVE MOTOR
55
B
48
54
46
47
49
9
56
A
51
B
50
C
P
12
TILT
CYLINDER
SPOOL
21
53
18
44
D
P1
5
P2
20
LIFT CYLINDERS
17
13
PP
A
57
B
LIFT
CYLINDER
SPOOL
A
31
42
18
32
19
16
T
41
14
16
2
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY- PASS VALVE
15
1
Printed in U.S.A.
V-0162 (11-5-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
863 (S/N 514449484 - 514449563)
(S/N 514641171 - 514641175)
(PRINTED NOVEMBER 2002)
V-0159legend Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . . . 18.8 Qts. (17.8 L)
16 FILTER - BICS CONTROL VALVE
(SCREEN)
2
FILTER - CASE DRAIN (90 Micron)
17 BOOM DOWN RESTRICTOR
3
FILTER - HYDRAULIC (CANISTER)
18 LIFT AND TILT LOAD CHECK VALVE
4
SPRING LOADED FILTER BY- PASS
VALVE: . . . 45-55 PSI (311-379 kPa)
19 RELIEF VALVE - MAIN:
2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers
5
6
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
SHUTTLE RELIEF VALVE:
200 PSI (1378 kPa)
49
PRESSURE COMPENSATED FLOW
CONTROL
21 ANTICAVITATION VALVE
33
REAR AUXILIARY BLEED SHUTTLE VALVE
22 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END)
3500 PSI (24132 kPa)
34
LOAD CHECK VALVE - SELECT VALVE
(HIGH FLOW)
50 CHECK VALVE WITH .015 (0,38mm)
ORIFICE)
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
25
RELIEF VALVE - PORT: . . . . . . (Optional)
3500 PSI (24132 kPa)
26
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE: 5000 PSI (34475 kPa)
27
CHARGE PRESSURE SWITCH
28
RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.)Fluid
at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa)
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
15
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
32
24
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
47
20 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
23 ONE WAY RESTRICTOR VALVE
14
TWO STAGE RELIEF VALVE 1000 PSI/
2000 PSI (6894 kPa/ 13788 kPa)
RELIEF VALVE - 1200 PSI (8268 kPa)
CHECK VALVE - BUCKET POSITION
VALVE
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
46
48
8
11 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
DRIVE MOTOR SHUTTLE VALVE
FLOW DIVIDER ADJUSTMENT VALVE
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
*
45
31
7
9
30 HYDRAULIC PUMP . . . . . . . Gear Type
20.7 GPM (78,4 L/min.) at 2450
Engine RPM
HIGH FLOW CAPACITY: (Includes 53 )
30.7 GPM (116,2 L/min.) at 2450
Engine RPM
29
CHARGE PUMP:
14.0 GPM (53,0 L/min.) at 2450 Engine RPM
35
36
37
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - HIGH FLOW
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - DIVERTER
RELIEF VALVE - MAIN (HIGH FLOW)
3000 PSI (20685 kPa)
51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
53 HYDRAULIC HIGH FLOW PUMP:
10.0 GPM (37,8 L/min.) at 2450 Engine RPM
38
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
54
FILTER - CASE DRAIN (ATTACHMENT)
39
PILOT TO OPEN CHECK VALVE
55
RESTRICTION - SELECT VALVE
40
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF
56
ACCUMULATOR
41
CHECK VALVE - BICS CONTROL VALVE
42
LIFT ARM BY-PASS RESTRICTOR
43
CHECK VALVE - AUXILIARY
44
MUFFLER (If Equipped)
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY- PASS
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
Printed in U.S.A.
V-0159legend (11-5-02)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
863 (S/N 514449484 - 514449563)
(S/N 514641171 - 514641175)
MALE
SELECT VALVE
C2
C1
(RIGHT SIDE LIFT ARM
QUICK COUPLERS)
39
DRIVE MOTOR
FEMALE
39
MALE
33
Printable Version Click Here
FEMALE
(PRINTED NOVEMBER 2002)
V-0159
MALE
40
(REAR QUICK COUPLERS)
55
31
*
32
55
44
34
38
FEMALE
PB
PRESS
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
36
MALE
37
35
9
T
DRAIN
(MALE)
HYDRAULIC FILTER
54
3
HYDROSTATIC PUMPS
4
45
28
26
BUCKET POSITION VALVE (OPTIONAL)
OIL
COOLER
D
8
26
7
6
56
A
CHARGE INLET
OUTLET
52
C
10
HYDRAULIC CONTROL VAVLE
29
43
26
11
27
26
45
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
BOB-TACH
CYLINDER
(OPTIONAL)
24
25
24
B
A
B
AUXILIARY
SPOOL
DR
INLET
30
23
22
OUTLET
TILT CYLINDER
BICS CONTROL VALVE
53
48
46
47
A
49
12
TILT
CYLINDER
SPOOL
50
DRIVE MOTOR
21
18
9
20
P1
5
LIFT CYLINDERS
17
P2
13
A
31
B
51
B
LIFT
CYLINDER
SPOOL
32
42
18
*
2
19
44
16
41
14
16
*
(If Equipped)
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY- PASS VALVE
15
1
Printed in U.S.A.
V-0159 (11-5-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW AND TWO SPEED VALVE OPTION
863 (S/N 514449484 - 514449563)
(S/N 514641171 - 514641175)
(PRINTED NOVEMBER 2002)
V-0160legend Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . . . . 18.8 Qts. (17.8 L)
2
FILTER - CASE DRAIN (90 Micron)
3
FILTER - HYDRAULIC (CANISTER)
4
SPRING LOADED FILTER BY-PASS
VALVE:
45-55 PSI (311-379 kPa)
5
6
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
19 RELIEF VALVE - MAIN:
2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers
20 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
34
LOAD CHECK VALVE - SELECT VALVE
(HIGH FLOW)
50 CHECK VALVE WITH .015 (0,38mm)
ORIFICE
35
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - HIGH FLOW
51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
53 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
54 HYDRAULIC BRAKE - SPRING APPLIED PRESSURE TO RELEASE
21 ANTICAVITATION VALVE
36 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - DIVERTER
22 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END)
3500 PSI (24132 kPa)
37 RELIEF VALVE - MAIN (HIGH FLOW)
3000 PSI (20685 kPa)
23 ONE WAY RESTRICTOR VALVE
38
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
39
PILOT TO OPEN CHECK VALVE
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
24
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
7
FLOW DIVIDER ADJUSTMENT VALVE
25
8
CHECK VALVE - BUCKET POSITION
VALVE
RELIEF VALVE - PORT: . . . . .
(Optional)
3500 PSI (24132 kPa)
26
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE:
5000 PSI (34475 kPa)
41
CHECK VALVE - BICS CONTROL VALVE
27
CHARGE PRESSURE SWITCH
42
LIFT ARM BY-PASS RESTRICTOR
28
RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.)Fluid
at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa)
43
CHECK VALVE - AUXILIARY
9
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
11 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
14
15
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
16 FILTER - BICS CONTROL VALVE
(SCREEN)
17 BOOM DOWN RESTRICTOR
18 LIFT AND TILT LOAD CHECK VALVE
Printed in U.S.A.
29
CHARGE PUMP
14.0 GPM (53,0 L/min.) at 2450 Engine RPM
30 HYDRAULIC PUMP . . . . . . . Gear Type
20.7 GPM (78,4 L/min.) at 2450
Engine RPM
HIGH FLOW CAPACITY: (Includes 60 )
30.7 GPM (116,2 L/min.) at 2450
Engine RPM
31
DRIVE MOTOR SHUTTLE VALVE
32
SHUTTLE RELIEF VALVE: 200 PSI (1378 kPa)
33
REAR AUXILIARY BLEED SHUTTLE VALVE
40 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF
44 FILTER - CASE DRAIN (Attachment)
55 PUSH BUTTON SOLENOID ACTIVATED
DIRECTIONAL CONTROL VALVE BRAKE
56 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - MAKE-UP
57 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
58 BRAKE DIAGNOSTIC PLUG
59 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
DRIVE MOTOR
45
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
46
TWO STAGE RELIEF VALVE 1000 PSI/
2000 PSI (6894 kPa/13788 kPa)
47
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
61 RESTRICTION - SELECT VALVE
48
RELIEF VALVE - 1200 PSI (8268 kPa)
62 ACCUMULATOR
49
PRESSURE COMPENSATED FLOW
CONTROL
60 HYDRAULIC HIGH FLOW PUMP
10 GPM (37.85 L/min.) at 2450 RPM
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-0160legend (11-5-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW AND TWO SPEED VALVE OPTION
863 (S/N 514449484 - 514449563)
(S/N 514641171 - 514641175)
(PRINTED NOVEMBER 2002)
Printable Version Click Here
V-0160
SELECT VALVE
C2
C1
(RIGHT SIDE LIFT ARM
QUICK COUPLERS)
FEMALE
39
MALE
33
39
FEMALE
TWO SPEED DRIVE MOTOR
MALE
40
(REAR QUICK COUPLERS)
31
32
61
61
34
38
FEMALE
PB
PRESS
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
36
MALE
59
54
37
35
53
T
9
DRAIN
(MALE)
HYDRAULIC FILTER
44
3
HYDROSTATIC PUMPS
4
45
26
BUCKET POSITION VALVE (OPTIONAL)
OIL
COOLER
D
8
26
28
7
6
62
A
CHARGE
INLET
52
OUTLET
C
10
HYDRAULIC CONTROL VAVLE
29
43
11
27
26
24
25
45
26
30
INLET
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
OUTLET
58
24
B
A
BOB-TACH
CYLINDER
(OPTIONAL)
B
AUXILIARY
SPOOL
DR
TWO SPEED VALVE
23
22
B1
TILT CYLINDER
BICS CONTROL VALVE
60
TWO SPEED DRIVE MOTOR
55
B
54
48
46
12
TILT
CYLINDER
SPOOL
21
53
50
59
D
P
B
47
49
C
A
51
9
56
18
20
LIFT CYLINDERS
17
13
57
P1
5
A
P2
B
LIFT
CYLINDER
SPOOL
A
31
42
18
32
19
16
T
41
14
16
2
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY- PASS VALVE
15
1
Printed in U.S.A.
V-0160 (11-5-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
863 (S/N 514449564 - 514451083)
(S/N 514541073 - 514541113)
(PRINTED NOVEMBER 2002)
V-0165legend Printable Version Click Here
LEGEND
1
2
RESERVOIR:
Capacity . . . . . . .
15
18.8 Qts. (17.8 L)
FILTER - CASE DRAIN (90 Micron)
3
FILTER - HYDRAULIC (CANISTER)
4
SPRING LOADED FILTER BY-PASS
VALVE:
45-55 PSI (311-379 kPa)
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
16 FILTER - BICS CONTROL VALVE
(SCREEN)
17 BOOM DOWN RESTRICTOR
18 LIFT AND TILT LOAD CHECK VALVE
5
6
7
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
19 RELIEF VALVE - MAIN:
2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers
9
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
11 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
14
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
Printed in U.S.A.
CHECK VALVE - BICS CONTROL VALVE
30
HYDRAULIC PUMP . . . . . . . Gear Type
20.7 GPM (78,4 L/min.) at 2450 Engine RPM
42
LIFT ARM BY-PASS RESTRICTOR
31
DRIVE MOTOR SHUTTLE VALVE
43
CHECK VALVE - AUXILIARY
32
SHUTTLE RELIEF VALVE:
200 PSI (1378 kPa)
33
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR
AUXILIARY ("SV2")
34
LOAD SHUTTLE VALVE - BLEED OFF
35
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P2" and "F2")
3500 PSI (24132 kPa)
FLOW DIVIDER ADJUSTMENT VALVE
CHECK VALVE - BUCKET POSITION
VALVE
41
20 RELIEF VALVE - PORT:
21 ANTICAVITATION VALVE
8
29 CHARGE PUMP
14.0 GPM (53,0 L/min.) at 2450 Engine RPM
22 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END)
3500 PSI (24132 kPa)
36
37
23 ONE WAY RESTRICTOR VALVE
24
25
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
38
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE: 5000 PSI (34475 kPa)
27
CHARGE PRESSURE SWITCH
28
RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.) Fluid
at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa)
FILTER - DIVERTER VALVE (SCREEN)
INTEGRATED IN SOLENOID
39
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TO ACTIVATE
REAR AUXILIARY ("SV1")
40
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P1" and "F1")
RELIEF VALVE - PORT: . . . . . . . . (Optional)
3500 PSI (24132 kPa)
26
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D1" and "P1")
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D2" and "P2")
44 FRONT AUXILIARY MANUAL
PRESSURE BLEED-OFF VALVE
45
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
46
TWO STAGE RELIEF VALVE 1000 PSI/
2000 PSI (6894 kPA/ 13788 kPA)
47
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
48
RELIEF VALVE - 1200 PSI (8268 kPa)
49
PRESSURE COMPENSATED FLOW
CONTROL
50
CHECK VALVE WITH .015 (0,38mm)
ORIFICE
51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-0165legend (11-5-02)
DIVERTER VALVE (OPTIONAL)
HYDRAULIC/HYDROSTATIC SCHEMATIC
863 (S/N 514449564 - 514451083)
(S/N 514541073 - 514541113)
38
39
PILOT
(PRINTED NOVEMBER 2002)
V-0165
Printable Version Click Here
DRIVE MOTOR
40
MALE
31
MALE
F1
FRONT AUXILIARY
LEFT SIDE LIFT ARM
D1
32
MALE
DRAIN
(MALE)
34
REAR QUICK
COUPLERS
(OPTIONAL)
33
F2
FEMALE
44
36
FEMALE
37
35
44
D2
FEMALE
9
DRAIN
P1
P2
HYDRAULIC FILTER
3
2
HYDROSTATIC PUMPS
BUCKET POSITION VALVE (OPTIONAL)
OIL
COOLER
4
45
D
8
28
26
26
7
6
A
OUTLET
CHARGE INLET
C
52
10
HYDRAULIC CONTROL VAVLE
29
43
26
11
27
26
45
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
24
25
BOB-TACH
CYLINDER
(OPTIONAL)
24
B
A
B
AUXILIARY
SPOOL
DR
OUTLET
INLET
23
22
48
46
47
A
51
B
50
21
18
9
P2
P1
31
12
TILT
CYLINDER
SPOOL
49
DRIVE MOTOR
TILT CYLINDER
BICS CONTROL VALVE
30
5
20
LIFT CYLINDERS
17
13
PP
A
B
LIFT
CYLINDER
SPOOL
32
42
18
19
16
2
41
14
16
*
(If Equipped)
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY- PASS VALVE
15
1
Printed in U.S.A.
V-0165 (11-4-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE OPTION
863 (S/N 514449564 - 514451083)
(S/N 514541073 - 514541113)
(PRINTED NOVEMBER 2002)
V-0166legend Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . .
18.8 Qts. (17.8 L)
2
FILTER - CASE DRAIN (90 Micron)
3
FILTER - HYDRAULIC (CANISTER)
4
SPRING LOADED FILTER BY-PASS
VALVE:
45-55 PSI (311-379 kPa)
5
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
6
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
7
FLOW DIVIDER ADJUSTMENT VALVE
8
CHECK VALVE - BUCKET POSITION
VALVE
9
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
11 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
19 RELIEF VALVE - MAIN:
2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers
21 ANTICAVITATION VALVE
35
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P2" and "F2")
48
RELIEF VALVE - 1200 PSI (8268 kPa)
49
PRESSURE COMPENSATED FLOW
CONTROL
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D1" and "P1")
50 CHECK VALVE WITH .015 (0,38mm)
ORIFICE
36
22 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END)
3500 PSI (24132 kPa)
23 ONE WAY RESTRICTOR VALVE
37
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D2" and "P2")
24
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
25
RELIEF VALVE - PORT: . . . . . . . (Optional)
3500 PSI (24132 kPa)
38
FILTER - DIVERTER VALVE (SCREEN)
INTEGRATED IN SOLENOID
26
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE:
5000 PSI (34475 kPa)
39
27
CHARGE PRESSURE SWITCH
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TO ACTIVATE
REAR AUXILIARY ("SV1")
28
RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.)Fluid
at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa)
29
CHARGE PUMP
14.0 GPM (53,0 L/min.) at 2450 Engine RPM
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
31
DRIVE MOTOR SHUTTLE VALVE
14
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
32
SHUTTLE RELIEF VALVE:
200 PSI (1378 kPa)
15
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
33
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR
AUXILIARY ("SV2")
Printed in U.S.A.
47
3500 PSI (24132 kPa)
30
18 LIFT AND TILT LOAD CHECK VALVE
LOAD SHUTTLE VALVE - BLEED OFF
20 RELIEF VALVE - PORT:
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
16 FILTER - BICS CONTROL VALVE
(SCREEN)
17 BOOM DOWN RESTRICTOR
34
HYDRAULIC PUMP . . . . . . . . Gear Type
20.7 GPM (78,4 L/min.) at 2450 Engine RPM
40
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P1" and "F1")
51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
53 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
54 HYDRAULIC BRAKE - SPRING APPLIED PRESSURE TO RELEASE
55 PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE BRAKE
56 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - MAKE-UP
41
CHECK VALVE - BICS CONTROL VALVE
57 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
42
LIFT ARM BY-PASS RESTRICTOR
58 BRAKE DIAGNOSTIC PLUG
43
CHECK VALVE - AUXILIARY
44 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
DRIVE MOTOR
45
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
46
TWO STAGE RELIEF VALVE 1000 PSI/
2000 PSI (6894 kPa/ 13788 kPa)
59 FRONT AUXILIARY MANUAL PRESSURE
BLEED-OFF VALVE
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-0166legend (11-5-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE OPTION
863 (S/N 514449564 - 514451083)
(S/N 514541073 - 514541113)
(PRINTED NOVEMBER 2002) Printable Version Click Here
DIVERTER VALVE (OPTIONAL)
38
39
PILOT
V-0166
TWO SPEED DRIVE MOTOR
FRONT AUXILIARY
LEFT SIDE LIFT ARM
40
31
MALE
32
36
MALE F1
D1
33
F2
44
FEMALE
DRAIN
(MALE)
FEMALE
37
35
59
D2
FEMALE
53
33
DRAIN
9
MALE
34
(REAR QUICK
COUPLERS)
54
59
P1
P2
HYDRAULIC FILTER
3
OIL
COOLER
4
45
26
BUCKET POSITION VALVE (OPTIONAL)
2
HYDROSTATIC PUMPS
D
8
26
28
7
6
A
CHARGE
INLET
52
OUTLET
C
10
HYDRAULIC CONTROL VAVLE
29
43
11
27
45
26
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
26
30
INLET
BOB-TACH
CYLINDER
(OPTIONAL)
24
25
24
B
A
B
DR
OUTLET
AUXILIARY
SPOOL
58
TWO SPEED VALVE
B1
23
22
TILT CYLINDER
BICS CONTROL VALVE
TWO SPEED DRIVE MOTOR
55
B
48
54
46
47
49
9
56
A
51
B
50
C
P
12
TILT
CYLINDER
SPOOL
21
53
18
44
D
20
P1
5
LIFT CYLINDERS
17
P2
13
PP
A
57
B
LIFT
CYLINDER
SPOOL
A
31
42
18
32
19
16
T
41
14
16
2
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY- PASS VALVE
15
1
Printed in U.S.A.
V-0166 (11-4-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
863 (S/N 514449564 - 514450945)
(S/N 514641176 - 514641254)
(PRINTED NOVEMBER 2002)
V-0163legend Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . . . 18.8 Qts. (17.8 L)
16 FILTER - BICS CONTROL VALVE
(SCREEN)
2
FILTER - CASE DRAIN (90 Micron)
17 BOOM DOWN RESTRICTOR
3
FILTER - HYDRAULIC (CANISTER)
18 LIFT AND TILT LOAD CHECK VALVE
4
SPRING LOADED FILTER BY- PASS
VALVE: . . . 45-55 PSI (311-379 kPa)
31
DRIVE MOTOR SHUTTLE VALVE
5
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
19 RELIEF VALVE - MAIN:
2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers
32
20 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
SHUTTLE RELIEF VALVE:
200 PSI (1378 kPa)
33
REAR AUXILIARY BLEED SHUTTLE VALVE
34
LOAD CHECK VALVE - SELECT VALVE
(HIGH FLOW)
30
21 ANTICAVITATION VALVE
HYDRAULIC PUMP . . . . . . . Gear Type
20.7 GPM (78,4 L/min.) at 2450
Engine RPM
HIGH FLOW CAPACITY: (Includes 53 )
30.7 GPM (116,2 L/min.) at 2450
Engine RPM
6
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
7
FLOW DIVIDER ADJUSTMENT VALVE
22 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END)
3500 PSI (24132 kPa)
35
8
CHECK VALVE - BUCKET POSITION
VALVE
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - HIGH FLOW
23 ONE WAY RESTRICTOR VALVE
36
9
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
24
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - DIVERTER
25
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
37
RELIEF VALVE - PORT: . . . . . . (Optional)
3500 PSI (24132 kPa)
38
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE:
5000 PSI (34475 kPa)
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
39
PILOT TO OPEN CHECK VALVE
40
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF
41
CHECK VALVE - BICS CONTROL VALVE
42
LIFT ARM BY-PASS RESTRICTOR
43
CHECK VALVE - AUXILIARY
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
26
11 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
27
CHARGE PRESSURE SWITCH
28
RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.)Fluid
at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa)
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
14
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
15
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY- PASS
29
CHARGE PUMP:
14.0 GPM (53,0 L/min.) at 2450 Engine RPM
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
48
RELIEF VALVE - 1200 PSI (8268 kPa)
49
PRESSURE COMPENSATED FLOW
CONTROL
50 CHECK VALVE WITH .015 (0,38mm)
ORIFICE)
51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
53 HYDRAULIC HIGH FLOW PUMP:
10.0 GPM (37,8 L/min.) at 2450 Engine RPM
54
FILTER - CASE DRAIN (ATTACHMENT)
55
RESTRICTION - SELECT VALVE
44 FRONT AUXILIARY MANUAL PRESSURE
BLEED-OFF VALVE
*
Printed in U.S.A.
RELIEF VALVE - MAIN (HIGH FLOW)
3000 PSI (20685 kPa)
47
45
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
46
TWO STAGE RELIEF VALVE 1000 PSI/
2000 PSI (6894 kPa/ 13788 kPa)
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-0163legend (11-5-02)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
863 (S/N 514449564 - 514450945)
(S/N 514641176 - 514641254)
MALE
SELECT VALVE
C2
C1
RIGHT SIDE LIFT ARM
QUICK COUPLERS
(OPTIONAL)
39
DRIVE MOTOR
FEMALE
39
MALE
33
Printable Version Click Here
FEMALE
(PRINTED NOVEMBER 2002)
V-0163
MALE
40
REAR QUICK COUPLERS
(OPTIONAL)
55
31
FRONT AUXILIARY
(LEFT SIDE LIFT ARM)
55
44
34
38
32
FEMALE
PB
PRESS
DRAIN
(MALE)
36
37
35
MALE
9
T
44
HYDRAULIC FILTER
54
3
HYDROSTATIC PUMPS
4
45
28
26
BUCKET POSITION VALVE (OPTIONAL)
OIL
COOLER
D
8
26
7
6
A
CHARGE INLET
OUTLET
52
C
10
HYDRAULIC CONTROL VAVLE
29
43
26
11
27
26
45
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
BOB-TACH
CYLINDER
(OPTIONAL)
24
25
24
B
A
B
AUXILIARY
SPOOL
DR
INLET
30
23
22
OUTLET
TILT CYLINDER
BICS CONTROL VALVE
53
48
46
47
A
49
12
TILT
CYLINDER
SPOOL
50
DRIVE MOTOR
21
18
9
20
P1
5
LIFT CYLINDERS
17
P2
13
A
31
B
51
B
LIFT
CYLINDER
SPOOL
32
42
18
19
16
2
41
14
16
*
(If Equipped)
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY- PASS VALVE
15
1
Printed in U.S.A.
V-0163 (11-4-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW AND TWO SPEED VALVE OPTION
863 (S/N 514449564 - 514450945)
(S/N 514641176 - 514641254)
(PRINTED NOVEMBER 2002)
V-0164legend Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . . . . 18.8 Qts. (17.8 L)
2
FILTER - CASE DRAIN (90 Micron)
3
FILTER - HYDRAULIC (CANISTER)
4
SPRING LOADED FILTER BY-PASS
VALVE:
45-55 PSI (311-379 kPa)
5
6
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
19 RELIEF VALVE - MAIN:
2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers
20 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
34
LOAD CHECK VALVE - SELECT VALVE
(HIGH FLOW)
50 CHECK VALVE WITH .015 (0,38mm)
ORIFICE
35
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - HIGH FLOW
51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
53 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
54 HYDRAULIC BRAKE - SPRING APPLIED PRESSURE TO RELEASE
21 ANTICAVITATION VALVE
36 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - DIVERTER
22 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END)
3500 PSI (24132 kPa)
37 RELIEF VALVE - MAIN (HIGH FLOW)
3000 PSI (20685 kPa)
23 ONE WAY RESTRICTOR VALVE
38
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
39
PILOT TO OPEN CHECK VALVE
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
24
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
7
FLOW DIVIDER ADJUSTMENT VALVE
25
8
CHECK VALVE - BUCKET POSITION
VALVE
RELIEF VALVE - PORT: . . . . .
(Optional)
3500 PSI (24132 kPa)
26
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE:
5000 PSI (34475 kPa)
41
CHECK VALVE - BICS CONTROL VALVE
27
CHARGE PRESSURE SWITCH
42
LIFT ARM BY-PASS RESTRICTOR
28
RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.)Fluid
at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa)
43
CHECK VALVE - AUXILIARY
9
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
11 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
14
15
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
16 FILTER - BICS CONTROL VALVE
(SCREEN)
17 BOOM DOWN RESTRICTOR
18 LIFT AND TILT LOAD CHECK VALVE
Printed in U.S.A.
29
CHARGE PUMP
14.0 GPM (53,0 L/min.) at 2450 Engine RPM
30 HYDRAULIC PUMP . . . . . . . Gear Type
20.7 GPM (78,4 L/min.) at 2450
Engine RPM
HIGH FLOW CAPACITY: (Includes 60 )
30.7 GPM (116,2 L/min.) at 2450
Engine RPM
31
DRIVE MOTOR SHUTTLE VALVE
32
SHUTTLE RELIEF VALVE: 200 PSI (1378 kPa)
33
REAR AUXILIARY BLEED SHUTTLE VALVE
40 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF
44 FILTER - CASE DRAIN (Attachment)
55 PUSH BUTTON SOLENOID ACTIVATED
DIRECTIONAL CONTROL VALVE BRAKE
56 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - MAKE-UP
57 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
58 BRAKE DIAGNOSTIC PLUG
59 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
DRIVE MOTOR
45
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
46
TWO STAGE RELIEF VALVE 1000 PSI/
2000 PSI (6894 kPa/13788 kPa)
47
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
61 RESTRICTION - SELECT VALVE
48
RELIEF VALVE - 1200 PSI (8268 kPa)
62 FRONT AUXILIARY MANUAL
PRESSURE BLEED-OFF VALVE
49
PRESSURE COMPENSATED FLOW
CONTROL
60 HYDRAULIC HIGH FLOW PUMP:
10.0 GPM (38,7 L/min.) at 2450 Engine RPM
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-0164legend (11-5-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW AND TWO SPEED VALVE OPTION
863 (S/N 514449564 - 514450945)
(S/N 514641176 - 514641254)
(PRINTED NOVEMBER 2002) Printable Version Click Here
SELECT VALVE
C2
C1
FEMALE
39
MALE
33
39
FEMALE
TWO SPEED DRIVE MOTOR
MALE
V-0164
31
RIGHT SIDE LIFT ARM
QUICK COUPLERS
(OPTIONAL)
40
REAR QUICK COUPLERS
(OPTIONAL)
32
61
61
FRONT AUXILIARY
LEFT SIDE LIFT ARM
34
38
62
FEMALE
PB
PRESS
36
59
54
37
DRAIN
(MALE)
35
53
T
9
MALE
62
HYDRAULIC FILTER
44
3
HYDROSTATIC PUMPS
4
45
26
BUCKET POSITION VALVE (OPTIONAL)
OIL
COOLER
D
8
26
28
7
6
A
CHARGE
INLET
52
OUTLET
C
10
HYDRAULIC CONTROL VAVLE
29
43
11
27
26
24
25
45
26
30
INLET
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
OUTLET
58
24
B
A
BOB-TACH
CYLINDER
(OPTIONAL)
B
AUXILIARY
SPOOL
DR
TWO SPEED VALVE
23
22
B1
TILT CYLINDER
BICS CONTROL VALVE
60
TWO SPEED DRIVE MOTOR
55
B
54
48
46
12
TILT
CYLINDER
SPOOL
21
53
50
59
D
P
B
47
49
C
A
51
9
56
18
20
LIFT CYLINDERS
17
13
57
P1
5
A
P2
B
LIFT
CYLINDER
SPOOL
A
31
42
18
32
19
16
T
41
14
16
2
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY- PASS VALVE
15
1
Printed in U.S.A.
V-0164 (11-5-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
863 (S/N 514450946 - 514451083)
(S/N 514641255 - 514641266)
Printable Version Click Here
(PRINTED DECEMBER 2003)
V-0236legend
LEGEND
16 FILTER - BICS CONTROL VALVE
(SCREEN)
2
RESERVOIR:
Capacity . . . . . . . . . 18.8 Qts. (17.8
L)
FILTER - CASE DRAIN (90 Micron)
3
FILTER - HYDRAULIC (CANISTER)
18 LOAD CHECK VALVE
4
SPRING LOADED FILTER BYPASS
VALVE: 45-55 PSI (311-379 kPa)
5
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
19 RELIEF VALVE - MAIN:
2950-3050 PSI (20340-22030 kPa)
at Front Quick Couplers
1
6
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
7
FLOW DIVIDER ADJUSTMENT VALVE
8
CHECK VALVE - BUCKET POSITION
VALVE
9
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
11 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
17 ONE WAY RESTRICTOR
20 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
DRIVE MOTOR SHUTTLE VALVE
44
32
SHUTTLE RELIEF VALVE:
200 PSI (1378 kPa)
FRONT AUXILIARY MANUAL
PRESSURE BLEED-OFF VALVE
45
33
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR
AUXILIARY ("SV2")
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
46
TWO STAGE RELIEF 1000 PSI/2000 PSI
(6894kPa/13788 kPa)
34
LOAD SHUTTLE VALVE - BLEED OFF
47
35
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P2" and "F2")
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
48
RELIEF VALVE - 1200 PSI (8268 kPa)
49
PRESSURE COMPENSATED FLOW
CONTROL
21 ANTICAVITATION VALVE
22 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END)
3500 PSI (24132 kPa)
23 ONE WAY RESTRICTOR VALVE
24
25
26
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
36
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D1" and "P1")
37
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D2" and "P2")
RELIEF VALVE - PORT: . . . . . (Optional)
3500 PSI (24132 kPa)
38
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE: 5000 PSI (34474 kPa)
FILTER - DIVERTER VALVE (SCREEN)
INTEGRATED IN SOLENOID
39
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TO ACTIVATE
REAR AUXILIARY ("SV1")
40
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P1" and "F1")
27
CHARGE PRESSURE SWITCH
28
RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.)Fluid
at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa)
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
29
CHARGE PUMP
14.0 GPM (53.0 L/min.) at 2450 RPM
14
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
30
15
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY PASS
HYDRAULIC PUMP . . . . . . . Gear Type
20.7 GPM (78,4 L/min.) at 2450
Engine RPM
HIGH FLOW CAPACITY: (Includes 53 )
30.7 GPM (116,2 L/min.) at 2450
Engine RPM
Printed in U.S.A.
31
41
CHECK VALVE - BICS CONTROL VALVE
42
LIFT ARM BY-PASS RESTRICTOR
43
CHECK VALVE - AUXILIARY
50 CHECK VALVE WITH 0.015 (0,38 mm)
RESTRICTION
51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
AUXILIARY
HYDRAULIC PUMP
53
10 GPM (37.85 L/min.)at 2450 RPM
54
FILTER - CASE DRAIN (ATTACHMENT)
55
RELIEF VALVE - 3300 PSI (22754 kPa)
56
DUMP VALVE (ON/OFF)
57
CHECK VALVE
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-0236legend (11-26-03)
DIVERTER VALVE (OPTIONAL)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
863 (S/N 514450946 - 514451083 )
(S/N 514641255 - 514641266) Printable Version Click Here
(PRINTED DECEMBER 2003)
V-0236
38
39
PILOT
DRIVE MOTOR
40
MALE
31
MALE
INTEGRATED QUICK COUPLER BLOCK
36
F1
D1
MALE
32
34
(REAR QUICK
COUPLERS)
FEMALE
MALE
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
44
33
F2
9
44
37
35
D2
FEMALE
FEMALE
DRAIN
P1
P2
HYDRAULIC FILTER
3
HYDROSTATIC PUMPS
45
26
28
BUCKET POSITION VALVE (OPTIONAL)
54
OIL
COOLER
4
D
8
26
7
6
A
CHARGE INLET
OUTLET
52
43
45
11
27
BOB-TACH
CYLINDER
(OPTIONAL)
26
26
C
10
HYDRAULIC CONTROL VAVLE
29
24
25
24
B
A
B
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
INLET
AUXILIARY
SPOOL
OUTLET
23
22
TILT CYLINDERS
BICS CONTROL VALVE
30
53
57
47
48
55
46
56
A
DR
DRIVE MOTOR
B
50
12
TILT
CYLINDER
SPOOL
51
49
21
9
18
P1
5
P2
20
LIFT CYLINDERS
17
PP
13
A
31
B
LIFT
CYLINDER
SPOOL
32
42
18
19
16
2
41
14
16
*
(If Equipped)
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY PASS VALVE
15
1
Printed in U.S.A.
V-0236 (11-26-03)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE AND HIGH FLOW OPTION
863 (S/N 514450946 - 514451083)
(S/N 514641255 - 514641266)
Printable Version Click Here
(PRINTED DECEMBER 2003)
V-0237legend
LEGEND
1
RESERVOIR:
Capacity . . . . . . 18.8 Qts. (17,8 L)
2
FILTER - CASE DRAIN (90 Micron)
3
FILTER - HYDRAULIC (CANISTER)
4
SPRING LOADED FILTER BYPASS
VALVE: 45-55 PSI (311-379 kPa)
5
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
16 FILTER - BICS CONTROL VALVE
(SCREEN)
17 ONE WAY RESTRICTOR
32
33
18 LOAD CHECK VALVE
19
RELIEF VALVE - MAIN:
2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers
34
LOAD SHUTTLE VALVE - BLEED OFF
35
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P2" and "F2")
20 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
21 ANTICAVITATION VALVE
SHUTTLE RELIEF VALVE:
200 PSI (1378 kPa)
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR
AUXILIARY ("SV2")
36
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D1" and "P1")
37
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
25 RELIEF VALVE - PORT: . . . . . (Optional)
3500 PSI (24132 kPa)
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D2" and "P2")
38
FILTER - DIVERTER VALVE (SCREEN)
INTEGRATED IN SOLENOID
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
26
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE: 5000 PSI (34475 kPa)
39
27
CHARGE PRESSURE SWITCH
40
11 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
28
RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.)Fluid
at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa)
6
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
7
FLOW DIVIDER ADJUSTMENT VALVE
8
CHECK VALVE - BUCKET POSITION
VALVE
9
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
14
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
15
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY PASS
Printed in U.S.A.
22 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END)
3500 PSI (24132 kPa)
23 ONE WAY RESTRICTOR VALVE
24
29
CHARGE PUMP
14.0 GPM (53,0 L/min.) at 2450 RPM
30 HYDRAULIC PUMP . . . . . . . Gear Type
20.7 GPM (78,4 L/min.) at 2450
Engine RPM
HIGH FLOW CAPACITY: (Includes 64 )
30.7 GPM (116,2 L/min.) at 2450
Engine RPM
31
DRIVE MOTOR SHUTTLE VALVE
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TO ACTIVATE
REAR AUXILIARY ("SV1")
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P1" and "F1")
47
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
48
RELIEF VALVE - 1200 PSI (8268 kPa)
49
PRESSURE COMPENSATED FLOW
CONTROL
50 CHECK VALVE WITH 0.015 (0,38 mm)
RESTRICTION
51
RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
53 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
54 HYDRAULIC BRAKE - SPRING APPLIED PRESSURE TO RELEASE
SOLENOID
ACTIVATED DIRECTIONAL
55
CONTROL VALVE - BRAKE
56 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - MAKE-UP
57 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
58 FRONT AUXILIARY MANUAL
PRESSURE BLEED-OFF VALVE
59 FILTER - CASE DRAIN (ATTACHMENT)
41
CHECK VALVE - BICS CONTROL VALVE
60 RELIEF VALVE - 3300 PSI (22754 kPa)
42
LIFT ARM BY-PASS RESTICTOR
61 DUMP VALVE (ON/OFF)
43
CHECK VALVE - AUXILIARY
62 CHECK VALVE
44 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
DRIVE MOTOR
45 VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
46
TWO STAGE RELIEF 1000 PSI/2000 PSI
(6894 kPa/13788 kPa)
63 FILTER (BRAKE)
64 AUXILIARY HYDRAULIC PUMP
10 GPM (37.85 L/min.) at 2450 RPM
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-0237legend (11-26-03)
DIVERTER VALVE (OPTIONAL)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE AND HIGH FLOW OPTION
863 (S/N 514450946 - 514451083)
(S/N 514641255 - 514641266) Printable Version Click Here
(PRINTED DECEMBER 2002)
V-0237
38
39
PILOT
TWO SPEED DRIVE MOTOR
40
31
MALE
32
D1
54
58
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
MALE
58
33
F2
FEMALE
MALE
34
(REAR QUICK
COUPLERS)
44
INTEGRATED QUICK COUPLER BLOCK
36
MALE F1
37
35
D2
FEMALE
FEMALE
53
DRAIN
9
P1
P2
HYDRAULIC FILTER
3
HYDROSTATIC PUMPS
4
45
26
BUCKET POSITION VALVE (OPTIONAL)
59
OIL
COOLER
D
8
26
28
7
6
A
CHARGE
INLET
26
52
OUTLET
C
10
HYDRAULIC CONTROL VAVLE
29
43
11
27
BOB-TACH
CYLINDER
(OPTIONAL)
45
26
26
30
INLET
55
63
B
B
B
AUXILIARY
SPOOL
23
22
61
64
24
A
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
OUTLET
TWO SPEED VALVE
24
25
TILT CYLINDERS
BICS CONTROL VALVE
62
60
47
TWO SPEED DRIVE MOTOR
63
48
46
C
P
54
A
51
9
56
B
12
TILT
CYLINDER
SPOOL
49
21
53
DR
50
44
D
P1
5
18
P2
20
LIFT CYLINDERS
17
13
PP
A
57
B
LIFT
CYLINDER
SPOOL
A
31
42
18
32
19
16
T
41
14
16
2
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY PASS VALVE
15
1
Printed in U.S.A.
V-0237 (11-26-03)
HYDRAULIC/HYDROSTATIC SCHEMATIC
863 (S/N 514451084 AND ABOVE)
(S/N 514541114 AND ABOVE)
(PRINTED DECEMBER 2003)
V-0238legend Printable Version Click Here
LEGEND
1
2
RESERVOIR:
Capacity . . . . . . .
15
18.8 Qts. (17.8 L)
FILTER - CASE DRAIN (90 Micron)
3
FILTER - HYDRAULIC (CANISTER)
4
SPRING LOADED FILTER BY-PASS
VALVE:
45-55 PSI (311-379 kPa)
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
16 FILTER - BICS CONTROL VALVE
(SCREEN)
17 BOOM DOWN RESTRICTOR
18 LIFT AND TILT LOAD CHECK VALVE
5
6
7
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
19 RELIEF VALVE - MAIN:
2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers
9
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
11 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
14
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
Printed in U.S.A.
CHECK VALVE - BICS CONTROL VALVE
30
HYDRAULIC PUMP . . . . . . . Gear Type
20.7 GPM (78,4 L/min.) at 2450 Engine RPM
42
LIFT ARM BY-PASS RESTRICTOR
31
DRIVE MOTOR SHUTTLE VALVE
43
CHECK VALVE - AUXILIARY
32
SHUTTLE RELIEF VALVE:
200 PSI (1378 kPa)
33
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR
AUXILIARY ("SV2")
34
LOAD SHUTTLE VALVE - BLEED OFF
35
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P2" and "F2")
3500 PSI (24132 kPa)
FLOW DIVIDER ADJUSTMENT VALVE
CHECK VALVE - BUCKET POSITION
VALVE
41
20 RELIEF VALVE - PORT:
21 ANTICAVITATION VALVE
8
29 CHARGE PUMP
14.0 GPM (53,0 L/min.) at 2450 Engine RPM
22 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END)
3500 PSI (24132 kPa)
36
37
23 ONE WAY RESTRICTOR VALVE
24
25
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
38
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE: 5000 PSI (34475 kPa)
27
CHARGE PRESSURE SWITCH
28
RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.) Fluid
at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa)
FILTER - DIVERTER VALVE (SCREEN)
INTEGRATED IN SOLENOID
39
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TO ACTIVATE
REAR AUXILIARY ("SV1")
40
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P1" and "F1")
RELIEF VALVE - PORT: . . . . . . . . (Optional)
3500 PSI (24132 kPa)
26
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D1" and "P1")
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D2" and "P2")
44 FRONT AUXILIARY MANUAL
PRESSURE BLEED-OFF VALVE
45
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
46
TWO STAGE RELIEF VALVE 1000 PSI/
2000 PSI (6894 kPA/ 13788 kPA)
47
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
48
RELIEF VALVE - 1200 PSI (8268 kPa)
49
PRESSURE COMPENSATED FLOW
CONTROL
50
CHECK VALVE WITH .015 (0,38mm)
ORIFICE
51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-0238legend (11-26-03)
DIVERTER VALVE (OPTIONAL)
HYDRAULIC/HYDROSTATIC SCHEMATIC
863 (S/N 514451084 AND ABOVE)
(S/N 514541114 AND ABOVE)
38
39
PILOT
(PRINTED NOVEMBER 2002)
V-0238
Printable Version Click Here
DRIVE MOTOR
40
MALE
31
MALE
F1
FRONT AUXILIARY
LEFT SIDE LIFT ARM
D1
32
MALE
DRAIN
(MALE)
34
REAR QUICK
COUPLERS
(OPTIONAL)
33
F2
FEMALE
44
36
FEMALE
37
35
44
D2
FEMALE
9
DRAIN
P1
P2
HYDRAULIC FILTER
3
2
HYDROSTATIC PUMPS
BUCKET POSITION VALVE (OPTIONAL)
OIL
COOLER
4
45
D
8
28
26
26
7
6
A
OUTLET
CHARGE INLET
C
52
10
HYDRAULIC CONTROL VAVLE
29
43
26
11
27
26
45
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
24
25
BOB-TACH
CYLINDER
(OPTIONAL)
24
B
A
B
AUXILIARY
SPOOL
DR
OUTLET
INLET
23
22
48
46
47
A
51
B
50
21
18
9
P2
P1
31
12
TILT
CYLINDER
SPOOL
49
DRIVE MOTOR
TILT CYLINDER
BICS CONTROL VALVE
30
5
20
LIFT CYLINDERS
17
13
PP
A
B
LIFT
CYLINDER
SPOOL
32
42
18
19
14
16
2
16
*
(If Equipped)
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
41
LIFT ARM BY- PASS VALVE
15
1
Printed in U.S.A.
V-0238 (11-6-02)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE OPTION
863 (S/N 514451084 AND ABOVE)
(S/N 514541114 AND ABOVE)
(PRINTED DECEMBER 2003)
V-0239legend Printable Version Click Here
LEGEND
1
RESERVOIR:
Capacity . . . . . . . .
18.8 Qts. (17.8 L)
2
FILTER - CASE DRAIN (90 Micron)
3
FILTER - HYDRAULIC (CANISTER)
4
SPRING LOADED FILTER BY-PASS
VALVE:
45-55 PSI (311-379 kPa)
5
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
6
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
7
FLOW DIVIDER ADJUSTMENT VALVE
8
CHECK VALVE - BUCKET POSITION
VALVE
9
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
11 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
19 RELIEF VALVE - MAIN:
2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers
21 ANTICAVITATION VALVE
35
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P2" and "F2")
48
RELIEF VALVE - 1200 PSI (8268 kPa)
49
PRESSURE COMPENSATED FLOW
CONTROL
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D1" and "P1")
50 CHECK VALVE WITH .015 (0,38mm)
ORIFICE
36
22 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END)
3500 PSI (24132 kPa)
23 ONE WAY RESTRICTOR VALVE
37
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D2" and "P2")
24
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
25
RELIEF VALVE - PORT: . . . . . . . (Optional)
3500 PSI (24132 kPa)
38
FILTER - DIVERTER VALVE (SCREEN)
INTEGRATED IN SOLENOID
26
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE:
5000 PSI (34475 kPa)
39
27
CHARGE PRESSURE SWITCH
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TO ACTIVATE
REAR AUXILIARY ("SV1")
28
RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.)Fluid
at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa)
29
CHARGE PUMP
14.0 GPM (53,0 L/min.) at 2450 Engine RPM
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
31
DRIVE MOTOR SHUTTLE VALVE
14
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
32
SHUTTLE RELIEF VALVE:
200 PSI (1378 kPa)
15
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS
33
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR
AUXILIARY ("SV2")
Printed in U.S.A.
47
3500 PSI (24132 kPa)
30
18 LIFT AND TILT LOAD CHECK VALVE
LOAD SHUTTLE VALVE - BLEED OFF
20 RELIEF VALVE - PORT:
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
16 FILTER - BICS CONTROL VALVE
(SCREEN)
17 BOOM DOWN RESTRICTOR
34
HYDRAULIC PUMP . . . . . . . . Gear Type
20.7 GPM (78,4 L/min.) at 2450 Engine RPM
40
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P1" and "F1")
51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
53 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
54 HYDRAULIC BRAKE - SPRING APPLIED PRESSURE TO RELEASE
55 PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE BRAKE
56 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - MAKE-UP
41
CHECK VALVE - BICS CONTROL VALVE
57 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
42
LIFT ARM BY-PASS RESTRICTOR
58 BRAKE DIAGNOSTIC PLUG
43
CHECK VALVE - AUXILIARY
44 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
DRIVE MOTOR
45
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
46
TWO STAGE RELIEF VALVE 1000 PSI/
2000 PSI (6894 kPa/ 13788 kPa)
59 FRONT AUXILIARY MANUAL PRESSURE
BLEED-OFF VALVE
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-0239legend (11-26-03)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE OPTION
863 (S/N 514451084 AND ABOVE)
(S/N 514541114 AND ABOVE)
(PRINTED DECEMBER 2003)
Printable Version Click Here
DIVERTER VALVE (OPTIONAL)
38
39
PILOT
V-0239
TWO SPEED DRIVE MOTOR
FRONT AUXILIARY
LEFT SIDE LIFT ARM
40
31
MALE
32
36
MALE F1
D1
33
F2
44
FEMALE
DRAIN
(MALE)
FEMALE
37
35
59
D2
FEMALE
53
33
DRAIN
9
MALE
34
(REAR QUICK
COUPLERS)
54
59
P1
P2
HYDRAULIC FILTER
3
OIL
COOLER
4
45
26
BUCKET POSITION VALVE (OPTIONAL)
2
HYDROSTATIC PUMPS
D
8
26
28
7
6
A
CHARGE
INLET
52
OUTLET
C
10
HYDRAULIC CONTROL VAVLE
29
43
11
27
45
26
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
26
30
INLET
BOB-TACH
CYLINDER
(OPTIONAL)
24
25
24
B
A
B
DR
OUTLET
AUXILIARY
SPOOL
58
TWO SPEED VALVE
B1
23
22
TILT CYLINDER
BICS CONTROL VALVE
TWO SPEED DRIVE MOTOR
55
B
48
54
46
47
49
9
56
A
51
B
50
C
P
12
TILT
CYLINDER
SPOOL
21
53
18
44
D
20
P1
5
LIFT CYLINDERS
17
P2
13
PP
A
57
B
LIFT
CYLINDER
SPOOL
A
31
42
18
32
19
14
16
T
16
2
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
41
LIFT ARM BY- PASS VALVE
15
1
Printed in U.S.A.
V-0239 (11-26-03)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
863 (S/N 514451084 AND ABOVE)
(S/N 514641267 AND ABOVE)
Printable Version Click Here
(PRINTED DECEMBER 2003)
V-0240legend
LEGEND
16 FILTER - BICS CONTROL VALVE
(SCREEN)
2
RESERVOIR:
Capacity . . . . . . . . . 18.8 Qts. (17.8
L)
FILTER - CASE DRAIN (90 Micron)
3
FILTER - HYDRAULIC (CANISTER)
18 LOAD CHECK VALVE
4
SPRING LOADED FILTER BYPASS
VALVE: 45-55 PSI (311-379 kPa)
5
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
19 RELIEF VALVE - MAIN:
2950-3050 PSI (20340-22030 kPa)
at Front Quick Couplers
1
6
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
7
FLOW DIVIDER ADJUSTMENT VALVE
8
CHECK VALVE - BUCKET POSITION
VALVE
9
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
11 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
17 ONE WAY RESTRICTOR
20 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
DRIVE MOTOR SHUTTLE VALVE
44
32
SHUTTLE RELIEF VALVE:
200 PSI (1378 kPa)
FRONT AUXILIARY MANUAL
PRESSURE BLEED-OFF VALVE
45
33
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR
AUXILIARY ("SV2")
VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
46
TWO STAGE RELIEF 1000 PSI/2000 PSI
(6894kPa/13788 kPa)
34
LOAD SHUTTLE VALVE - BLEED OFF
47
35
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P2" and "F2")
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
48
RELIEF VALVE - 1200 PSI (8268 kPa)
49
PRESSURE COMPENSATED FLOW
CONTROL
21 ANTICAVITATION VALVE
22 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END)
3500 PSI (24132 kPa)
23 ONE WAY RESTRICTOR VALVE
24
25
26
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
36
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D1" and "P1")
37
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D2" and "P2")
RELIEF VALVE - PORT: . . . . . (Optional)
3500 PSI (24132 kPa)
38
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE: 5000 PSI (34474 kPa)
FILTER - DIVERTER VALVE (SCREEN)
INTEGRATED IN SOLENOID
39
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TO ACTIVATE
REAR AUXILIARY ("SV1")
40
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P1" and "F1")
27
CHARGE PRESSURE SWITCH
28
RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.)Fluid
at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa)
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
29
CHARGE PUMP
14.0 GPM (53.0 L/min.) at 2450 RPM
14
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
30
15
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY PASS
HYDRAULIC PUMP . . . . . . . Gear Type
20.7 GPM (78,4 L/min.) at 2450
Engine RPM
HIGH FLOW CAPACITY: (Includes 53 )
30.7 GPM (116,2 L/min.) at 2450
Engine RPM
Printed in U.S.A.
31
41
CHECK VALVE - BICS CONTROL VALVE
42
LIFT ARM BY-PASS RESTRICTOR
43
CHECK VALVE - AUXILIARY
50 CHECK VALVE WITH 0.015 (0,38 mm)
RESTRICTION
51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
AUXILIARY
HYDRAULIC PUMP
53
10 GPM (37.85 L/min.) at 2450 RPM
54
FILTER - CASE DRAIN (ATTACHMENT)
55
RELIEF VALVE - 3300 PSI (22754 kPa)
56
DUMP VALVE (ON/OFF)
57
CHECK VALVE
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-0240legend (11-26-03)
DIVERTER VALVE (OPTIONAL)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
863 (S/N 514451084 AND ABOVE )
(S/N 514641267 AND ABOVE) Printable Version Click Here
(PRINTED DECEMBER 2003)
V-0240
38
39
PILOT
DRIVE MOTOR
40
MALE
31
MALE
INTEGRATED QUICK COUPLER BLOCK
36
F1
D1
MALE
32
34
(REAR QUICK
COUPLERS)
FEMALE
MALE
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
44
33
F2
9
44
37
35
D2
FEMALE
FEMALE
DRAIN
P1
P2
HYDRAULIC FILTER
3
HYDROSTATIC PUMPS
45
26
28
BUCKET POSITION VALVE (OPTIONAL)
54
4
OIL
COOLER
D
8
26
7
6
A
CHARGE INLET
OUTLET
52
43
11
27
26
26
C
10
HYDRAULIC CONTROL VAVLE
29
45
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
INLET
24
25
BOB-TACH
CYLINDER
(OPTIONAL)
24
B
A
B
AUXILIARY
SPOOL
OUTLET
23
22
TILT CYLINDERS
BICS CONTROL VALVE
30
53
57
47
48
55
46
56
A
DR
DRIVE MOTOR
B
50
21
9
18
P1
5
P2
20
LIFT CYLINDERS
17
PP
13
A
31
12
TILT
CYLINDER
SPOOL
51
49
B
LIFT
CYLINDER
SPOOL
32
42
18
19
14
16
2
16
*
(If Equipped)
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
41
LIFT ARM BY PASS VALVE
15
1
Printed in U.S.A.
V-0240 (11-26-03)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE AND HIGH FLOW OPTION
863 (S/N 514451084 AND ABOVE)
(S/N 514641267 AND ABOVE)
Printable Version Click Here
(PRINTED DECEMBER 2003)
V-0241legend
LEGEND
1
RESERVOIR:
Capacity . . . . . . 18.8 Qts. (17,8 L)
2
FILTER - CASE DRAIN (90 Micron)
3
FILTER - HYDRAULIC (CANISTER)
4
SPRING LOADED FILTER BYPASS
VALVE: 45-55 PSI (311-379 kPa)
5
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
16 FILTER - BICS CONTROL VALVE
(SCREEN)
17 ONE WAY RESTRICTOR
32
33
18 LOAD CHECK VALVE
19
RELIEF VALVE - MAIN:
2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers
34
LOAD SHUTTLE VALVE - BLEED OFF
35
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P2" and "F2")
20 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
21 ANTICAVITATION VALVE
SHUTTLE RELIEF VALVE:
200 PSI (1378 kPa)
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR
AUXILIARY ("SV2")
36
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D1" and "P1")
37
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
25 RELIEF VALVE - PORT: . . . . . (Optional)
3500 PSI (24132 kPa)
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D2" and "P2")
38
FILTER - DIVERTER VALVE (SCREEN)
INTEGRATED IN SOLENOID
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
26
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE: 5000 PSI (34475 kPa)
39
27
CHARGE PRESSURE SWITCH
40
11 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
28
RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.)Fluid
at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa)
6
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
7
FLOW DIVIDER ADJUSTMENT VALVE
8
CHECK VALVE - BUCKET POSITION
VALVE
9
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
12 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL
13 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
14
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL
15
PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY PASS
Printed in U.S.A.
22 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END)
3500 PSI (24132 kPa)
23 ONE WAY RESTRICTOR VALVE
24
29
CHARGE PUMP
14.0 GPM (53,0 L/min.) at 2450 RPM
30 HYDRAULIC PUMP . . . . . . . Gear Type
20.7 GPM (78,4 L/min.) at 2450
Engine RPM
HIGH FLOW CAPACITY: (Includes 64 )
30.7 GPM (116,2 L/min.) at 2450
Engine RPM
31
DRIVE MOTOR SHUTTLE VALVE
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TO ACTIVATE
REAR AUXILIARY ("SV1")
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P1" and "F1")
47
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
48
RELIEF VALVE - 1200 PSI (8268 kPa)
49
PRESSURE COMPENSATED FLOW
CONTROL
50 CHECK VALVE WITH 0.015 (0,38 mm)
RESTRICTION
51
RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
53 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
54 HYDRAULIC BRAKE - SPRING APPLIED PRESSURE TO RELEASE
SOLENOID
ACTIVATED DIRECTIONAL
55
CONTROL VALVE - BRAKE
56 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - MAKE-UP
57 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
58 FRONT AUXILIARY MANUAL
PRESSURE BLEED-OFF VALVE
59 FILTER - CASE DRAIN (ATTACHMENT)
41
CHECK VALVE - BICS CONTROL VALVE
60 RELIEF VALVE - 3300 PSI (22754 kPa)
42
LIFT ARM BY-PASS RESTICTOR
61 DUMP VALVE (ON/OFF)
43
CHECK VALVE - AUXILIARY
62 CHECK VALVE
44 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
DRIVE MOTOR
45 VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP
46
TWO STAGE RELIEF 1000 PSI/2000 PSI
(6894 kPa/13788 kPa)
63 FILTER (BRAKE)
64 AUXILIARY HYDRAULIC PUMP
10 GPM (37.85 L/min.) at 2450 RPM
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
V-0241legend (11-26-03)
DIVERTER VALVE (OPTIONAL)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE AND HIGH FLOW OPTION
863 (S/N 514451084 AND ABOVE)
(S/N 514641267 AND ABOVE) Printable Version Click Here
(PRINTED DECEMBER 2003)
V-0241
38
39
PILOT
TWO SPEED DRIVE MOTOR
40
31
MALE
32
D1
54
58
(FRONT AUXILIARY
LEFT SIDE LIFT ARM)
MALE
58
33
F2
FEMALE
MALE
34
(REAR QUICK
COUPLERS)
44
INTEGRATED QUICK COUPLER BLOCK
36
MALE F1
37
35
D2
FEMALE
FEMALE
53
DRAIN
9
P1
P2
HYDRAULIC FILTER
3
HYDROSTATIC PUMPS
4
45
26
BUCKET POSITION VALVE (OPTIONAL)
59
OIL
COOLER
D
8
26
28
7
6
A
CHARGE
INLET
26
52
OUTLET
C
10
HYDRAULIC CONTROL VAVLE
29
43
11
27
24
25
45
24
B
A
26
26
30
INLET
OUTLET
TWO SPEED VALVE
55
63
HYDRAULIC
POWERED
BOB-TACH
(OPTIONAL)
B
BOB-TACH
CYLINDER
(OPTIONAL)
AUXILIARY
SPOOL
23
22
61
64
B
TILT CYLINDERS
BICS CONTROL VALVE
62
60
47
TWO SPEED DRIVE MOTOR
63
48
46
C
P
54
A
51
9
56
B
12
TILT
CYLINDER
SPOOL
49
21
53
DR
50
44
D
P1
5
18
P2
20
LIFT CYLINDERS
17
13
PP
A
57
B
LIFT
CYLINDER
SPOOL
A
31
42
18
32
19
14
16
T
16
41
2
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY PASS VALVE
15
1
Printed in U.S.A.
V-0241 (11-26-03)
HYDRAULIC SYSTEM INFORMATION
MC 2340 (6-2-98)
20-10-1
863 Bobcat Loader
Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)
MC 2340-2 (6-2-98)
20-10-2
863 Bobcat Loader
Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)
MC 2340-3 (6-2-98)
20-10-3
863 Bobcat Loader
Service Manual
20-10-4
863 Bobcat Loader
Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)
Troubleshooting Chart
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are
most common. Many of the recommended procedures
must be done by authorized Bobcat Service Personnel
only.
WARNING
I-2003-0888
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
Tighten Procedures
W-2004-1285
For tightening torques for hydraulic fittings, tubelines etc.,
(See HYDRAULIC FLUID SPECIFICATIONS on Page
SPEC-60-1.).
PROBLEM
CAUSE
The hydraulic system will not operate.
The transmission warning light comes ON when hydraulics are operating.
Slow hydraulic system action.
Hydraulic action is not smooth.
Lift arms go up slowly at full engine RPM.
The lift arms or Bob-Tach will move when the pedal is in neutral position.
By-pass valve stuck.
By-pass valve stem bent or broke.
1, 2, 3, 5, 8
1, 3,
1, 3, 4, 6, 8
1, 4, 5, 6, 7
1, 3, 4, 5, 6, 7, 8, 9
4, 9, 10, 11
12
13
KEY TO CORRECT THE CAUSE
1. The fluid level is not correct.
2. The pedal linkage is disconnected.
3. The hydraulic pump has damage.
4. The pedal linkage is not adjusted correctly.
5. Relief valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold. Wrong viscosity fluid. (See Hydraulic System on Page SPEC-10-3.)
8. Using the loader for more than its rated capacity.
9. Internal leak in the lift cylinder(s).
10. External leak from the lift cylinder(s).
11. Damaged lift spool.
12. Rotate shaft.
13. Replace manual spool cartridge.
20-10-5
863 Bobcat Loader
Service Manual
20-10-6
863 Bobcat Loader
Service Manual
CYLINDER (LIFT)
Figure 20-20-2
Checking
1
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
CD-15068
W-2072-0496
Figure 20-20-1
Install a plug (Item 1) [Figure 20-20-2] in the hose and
tighten.
Engage the parking brake. Lower the seat bar. Start the
engine and push the top (toe) of the lift pedal.
1
If there is any leakage from the open port, remove the lift
cylinder for repair. Repeat the procedure to check the
other lift cylinder.
CD-15067
Lower the lift arms. Stop the engine. Raise the seat bar.
Check only one cylinder at a time. Disconnect the hose
(Item 1) [Figure 20-20-1] which goes to the base end of
the lift cylinder.
20-20-1
863 Bobcat Loader
Service Manual
CYLINDER (LIFT) (CONT’D)
Figure 20-20-5
Removal And Installation
Figure 20-20-3
1
CD-15070
Remove the retaining bolt and nut (Item 1) [Figure 2020-5] from the pivot pin base end of the cylinder.
P-7960
Raise the lift arms so the rod end retaining pin will clear
the loader frame for removal.
Installation: Tighten the retainer bolt and nut to 18-20 ft.lbs. (24-27 Nm) torque.
Figure 20-20-6
Have a second person put jackstands under the BobTach to support the lift arms [Figure 20-20-3]. Stop the
engine.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Figure 20-20-4
CD-15072
1
Remove the pivot pin from the base end of the cylinder
[Figure 20-20-6].
Slide the cylinder forward for clearance to disconnect the
hoses.
CD-15069
Mark the hoses for correct installation.
Remove the retaining bolt and nut (Item 1) [Figure 2020-4] from the pivot pin on the rod end of the cylinder.
Installation: Tighten the retainer bolt and ut to 18-20 ft.lbs. (24-27 Nm) torque.
Remove the pivot pin from the rod end of the cylinder.
20-20-2
863 Bobcat Loader
Service Manual
CYLINDER (LIFT) (CONT’D)
Removal And Installation (Cont’d)
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Figure 20-20-7
1
CD-15073
Disconnect the two hoses (Item 1) [Figure 20-20-7] from
the lift cylinder.
Remove the lift cylinder.
20-20-3
863 Bobcat Loader
Service Manual
CYLINDER (LIFT) (CONT’D)
Parts Identification
1.
2.
3.
4.
5.
6.
7.
8.
9.
Tube
O-Ring
Plug
Case
O-Ring
Nut
Piston
Ring
O-ring
10. Spacer
11. O-ring
12. Washer
13. Head
14. Seal
15. Seal
16. Rod
10
9
B-14213A
B-14213B
8
7
16
6
3
2
5
15
1
14
3
2
13
4
12
11
B-13593B
TS-1060
20-20-4
863 Bobcat Loader
Service Manual
Figure 20-20-10
CYLINDER (LIFT) (CONT’D)
Disassembly
4
Figure 20-20-8
1
3
2
P-7428
Lift Cylinder: Remove the head and the rod assembly
from the cylinder [Figure 20-20-10]. Put the rod end in a
vise.
P-7429
Figure 20-20-9
Lift Cylinder: Remove the nut (Item 1) [Figure 20-20-10],
piston (Item 2) [Figure 20-20-10], spacer (Item 3)
[Figure 20-20-10]. and head (Item 4) [Figure 20-20-10].
Figure 20-20-11
2
3
1
P-7435
Use the following tools to disassemble the cylinder:
P-7434
MEL1074 - O-ring Seal Hook
Spanner Wrench
The lift and tilt cylinders internal components are similar,
the differences are listed below:
Tilt Cylinder: Remove the head and rod assembly from
the cylinder [Figure 20-20-11]. Put the rod end in a vise.
Tilt: Cylinder: Remove the nut (Item 1) [Figure 20-20-11],
piston (Item 2) [Figure 20-20-11] and head (Item 3)
[Figure 20-20-11].
Tilt rod diameter is larger.
Piston relief area is slightly different.
No spacer in the tilt cylinder.
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.
Put the base end of the cylinder in a vise.
Use a spanner wrench to loosen the head [Figure 20-208] & [Figure 20-20-9].
20-20-5
863 Bobcat Loader
Service Manual
CYLINDER (LIFT) (CONT’D)
Figure 20-20-14
Disassembly (Cont’d)
Figure 20-20-12
3
3
2
1
2
1
P-07422
P-7430
Standard Piston: Remove the seal (Item 1) [Figure 2020-12], and O-ring (Item 2) [Figure 20-20-12] from the
piston (Item 3) [Figure 20-20-12].
Remove the thick O-ring (Item 1) [Figure 20-20-14] and
the back-up washer (Item 2) [Figure 20-20-14] from the
groove in the head. Remove the thin O-ring (Item 3)
[Figure 20-20-14].
Figure 20-20-15
Figure 20-20-13
3
2
2
3
1
1
P-7426
Remove the wiper seal (Item 1) [Figure 20-20-15], and
rod seal (Item 2) [Figure 20-20-15].
P-7439
Cushion Piston: Remove the seal (Item 1) [Figure 20-2013] and O-ring (Item 2) [Figure 20-20-13] from the piston
(Item 3) [Figure 20-20-13].
Remove the O-ring (Item 3) [Figure 20-20-15] from the
rod seal.
20-20-6
863 Bobcat Loader
Service Manual
CYLINDER (LIFT) (CONT’D)
Figure 20-20-17
Assembly
3
Figure 20-20-16
2
1
P-7430
Standard Piston: Install the seal (Item 1) [Figure 20-2017] and O-ring (Item 2) [Figure 20-20-17] on the piston
(Item 3) [Figure 20-20-17].
P-7424
Figure 20-20-18
Use the following tools to assemble the cylinder:
MEL 1396 - Seal Installation Tool
MEL 1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
1
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other
damage. Replace any damaged parts.
Always install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic oil during
installtion.
Install a new seal on the tool and slowly stretch it until it
fits the piston (Item 1) [Figure 20-20-16].
Allow the seal the stretch for 30 seconds before installing
it on the piston.
P-7438
Cushion Piston: Install the seal and O-ring on the piston
(Item 1) [Figure 20-20-18].
Using a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for
about three minutes.
20-20-7
863 Bobcat Loader
Service Manual
CYLINDER (LIFT) (CONT’D)
Figure 20-20-21
Assembly (Cont’d)
Figure 20-20-19
1
3
2
P-7422
Install the thin O-ring (Item 1) [Figure 20-20-21].
P-7427
Install the rod seal on the rod seal tool [Figure 20-20-19].
Install the back-up washer (Item 2) [Figure 20-20-21]
and thick O-ring (Item 3) [Figure 20-20-21] into the
groove in the head.
NOTE: During Installation the O-ring side of the seal
must be toward the inside of the cylinder.
NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit.
Rotate the handles to collapse the rod seal [Figure 2020-19].
Figure 20-20-22
Figure 20-20-20
2
1
3
P-7434
Tilt Cylinder: Install the head (Item 1) [Figure 20-20-22],
and piston (Item 2) [Figure 20-20-22]. The small
diameter of the piston goes into the cylinder tube first.
P-7425
Install the rod seal in the head [Figure 20-20-20].
Install the wiper seal with the wiper toward the outside of
the head.
Tilt Cylinder: Grease the piston where the nut contacts
the piston. Do not get grease on the threads.
Tilt Cylinder: Install the nut (Item 3) [Figure 20-20-22].
Tilt Cylinder: Tighten the nut to 100 ft.-lbs. (136 Nm)
torque.
20-20-8
863 Bobcat Loader
Service Manual
CYLINDER (LIFT) (CONT’D)
Figure 20-20-25
Assembly (Cont’d)
Figure 20-20-23
P-7429
Figure 20-20-26
P-10450
P-10456
Tilt Cylinder: Mark the end of the shaft and nut [Figure
20-20-23]. Tighten the nut an additional 135 degrees or
2-1/4 flats [Figure 20-20-23].
NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit.
Figure 20-20-24
1
4
3
2
P-7435
Tighten the head using a spanner wrench [Figure 20-2025] & [Figure 20-20-26].
P-7428
Lift Cylinder: Install the head (Item 1) [Figure 20-20-24],
and spacer (Item 2) [Figure 20-20-24].
Lift Cylinder: Install the piston (Item 3) [Figure 20-20-24],
and the nut (Item 4) [Figure 20-20-24].
Lift Cylinder: Tighten the nut (Item 4) [Figure 20-20-24]
to 400 ft.-lbs. (542 Nm) torque.
Put the base end of the hydraulic cylinder in a vise.
20-20-9
863 Bobcat Loader
Service Manual
20-20-10
863 Bobcat Loader
Service Manual
CYLINDER (TILT)
Removal And Installation
Checking
Figure 20-21-2
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496
P-7694
Figure 20-21-1
Remove the attachment. Roll the Bob-Tach fully forward
[Figure 20-21-2].
Stop the engine. Raise the seat bar.
2
Figure 20-21-3
1
1
P-1187
Remove the attachment. Roll the Bob-Tach fully back.
Stop the engine. Raise the seat bar.
Disconnect the hose (Item 1) [Figure 20-21-1] which
goes to the base end of the tilt cylinder.
P-7693
Put a plug in the hose and tighten.
Remove the retainer bolt and nut (Item 1) [Figure 20-213] from the rod end pivot pin.
Install a test hose between cylinder and drain pan.
Engage the parking brake. Lower the seat bar. Start the
engine and push the bottom (heel) of the tilt pedal. If
there is leakage from the open port, remove the tilt
cylinder for repair.
Installation: Tighten the retainer nut to 18-20 ft.-lbs. (2427 Nm) torque.
20-21-1
863 Bobcat Loader
Service Manual
CYLINDER (TILT) (CONT’D)
Figure 20-21-5
Removal And Installation (Cont’d)
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
1
W-2103-1285
Figure 20-21-4
P-7678
Remove the retainer bolt and nut (Item 1) [Figure 20-215] from the base end pivot pin.
Installation: Tighten the retainer nut and bolt to 18-20 ft.lbs. (24-27 Nm) torque.
Figure 20-21-6
1
P-7695
Remove the rod end pivot pin (Item 1) [Figure 20-21-4].
Engage the parking brake. Lower the seat bar. Start the
engine and push the bottom (heel) of the tilt pedal until
rod end of cylinder is fully retracted.
1
Disconnect the hoses (Items 1 & 2) [Figure 20-21-1 on
Page 1]. (See Checking on Page 20-21-1.)
Plug fittings on tilt cylinder
P-7679
Remove the base end pivot pin (Item 1) [Figure 20-21-6].
Remove the tilt cylinder from the loader.
20-21-2
863 Bobcat Loader
Service Manual
CYLINDER (TILT)
Figure 20-21-8
Rod End Seal
Figure 20-21-7
1
P-3910
Using two pieces of shim stock, install the rod end of the
tilt cylinder into the Bob-Tach (Item 1) [Figure 20-21-8].
P-3911
Remove the old seal (both sides) from the rod end of the
tilt cylinder.
Install the new seals (Item 1) [Figure 20-21-7] with the lip
facing out.
Be careful not to damage the new seals during
installation.
Hold the rod end in position and remove the shim stock.
20-21-3
863 Bobcat Loader
Service Manual
CYLINDER (TILT) (CONT’D)
Parts Identification
1. Case
2. Plug
3. O-Ring
4. Tube
5. Nut
6. Clamp
7. Bolt
8. Nut
9. Piston
10. Seal
11. O-Ring
12. O-Ring
13. Washer
14. O-Ring
15. Head
16. Seal
17. Seal
18. Rod
19. Seal
20. Bushing
MC-1688B
3
2
MC-1688A
4
6
5
1
7
8
15
9
16
10
17
11
12
13
19 20 19
18
14
MC-1688C
MC-1688D
TS-1233
20-21-4
863 Bobcat Loader
Service Manual
CYLINDER (TILT) (CONT’D)
Figure 20-21-10
Disassembly
Use the following tools to disassemble the cylinder:
MEL 1074 - O-ring Seal Hook
Spanner Wrench
The lift and tilt cylinders internal components are similar,
the differences are listed below.
Tilt rod is larger in diameter.
Piston relief area is slightly different.
No spacer in the tilt cylinder.
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.
Put the base end of the cylinder in a vise.
P-7435
Use a spanner wrench to loosen the head [Figure 20-219] & [Figure 20-21-10].
Figure 20-21-9
P-7429
20-21-5
863 Bobcat Loader
Service Manual
CYLINDER (TILT) (CONT’D)
Figure 20-21-13
Disassembly (Cont’d)
3
Figure 20-21-11
2
4
1
1
3
2
P-7430
Standard piston: Remove the seal (Item 1) [Figure 2021-13], and O-ring (Item 2) [Figure 20-21-13] from the
piston (Item 3) [Figure 20-21-13].
P-7428
Lift Cylinder: Remove the head and the rod assembly
from the cylinder [Figure 20-21-11]. Put the rod end in a
vise.
Figure 20-21-14
3
Lift Cylinder: Remover the nut (Item 1) [Figure 20-2111], piston (Item 2) [Figure 20-21-11], spacer (Item 3)
[Figure 20-21-17] and head (Item 4) [Figure 20-21-11].
2
1
Figure 20-21-12
2
3
1
P-7439
Cushion Piston: Remove the seal (Item 1) [Figure 20-2114], and O-ring (Item 2) [Figure 20-21-14] from the
piston (Item 3) [Figure 20-21-14].
P-7434
Tilt Cylinder: Remove the head and rod assembly from
the cylinder [Figure 20-21-12]. Put the rod end in a vise.
Tilt Cylinder: Remove the nut (Item 1) [Figure 20-21-12],
piston (Item 2) [Figure 20-21-12] and head (Item 3)
[Figure 20-21-12].
20-21-6
863 Bobcat Loader
Service Manual
CYLINDER (TILT) (CONT’D)
Assembly
Disassembly (Cont’d)
Use the following tools to assemble the cylinder:
Figure 20-21-15
MEL1396 - Seal Installation Tool
MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other
damage. Replace any damaged parts.
2
1
3
ALways install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic oil during
installation.
Figure 20-21-17
P-7426
Remove the thick O-ring (Item 1) [Figure 20-21-15], and
the back-up washer (Item 2) [Figure 20-21-15] from the
groove in the head. Remove the thin O-ring (Item 3)
[Figure 20-21-15].
Figure 20-21-16
2
3
P-7424
1
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-21-17].
Allow the seal to stretch for 30 seconds before installing it
on the piston.
P-7426
Remove the wiper seat (Item 1) [Figure 20-21-16], and
rod seal (Item 2) [Figure 20-21-16].
Remove the O-ring (Item 3) [Figure 20-21-16] from the
rod seal.
20-21-7
863 Bobcat Loader
Service Manual
CYLINDER (TILT) (CONT’D)
Figure 20-21-20
Assembly (Cont’d)
Figure 20-21-18
3
2
1
P-7427
Install the rod seal on the rod seal tool [Figure 20-21-20].
P-7430
Standard Piston: Install the seal (Item 1) [Figure 20-2118] and O-ring (Item 2) [Figure 20-21-18] on the piston
(Item 3) [Figure 20-21-18].
Figure 20-21-19
NOTE: During installation the O-ring side of the seal
must be toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [Figure 2021-20].
Figure 20-21-21
1
P-7438
P-7425
Cushion Piston: Install the seal and O-ring on the piston
(Item 1) [Figure 20-21-19].
Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for
about three minutes.
Install the rod seal in the head [Figure 20-21-21].
Install the wiper seal with the wiper toward the outside of
the head.
20-21-8
863 Bobcat Loader
Service Manual
CYLINDER (TILT) (CONT’D)
Tilt Cylinder: Tighten the nut to 100 ft.-lbs. (136 Nm)
torque.
Assembly (Cont’d)
Figure 20-21-24
Figure 20-21-22
1
3
2
P-10450
P-10456
P-7422
Tilt Cylinder: Mark the end of the shaft and nut [Figure
20-21-24]. Tighten the nut an additional 135 degrees or
2-1/4 flats [Figure 20-21-24].
Install the thin O-ring (Item 1) [Figure 20-21-22].
Install the back-up washer (Item 2) [Figure 20-21-22]
and thick O-ring (Item 3) [Figure 20-21-22]into the
groove on the head.
NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit.
NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit.
Figure 20-21-25
1
Figure 20-21-23
4
2
3
2
1
3
P-7428
Lift Cylinder: Install the head (Item 1) [Figure 20-21-25],
and spacer (Item 2) [Figure 20-21-25].
P-7434
Tilt Cylinder: Install the head (Item 1) [Figure 20-21-23],
and the piston (Item 2) [Figure 20-21-23]. The small
diameter of the piston goes into the cylinder tube first.
Tilt Cylinder: Grease the piston where the nut contacts
the piston. Do not get grease on the threads.
Tilt Cylinder: Install the nut (Item 3) [Figure 20-21-23].
Lift Cylinder: Install the piston (Item 3) [Figure 20-21-25],
and the nut (Item 4) [Figure 20-21-25].
Lift Cylinder: Tighten the nut (Item 4) [Figure 20-21-25]
to 400 ft.-lbs. (542 Nm) torque.
Put the base end of the hydraulic cylinder in a vise.
20-21-9
863 Bobcat Loader
Service Manual
CYLINDER (TILT) (CONT’D)
Assembly (Cont’d)
Figure 20-21-26
P-7429
Figure 20-21-27
P-7435
Tighten the head using a spanner wrench [Figure 20-2126] & [Figure 20-21-27].
20-21-10
863 Bobcat Loader
Service Manual
CYLINDER (POWER BOB-TACH)
Figure 20-22-2
Checking
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
1
N-23032
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
Disconnect the hose (Item 1) [Figure 20-22-2]from the
power Bob-Tach cylinder base end port.
Figure 20-22-3
1
W-2072-0496
2
Figure 20-22-1
N-23033
Install a plug in the hose (Item 1) [Figure 20-22-3] and
tighten.
Engage the parking brake. Lower the seat bar. Start the
engine.
N-23031
Push and hold the BOB-TACH “WEDGES UP” Switch
(Front Accessory Panel).
Tilt the Bob-Tach forward, so it is parallel to the floor
[Figure 20-22-1].
If there is any leakage from the base end cylinder port
(Item 2) [Figure 20-22-3], remove the lift cylinder for
repair.
20-22-1
863 Bobcat Loader
Service Manual
CYLINDER (POWER BOB-TACH) (CONT’D)
Figure 20-22-5
Removal And Installation
Figure 20-22-4
1
1
1
N-23034
2
Remove the bolts (Item 1) [Figure 20-22-5].
N-23031
Disconnect the hoses (Item 1 & 2) [Figure 20-22-4] from
the cylinder fittings.
Installation: Tighten the bolts to 25-28 ft.-lbs. (34-38
Nm) torque.
Remove the washers and cylinder from the lever pivots.
Install plugs and cap in fittings.
20-22-2
863 Bobcat Loader
Service Manual
CYLINDER (POWER BOB-TACH) (CONT’D)
Parts Identification
1. Cylinder
2. Nut
3. Piston
4. O-Ring
5. Ring
6. Spacer
7. O-Ring
8. Ring
9. O-Ring
10. Head
11. Seal
12. Seal
13. Rod
1
2
3
4
5
6
7
8
9
10
11
12
13
TS-1233
20-22-3
863 Bobcat Loader
Service Manual
CYLINDER (POWER BOB-TACH) (CONT’D)
Figure 20-22-7
Disassembly
2
3
Figure 20-22-6
1
P-16294
Remove the head and rod assembly from the cylinder
[Figure 20-22-7].
P-16293
Put the rod end in a vise.
Use the following tools to disassemble the cylinder:
Remove the nut (Item 1) [Figure 20-22-7], piston (Item 2)
[Figure 20-22-7] and head (Item 3) [Figure 20-22-7]
from the rod.
MEL 1074 - O-ring Seal Hook
Spanner Wrench
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.
Figure 20-22-8
3
2
Put the base end of the cylinder in a vise.
1
Use a spanner wrench to loosen the head [Figure 20-226].
P-16295
Piston: Remove the O-ring (Item 1) [Figure 20-22-8], and
seal (Item 2) [Figure 20-22-8] from the piston (Item 3)
[Figure 20-22-8].
20-22-4
863 Bobcat Loader
Service Manual
CYLINDER (POWER BOB-TACH) (CONT’D)
Assembly
Disassembly (Cont’d)
Figure 20-22-10
Figure 20-22-9
4
3
5
2
1
P-7424
N-20611
Use the following tools to assemble the cylinder:
Remove the wiper seal (Item 1) [Figure 20-22-9], and
rod seal (Item 2) [Figure 20-22-9], the back-up washer
(Item 3) [Figure 20-22-9] the thin O-ring (Item 4) [Figure
20-22-9] and the thick O-ring (Item 5) [Figure 20-22-9]
from the head.
MEL1396 - Seal Installation Tool
MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other
damage. Replace any damaged parts.
Always install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic oil during
installation.
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-22-10].
Allow the seal to stretch for 30 seconds before installing it
on the piston.
20-22-5
863 Bobcat Loader
Service Manual
CYLINDER (POWER BOB-TACH) (CONT’D)
Figure 20-22-13
Assembly (Cont’d)
Figure 20-22-11
3
1
2
4
N-20613
Rotate the handles to collapse the rod seal [Figure 2022-13].
P-16295
Piston: Install the O-ring (Item 1) [Figure 20-22-11]and
seal (Item 2) [Figure 20-22-11] on the piston (Item 3)
[Figure 20-22-11].
Figure 20-22-14
NOTE: The piston center hole (Item 4) [Figure 20-2211] has a bevel on one end. The bevel goes
toward the rod.
Figure 20-22-12
P-7425
Install the rod seal in the head [Figure 20-22-14].
Install the wiper seal with the wiper toward the outside of
the head.
N-20612
Install the rod seal on the rod seal tool[Figure 20-22-12].
NOTE: During installation the O-ring side of the seal
must be toward the inside of the cylinder.
20-22-6
863 Bobcat Loader
Service Manual
CYLINDER (POWER BOB-TACH) (CONT’D)
Figure 20-22-16
Assembly (Cont’d)
1
Figure 20-22-15
2
3
4
1
3
2
P-16294
Install the head (Item 1) [Figure 20-22-16], and spacer
(Item 2) [Figure 20-22-16].
P-7422
Install the piston (Item 3) [Figure 20-22-16].
Install the thin O-ring (Item 1) [Figure 20-22-15].
Install the back-up washer (Item 2) [Figure 20-22-15]
and thick O-ring (Item 3) [Figure 20-22-15] into the
groove on the head.
NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the seal kit.
Lift Cylinder: Grease the piston where the nut contacts
the piston, do not get grease on the threads. Install the
new nut (Item 4) [Figure 20-22-16].
Tighten the nut to 90 ft.-lbs. (122 Nm) torque.
Figure 20-22-17
P-16293
Put the base end of the hydraulic cylinder in a vise.
Tighten the head using a spanner wrench [Figure 20-2217].
20-22-7
863 Bobcat Loader
Service Manual
20-22-8
863 Bobcat Loader
Service Manual
MAIN RELIEF VALVE (FOOT CONTROL)
IMPORTANT
Checking The Main Relief Valve At Front Auxiliary
Hydraulics
NOTE: This procedure is the same for 863 and 863 H
in the standard flow mode.
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
The 863H is a single pressure (3000 PSI) system with 2
flow modes. There are 2 pumps with a relief valve for
each pump. Only the standard flow (main relief valve) is
adjustable.
The tool listed will be needed to do the following
procedure:
MEL 10003 - Hydraulic Tester
MEL 10006 - Hydraulic Test Kit
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Turn the key switch to the OFF position, as the engine
stops running, turn the key switch all the way to the left to
release the hydraulic pressure at the front auxiliary quick
couplers.
Figure 20-30-2
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Figure 20-30-1
B-15551
Start the engine and run at low engine idle RPM. Push
the mode switch (Item 1) [Figure 20-30-2] (on the
instrument panel) two times to engage the front auxiliary
hydraulics, the light (Item 2) [Figure 20-30-2]will come
ON.
P-5061
Connect the IN port of the hydraulic tester to the female
quick coupler on the loader [Figure 20-30-1].
Connect the OUT port of the hydraulic tester to the male
quick coupler on the loader [Figure 20-30-1].
20-30-1
863 Bobcat Loader
Service Manual
MAIN RELIEF VALVE (FOOT CONTROL) (CONT’D)
Checking The Main Relief Valve Without Front
Auxiliaries
Checking The Main Relief Valve At Front Auxiliary
Hydraulics (Cont’d)
The tools listed will be needed to do the following
procedure:
Figure 20-30-3
MEL 10003 - Hydraulic Tester
MEL - 10006 - Hydraulic Test Kit
Stop the engine.
Right
Steering
Lever
Control
(Optional)
Left
Steering
Lever
Control
(Optional)
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Figure 20-30-4
1
1
P-2154
P-2152
Push the button (Item 1) [Figure 20-30-3] for fluid
pressure to the quick couplers.
1
Watch the flow meter on the hydraulic tester to make sure
the flow is correct. Increase the engine speed to full
RPM.
There should be 18.0 GPM (68,1 L/min.) free flow (S/N
51444001-514441938) & 20.7 GPM (78,4 L/min.) free
flow (S/N 514441939 & Above). Turn the restrictor
control, on the tester, until the main relief valve opens.
The correct pressure for the main relief is 3000 PSI
(20685 kPa).
CD-15074
Disconnect the hydraulic hoses (Item 1) [Figure 20-30-4]
from the tilt cylinder.
Stop the engine. Replace or adjust the main relief valve.
(See Removal And Installation on Page 20-30-4.)
20-30-2
863 Bobcat Loader
Service Manual
MAIN RELIEF VALVE (FOOT CONTROL ) (CONT’D)
IMPORTANT
Checking The Main Relief Valve Without Front
Auxiliaries (Cont’d)
The hydraulic tester must be in the fully open
position before you start the engine.
Figure 20-30-5
I-2024-0284
Start the engine and run at idle RPM.
Push the tilt pedal at the top (toe) or bottom (heel) until
the hydraulic tester shows the correct fluid flow through
the flow meter.
Increase the engine RPM to maximum.
There should be 18.0 GPM (68,1 L/min.) free flow (S/N
51444001-514441938) & 20 GPM (75,7 L/min.) free flow
(S/N 514441939 & Above).
P-1193
Connect the hydraulic tester to the tilt cylinder hoses
[Figure 20-30-5].
Have a second person in the operator seat, with seat bar
in down position.
Turn the restrictor control, on the tester, to increase the
pressure until the main relief valve opens.
The correct pressure is 3000 PSI (20685 kPa).
Stop the engine.
Replace or adjust the main relief valve. (See Removal
And Installation on Page 20-30-4.)
WARNING
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-1285
20-30-3
863 Bobcat Loader
Service Manual
MAIN RELIEF VALVE (FOOT CONTROL) (CONT’D)
Figure 20-30-7
Removal And Installation
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
2
N-19735
I-2003-0888
Loosen and remove the main relief valve (Item 1) [Figure
20-30-7].
Figure 20-30-6
Installation: Tighten the main relief valve to 35-40 ft.-lbs.
(47-54 Nm) torque.
Figure 20-30-8
1
N-20039
The main relief valve (Item 1) [Figure 20-30-6] is located
at the lower front of the control valve.
CD-15092
Remove the right side motor cover. (See Disassembly on
Page 30-20-4.)
Clean the area around the control valve.
Remove the O-rings and back-up washers from the main
relief valve [Figure 20-30-8].
Clean the main relief valve in clean solvent.
pressure to dry the valve.
Use air
Install new O-rings and backup washers. Install the main
relief valve and tighten [Figure 20-30-6]. Check the
pressure again. (See Checking The Main Relief Valve
Without Front Auxiliaries on Page 20-30-2.)
20-30-4
863 Bobcat Loader
Service Manual
MAIN RELIEF VALVE (FOOT CONTROL) (CONT’D)
Adjustment
If the pressure is not correct, adjust the main relief valve.
Remove the end cap (Item 2) [Figure 20-30-7 on Page
4].
Figure 20-30-9
1
N-19743
Turn the adjusting screw (Item 1) [Figure 20-30-9] in or
out until the pressure is correct. Turning screw in will
increase pressure.
NOTE: If the correct pressure can not be reached,
replace the main relief valve. Check the
pressure setting of the new relief valve.
20-30-5
863 Bobcat Loader
Service Manual
20-30-6
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
Figure 20-40-1
Removal And Installation (S/N 514447863 & Below)
2
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
1
I-2003-0888
N-19669
Disconnect the linkage (Item 1 & 2) [Figure 20-40-1]
from the lift and tilt spools at the control valve.
Figure 20-40-2
1
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
1
1
W-2059-0598
N-19746
Raise the lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
Remove the three hydraulic hoses (Item 1) [Figure 2040-2] from the lift arm by-pass valve.
Stop the engine. Raise the seat bar.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the control panel.
Installation on Page 50-100-1.)
(See Removal And
Clean the area around the control valve.
20-40-1
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-5
Removal And Installation (S/N 514447863 & Below)
(Cont’d)
1
Figure 20-40-3
1
1
2
N-19756
Disconnect the hydraulic hose (Item 1) [Figure 20-40-5]
from the hydraulic pump to the control valve.
1
NOTE: Loosen all hydraulic tubelines that are
connected to the control valve.
N-19754
Disconnect the wire harness connectors (Item 1) [Figure
20-40-3] from the auxiliary solenoids and the lift and tilt
lock solenoids.
Remove the Never Modify tie strap, and disconnect the
wire harness connector (Item 2) [Figure 20-40-3] from
the BICS valve solenoid connector.
Connect a chain to the control valve and support the
valve with an arm hoist.
Figure 20-40-6
Figure 20-40-4
1
1
2
N-19759
At the right side motor cover hole, remove the two control
valve mounting bolts (Item 1) [Figure 20-40-6] from the
back side of the control valve.
N-19755
Remove the case drain hose (Item 1) [Figure 20-40-4]
from the control valve.
Remove the charge pressure sender (Item 2) [Figure 2040-4] from the control valve.
20-40-2
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-9
Removal And Installation (S/N 514447863 & Below)
(Cont’d)
1
Figure 20-40-7
2
2
N-19760
1
Remove tubeline (Item 1) [Figure 20-40-9] from control
valve to hydraulic oil cooler.
Remove the two auxiliary tubelines (Item 2) [Figure 2040-9] from the control valve.
N-19757
Disconnect the hydraulic tubeline (Item 1) [Figure 20-407] from the bottom of the control valve.
Figure 20-40-10
Figure 20-40-8
1
2
1
N-19761
Remove the two tilt tubelines (Item 1) [Figure 20-40-10]
from the control valve.
N-19758
Remove the tubeline mount clamp and bolt (Item 1)
[Figure 20-40-8].
Remove the tubeline from the loader.
Remove the two control valve mount plate mounting bolts
(Item 2) [Figure 20-40-8].
Remove the control valve from the loader.
20-40-3
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Removal And Installation (S/N 514447864 & Above)
Remove the control valve from the loader.
Removal And Installation (S/N 514447863 & Below)
(Cont’d)
Figure 20-40-11
WARNING
1
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
1
N-19762
W-2059-0598
Remove the three lift tubelines (Item 1) [Figure 20-4011] from the control valve.
Raise the lift arms and install an approved lift arm
support device.
Stop the engine. Raise the seat bar.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Drain the hydraulic reservoir. (See Draining The Fluid
Reservoir on Page 20-80-1.)
Remove the control panel.
Installation on Page 50-100-1.)
(See Removal And
Clean around the control valve.
Open rear door.
Remove the loader alternator.
Installation on Page 60-30-3.)
20-40-4
(See Removal And
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-14
Removal And Installation (S/N 514447864 & Above)
(Cont’d)
Figure 20-40-12
1
1
N-23632
At the right fender, remove the two mounting bolts and
nuts (Item 1) [Figure 20-40-14] from the lift arm by-pass
valve.
P-28544
Figure 20-40-15
The fixed end main valve hose assembly (Item 1) [Figure
20-40-12] is connected to a fixed end fitting on the control
valve. The hose is routed to the upright where the hose
is connected to a tee fitting that feeds the base end of
both lift cylinders. The hose can only be removed by
first removing it from the tee fitting located at the rear
of the loader.
1
Cap and plug the hose and fitting.
Figure 20-40-13
P-28561
Disconnect the wire harness connector (Item 1) [Figure
20-40-15] from the charge pressure sender.
1
P-28560
Disconnect the three hoses (Item 1) [Figure 20-40-13]
from the lift arm by-pass valve.
Cap and plug hoses and fittings.
20-40-5
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-18
Removal And Installation (S/N 514447864 & Above)
(Cont’d)
Figure 20-40-16
1
1
1
P-28580
Disconnect the foot control linkage (Item 1) [Figure 2040-18].
Figure 20-40-19
P-28545
Disconnect the wire harness connector (Item 1) [Figure
20-40-16] from auxiliary valve solenoids.
Figure 20-40-17
1
P-28547
Loosen the fixed end main valve hose assembly (Item 1)
[Figure 20-40-19] from the control valve.
1
The hose can be removed from the control valve by
rotating the hose assembly.
P-28563
Disconnect the harness connector (Item 1) [Figure 2040-17] from the BICS™ valve solenoid connector.
Cap the hose and plug the fitting.
20-40-6
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-22
Removal And Installation (S/N 514447864 & Above)
(Cont’d)
Figure 20-40-20
1
1
2
P-26833
At the right side motor cover access hose, remove the
inlet tubeline fitting (Item 1) [Figure 20-40-22] from the
bottom of the control valve.
P-28545
Figure 20-40-23
Remove the auxiliary hose (Item 1) [Figure 20-40-20]
from the control valve to the auxiliary pressure release
accumulator.
Remove the case drain filter hose (Item 2) [Figure 20-4020] from the control valve to the case drain filter.
2
1
Figure 20-40-21
2
3
P-26832
1
At the top of the control valve, remove the tubeline clamp
mount bolt (Item 1) [Figure 20-40-23] and remove the
inlet tubeline (Item 2) [Figure 20-40-23] from the control
valve mount plate.
P-28549
Install a chain hoist (Item 1) [Figure 20-40-21] to the
control valve.
Remove the two control valve mount plate mounting bolts
and nuts (Item 3) [Figure 20-40-23] from the loader
fender.
Disconnect the hydraulic hose (Item 2) [Figure 20-40-21]
that goes from the control valve to the auxiliary pump.
Cap the hose and plug the fitting.
Remove the right side motor cover.
Remove the right rear wheel/tire assembly from the
loader.
Remove the right side pump access cover.
20-40-7
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-26
Removal And Installation (S/N 514447864 & Above)
(Cont’d)
1
Figure 20-40-24
1
P-28552
Disconnect the hydraulic fitting (Item 1) [Figure 20-4026] from the charge pressure sender.
Move the charge pressure sender and hose assembly to
the side to allow clearance for the control valve removal.
P-26831
At the right side pump access hole, remove the two
control valve mounting bolts (Item 1) [Figure 20-40-24]
from the mounting plate.
Figure 20-40-27
Figure 20-40-25
1
2
1
P-28553
Mark all tubelines for correct installation.
P-28551
Disconnect the lift tubeline (Item 1) [Figure 20-40-25]
from the control valve.
Cap and plug the tubeline and fitting.
Remove the two bucket position tubelines (Item 1)
[Figure 20-40-27]. (If so equipped.)
Remove the lift tubeline (Item 2) [Figure 20-40-27] that
goes from control valve to bucket position valve. (If so
equipped.)
Remove the control valve mount bracket from the loader.
20-40-8
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-30
Removal And Installation (S/N 514447864 & Above)
(Cont’d)
Figure 20-40-28
3
1
P-28557
Lower the chain hoist and valve to allow clearance
between valve spool and tubelines.
2
Rotate the valve upward until the valve spools are above
the tubelines [Figure 20-40-30].
P-28554
Disconnect the three auxiliary tubelines that are
connected to the fitting (Item 1) [Figure 20-40-28].
Remove the control valve from the loader.
Remove the fitting from the loader.
Disconnect the tilt tubeline (Item 2) [Figure 20-40-28]
from the fitting on the control valve.
Loosen the bolt on tubeline clamp (Item 3) [Figure 2040-28] this will allow tubeline movement that will aid in
removal and installation.
Figure 20-40-29
1
P-28556
Disconnect the auxiliary tubeline (Item 1) [Figure 20-4029] from the control valve.
Cap and plug the tubeline and fitting.
20-40-9
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-33
BICS™ Valve, Removal And Installation
Remove the control valve (See Removal And Installation
(S/N 514447863 & Below) on Page 20-40-1.)
1
Figure 20-40-31
1
2
1
1
1
1
1
N-20035
1
Remove the four large O-rings (Item 1) [Figure 20-40-33]
and the small O-ring (Item 2) [Figure 20-40-33] from the
top of the control valve.
Install the four large O-rings (Item 1) [Figure 20-40-33]
and the small O-ring (Item 2) [Figure 20-40-33] on top of
the control valve.
N-20033
To remove the BICS™ valve from the control valve,
loosen and remove the six mounting bolts (Item 1)
[Figure 20-40-31].
Figure 20-40-34
Figure 20-40-32
3
6
1
2
5
4
N-18679
Install the six mounting bolts [Figure 20-40-34].
N-20034
Remove the BICS™ valve assembly from the top of the
control valve (Item 1) [Figure 20-40-32].
The See BICS™ Valve, Removal And Installation
(Cont’d) on Page 20-40-11 lists the correct torque
specifications and tightening sequence when reinstalling
the BICS™ valve assembly to the control valve.
Thoroughly clean and dry bolts and threads in valve. Use
liquid adhesive LOCTITE #242 or equivalent.
20-40-10
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-36
BICS™ Valve, Removal And Installation (Cont’d)
Step
1
2
3*
Torque
110-130 in.-lbs.
(12,4-14,7 Nm)
190-210 in.-lbs.
(21,5-23,7 Nm)
190-210 in.-lbs.
(21,5-23,7 Nm)
Sequence
1, 2, 3, 4, 5 & 6
1
*Torque must be 190-210 in.-lbs. (21,5-23,7 Nm) for ever
bolt or repeat step 3.
BICS™ Valve, Lift arm By-Pass Orifice Disassembly
And Assembly
N-20041
Figure 20-40-37
Figure 20-40-35
1
1
N-18685
N-20040
Remove the fitting (Item 1) [Figure 20-40-35] from the
valve.
Using a flat blade screw driver, remove the lift arm bypass orifice (Item 1) [Figure 20-40-36] & [Figure 20-4037].
Orifice size is 0.078 inch.
Reverse the removal procedure to install the lift arm bypass orifice.
20-40-11
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-40
BICS™ Valve, Check Valve Disassembly And
Assembly (S/N 514450007 & Below)
1
Figure 20-40-38
P-8956
Clean and inspect the screen (Item 1) [Figure 20-40-40]
on the end of the valve.
1
N-20037
Remove the check valve (Item 1) [Figure 20-40-38].
Installation: Tighten the valve to 20 ft.-lbs. (27 Nm)
torque.
Figure 20-40-39
2
1
N-18684
Remove the O-rings (Item 1) [Figure 20-40-39] and
back-up ring (Item 2) [Figure 20-40-39] from the check
valve.
Install new O-rings and back-up ring on the check valve.
The check valve has a rating of 5-10 PSI.
20-40-12
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-43
BICS™ Valve, Check Valve Disassembly And
Assembly (514450007 & Above)
Figure 20-40-41
1
P-37710
Remove the 90° fitting (Item 1) [Figure 20-40-43] out of
the control valve.
2
1
Figure 20-40-44
P-37712
Remove the tubeline (Item 1) and the check valve (Item
2) [Figure 20-40-41].
2
1
Installation: Tighten the valve to 20 ft.-lbs. (27 Nm)
torque.
Figure 20-40-42
1
P-37721
2
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-40-44] from the fitting.
Install new O-rings and back-up ring on the check valve.
P-37706
Clean and inspect the screen (Item 1) and replace the oring (Item 2) [Figure 20-40-42] on the check valve.
20-40-13
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Installation: Tighten the lock valves to 25 ft.-lbs. (34 Nm)
torque.
BICS™ Valve, Lock Valve Disassembly And
Assembly
Figure 20-40-48
1
Figure 20-40-45
1
1
1
2
2
2
N-18690
N-20033
Remove the O-rings (Item 1) [Figure 20-40-48] and
back-up rings (Item 2) [Figure 20-40-48] from both the tilt
and lift lock valves.
Figure 20-40-46
Install new O-rings (Item 1) [Figure 20-40-48] and backup rings (Item 2) [Figure 20-40-48] on the tilt and lift lock
valves.
Reverse the removal procedure to install the lock valve.
1
N-20039
Figure 20-40-47
1
N-20040
Remove the lock valves (Item 1) [Figure 20-40-45],
[Figure 20-40-46] & [Figure 20-40-47] from the BICS™
valve.
20-40-14
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-51
BICS™ Valve, Solenoid Disassembly And Assembly
1
Figure 20-40-49
1
2
N-20038
Remove the solenoid stem (Item 1) [Figure 20-40-51].
Installation: tighten the solenoid stem to 20 ft.-lbs. (27
Nm) torque.
N-20037
Remove the mounting nut (Item 1) [Figure 20-40-49]
from the solenoid cartridge.
Figure 20-40-52
Installation: Tighten the mounting nut to 53 in.-lbs. (6
Nm) torque.
2
Remove the solenoid (Item 2) [Figure 20-40-49].
3
NOTE: The solenoid resistance is (8-10 ohms).
Figure 20-40-50
1
1
1
N-18694
Remove the O-rings (Item 1) [Figure 20-40-52] and
back-up washers (Item 2) [Figure 20-40-52] on the stem.
Clean all parts in solvent and dry with compressed air.
Inspect all parts for wear and replace any part showing
excessive wear.
N-18693
Remove the O-rings (Item 1) [Figure 20-40-50] form both
ends of the solenoid.
NOTE: The screen (Item 3) [Figure 20-40-52] may be
cleaned with solvent. If it is torn or worn
replace the solenoid stem.
Use only new O-rings and apply oil to all O-rings and
back-up washers before installation.
Install new O-rings and new back-up washers on the
solenoid stem.
20-40-15
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Identification Chart
BICS™ Valve, Solenoid Testing
Figure 20-40-53
P-9175
Use a test meter to measure the coil resistance [Figure
20-40-53]. Coil wires do not have polarity. Correct
resistance for the auxiliary pressure relief (small) coil is 710 ohm and the other coils 5-8 ohms.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
Item
A1
A2
A3
B1
B2
B3
C1
C2
C3
C4
D1
D2
D3
E1
E2
F1
F2
G1
G2
G3
H1
H2
H3
H4
H5
MR
863 Loader
Lift Cylinder Base End/Restrictor
Tilt Cylinder Base End
Auxiliary Hydraulics
Lift Cylinder Rod End
Tilt Cylinder Rod End
Auxiliary Hydraulics
Load Check Valve/Lift Function
Load Check Valve/Tilt Function
Orifice Load Check Valve/Auxiliary Function
Outlet Fluid Flow
Lift Spool Detent
Tilt Spool Centering Spring
Auxiliary Spool/Centering Springs
Port Relief Valve - 3500 PSI
Anti-Cavitation/Port Relief Valve - 2500 PSI
Anti-Cavitation Valve
Port Relief Valve - 3500 PSI
Lift Spool End
Tilt Spool End
Auxiliary Electric Solenoid
Auxiliary Electric Solenoid
Plug/Port Relief (Optional) - 3500 PSI
Auxiliary Electric Solenoid
Lift Lock Solenoid
Tilt Lock Solenoid
Main Relief Valve - 3000 PSI
H2
H1
H3
C4
G3
H5
B3
G2
F2
G1
B2
F1
MR
20-40-16
H4
A3
C3
C2
B1
D3
A2 E2
D2
A1 E1
C1
D1
TS-1971
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-55
Load Check Valve
Remove the BICS valve assembly from the control valve.
(See Removal And Installation (S/N 514447864 & Above)
on Page 20-40-4.)
2
Figure 20-40-54
1
1
1
1
N-18698
1
Loosen the load check plugs (Item 1) [Figure 20-40-55]
from the lift and tilt sections of the control valve.
2
Installation: Always use new O-ring. Tighten the plug to
35-40 ft.-lbs. (47-54 Nm) torque.
Figure 20-40-56
N-20035
Remove the four large O-rings (Item 1) [Figure 20-40-54]
and small O-ring (Item 2) [Figure 20-40-54]. Always
replace these O-rings before installing the BICS valve
assembly.
3
IMPORTANT
1
2
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
N-20077
I-2003-0888
Remove the load check plugs (Item 1) [Figure 20-40-56].
Mark each valve section, spool and related parts so that
they will be returned to its original valve section during
assembly.
Remove the spring (Item 2) [Figure 20-40-56] and
poppet (Item 3) [Figure 20-40-56].
Use bolts to fasten the control valve to a work bench for
easier disassembly and assembly procedures.
NOTE: Both load checks poppets, plugs and springs
are the same for the lift and tilt.
Loosen the load check plug (Item 2) [Figure 20-40-55]
from the auxiliary section of the control valve.
20-40-17
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Main Relief Valve
Figure 20-40-58
Load Check Valve (Cont’d)
Figure 20-40-57
1
N-20039
1
Loosen and remove the main relief valve (Item 1) [Figure
20-40-58].
N-20078
The auxiliary section uses a load check poppet with an
orifice (Item 1) [Figure 20-40-57].
NOTE:
Figure 20-40-59
2
For correct port locations and valve
component See Identification Chart on Page
20-40-16.
3
4
5
1
B-6764
1. Relief Valve
2. O-Ring
3. Sleeve
4. Glide Ring
5. O-Ring
CD-15092
Remove the O-rings, sleeve, and glide ring from the main
relief valve [Figure 20-40-59].
Installation: Always use new O-rings, sleeve and glide
ring. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
20-40-18
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Port Relief Valve, Lift Spool
Figure 20-40-62
Port Relief Valve, Tilt Spool
Figure 20-40-60
1
1
N-20040
Remove the port relief valve (Item 1) [Figure 20-40-62]
from the control valve lift section.
N-20043
Remove the port relief valve (Item 1) [Figure 20-40-60]
from the control valve tilt section.
Figure 20-40-63
Figure 20-40-61
3
3
1
4
1
4
2
2
1. O-Ring
2. Back-up Washer
3. O-Ring
4. Relief Valve
1. O-Ring
2. Back-up Washer
3. O-Ring
4. Relief Valve
N-18844
Remove the O-rings and back-up washer from the port
relief valve [Figure 20-40-63].
N-18844
Remove the O-rings and back-up washer from the port
relief valve [Figure 20-40-61].
Installation: Always use new O-rings and back-up
washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
Installation: Always use new O-rings and back-up
washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
20-40-19
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Anti-Cavitation Valve, Lift Spool
Figure 20-40-66
Anti-Cavitation Valve/Port Relief Valve, Tilt Spool
Figure 20-40-64
2
1
1
N-20043
Remove the lift lock solenoid (Item 1) [Figure 20-40-66].
N-20042
Remove the anti-cavitation/port relief valve (Item 1)
[Figure 20-40-64] from the control valve tilt section.
Remove the anti-cavitation valve (Item 2) [Figure 20-4066] from the control valve lift section.
Figure 20-40-67
Figure 20-40-65
1
2
3
4
1
E-1509
1. Anti-Cavitation Valve
2. O-Ring
3. Back-Up Washer
4. O-Ring
N-18839
N-18843
Remove the O-rings (Item 1) [Figure 20-40-65] from the
anti-cavitation/port relief valve.
Remove the O-rings and back-up washer from the anticavitation valve [Figure 20-40-67].
Installation: Always use new O-rings and back-up
washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
20-40-20
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Lift And Tilt Block
Figure 20-40-70
Rubber Boot
Figure 20-40-68
1
1
1
2
N-20043
Figure 20-40-71
N-20043
Remove the two screws (Item 1) [Figure 20-40-68] on
the rubber boot retainer.
1
Installation: Tighten the screws to 90-100 in.-lbs. (10,211,3 Nm) torque.
Figure 20-40-69
1
2
2
2
N-20021
2
1
Remove the lock solenoid (Item 1) [Figure 20-40-70] &
[Figure 20-40-71] from the lift and tilt block.
1
Remove the rubber boot (Item 2) [Figure 20-40-70] &
[Figure 20-40-71]. (See Identification Chart on Page 2040-16.)
N-20020
Remove the rubber boot (Item 1) [Figure 20-40-69] and
retainer (Item 2) [Figure 20-40-69].
20-40-21
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Lift Spool And Detent
The tool listed will be needed to do the following
procedure:\
Lift And Tilt Lock Block (Cont’d)
Figure 20-40-72
MEL1278 - Detent Tool
MEL1285 - Detent Spring Tool
Figure 20-40-73
1
N-20022
Remove the lift and tilt block [Figure 20-40-72].
N-20022
The lock must be clean and oil free. (Oil can cause the
solenoids not to function properly.)
Remove the lift and tilt lock block (Item 1) [Figure 20-4073] from the control valve. (See Lift And Tilt Block on
Page 20-40-21.)
Figure 20-40-74
1
2
N-20023
Remove the bushing (Item 1) [Figure 20-40-74] and Oring (Item 2) [Figure 20-40-74] from the lift spool.
20-40-22
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-77
Lift Spool And Detent (Cont’d)
Figure 20-40-75
1
2
1
N-18972
1
Remove the screws (Item 1) [Figure 20-40-77] from the
detent bonnet.
N-20040
Remove the detent bonnet (Item 2) [Figure 20-40-77].
Remove the end cap (Item 1) [Figure 20-40-75].
IMPORTANT
Figure 20-40-76
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
1
Figure 20-40-78
2
N-18971
Use a screwdriver to remove the snap ring (Item 1)
[Figure 20-40-76].
Remove the washer (Item 2) [Figure 20-40-76].
N-18973
Put a rag around the detent assembly [Figure 20-40-78].
This will prevent the detent balls and spring from being
lost when the detent sleeve is removed.
20-40-23
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-81
Lift Spool And Detent (Cont’d)
Figure 20-40-79
3
2
1
1
N-18930
Remove the spool seal (Item 1) [Figure 20-40-81] from
the linkage end of the valve.
2
N-18974
Figure 20-40-82
Remove the detent sleeve (Item 1) [Figure 20-40-79],
detent balls (Item 2) [Figure 20-40-79] and spring (Item
3) [Figure 20-40-79].
Figure 20-40-80
P-8988
Clamp the linkage end of the spool in a vise [Figure 2040-82].
1
N-18975
Remove the spool assembly and seal (Item 1) [Figure
20-40-80] from the control valve.
20-40-24
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-85
Lift Spool And Detent (Cont’d)
1
Figure 20-40-83
2
1
3
N-19004
Remove the detent adapter (Item 1) [Figure 20-40-85]
from the spring assembly.
N-18915
Figure 20-40-86
Install the spring tool (Item 1) [Figure 20-40-83] over the
centering spring.
1
NOTE: Be careful when removing the detent adapter
(Item 2) [Figure 20-40-83] from the centering
spring, as it is under spring pressure.
NOTE: The centering spring (Item 3) [Figure 20-40-83]
is orange on all 800 series loaders.
Figure 20-40-84
N-19009
Remove the spring tool (Item 1) [Figure 20-40-86] from
the spring assembly.
2
1
N-18916
Put a rag around to detent assembly [Figure 20-40-84].
This will prevent the detent balls and spring from being
lost when the detent adapter is removed.
Remove the detent adapter with and allen wrench.
Remove the back-up washer (Item 1) [Figure 20-40-84]
and spool seal (Item 2) [Figure 20-40-84].
20-40-25
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-89
Lift Spool And Detent (Cont’d)
Figure 20-40-87
2
1
3
4
1
N-18920
Turn a 6-32 tap (Item 1) [Figure 20-40-89] into the plug.
Pull the tap and plug out of the spool. Be careful, do not
break the tap.
N-18919
Inspect the adapter (Item 1) [Figure 20-40-87], collar
(Item 2) [Figure 20-40-87], spring (Item 3) [Figure 2040-87] and washer (Item 4) [Figure 20-40-87].
Figure 20-40-88
Clean all the debris from inside the spool bore.
NOTE: DO NOT USE LOCTITE ON THE STUD
THREADS
Figure 20-40-90
2
1
N-18918
N-18961
Remove the stud from the end of the spool [Figure 2040-88].
Install the O-ring (Item 1) [Figure 20-40-90] over the
nipple on the plastic plug (Item 2) [Figure 20-40-90].
Removal of the plastic plug:
Make a center point in the plug using a 1/16 inch drill.
Drill a hole all the way through the plug using a 7/64 inch
tap drill.
20-40-26
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-93
Lift Spool And Detent (Cont’d)
Figure 20-40-91
1
N-18967
Clamp the collar (Item 1) [Figure 20-40-93] in a vise.
Figure 20-40-94
N-18963
Install the plastic plug and O-ring in the spool [Figure 2040-91].
2
Figure 20-40-92
O-ring
1
3
2
N-18958
Plastic
Plug
Apply grease on all the detent component surfaces
before assembly [Figure 20-40-94].
0.60 inch
(15,2 mm)
B-14712
Install the stud and tighten until the other end of the stud
is out about 0.600 inch (15,2 mm) from the spool [Figure
20-40-92].
Install the spring (Item 1) [Figure 20-40-94] and detent
balls (Item 2) [Figure 20-40-94] into the adapter (Item 3)
[Figure 20-40-94] and compress with the detent pliers
(Item 1) [Figure 20-40-95 on Page 28].
20-40-27
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-97
Lift Spool And Detent (Cont’d)
Figure 20-40-95
2
1
N-18917
1
Install the spool seal (Item 1) [Figure 20-40-97] and
back-up washer (Item 2) [Figure 20-40-97].
N-18968
Figure 20-40-98
Install the detent adapter to the collar [Figure 20-40-95].
NOTE: The collar and the detent adapter are held
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.
1
Figure 20-40-96
N-19005
1
Install the spring assembly to the lift spool hand tight
[Figure 20-40-98].
Remove the spring tool.
Check the alignment of the detent adapter and the
washer.
N-19004
Tighten the adapter to 90-100 in.-lbs. (10,2-11,3 Nm).
Install the spring tool (Item 1) [Figure 20-40-96] over the
washer, spring, collar and detent adapter.
NOTE: The adapter must fit in the center of the washer
(Item 1) [Figure 20-40-98].
20-40-28
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-101
Lift Spool And Detent (Cont’d)
Figure 20-40-99
1
N-19008
Install the detent sleeve (Item 1) [Figure 20-40-101] to
the detent adapter.
CD-15051
Figure 20-40-102
Install the detent balls and spring [Figure 20-40-99].
Figure 20-40-100
2
1
2
N-18972
Install the lift spool assembly in the spool bore [Figure
20-40-102].
N-19007
Hold the detent balls in place with the detent pliers
[Figure 20-40-100].
Install the detent bonnet (Item 1) [Figure 20-40-102].
Install the mounting screws (Item 2) [Figure 20-40-102].
Installation: Tighten the screws to 90-100 in.-lbs. (10,211,3 Nm) torque.
20-40-29
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-105
Lift Spool And Detent (Cont’d)
Figure 20-40-103
1
2
N-18930
1
Install the spool seal (Item 1) [Figure 20-40-105] on the
linkage end of the valve.
N-18971
Figure 20-40-106
Install the washer (Item 1) [Figure 20-40-103] and snap
ring (Item 2) [Figure 20-40-103].
Figure 20-40-104
1
2
N-18927
1
N-20040
Install the bushing (Item 1) [Figure 20-40-106] and Oring (Item 2) [Figure 20-40-106] on the linkage end of the
lift spool.
Install the end cap (Item 1) [Figure 20-40-104].
20-40-30
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Tilt Spool Removal And Installation
Figure 20-40-108
Lift Spool And Detent (Cont’d)
Figure 20-40-107
1
N-20022
1
N-20022
Install the lift and tilt block (Item 1) [Figure 20-40-107].
(See Lift And Tilt Block on Page 20-40-21.)
Remove the lift and tilt block (Item 1) [Figure 20-40-108]
from the control valve. (See Lift And Tilt Block on Page
20-40-21.)
Figure 20-40-109
1
2
N-20024
Remove the bushing (Item 1) [Figure 20-40-109] and Oring (Item 2) [Figure 20-40-109] from the tilt spool.
20-40-31
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-112
Tilt Spool Removal And Installation (Cont’d)
1
Figure 20-40-110
1
N-18942
Put the linkage end of the spool in the vise [Figure 2040-112].
N-20042
Remove the screws (Item 1) [Figure 20-40-110] from the
end cap.
Install the spool tool (Item 1) [Figure 20-40-112] over the
centering spring.
Figure 20-40-113
Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3
Nm) torque.
1
Figure 20-40-111
N-19014
Remove the bolt (Item 1) [Figure 20-40-113] holding the
centering spring to the spool.
N-18816
Remove the spool, centering spring, back-up washer and
spool seal [Figure 20-40-111].
Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3
Nm) torque.
Remove spring tool from the spring assembly.
Assembly: Always use a new spool seal.
20-40-32
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Auxiliary Spool Removal And Installation
Figure 20-40-116
Tilt Spool Removal And Instalaltion (Cont’d)
Figure 20-40-114
2
1
3
4
1
N-20042
Remove the screws (Item 1) [Figure 20-40-116] from the
end cap.
N-18944
Inspect the adapter (Item 1) [Figure 20-40-114], collar
(Item 2) [Figure 20-40-114], spring (Item 3) [Figure 2040-114] and washer (Item 4) [Figure 20-40-114].
Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3
Nm) torque.
Figure 20-40-117
Figure 20-40-115
1
2
1
N-18990
N-19098
N-18943
Remove the spool seal(s) (Item 1) [Figure 20-40-115]
and the back-up washer (Item 2) [Figure 20-40-115].
Assembly: Always use a new spool seal.
Remove the end cap, O-ring, springs and spring guide
[Figure 20-40-117].
Assembly: Always use a new spool seal.
20-40-33
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-120
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-40-118
1
2
1
N-20073
Remove the screws (Item 1) [Figure 20-40-120] from the
auxiliary bleed block (Item 2) [Figure 20-40-120].
N-18989
Installation: Tighten the bolt to 90-100 in.-lbs. (10,211,3 Nm) torque.
Remove the spool (Item 1) [Figure 20-40-118].
Assembly: Put grease on all the centering spring
component parts.
Figure 20-40-121
1
Figure 20-40-119
1
N-20074
Remove the auxiliary bleed block (Item 1) [Figure 20-40121] and O-ring.
N-20043
Remove the lock solenoid (Item 1) [Figure 20-40-119]
from the tilt lock block.
Assembly: Always use a new O-ring.
20-40-34
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Auxiliary Plug Removal And Installation
Figure 20-40-123
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-40-122
1
3
1
P-37717
2
Remove the plug (Item 1) [Figure 20-40-123] auxiliary
section of the control valve.
N-20075
Remove the spring guide (Item 1) [Figure 20-40-122]
and springs (Item 2) [Figure 20-40-122].
Figure 20-40-124
Remove the spool (Item 3) [Figure 20-40-122].
Assembly: Put grease on all the centering spring
component parts.
1
P-37718
Replace the O-rings (Item 1) [Figure 20-40-124].
20-40-35
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Figure 20-40-127
Auxiliary Electric Solenoid Disassembly
Figure 20-40-125
3
2
1
1
N-20027
Remove the coil (Item 1) [Figure 20-40-127] and end
plate (Item 2) [Figure 20-40-127].
1
N-20025
Remove the solenoid stem (Item 3) [Figure 20-40-127].
Remove the nut (Item 1) [Figure 20-40-125] from both
solenoids.
Installation: Tighten the nut to 8-12 ft.-lbs. (11-16 Nm)
torque.
Installation: Tighten valve to 8-12 ft.-lbs. (11-16 Nm)
torque.
Figure 20-40-128
Figure 20-40-126
1
2
1
N-18795
Remove the O-rings (Item 1) [Figure 20-40-128] from the
solenoid stem.
N-20026
Remove the end plate (Item 1) [Figure 20-40-126] and
housing (Item 2) [Figure 20-40-126].
20-40-36
863 Bobcat Loader
Service Manual
HYDRAULIC VALVE CONTROL (FOOT CONTROL)
(CONT’D)
Figure 20-40-130
Plug
Port Relief-Auxiliary Section Disassembly
Figure 20-40-129
2
1
1
1
N-18800
Figure 20-40-131
N-20031
Port Relief (Optional)
Remove the plug (Item 1) [Figure 20-40-129] or optional
port relief valve from the control valve.
1
2
NOTE: Optional port relief (Item 1) [Figure 20-40-129]
is 3500 PSI (24129 kPa).
1
N-18843
Remove the O-rings (Item 1) [Figure 20-40-130] &
[Figure 20-40-131] and back-up ring (Item 2) [Figure 2040-130] & [Figure 20-40-131] from the plug.
20-40-37
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Cleaning And Inspection
Clean all components with clean solvent and dry with
compressed air.
Check the spools for wear or scratches.
Check that the spools are not loose in their bore.
Check that the centering springs are not broken.
Check that the load check valve seats are not worn.
Check the load check poppets for damage.
Check the rubber boots and retainers.
Replace the parts as needed.
Use New O-rings and back-up rings.
Apply oil to all new O-rings and back-up rings before
installation.
20-40-38
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM) (ACS)
Figure 20-41-2
Description
the Advanced Control System (ACS) includes the
Advanced Hand Control (AHC) and/or the Selectable
Hand/Foot Control Systems.
Actuator Removal And Installation (In Loader)
2
1
Raise the lift arms and install and approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
P-26842
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Remove the screws (Item 1) [Figure 20-41-2] from the
actuator retainer.
Installation: Tighten the bolts to 90-100 in.-lbs. (10,211,3 Nm) torque.
Figure 20-41-3
Figure 20-41-1
1
2
1
P-26819
Pull the actuator (Item 1) [Figure 20-41-3] away from the
control valve.
N-23246
Stop the engine. Raise the seat bar.
Remove the access cover (Item 1) [Figure 20-41-1] from
the right side of the loader frame.
Use a punch and hammer to remove the actuator pin
(Item 2) [Figure 20-41-3] from the actuator and spool.
Remove the actuator from the hydraulic control valve.
20-41-1
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-6
Actuator Removal And Installation (In Loader)
(Cont’d)
Figure 20-41-4
1
1
P-28621A
Check and replace the O-ring (Item 1) [Figure 20-41-6]
on the control valve housing.
P-26820
Remove the spacer (Item 1) [Figure 20-41-4].
Figure 20-41-5
1
P-28622A
Check and replace the O-ring (Item 1) [Figure 20-41-5]
on the spacer.
20-41-2
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Loosen the tubeline clamps (Item 1) [Figure 20-41-7] at
the engine compartment.
Removal & Installation (S/N 514447863 & Below)
Clean the area around the control valve.
Figure 20-41-8
1
WARNING
1
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Raise the lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
N-23630
Disconnect the three hoses (Item 1) [Figure 20-41-8]
from the lift arm by-pass control valve.
Figure 20-41-9
Stop the engine. Raise the seat bar.
1
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Drain the hydraulic reservoir. (See Draining The Fluid
Reservoir on Page 20-80-1.)
Remove the control panel.
Installation on Page 50-100-1.)
(See Removal And
Figure 20-41-7
N-23632
At the right fender, remove the two mounting bolts (Item
1) [Figure 20-41-9].
Remove the lift arm by-pass valve and mount from the
loader.
1
N-19865
20-41-3
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-12
Removal And Installation (S/N 514447863 & Below)
(Cont’d)
Figure 20-41-10
2
1
1
N-23636
Disconnect both harness connectors (Item 1) [Figure 2041-12] from the actuators.
Figure 20-41-13
N-23631
Disconnect the wiring harness connectors (Item 1)
[Figure 20-41-10] from the auxiliary solenoids
connectors.
Disconnect the wire harness connector (Item 2) [Figure
20-41-10] from the BICS™ valve solenoid connector.
Figure 20-41-11
1
N-23637
1
Disconnect the case drain hose (Item 1) [Figure 20-4113].
2
N-23635
Disconnect the harness connector (Item 1) [Figure 2041-11] from the auxiliary solenoid.
Disconnect the harness connector (Item 2) [Figure 2041-11] from the BICS™ valve solenoid connector.
20-41-4
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-16
Removal And Installation (S/N 514447863 & Below)
(Cont’d)
Figure 20-41-14
1
1
2
3
1
N-23639
Remove the rod end tilt cylinder tubeline (Item 1) [Figure
20-41-16] and (Item 2) [Figure 20-41-16] if equipped.
Remove the rod end lift cylinder tubeline (Item 3) [Figure
20-41-16].
N-23634
Remove the two tubelines clamps (Item 1) [Figure 2041-14].
Figure 20-41-17
Figure 20-41-15
1
3
2
2
1
2
3
4
N-23640
N-23638
Remove the hydraulic tubeline (Item 1) [Figure 20-41-15]
from the control valve to the oil cooler.
Remove the two auxiliary tubelines (Item 2) [Figure 2041-15] from the control valve.
Remove the base end tilt cylinder tubeline (Item 1)
[Figure 20-41-17] and (Item 2) [Figure 20-41-17] if
equipped.
Remove the base end lift cylinder tubeline (Item 3)
[Figure 20-41-17] and (Item 4) [Figure 20-41-17] if
equipped.
Remove the charge pressure hose and sending unit
(Item 3) [Figure 20-41-15].
20-41-5
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-20
Removal And Installation (S/N 514447863 & Below)
(Cont’d)
Figure 20-41-18
1
1
N-23633
At the right fender, remove the two control valve mount
bracket mounting bolts (Item 1) [Figure 20-41-20].
Remove the control valve mount bracket from the loader.
N-23641
Disconnect the inlet hose (Item 1) [Figure 20-41-18] that
comes from the pump.
Figure 20-41-21
Figure 20-41-19
1
N-23643
Remove the control valve from the loader [Figure 20-4121].
N-23642
Install a chain hoist to the control valve for support
[Figure 20-41-19].
20-41-6
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-22
Removal And Installation (S/N 514447864 & Above)
1
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Raise the lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
P-28544
The fixed end main valve hose assembly (Item 1) [Figure
20-41-22] is connected to a fixed end fitting on the control
valve. The hose is routed to the back upright where the
hose is connected to a tee fitting that feeds the base end
of both lift cylinders. The hose can only be removed
from the tee fitting located and the rear of the loader
first.
Cap and plug the hose and fitting.
Figure 20-41-23
Stop the engine. Raise the seat bar.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
1
Drain the hydraulic reservoir. (See Draining The Fluid
Reservoir on Page 20-80-1.)
Remove the control panel.
Installation on Page 50-100-1.)
(See Removal And
1
1
Clean the area around the control valve.
Open the rear door.
Remove the loader alternator.
Installation on Page 60-30-3.)
P-26823
(See Removal And
Disconnect the three hoses (Item 1) [Figure 20-41-23]
from the lift arm by-pass control valve.
Cap and plug the hoses and fittings.
20-41-7
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-26
Removal And Installation (S/N 514447864 & Above)
(Cont’d)
1
1
Figure 20-41-24
1
P-28545
Disconnect the wire harness connector (Item 1) [Figure
20-41-26] from the auxiliary valve solenoids.
Figure 20-41-27
N-23632
At the right fender, remove the two mounting bolts and
nuts (Item 1) [Figure 20-41-24] from the lift arm by-pass
mount.
Remove the lift arm by-pass valve and mount from the
loader.
Figure 20-41-25
1
1
N-23635
Disconnect the harness connector (Item 1) [Figure 2041-27] from the BICS valve solenoid connector.
P-26824
Disconnect the wire harness connector (Item 1) [Figure
20-41-25] from the charge pressure sender.
20-41-8
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-30
Removal And Installation (S/N 514447864 & Above)
(Cont’d)
1
Figure 20-41-28
2
1
P-28545
Remove the hydraulic hose (Item 1) [Figure 20-41-30]
from the control valve to the auxiliary pressure release
accumulator.
P-26826
Disconnect both harness connectors (Item 1) [Figure 2041-28] from the actuators.
Remove the case drain hose (Item 2) [Figure 20-41-30]
from the control valve to the case drain filter.
Figure 20-41-31
Figure 20-41-29
2
1
1
P-28549
P-26828
Loosen the fixed end main valve hose assembly (Item 1)
[Figure 20-41-29] from the control valve.
The hose can be removed from the control valve by
rotating the hose assembly.
Cap the hose and plug the fitting.
Install a chain hoist (Item 1) [Figure 20-41-31] to the
control valve.
Disconnect the hydraulic hose (Item 2) [Figure 20-41-31]
that goes from the control valve to the auxiliary gear
pump.
Cap the hose and plug the fitting.
Remove the right side motor cover.
Remove the right rear wheel/tire assembly from the
loader.
Remove the right side pump access cover.
20-41-9
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-34
Removal And Installation (S/N 514447864 & Above)
(Cont’d)
Figure 20-41-32
1
1
P-26831
At the right side pump access cover hole, remove the two
control valve mount bolts (Item 1) [Figure 20-41-34] from
the mounting plate.
P-26833
Figure 20-41-35
At the right side motor cover access hole, remove the
inlet tubeline fitting (Item 1) [Figure 20-41-32] from the
bottom of the control valve.
Figure 20-41-33
1
2
1
P-26834
3
Disconnect the lift tubeline (Item 1) [Figure 20-41-35]
from the control valve.
Cap and plug the tubeline and fitting.
P-26832
At the top of the control valve, remove the tubeline clamp
mount bolt (Item 1) [Figure 20-41-33] and remove the
inlet tubeline (Item 2) [Figure 20-41-33] from the control
valve mount plate.
Remove the control valve mount bracket from the loader.
Remove the two control valve mount plate mounting bolts
and nuts (Item 3) [Figure 20-41-33] from the loader
fender.
20-41-10
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-38
Removal And Installation (S/N 514447864 & Above)
(Cont’d)
2
Figure 20-41-36
1
1
P-26837
Disconnect the three auxiliary tubelines that are
connected to the fitting (Item 1) [Figure 20-41-38].
Remove the fitting from the loader.
P-28547
Disconnect the hydraulic fitting (Item 1) [Figure 20-4136] from the charge pressure sender.
Move the charge pressure sender and hose assembly to
the side, to allow clearance for the control valve removal.
Disconnect the tilt tubeline (Item 2) [Figure 20-41-38]
from the fitting on the control valve.
Figure 20-41-39
Mark all tubelines for correct installation.
Figure 20-41-37
1
1
1
P-26838
Remove the lift tubeline (Item 1) [Figure 20-41-39] that
goes from the control valve to the bucket position valve.
(If so equipped.)
P-26836
Remove the two bucket position tubelines (Item 1)
[Figure 20-41-37]. (If so equipped.)
20-41-11
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Actuator Removal And Installation (Out Of Loader)
Figure 20-41-42
Removal And Installation (S/N 514447864 & Above)
(Cont’d)
Figure 20-41-40
2
1
1
P-28319
1
Remove the two screws (Item 1) [Figure 20-41-42] on
the actuator retainer.
P-26839
Disconnect the auxiliary tubeline (Item 1) [Figure 20-4140] from the control valve.
Installation: Tighten the bolt and nut to 90-100 in.-lbs.
(10,2-11,3 Nm) torque.
Cap and plug the tubeline and fitting.
Pull the actuator (Item 2) [Figure 20-41-42] away the
control valve.
Figure 20-41-41
Figure 20-41-43
1
P-26840
P-28320
Lower the chain hoist and valve to allow clearance so the
actuators can clear the tubelines.
Rotate the valve upward until the actuators are above the
tubelines [Figure 20-41-41].
Use a drift pin and hammer to remove the actuator pin
(Item 1) [Figure 20-41-43] from the actuator and the lift
or tilt spool.
Remove the control valve from the loader.
20-41-12
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
BICS™ Valve Removal And Installation
Actuator Removal And Installation (Out Of Loader)
(Cont’d)
Figure 20-41-45
Figure 20-41-44
1
1
1
P-28322
2
4
3
P-28321
Remove the actuator (Item 1) [Figure 20-41-44].
Remove the O-ring (Item 2) [Figure 20-41-44].
Loosen the six mounting bolts (Item 1) [Figure 20-41-45]
from the BICS valve.
Remove the mounting bolts.
Figure 20-41-46
Remove the spacer block (Item 3) [Figure 20-41-44].
Remove the O-ring (Item 4) [Figure 20-41-44].
P-28323
Remove the BICS valve assembly (Item 1) [Figure 2041-46] from the top of the control valve.
20-41-13
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
The chart below lists the correct torque specifications
and tightening sequence when reinstalling the BICS™
valve assembly to the hydraulic control valve.
Thoroughly clean and dry bolts and threads in valve. Use
liquid adhesive LOCTITE #242.
BICS™ Valve Removal And Installation (Cont’d)
Figure 20-41-47
Step
1
2
3*
1
1
Torque
110-130 in.-lbs.
(12,4-14,7 Nm)
190-210 in.-lbs.
(21,5-23,7 Nm)
190-210 in.-lbs.
(21,5-23,7 Nm)
Sequence
1, 2, 3, 4, 5 & 6
*Torque must be 190-210 in.-lbs. (21,5-23,7 Nm) for
every bolt or repeat step 3.
2
P-28324
Replace the four large O-rings (Item 1) [Figure 20-41-47]
and small O-ring (Item 2) [Figure 20-41-47] from the top
of the control valve.
Figure 20-41-48
3
6
2
1
5
4
P-28322
Install the six mounting bolts (Item 1) [Figure 20-41-48].
20-41-14
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-51
BICS™ Valve Lift Arm By-Pass Orifice Removal And
Installation
Figure 20-41-49
1
1
N-18685
Using a flat blade screwdriver, remove the lift arm bypass orifice (Item 1) [Figure 20-41-50] & [Figure 20-4151].
P-28332
Orifice size is 0.078 inch.
Remove the fitting (Item 1) [Figure 20-41-49] from the
BICS valve.
Clean and inspect the orifice. Replace as needed.
Figure 20-41-50
Reverse the removal procedure to install the lift arm bypass orifice.
1
P-28333
20-41-15
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-54
BICS™ Valve Check Valve Removal And Installation
1
Figure 20-41-52
1
P-8956
Clean and inspect the screen (Item 1) [Figure 20-41-54]
on the end of the valve.
P-28334
Reverse the removal procedure to install the BICS™
check valve.
Remove the check valve (Item 1) [Figure 20-41-52].
Installation: Tighten the check valve to 20 ft.-lbs. (27
Nm) torque.
Figure 20-41-53
3
2
1
N-18684
Remove the O-rings (Item 1) [Figure 20-41-53] and
back-up ring (Item 2) [Figure 20-41-53].
Install new O-rings (Item 1) [Figure 20-41-53] and backup ring (Item 2) [Figure 20-41-53] on the check valve.
Check valve (Item 3) [Figure 20-41-53] has a rating of 510 PSI.
20-41-16
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-57
BICS™ Valve Lock Valve Removal And Installation
Figure 20-41-55
1
2
1
P-28337
Loosen and remove the lock valve(s) (Item 1) [Figure 2041-56] & [Figure 20-41-57] from the valve.
P-28335
There are two lock valves on the BICS valve, lift lock
valve (Item 1) [Figure 20-41-55] and tilt lock valve (Item
2) [Figure 20-41-55].
Installation: Tighten the lock valve(s) to 25 ft.-lbs. (34
Nm) torque.
Figure 20-41-58
1
Figure 20-41-56
1
1
2
2
P-28336
2
N-18690
Remove the O-rings (Item 1) [Figure 20-41-58] and
back-up rings (Item 2) [Figure 20-41-58] from both the tilt
and lift lock valves.
Install new O-rings (Item 1) [Figure 20-41-58] and backup rings (Item 2) [Figure 20-41-58] on the tilt and lift lock
valves.
Reverse the removal procedure to install the lock valve.
20-41-17
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-61
BICS™ Valve Removal Solenoid And Installation
1
Figure 20-41-59
1
P-28340
2
Remove the solenoid (Item 1) [Figure 20-41-61].
Installation: Tighten the stem to 20 ft.-lbs. (27 Nm)
torque.
P-28338
Remove the nut (Item 1) [Figure 20-41-59] from the
solenoid cartridge.
Figure 20-41-62
Installation: Tighten the mounting nut to 53 in.-lbs. (6
Nm) torque.
2
3
Remove the coil (Item 2) [Figure 20-41-59].
Figure 20-41-60
1
1
1
N-18694
Remove the O-rings (Item 1) [Figure 20-41-62] and
back-up rings (Item 2) [Figure 20-41-62] from the stem.
Clean all parts in solvent and dry with compressed air.
Inspect all parts for wear and replace as needed.
N-18693
Remove the O-rings (Item 1) [Figure 20-41-60] from both
ends of the coil.
NOTE: the screen (Item 3) [Figure 20-41-62] can be
cleaned with solvent. If it is torn or worn it
needs to be replaced.
Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-41-60] & [Figure
20-41-62] and new back-up rings (Item 2) [Figure 20-4162] on the stem.
20-41-18
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Identification Chart
BICS™ Valve Solenoid Testing
Figure 20-41-63
P-9175
Use an Ohm meter to measure coil resistance [Figure
20-41-63].
Coil wires do not have polarity.
Correct resistance for the auxiliary, lift and tilt lock coils
are 7-10 ohms.
Item
A1
A2
A3
B1
B2
B3
C1
C2
C3
C4
D1
D2
D3
E1
E2
F1
F2
G1
G2
G3
H1
H2
H3
MR
863 Loader
Lift Cylinder Base End/Restrictor
Tilt Cylinder Base End
Auxiliary Hydraulics
Lift Cylinder Rod End
Tilt Cylinder Rod End
Auxiliary Hydraulics
Load Check Valve/Lift Function
Load Check Valve/Tilt Function
Orifice Load Check Valve/Auxiliary Function
Outlet Fluid Flow
Lift Spool Detent
Tilt Spool Centering Spring
Auxiliary Spool/Centering Springs
Port Relief Valve - (863) - 3500 PSI
Anti-Cavitation/Port Relief Valve - 3500 PSI
Anti-Cavitation Valve
Port Relief Valve - 3500 PSI
Lift Spool End
Tilt Spool End
Auxiliary Spool/Centering Springs
Auxiliary Electric Solenoid
Plug/Port Relief (Optional) - 3500 PSI
Auxiliary Electric Solenoid
Main Relief Valve - (863)-2950-3050 PSI
H2
The other coils (BICS, diverter, select valve) are 5-8
ohms.)
C4
G3
G2
F2
G1
F1
MR
20-41-19
H1
H3
B3
B2
A3
C3
C2
B1
D3
A2 E2
D2
A1 E1
D1
C1
TS-2136
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Load Check Valve
Lift Base End Restrictor
Remove the BICS™ valve assembly from the control
valve. (See BICS™ Valve Removal And Installation on
page 20-41-13.)
Figure 20-41-64
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-41-65
1
1
1
N-21159
Remove the restrictor (Item 1) [Figure 20-41-64] from
the lift section base end port.
2
P-28324
Remove the BICS™ valve assembly from the control
valve. (See BICS™ Valve Removal And Installation on
page 20-41-13.)
Remove the four large O-rings (Item 1) [Figure 20-41-65]
and small O-ring (Item 2) [Figure 20-41-65]. Always
replace these O-rings before installing the BICS valve
assembly.
Mark each valve section, spool and related parts so that
they will be returned to their original valve section during
assembly.
Use bolts to fasten the control valve to a work bench for
easier disassembly and assembly procedures.
20-41-20
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-68
Load Check Valve (Cont’d)
1
Figure 20-41-66
2
1
N-20078
P-28324
The auxiliary section (Item 1) [Figure 20-41-68] may
have a load check with an orifice located in the center of
the poppet (Item 2) [Figure 20-41-68].
P-28324
Loosen and remove the load check valve plugs (Item 1)
[Figure 20-41-66].
Installation: Always use new O-rings. Tighten the plugs
to 35-40 ft.-lbs. (47-54 Nm) torque.
Figure 20-41-67
1
2
3
P-28325
Remove the spring (Item 1) [Figure 20-41-67] and
poppet (Item 2) [Figure 20-41-67] from the load check
plug (Item 3) [Figure 20-41-67].
20-41-21
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-71
2
Main Relief Valve
Figure 20-41-69
3
5
4
1
B-6764
1. Relief Valve
2. O-Ring
3. Sleeve
4. O-Ring
5. Glide Ring
P-28328
1
Remove the O-rings, sleeve and glide ring from the main
relief valve [Figure 20-41-71].
P-28326
Installation: Always use new O-rings, sleeve and glide
ring. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
Loosen the main relief valve (Item 1) [Figure 20-41-69].
Figure 20-41-70
1
P-28327
Remove the main relief valve (Item 1) [Figure 20-41-70].
20-41-22
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-74
Port Relief Valve(s)
Figure 20-41-72
1
1
N-18981
Remove the port relief valve (Item 1) [Figure 20-41-74].
Figure 20-41-75
N-19000
Figure 20-41-73
3
4
2
1
1
1. O-Ring
2. Backup Washer
3. O-Ring
4. Relief Valve
N-18844
Remove the O-rings and back-up washer from the port
relief valve [Figure 20-41-75].
N-19034
Loosen the port relief valve (Item 1) [Figure 20-41-72] &
[Figure 20-41-73].
Installation: Always use new O-rings and back-up
washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
20-41-23
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-78
Anti-Cavitation Valve/Port Relief Valve
Figure 20-41-76
1
1
N-18843
Remove the O-rings (Item 1) [Figure 20-41-78] from the
anti-cavitation/port relief valve.
N-19003
Loosen the anti-cavitation valve (Item 1) [Figure 20-4176].
Installation: Always use new O-rings and back-up
washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
Figure 20-41-77
1
N-18980
Remove the anti-cavitation/port relief valve (Item 1)
[Figure 20-41-77] from the control valve for the tilt
section.
20-41-24
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-81
1
Anti-Cavitation Valve
2
3
4
Figure 20-41-79
E-1509
1. Anti-Cavitation Valve
2. O-Ring
3. Backup Washer
4. O-Ring
1
P-28331
Remove the O-rings and back-up washer from the anticavitation valve [Figure 20-41-81].
P-28329
Figure 20-41-80
1
N-19036
Remove the anti-cavitation valve (Item 1) [Figure 20-4179] & [Figure 20-41-80] from the control valve.
20-41-25
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-84
Lift Spool Removal And Installation
Figure 20-41-82
N-19003
Remove the screws (Item 1) [Figure 20-41-84] from the
cap.
1
N-19112
Figure 20-41-85
Remove the actuator (Item 1) [Figure 20-41-82] from the
control valve. (See Actuator Removal And Installation (In
Loader) on page 20-41-1.)
Figure 20-41-83
1
N-18983
2
2
Remove the spool assembly (Item 1) [Figure 20-41-85]
and seal from the control valve.
1
N-19114
Remove the spacer (Item 1) [Figure 20-41-83] and Oring (Item 2) [Figure 20-41-83] from the lift spool.
20-41-26
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-88
Tilt Spool Removal And Installation
Figure 20-41-86
1
1
N-19003
1
2
Remove the screws (Item 1) [Figure 20-41-88] from the
end cap.
P-28320
Remove the bolts (Item1) [Figure 20-41-86] to pull the
actuator (Item 2) [Figure 20-41-86] from the spacer.
Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3
Nm) torque.
Figure 20-41-89
Figure 20-41-87
1
2
2
1
N-18985
P-28321
Remove the spacer (Item 1) [Figure 20-41-87] and the
O-rings (Item 2) [Figure 20-41-87] from the tilt spool.
Remove the spool assembly (Item 1) [Figure 20-41-89]
and seal from the control valve.
Assembly: Always use a new spool seal.
20-41-27
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-92
2
Lift And Tilt Spool Disassembly And Assembly
1
3
Figure 20-41-90
4
1
N-18944
NOTE: The centering spring (Item 3) [Figure 20-41-92]
is orange on all 800 Series loaders.
N-18942
Put the linkage end of the spool in the vise [Figure 2041-90].
Install the spool tool (Item 1) [Figure 20-41-90] over the
centering spring.
Inspect the adapter (Item 1) [Figure 20-41-92], collar
(Item 2) [Figure 20-41-92], spring (Item 3) [Figure 2041-92] and washer (Item 4) [Figure 20-41-92].
Figure 20-41-93
1
Figure 20-41-91
1
1
2
N-18943
N-18930
Remove the spool seal(s) (Item 1) [Figure 20-41-93] and
the back-up washer (Item 2) [Figure 20-41-93].
N-19014
Remove the bolt (Item 1) [Figure 20-41-91] holding the
centering spring to the spool.
Assembly: Always use a new spool seal.
Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3
Nm) torque.
Remove the spring tool from the spring assembly.
20-41-28
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-96
Auxiliary Spool Removal And Installation
1
Figure 20-41-94
1
N-18988
Remove the spool (Item 1) [Figure 20-41-96].
Assembly: Put grease on all the centering spring
component parts.
N-19003
Remove the screws (Item 1) [Figure 20-41-94] from the
end cap (both sides).
Installation: Tighten the screws to 90-100 in.-lbs. (10,211,3 Nm) torque.
Figure 20-41-95
N-18987
Remove the end cap, O-ring, springs and washer (both
sides) [Figure 20-41-95].
Assembly: Always use a new spool seal.
20-41-29
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-41-99
Auxiliary Electric Solenoid Disassembly And
Assembly
1
Figure 20-41-97
N-18795
Remove the O-rings (Item 1) [Figure 20-41-99] from the
stem.
1
Figure 20-41-100
P-28341
Remove the nut (Item 1) [Figure 20-41-97] from both
solenoids.
Installation: Tighten the nut to 8-12 ft.-lbs. (11-16 Nm)
torque.
Figure 20-41-98
2
1
2
P-28344
Disconnect the tubeline (Item 1) [Figure 20-41-100] and
remove the screws (Item 2) [Figure 20-41-100] from the
end cap.
1
Installation: Tighten the screws to 90-100 in.-lbs. (10,211,3 Nm) torque.
P-28342
Remove the coil (Item 1) [Figure 20-41-98] and the stem
(Item 2) [Figure 20-41-98].
Installation: Tighten the stem to 20 ft.-lbs. (27 Nm)
torque.
20-41-30
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Figure 20-40-103
Plug
Auxiliary Electric Solenoid Disassembly And
Assembly (Cont’d)
2
Figure 20-41-101
1
1
1
N-18800
Figure 20-41-104
Port Relief (Optional)
P-28345
Remove the end cap and solenoid assembly (Item 1)
[Figure 20-41-101]. Remove the O-ring, springs and
washer [Figure 20-41-101].
1
2
Port-Auxiliary Section Disassembly
Figure 20-41-102
1
N-18843
Remove the O-rings (Item 1) [Figure 20-40-103] &
[Figure 20-41-104] and back-up ring (Item 2) [Figure 2040-103] & [Figure 20-41-104] from the plug.
1
P-28343
Remove the plug (Item 1) [Figure 20-41-102] or optional
port relief valve from the control valve.
NOTE: The optional port relief (Item 1) [Figure 20-41102] is 3500 PSI (24129 kPa).
20-41-31
863 Bobcat Loader
Service Manual
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM (ACS) (CONT’D)
Cleaning And Inspection
Clean all components with clean solvent and dry with
compressed air.
Check the spools for wear or scratches.
Check that the spools are not loose in their bore.
Check that the centering springs are not broken.
Check that the load check valve seats are not worn.
Check the load check poppets for damage.
Check the rubber boots and retainers.
Replace the parts as needed.
Use new O-rings and back-up rings.
Apply oil to all new O-rings and back-up rings before
installation.
20-41-32
863 Bobcat Loader
Service Manual
Removal And Installation
LIFT ARM BY-PASS CONTROL VALVE
Inspecting
Raise the lift arms 6 feet (2 m) off the ground. Stop the
engine.
Turn the Lift Arm By-Pass Control Knob
clockwise 1/4 turn. Then pull up and hold the Lift Arm
By-Pass Control Knob until the lift arms slowly lower..
Additional Inspection For Loaders With ACS
Sit in the operator’s seat and fasten the Seat Belt. Lower
the Seat Bar, start the engine and press the green
PRESS TO OPERATE Button.
Raise the lift arms about 6 feet (2 meters) off the ground.
Turn the key OFF and wait for the engine to come to a
complete stop.
Turn the key ON. Press the green PRESS TO OPERATE
Button, move the let hand control toward the operator.
The lift arms should not lower.
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Move the right hand control away from the operator. The
bucket (or attachment) should not tilt forward.
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Raise the lift arms and install the lift arm support device.
(See Engaging The Lift Arm Support Device on Page 1020-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the control panel/steering levers. (See Removal
And Installation on Page 50-100-1.)
20-50-1
863 Bobcat Loader
Service Manual
LIFT ARM BY-PASS CONTROL VALVE (CONT’D)
Disassembly And Assembly
Removal And Installation (Cont’d)
Figure 20-50-3
Figure 20-50-1
2
1
1
2
1
1
P7939
P-28558
Disconnect the hydraulic hoses (Item 1) [Figure 20-50-1]
and cap the plug lines.
Remove the two mounting bolts (Item 2) [Figure 20-501].
Installation: Tighten the mounting bolts to 180-200 in.lbs. (21-23 Nm) torque.
Remove the by-pass valve (Item 1) [Figure 20-50-3] from
the valve block. Inspect the by-pass valve for damage
and replace if necessary.
Installation: Tighten the valve to 33-37 ft.-lbs. (45-50
Nm) torque.
Inspect the hydraulic fittings (Item 2) [Figure 20-50-3] on
the valve block for damage and replace if necessary.
Remove the by-pass valve.
Figure 20-50-2
1
N-19734
Remove the two bolts (Item 1) [Figure 20-50-2] to
replace the by-pass valve mounting bracket if necessary.
Reverse the removal procedure to install the lift arm bypass valve in the loader.
20-50-2
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 &
BELOW)
Figure 20-60-1
Checking The Output Of The Pump
1
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
N-19740
NOTE: This procedure is the same for 863 and 863H in
the standard flow mode.
The tools listed will be needed to do the following
procedure:
Disconnect the OUTLET hose (Item 1) [Figure 20-60-1]
from the pump.
Figure 20-60-2
MEL 10003 - Hydraulic Tester
MEL 10006 - Hydraulic Test Kit
NOTE: Make sure all the air is removed from the
hydraulic system before beginning the test.
Air in the system can give an inaccurate test.
2
1
*Relief pressure must be per specification
before the test is done.
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the lift arms and install the lift arm support device.
(See Engaging The Lift Arm Support Device on Page 1020-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Connect the remote start switch. (See REMOTE START
on Page 10-60-1.)
P-7753
Connect the INLET hose from the tester to the OUTLET
hose (Item 1) [Figure 20-60-1] of the pump. Connect the
OUTLET hose (Item 2) [Figure 20-60-2] from the tester
to the tubeline (Control Valve Inlet) which was previously
disconnected from the pump outlet hose (Item 1) [Figure
20-60-2].
Start the engine and ran at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM.
20-60-1
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 &
BELOW) (CONT’D)
Figure 20-60-3
Checking The Output Of The Pump (Cont’d)
Warm the fluid to 140°F (60°) by turning the restrictor
control on the tester about 1000 PSI (6895 kPa). DO
NOT exceed the system relief pressure. Open the
restrictor control and record the free flow (GPM) at full
RPM.
1
Turn the restrictor down to system operating pressure.
DO NOT EXCEED SYSTEM RELIEF PRESSURE. The
highest pressure flow must be at least 80% of free flow.
1
N-19741
%=
HIGH PRESSURE FLOW (GPM)
FREE FLOW (GPM)
x100
Loosen the hose clamps and disconnect the inlet hoses
(Item 1) [Figure 20-60-3] from the pump inlet fitting.
A low percentage may indicate a pump problem.
Figure 20-60-4
Removal And Installation
1
2
WARNING
N-17600
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Raise the lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
Disconnect the hose (Item 1) [Figure 20-60-4] from the
pump outlet to the control valve.
Remove the pump mounting bolts (Item 2) [Figure 2060-4] (both sides).
Installation: Tighten the mounting bolts to 25-27 ft.-lbs.
(34-37 Nm) torque.
Remove the hydraulic pump.
WARNING
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Drain the hydraulic reservoir. (See Draining The Fluid
Reservoir on Page 20-80-1.)
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
20-60-2
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 &
BELOW) (CONT’D)
Parts Identification
1
2
3
4
5
7
6
8
9
4
10
8
6
5
13
11
14
12
TS-1022A
Ref.
Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Bolt
Washer
End Housing
O-Ring Seal
Seal
Ring
Body
Bearing Housing
Drive Gear
Idler Gear
Bolt
Washer
Cover
Seal
20-60-3
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 &
BELOW) (CONT’D)
Figure 20-60-7
Disassembly
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
1
I-2003-0888
CD-15142
Figure 20-60-5
Remove the end housing (Item 1) [Figure 20-60-7].
Marks
Figure 20-60-8
CD-15160
1
Mark the pump for correct assembly (Item 1) [Figure 2060-5].
Figure 20-60-6
CD-15143
Remove the mounting flange end housing (Item 1)
[Figure 20-60-8].
1
1
CD-15141
Remove the pump housing bolts (Item 1) [Figure 20-606]
20-60-4
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 &
BELOW) (CONT’D)
Figure 20-60-11
Disassembly (Cont’d)
1
Figure 20-60-9
1
2
2
CD-15146
Remove the bearing housing (Item 1) [Figure 20-60-11]
from the gears.
CD-15144
Remove the gear/bearing housing assembly [Figure 2060-9].
Remove the back-up seals/O-ring seals (Item 2) [Figure
20-60-11] from the bearing housing.
Figure 20-60-12
Figure 20-60-10
1
CD-15150
1
CD-15145
Remove the O-rings (Item 1) [Figure 20-60-10] from the
pump housing.
Remove the drive gear shaft seals (Item 1) [Figure 2060-12].
20-60-5
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 &
BELOW) (CONT’D)
Figure 20-60-15
Inspection
Wash all parts in clean solvent.
Use air pressure to dry them.
Make a visual inspection of all the parts.
After visual inspection, those parts which show wear or
damage must be replaced.
Figure 20-60-13
CD-15149
Check the pump housing (Item 1) [Figure 20-60-15].
Check the surface in the gear area for scratches, wear,
etc.
CD-15148
Check the drive and idler gears [Figure 20-60-13].
If excessive wear is visible on the journals or side or face
of the gears, they must be replaced. If the splines are
worn, replace the drive gear.
Figure 20-60-14
CD-15147
Check the bushings in the housing [Figure 20-60-14].
If the bushings are worn, scratched, and etc. replace
them as needed.
20-60-6
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 &
BELOW) (CONT’D)
Figure 20-60-17
Assembly
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
CD-15151
Figure 20-60-16
Install the bearing housing/gears assembly into the pump
housing [Figure 20-60-17].
Figure 20-60-18
2
1
1
CD-15150
Always use new O-rings and seals when assembling the
hydraulic pump.
Install the two seals (Item 1) [Figure 20-60-16] into the
mounting flange housing using the correct size driver
tool.
Install the inside seal with the lip facing the drive gear
and the outside seal with the lip facing outward.
CD-15152
Install the back-up seals/O-ring seals (Item 1) [Figure
20-60-18].
Install the large O-ring (Item 2) [Figure 20-60-18]
20-60-7
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 &
BELOW) (CONT’D)
Figure 20-60-21
Assembly (Cont’d)
Figure 20-60-19
1
CD-15155
Install the end housing (Item 1) [Figure 20-60-21].
Install the four pump housing bolts [Figure 20-60-21].
CD-15153
Install the mounting flange housing on the pump housing
[Figure 20-60-19].
Figure 20-60-22
Figure 20-60-20
2
1
CD-15156
Tighten the bolts to 45-50 ft.-lbs. (61-68 Nm) torque
[Figure 20-60-22].
CD-15154
Install the back-up seals/O-ring seals (Item 1) [Figure
20-60-20].
Install the large O-ring (Item 2) [Figure 20-60-20].
20-60-8
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N
514449483 & BELOW)
Figure 20-61-1
Checking The Output Of The High Flow Pump
1
1
WARNING
1
1
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
1
1
1
W-2017-0286
2
N-23027
NOTE: This procedure is the same for 863 and 863H in
the standard flow mode.
The tools listed will be needed to do the following
procedure:
Remove the seven bolts (Item 1) [Figure 20-61-1] and
cover (Item 2) [Figure 20-61-1].
Figure 20-61-2
MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit
NOTE: Make sure all the air is removed from the
hydraulic system before beginning the test.
Air in the system can give an inaccurate test.
1
*Relief pressure must be per specification
before the test is done.
Lift and block the loader.
(See LIFTING AND
BLOCKING THE LOADER on Page 10-10-1.)
Remove the right side rear wheel.
N-18597
Disconnect the OUTLET hose from the pump fitting (Item
1) [Figure 20-61-2]. Remove the fitting (Item 1) [Figure
20-61-2] and install a 90° elbow fitting.
Connect the INLET hose from the tester to the OUTLET
of the pump. Connect the OUTLET hose from the tester
to the the hose which was disconnected from the pump.
Start the engine and ran at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM.
20-61-1
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N
514449483 & BELOW) (CONT’D)
Figure 20-61-3
Checking The Output Of The High FLow Pump
(Cont’d)
Warm the fluid to 140°F (60°) by turning the restrictor
control on the tester about 1000 PSI (6895 kPa). DO
NOT exceed the system relief pressure. Open the
restrictor control and record the free flow (GPM) at full
RPM.
Push the mode switch (on the remote start switch) to
engage the front auxiliary hydraulics, the light will come
ON. Push the button (on the right steering lever) for fluid
pressure to the quick coupler (Fluid pressure will go over
main relief). Record the highest pressure (PSI) and flow
(GPM). The high pressure flow must be at least 80% of
free flow.
%=
HIGH PRESSURE FLOW (GPM)
FREE FLOW (GPM)
1
N-19740
Disconnect the hydraulic hose (Item 1) [Figure 20-61-3]
from the hydraulic pump to the control valve.
Figure 20-61-4
x100
A low percentage may indicate a pump problem.
Removal And Installation
Lift and block the loader.
(See LIFTING AND
BLOCKING THE LOADER on Page 10-10-1.)
1
2
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Drain the hydraulic reservoir (See Draining The Fluid
Reservoir on Page 20-80-1.)
N-18594
Loosen the clamps and disconnect the pump inlet hoses
(Item 1) [Figure 20-61-4].
Remove the hydraulic hose (Item 2) [Figure 20-61-4]
from the pump.
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
20-61-2
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N
514449483 & BELOW) (CONT’D)
Removal And Installation (Cont’d)
Figure 20-61-5
1
N-18595
Remove the inlet fitting (Item 1) [Figure 20-61-5] from
the pump.
Figure 20-61-6
1
N-18596
Loosen and remove the two pump mounting bolts (Item
1) [Figure 20-61-6]. (Both sides.)
Installation: Install a new gasket. Tighten the mounting
bolts (Item 1) [Figure 20-61-6] to 25-27 ft.-lbs. (34-37
Nm) torque.
20-61-3
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N
514449483 & BELOW) (CONT’D)
Parts Identification
2
1
3
4
5
7
6
8
10
9
6
5
9
4
12
11
13
14
15
16
17
20
15
14
13
18
19
21
23
22
24
25
26
TS-1078C
Ref.
Description
Ref.
Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Bolt
Washer
Cover
O-Ring
Seal
Ring
Body
Dowel
Bearing
Drive Gear
Idler Gear
Cover
O-Ring Seal
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Seal
Ring
Body
Bearing
Drive Gear
Idler Gear
Bearing
Cover
Seal
Bolt
Seal
Washer
Bolt
20-61-4
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N
514449483 & BELOW) (CONT’D)
Figure 20-61-8
Disassembly
IMPORTANT
1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
3
2
I-2003-0888
CD-15017
Figure 20-61-7
Remove the four pump housing bolts (Item 1) [Figure 2061-8] from the small gear pump end housing.
Mark
Remove the small gear pump end housing (Item 2)
[Figure 20-61-8].
Remove the small gear pump housing (Item 3) [Figure
20-61-8] from the center housing.
Figure 20-61-9
Mark
CD-15159
Mark the pump sections for correct assembly [Figure 2061-7].
2
1
CD-15018
Remove the O-ring (Item 1) [Figure 20-61-9] from the
end housing.
Remove the back-up seal/O-ring seal (Item 2) [Figure
20-61-9] from the pump housing.
20-61-5
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N
514449483 & BELOW) (CONT’D)
Figure 20-61-12
Disassembly (Cont’d)
Figure 20-61-10
CD-15021
1
2
Remove the drive and idler gear from the bearing
housing [Figure 20-61-12].
CD-15019
Figure 20-61-13
Remove the O-ring (Item 1) [Figure 20-61-10] from the
center housing.
Remove the back-up seal/O-ring seal (Item 2) [Figure
20-61-10].
Figure 20-61-11
1
3
2
CD-15022
Remove the two hex bolts (Item 1) [Figure 20-61-13] and
two allen head bolts (Item 2) [Figure 20-61-13] from the
mounting flange housing (Item 3) [Figure 20-61-13].
Remove the mounting flange housing (Item 3) [Figure
20-61-13].
CD-15020
Remove the bearing housing/gears assembly from the
housing [Figure 20-61-11].
20-61-6
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N
514449483 & BELOW) (CONT’D)
Figure 20-61-16
Disassembly (Cont’d)
Figure 20-61-14
1
2
1
2
CD-15025
Remove the O-ring (Item 1) [Figure 20-61-16].
Remove the back-up seal/O-ring seal (Item 2) [Figure
20-61-16].
CD-15023
Remove the O-ring (Item 1) [Figure 20-61-14].
Figure 20-61-17
Remove the back-up seal/O-ring seal (Item 2) [Figure
20-61-14].
Figure 20-61-15
CD-15026
Remove the bearing housing/gears assembly from the
large pump housing [Figure 20-61-17].
1
CD-15024
Remove the center housing (Item 1) [Figure 20-61-15]
from the large gear pump housing.
20-61-7
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N
514449483 & BELOW) (CONT’D)
Figure 20-61-20
Disassembly (Cont’d)
Figure 20-61-18
1
CD-15031
Check the connecting coupler (Item 1) [Figure 20-61-20]
in the center housing. If worn or damaged, use a press
and correct size driver tool to remove it from the center
housing.
CD-15027
Remove the drive and idler gear from the bearing
housings [Figure 20-61-18].
Figure 20-61-19
1
CD-15032
Remove the two seals (Item 1) [Figure 20-61-19] from
the mounting flange housing.
20-61-8
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N
514449483 & BELOW) (CONT’D)
Figure 20-61-22
Inspection
Wash all parts in clean solvent.
Use air pressure to dry them.
Make a visual inspection of all the parts.
After visual inspection, those parts which are of
questionable condition must be replaced.
Figure 20-61-21
CD-15029
Check the drive and idler gears for the large and small
pumps [Figure 20-61-22].
If excessive wear is visible on the journal, side or face of
the gears they must be replaced. If the splines are worn,
replace the drive gear(s).
Figure 20-61-23
CD-15028
Check the bushings in the large and small bearing
housings [Figure 20-61-21].
If the bushings are worn, scratched, and etc., replace
them as needed.
CD-15030
Check the large and small pump housing [Figure 20-6123].
Check the surfaces in the gear area for scratches, wear
and etc.
Replace all parts as needed.
20-61-9
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N
514449483 & BELOW) (CONT’D)
Figure 20-61-25
Assembly
IMPORTANT
1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
CD-15026
Figure 20-61-24
Install the large drive and idler gears into the bearing
housing (Item 1) [Figure 20-61-25].
Figure 20-61-26
1
2
1
CD-15032
Install the two seals (Item 1) [Figure 20-61-24] into the
mounting flange housing using the correct size driver
tool.
Install the inside seal with the lip facing the drive gear
and the outside seal with the lip facing outward.
CD-15033
Install the bearing housing/gears assembly into the large
pump housing [Figure 20-61-26].
Install the back-up/O-ring seal (Item 1) [Figure 20-6126].
Install the large O-ring (Item 2) [Figure 20-61-26].
20-61-10
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N
514449483 & BELOW) (CONT’D)
Figure 20-61-29
Assembly (Cont’d)
Figure 20-61-27
1
1
2
CD-15036
Install the mounting flange housing (Item 1) [Figure 2061-29] on the large pump housing.
CD-15034
Figure 20-61-30
Turn the large pump housing around; install the back-up
seal/O-ring seal (Item 1) [Figure 20-61-27].
Install the large O-ring (Item 2) [Figure 20-61-27].
1
Figure 20-61-28
2
CD-15037
Install the hex head bolts (Item 1) [Figure 20-61-30] and
allen head bolts (Item 2) [Figure 20-61-30]. Finger
tighten only.
1
CD-15035
Install the center housing (Item 1) [Figure 20-61-28] on
the large pump housing.
20-61-11
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N
514449483 & BELOW) (CONT’D)
Figure 20-61-33
Assembly (Cont’d)
Figure 20-61-31
1
2
1
CD-15017
Install pump housing on the center housing [Figure 2061-33].
CD-15020
Install the large O-ring (Item 1) [Figure 20-61-33].
Install the drive and idler gears into the bearing housing
(Item 1) [Figure 20-61-31].
Install the back-up seal/O-ring seal (Item 2) [Figure 2061-33].
Figure 20-61-32
Install the end housing.
Install the four pump housing bolts.
Figure 20-61-34
2
1
1
CD-15019
Install the bearing housing/gears assembly into the pump
housing [Figure 20-61-32].
CD-15084
Install the large O-ring (Item 1) [Figure 20-61-32].
Install the back-up seal/O-ring seal (Item 2) [Figure 2061-32].
Tighten the small pump housing bolts to 20-25 ft.-lbs (2734 Nm) torque [Figure 20-61-34].
20-61-12
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N
514449483 & BELOW) (CONT’D)
Assembly (Cont’d)
Figure 20-61-35
CD-15038
Tighten the large pump housing bolts (hex head & allen
head) to 33-41 ft.-lbs. (46-56 Nm) torque [Figure 20-6135].
20-61-13
863 Bobcat Loader
Service Manual
20-61-14
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON) (S/N 514449260 &
ABOVE)
Figure 20-62-1
Check The Output Of The Hydraulic Pump Without
Power Bob-Tach
1
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
2
W-2017-0286
P-34154
Disconnect the OUTLET hose (Item 1) [Figure 20-62-1]
from the pump.
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
Figure 20-62-2
W-2059-0598
The tools listed will be needed to do the following
procedure:
2
1
MEL1563 - Remote Start Tool
MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
P-34153
Connect the INLET hose (Item 1) [Figure 20-62-2] from
the tester to the OUTLET fitting (Item 2) [Figure 20-62-1]
of the pump. Connect the OUTLET hose (Item 2) [Figure
20-62-2] from the tester to the hose (Item 1) [Figure 2062-1] which was disconnected from the pump.
Open the rear door of the loader.
Connect the remote start tool. (See REMOTE START on
Page 10-60-1.)
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
20-62-1
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON) (S/N 514449260 &
ABOVE) (S/N 514449260 & ABOVE) (CONT’D)
Check The Output Of The Hydraulic Pump Without
Power Bob-Tach (Cont'd)
Figure 20-62-3
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out
In
Hydraulic Control
Valve
1
BH-00196
Sample tester connection shown [Figure 20-62-3].
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Warm the fluid to 140°F. (60°C.) by turning the restrictor
control (Item 1) [Figure 20-62-3] on the tester to about
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free
flow (GPM) at full RPM.
Push the maximum/variable flow switch (on the remote
start tool) to engage the front auxiliary hydraulics, the
light will come ON. Push the button (on the right control
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (PSI)
and flow (GPM). The high pressure flow must be at least
80% of free flow.
%=
HIGH PRESSURE FLOW (GPM)
FREE FLOW (GPM)
X100
A low percentage may indicate a failed pump.
*See “Hydraulic System” on page SPEC-10-3 for system
relief pressure and full RPM.
20-62-2
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON) (S/N 514449260 &
ABOVE) (CONT’D)
Figure 20-62-4
Check The Output Of The Hydraulic Pump With
Power Bob-Tach
1
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
2
W-2017-0286
P-26916
Disconnect the OUTLET hose (Item 1) [Figure 20-62-4]
from the top of the Power Bob-Tach block.
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
Figure 20-62-5
W-2059-0598
1
2
The tools listed will be needed to do the following
procedure:
MEL1563 - Remote Start Tool
MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
P-26917
Connect the INLET hose (Item 1) [Figure 20-62-5] from
the tester to the OUTLET fitting (Item 2) [Figure 20-62-4]
on the top of the Power Bob-Tach block. Connect the
OUTLET hose (Item 2) [Figure 20-62-5] from the tester
to the hose (Item 1) [Figure 20-62-4] which was
disconnected from the Power Bob-Tach block.
Open the rear door of the loader.
IMPORTANT
Connect the remote start tool. (See REMOTE START on
Page 10-60-1.)
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
20-62-3
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON) (S/N 514449260 &
ABOVE) (CONT'D)
Removal And Installation
Check The Output Of The Hydraulic Pump With
Power Bob-Tach (Cont'd)
Figure 20-62-6
EXAMPLE: TESTER
CONNECTION
Reservoir
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
Hydraulic Pump
Out
In
Hydraulic Control
Valve
1
W-2059-0598
BH-00196
Raise the lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
Sample tester connection shown [Figure 20-62-6].
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Stop the engine. Raise the seat bar.
Lift and block the rear of the loader. (See LIFTING AND
BLOCKING THE LOADER on Page 10-10-1.)
Warm the fluid to 140°F. (60°C.) by turning the restrictor
control (Item 1) [Figure 20-62-6] on the tester to about
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free
flow (GPM) at full RPM.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Push the maximum/variable flow switch (on the remote
start tool) to engage the front auxiliary hydraulics, the
light will come ON. Push the button (on the right control
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (PSI)
and flow (GPM). The high pressure flow must be at least
80% of free flow.
Open the rear door of the loader.
%=
HIGH PRESSURE FLOW (GPM)
FREE FLOW (GPM)
Drain the hydraulic fluid from the reservoir. (See Draining
The Fluid Reservoir on Page 20-80-1.)
Remove the Power Bob-Tach block if equipped. (See
Removal And Installation on Page 20-120-1.)
X100
A low percentage may indicate a failed pump.
*See “Hydraulic System” on page SPEC-10-3 for system
relief pressure and full RPM.
20-62-4
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON) (S/N 514449260 &
ABOVE) (CONT’D)
Figure 20-62-9
Removal And Installation (Cont’d)
Figure 20-62-7
1
1
P-26316
Remove the two mounting bolts (Item 1) [Figure 20-62-9]
from the hydraulic pump.
P-34154
Disconnect and cap the hoses from the outlet fitting (Item
1) [Figure 20-62-7] of the hydraulic pump.
Installation: Tighten the mounting bolts to 27-37 ft.-lbs.
(37-50 Nm) torque.
Figure 20-62-10
Figure 20-62-8
1
1
1
1
2
1
P-26348
P-26318
P-34155
Disconnect and cap the inlet hoses (Item 1) [Figure 2062-8] from the front of the hydraulic pump.
Remove the hydraulic pump from the hydrostatic pump
[Figure 20-62-10].
Remove the coupler (Item 1) [Figure 20-62-10] from the
hydraulic shaft.
Remove the O-ring (Item 2) [Figure 20-62-10].
Reverse the removal procedure to install the hydraulic
pump.
Installation: Use a new O-ring when installing the
hydraulic pump.
See Disassembly And Assembly on Page 20-62-7 for the
proper procedure.
20-62-5
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON) (S/N 514449260 &
ABOVE) (CONT’D)
Identification
15
7
8
6
14
11
7
1
3
4
9
13
12
10
5
2
B-16050A
REF.
1
2
3
4
5
6
7
DESCRIPTION
REF.
DESCRIPTION
RETAINING RING
PUMP END SECTION
PRE-LOAD SEAL
LOAD SEAL
SECTION SEAL
WEAR PLATE
PINS
8
9
10
11
12
13
14
15
DRIVE GEAR
IDLER GEAR
PUMP CENTER SECTION
WEAR PLATE
SECTION SEAL
PUMP END SECTION
BOLT (4)
BOLT (4)
20-62-6
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON) (S/N 514449260 &
ABOVE) (CONT’D)
Figure 20-62-12
1
Disassembly And Assembly
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-26353
Figure 20-62-11
Remove the pump end section (Item 1) [Figure 20-6212].
Figure 20-62-13
1
P-26352
2
2
1
1
P-26351
Mark the pump sections for correct assembly [Figure 2062-11].
2
P-26354
Remove the four smaller pump housing bolts (Item 1)
[Figure 20-62-11].
Remove the four larger pump housing bolts (Item 2)
[Figure 20-62-11].
Installation: Tighten the four smaller bolts (Item 1)
[Figure 20-62-11] to 30 ft.-lbs. (40,7 Nm) torque. Tighten
the four larger bolts (Item 2) [Figure 20-62-11] to 54 ft.lbs. (73,2 Nm) torque.
20-62-7
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON) (S/N 514449260 &
ABOVE) (CONT’D)
Figure 20-62-15
Disassembly And Assembly (Cont'd)
1
Figure 20-62-14
4
3
1
P-26358
2
Figure 20-62-16
P-26355
Remove the wear plate (Item 1) [Figure 20-62-13] &
[Figure 20-62-14] and section seal (Item 2) [Figure 2062-13] & [Figure 20-62-14] from the pump end section.
1
NOTE: Position wear plate (Item 1) [Figure 20-62-14]
inlets and traps as shown with bronze side
toward gears.
NOTE: Inspect the pump end section (Item 3) [Figure
20-62-14] and bushings (Item 4) [Figure 20-6214]. If excessive wear or damage is visible, the
pump must be replaced.
P-26359
Remove the pump center section (Item 1) [Figure 20-6215] & [Figure 20-62-16] from the pump end section.
NOTE: Inspect the pump center section (Item 1)
[Figure 20-62-16]. If excessive wear or
damage is visible, the pump must be
replaced.
20-62-8
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON) (S/N 514449260 &
ABOVE) (CONT’D)
Figure 20-62-19
Disassembly And Assembly (Cont'd)
Figure 20-62-17
1
1
P-26391
Figure 20-62-20
P-26389
Figure 20-62-18
1
P-26364
1
1
P-26362
To remove the drive gear (Item 1) [Figure 20-62-19] from
the pump end section, locate and remove the retaining
ring (Item 1) [Figure 20-62-20] from the spline end of the
drive gear.
P-26390
Remove the idler gear (Item 1) [Figure 20-62-17] &
[Figure 20-62-18].
NOTE: Inspect the idler gear (Item 1) [Figure 20-6218]. If excessive wear or damage is visible, the
pump must be replaced.
20-62-9
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON) (S/N 514449260 &
ABOVE) (CONT’D)
Figure 20-62-23
Disassembly And Assembly (Cont'd)
Figure 20-62-21
1
2
1
P-26394
NOTE: Position wear plate (Item 1) [Figure 20-62-23]
inlets and traps as shown with bronze side
toward gears.
P-26392
Figure 20-62-24
Remove the drive gear (Item 1) [Figure 20-62-21].
NOTE: Inspect the drive gear (Item 1) [Figure 20-6221]. If excessive wear or damage is visible, the
pump must be replaced.
1
P-26396
Figure 20-62-22
1
1
P-26395
Remove the load seal (Item 1) [Figure 20-62-24].
2
P-26393
Remove the wear plate (Item 1) [Figure 20-62-22] &
[Figure 20-62-23] and section seal (Item 2) [Figure 2062-22] & [Figure 20-62-23] from the pump end section.
20-62-10
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON) (S/N 514449260 &
ABOVE) (CONT’D)
Figure 20-62-26
1
Disassembly And Assembly (Cont'd)
Figure 20-62-25
1
2
P-26398
1
P-26374
P-26397
NOTE: Inspect the pump end section (Item 1) [Figure
20-62-26] and bushings (Item 2) [Figure 20-6226]. If excessive wear or damage is visible, the
pump must be replaced.
Remove the pre-load seal (Item 1) [Figure 20-62-25].
20-62-11
863 Bobcat Loader
Service Manual
20-62-12
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HIGH FLOW) (S/N
514449484-514450945)
Figure 20-63-1
Check The Output Of The Hydraulic Pump Without
Power Bob-Tach
1
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-34690
Disconnect the OUTLET hose (Item 1) [Figure 20-63-1]
from the pump.
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
Figure 20-63-2
W-2059-0598
The tools listed will be needed to do the following
procedure:
1
2
MEL1563 - Remote Start Tool
MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
P-34153
Connect the INLET hose (Item 1) [Figure 20-63-2] from
the tester to the OUTLET fitting (Item 2) [Figure 20-63-1]
of the pump. Connect the OUTLET hose (Item 2) [Figure
20-63-2] from the tester to the hose (Item 1) [Figure 2063-1] which was disconnected from the pump.
Open the rear door of the loader.
Connect the remote start tool. (See REMOTE START on
Page 10-60-1.)
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
20-63-1
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N
514449484-514450945) (CONT’D)
Check The Output Of The Hydraulic Pump With
Power Bob-Tach
Check The Output Of The Hydraulic Pump Without
Power Bob-Tach (Cont'd)
WARNING
Figure 20-63-3
EXAMPLE: TESTER
CONNECTION
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.
Reservoir
W-2017-0286
WARNING
Hydraulic Pump
Out
In
Hydraulic Control
Valve
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
1
BH-00196
Sample tester connection shown [Figure 20-63-3].
W-2059-0598
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Warm the fluid to 140°F. (60°C.) by turning the restrictor
control (Item 1) [Figure 20-63-3] on the tester to about
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free
flow (GPM) at full RPM.
Push the maximum/variable flow switch (on the remote
start tool) to engage the front auxiliary hydraulics, the
light will come ON. Push the button (on the right control
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (PSI)
and flow (GPM). The high pressure flow must be at least
80% of free flow.
%=
HIGH PRESSURE FLOW (GPM)
FREE FLOW (GPM)
X100
The tools listed will be needed to do the following
procedure:
MEL1563 - Remote Start Tool
MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Open the rear door of the loader.
Connect the remote start tool. (See REMOTE START on
Page 10-60-1.)
A low percentage may indicate a failed pump.
*Refer to SPECIFICATIONS, Contents, Section SPEC-01
for system relief pressure and full RPM.
20-63-2
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N
514449484-514450945) (CONT'D)
Figure 20-63-6
EXAMPLE: TESTER
CONNECTION
Check The Output Of The Hydraulic Pump With
Power Bob-Tach (Cont'd)
Reservoir
Figure 20-63-4
1
Hydraulic Pump
Out
In
Hydraulic Control
Valve
2
1
BH-00196
Sample tester connection shown [Figure 20-63-6].
P-34689
Disconnect the OUTLET hose (Item 1) [Figure 20-63-4]
from the top of the Power Bob-Tach block.
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Warm the fluid to 140°F. (60°C.) by turning the restrictor
control (Item 1) [Figure 20-63-6] on the tester to about
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free
flow (GPM) at full RPM.
Figure 20-63-5
2
Push the maximum/variable flow switch (on the remote
start tool) to engage the front auxiliary hydraulics, the
light will come ON. Push the button (on the right control
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (PSI)
and flow (GPM). The high pressure flow must be at least
80% of free flow.
1
%=
P-26917
Connect the INLET hose (Item 1) [Figure 20-63-5] from
the tester to the OUTLET fitting (Item 2) [Figure 20-63-4]
on the top of the Power Bob-Tach block. Connect the
OUTLET hose (Item 2) [Figure 20-63-5] from the tester
to the hose (Item 1) [Figure 20-63-4] which was
disconnected from the Power Bob-Tach block.
HIGH PRESSURE FLOW (GPM)
FREE FLOW (GPM)
X100
A low percentage may indicate a failed pump.
*Refer to SPECIFICATIONS Section SPEC-01 for system
relief pressure and full RPM.
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
20-63-3
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N
514449484-514450945) (CONT’D)
Figure 20-63-7
Removal And Installation
2
1
WARNING
P-34689
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Disconnect and cap the outlet hose (Item 1) [Figure 2063-7] from the back of the hydraulic pump.
Disconnect and cap the hose (Item 2) [Figure 20-63-7]
from the high flow section of the hydraulic pump.
Figure 20-63-8
Raise the lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
1
Stop the engine. Raise the seat bar.
Lift and block the rear of the loader. (See LIFTING AND
BLOCKING THE LOADER on Page 10-10-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Drain the hydraulic fluid from the reservoir. (See Draining
The Fluid Reservoir on Page 20-80-1.)
P-34688
Open the rear door of the loader.
Remove the hoses from the Power Bob-Tach block if
equipped. (See Removal And Installation on Page 20120-1.)
Disconnect and cap the hoses from the inlet fitting (Item
1) [Figure 20-63-8] of the hydraulic pump.
20-63-4
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N
514449484-514450945) (CONT’D)
Removal And Installation (Cont’d)
Figure 20-63-9
1
1
P-28067
Remove the two mounting bolts (Item 1) [Figure 20-63-9]
from the hydraulic pump.
Installation: Tighten the mounting bolts to 27-37 in.-lbs.
(37-50 Nm) torque.
Remove the hydraulic pump from the hydrostatic pump.
Remove the coupler and the O-ring.
Reverse the removal procedure to install the hydraulic
pump.
Installation: Use a new O-ring when installing the
hydraulic pump.
See Disassembly And Assembly on Page 20-63-7 for the
proper procedure.
20-63-5
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N
514449484-514450945) (CONT’D)
Identification
26
22
23
19
27
24
25
23
15
16 17
18
21
20
8
7
14
13
11
1
3
4
5
6
7
12
9 10
2
B-16051A
REF.
DESCRIPTION
REF.
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
RETAINING RING
PUMP END SECTION
PRE-LOAD SEAL
LOAD SEAL
SECTION SEAL
WEAR PLATE
PINS
DRIVE GEAR
IDLER GEAR
PUMP SECTION
WEAR PLATE
SECTION SEAL
SPLINE SHAFT
14
15
16
17
18
19
20
21
22
23
24
25
26
27
PUMP CENTER SECTION
PRE-LOAD SEAL
LOAD SEAL
SECTION SEAL
WEAR PLATE
DRIVE GEAR
IDLER GEAR
PUMP SECTION
WEAR PLATE
PINS
SECTION SEAL
PUMP END SECTION
BOLT (4)
BOLT (4)
20-63-6
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N
514449484-514450945) (CONT’D)
Figure 20-63-11
Disassembly And Assembly
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-26624
Figure 20-63-10
Remove the pump end section (Item 1) [Figure 20-6311].
1
P-26623
2
2
1
P-26622
Mark the pump sections for correct assembly [Figure 2063-10].
Remove the four smaller pump housing bolts (Item 1)
[Figure 20-63-10].
Remove the four larger pump housing bolts (Item 2)
[Figure 20-63-10].
Installation: Tighten the four smaller bolts (Item 1)
[Figure 20-63-10] to 30 ft.-lbs. (40,7 Nm) torque. Tighten
the four larger bolts (Item 2) [Figure 20-63-10] to 54 ft.lbs. (73,2 Nm) torque.
20-63-7
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N
514449484-514450945) (CONT’D)
Figure 20-63-14
Disassembly And Assembly (Cont'd)
Figure 20-63-12
1
1
P-26627
Figure 20-63-15
2
P-26625
Figure 20-63-13
4
3
1
1
P-26628
2
Remove the pump section (Item 1) [Figure 20-63-14] &
[Figure 20-63-15] from the pump center section.
P-26626
Remove the wear plate (Item 1) [Figure 20-63-12] &
[Figure 20-63-13] and section seal (Item 2) [Figure 2063-12] & [Figure 20-63-13] from the pump end section.
NOTE: Inspect the pumps center section (Item 1)
[Figure 20-63-15]. If excessive wear or
damage is visible, the pump must be
replaced.
NOTE: Position wear plate (Item 1) [Figure 20-63-13]
inlets and traps as shown with bronze side
toward gears.
NOTE: Inspect the pump end section (Item 3) [Figure
20-63-13] and bushings (Item 4) [Figure 20-6313]. If excessive wear or damage is visible, the
pump must be replaced.
20-63-8
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N
514449484-514450945) (CONT’D)
Figure 20-63-18
Disassembly And Assembly (Cont'd)
Figure 20-63-16
1
1
P-26631
Figure 20-63-19
P-26629
Figure 20-63-17
1
1
P-26632
Remove the drive gear (Item 1) [Figure 20-63-18] &
[Figure 20-63-19].
P-26630
Remove the idler gear (Item 1) [Figure 20-63-16] &
[Figure 20-63-17].
NOTE: Inspect the drive gear (Item 1) [Figure 20-6319]. If excessive wear or damage is visible, the
pump must be replaced.
NOTE: Inspect the idler gear (Item 1) [Figure 20-6317]. If excessive wear or damage is visible, the
pump must be replaced.
20-63-9
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N
514449484-514450945) (CONT’D)
Figure 20-63-22
Disassembly And Assembly (Cont'd)
1
Figure 20-63-20
P-26636
1
1
P-26635
Remove the load seal (Item 1) [Figure 20-63-22].
2
Figure 20-63-23
P-26633
Figure 20-63-21
1
P-26638
1
1
2
P-26637
Remove the pre-load seal (Item 1) [Figure 20-63-23].
P-26634
Remove the wear plate (Item 1) [Figure 20-63-20] &
[Figure 20-63-21] and section seal (Item 2) [Figure 2063-20] & [Figure 20-63-21] from the pump center
section.
NOTE: Position wear plate (Item 1) [Figure 20-63-21]
inlets and traps as shown with bronze side
toward gears.
20-63-10
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N
514449484-514450945) (CONT’D)
Figure 20-63-26
3
Disassembly And Assembly (Cont'd)
Figure 20-63-24
4
1
1
2
P-26657
NOTE: Position wear plate (Item 1) [Figure 20-63-26]
inlets and traps as shown with bronze side
toward gears.
P-26654
Remove the pump center section (Item 1) [Figure 20-6324] from the pump sections.
Figure 20-63-25
NOTE: Inspect the pump center section (Item
[Figure 20-63-26] and bushings (Item
[Figure 20-63-26]. If excessive wear
damage is visible, the pump must
replaced.
3)
4)
or
be
Figure 20-63-27
1
1
2
P-26655
Remove the wear plate (Item 1) [Figure 20-63-25] &
([Figure 20-63-26]) and section seal (Item 2) [Figure 2063-25] & ([Figure 20-63-26]) from the pump section.
P-26659
Remove the pump section (Item 1) [Figure 20-63-27]
from the pump end section.
20-63-11
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N
514449484-514450945) (CONT’D)
Figure 20-63-30
Disassembly And Assembly (Cont'd)
Figure 20-63-28
1
1
P-26662
NOTE: Inspect the idler gear (Item 1) [Figure 20-6330]. If excessive wear or damage is visible, the
pump must be replaced.
P-26660
NOTE: Inspect the pump section (Item 1) [Figure 2063-28]. If excessive wear or damage is visible,
the pump must be replaced.
Figure 20-63-29
1
P-26661
Remove the idler gear (Item 1) [Figure 20-63-29] &
([Figure 20-63-30]).
20-63-12
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N
514449484-514450945) (CONT’D)
Figure 20-63-33
Disassembly And Assembly (Cont'd)
Figure 20-63-31
1
1
P-26666
Remove the drive gear (Item 1) [Figure 20-63-33] from
the pump end section.
P-26663
NOTE: Inspect the drive gear (Item 1) [Figure 20-6333]. If excessive wear or damage is visible, the
pump must be replaced.
Figure 20-63-32
Figure 20-63-34
1
P-26665
1
1
P-26664
To remove the drive gear (Item 1) [Figure 20-63-31] from
the pump end section, locate and remove the retaining
ring (Item 1) [Figure 20-63-32] from the spline end of the
drive gear.
P-26674
Remove the spline shaft (Item 1) [Figure 20-63-34] from
the end of the drive gear.
NOTE: Inspect the spline shaft (Item 1) [Figure 20-6334]. If excessive wear or damage is visible, the
pump must be replaced.
20-63-13
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N
514449484-514450945) (CONT’D)
Figure 20-63-37
Disassembly And Assembly (Cont'd)
1
Figure 20-63-35
P-26670
1
1
P-26669
Remove the load seal (Item 1) [Figure 20-63-37].
2
Figure 20-63-38
P-26667
Figure 20-63-36
1
P-26672
1
1
2
Remove the pre-load seal (Item 1) [Figure 20-63-38].
P-26668
Remove the wear plate (Item 1) [Figure 20-63-35] &
[Figure 20-63-36] and section seal (Item 2) [Figure 2063-35] & [Figure 20-63-36] from the pump end section.
NOTE: Position wear plate (Item 1) [Figure 20-63-36]
inlets and traps as shown with bronze side
toward gears.
20-63-14
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N
514449484-514450945) (CONT’D)
Disassembly And Assembly (Cont'd)
Figure 20-63-39
1
2
P-26673
NOTE: Inspect the pump end section (Item 1) [Figure
20-63-39] and bushings (Item 2) [Figure 20-6339]. If excessive wear or damage is visible, the
pump must be replaced.
20-63-15
863 Bobcat Loader
Service Manual
20-63-16
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE)
clockwise to free flow. Shut the front auxiliary hydraulics
off.
Hydraulic Pump Test
The tools listed will be needed to do the following
procedure:
MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit
If flow and pressure specs are not obtained, go to the
Inline Standard Hydraulic Pump Test. (See Removal And
Installation on Page 20-61-2.) If flow and pressure specs
are obtained continue on to the next paragraph.
With the engine running at low idle RPM. Press the Front
Auxiliary button. Engage the front auxiliary with the
trigger on the right handle. Make sure the tester is
connected correctly. If no flow is indicated on the tester,
the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Figure 20-64-1
1
Warm the fluid to 140°F. (60°C.) by turning the restrictor
control on the tester to about 1000 PSI (6895 kPa).
NOTE: DO NOT EXCEED 3300 PSI.
2
P-16903
P-31821
Install a hydraulic tester (Item 1) [Figure 20-64-1] onto
the front auxiliary quick couplers.
This procedure will require a operator in the cab and one
operator running the tester.
Start the engine and run at low idle RPM. Press the Front
Auxiliary button. Engage the front auxiliary with the
trigger on the right handle. Make sure the tester is
connected correctly. If no flow is indicated on the tester,
the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Turn the restrictor control on the tester counter clockwise,
to obtain free flow, the flow should be at 20 GPM. Press
the High Flow button. The flow should increase to 30
GPM. Start turning the restrictor clockwise, causing more
restriction on the flow. The GPM should drop off slightly
until the pressure reaches approximately 2700 PSI. At
approximately 2700 PSI the flow should start decreasing
rapidly until the pressure reaches 3000 PSI. At 3000 PSI
the flow should be at 0 GPM. Turn the restrictor counter
clockwise to free flow. Shut the front auxiliary hydraulics
off.
If the specs from above are reached, the high flow
hydraulic pump is OK.
If the flow and pressure were not obtained, go to the
Inline High Flow Hydraulic Pump Test (See Checking The
Output Of The High Flow Pump on Page 20-61-1.)
*Refer to SPECIFICATIONS Contents Page SPEC-01 for
system relief pressure and full RPM.
Warm the fluid to 140°F. (60°C.) by turning the restrictor
control on the tester to about 1000 PSI (6895 kPa).
NOTE: DO NOT EXCEED 3300 PSI.
Turn the restrictor control on the tester counter clockwise
to obtain free flow, the flow should be at 20 GPM. Start
turning the restrictor clockwise, causing more restriction
on the flow. The GPM should drop off slightly until the
pressure reaches approximately 2800 PSI. At
approximately 2800 PSI the flow should start decreasing
rapidly until the pressure reaches 3000 PSI. At 3000 PSI
the flow should be at 0 GPM. Back the restrictor counter
20-64-1
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
Figure 20-64-2
Inline Hydraulic Pump Test (Standard)
The tools listed will be needed to do the following
procedure:
1
MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit
2
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-34845
Disconnect the standard pump OUTLET hose (Item 1)
[Figure 20-64-2] from the tubeline.
Figure 20-64-3
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
2
1
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
P-34851
Connect the INLET hose (Item 1) [Figure 20-64-3] from
the tester to the OUTLET hose (Item 1) [Figure 20-64-2]
of the pump. Connect the OUTLET hose (Item 2) [Figure
20-64-3] from the tester to the tubeline (Item 2) [Figure
20-64-2] which goes to the control valve.
Lower the cab down.
20-64-2
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
Record the flow (GPM) at 2700 PSI, this is the high
pressure flow. The high pressure flow must be at least
80% of free flow.
Inline Hydraulic Pump Test (Standard) (Cont'd)
%=
IMPORTANT
HIGH PRESSURE FLOW (GPM)
FREE FLOW (GPM)
X 100
A low percentage may indicate a failed pump.
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
*Refer to SPECIFICATIONS Contents Page SPEC-01 for
system relief pressure and full RPM.
Figure 20-64-4
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out
In
Hydraulic Control
Valve
1
BH-196
Sample tester connection shown [Figure 20-64-4]].
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Warm the fluid to 140°F. (60°C.) by turning the restrictor
control (Item 1) [Figure 20-64-4] on the tester to about
1000 PSI (6895 kPa).
NOTE: DO NOT EXCEED 3300 PSI.
Open the restrictor control and record the free flow
(GPM) at full RPM.
20-64-3
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
WARNING
Inline Hydraulic Pump Test (High Flow)
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Figure 20-64-6
W-2017-0286
The tools listed will be needed to do the following
procedure:
MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit
1
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Figure 20-64-5
2
1
P-34844
Disconnect the high flow pump OUTLET hose (Item 1)
[Figure 20-64-6] from the fitting (Item 2) [Figure 20-646] at the control valve.
Figure 20-64-7
P-34847
2
1
Install a jumper hose (Item 1) [Figure 20-64-5] onto the
front auxiliary quick couplers.
Raise the lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
P-34851
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Connect the INLET hose (Item 1) [Figure 20-64-7] from
the tester to the OUTLET hose (Item 1) [Figure 20-64-6]
of the pump. Connect the OUTLET hose (Item 2) [Figure
20-64-7] from the tester to the tubeline (Item 2) [Figure
20-64-6] at the control valve.
Lower the cab down.
20-64-4
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
Turn the restrictor control on the tester clockwise to 3000
PSI and the flow should go to zero GPM. If the pressure
readings are not obtained go to the High Flow Relief
Pump Adjustment (See Contents Page 20-61-6). If the
pressure readings are correct, continue on to the next
paragraph.
Inline Hydraulic Pump Test (High Flow) (Cont’d)
IMPORTANT
Open the restrictor control and record the free flow
(GPM) at full RPM.
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
Record the flow (GPM) at 2500 PSI, this is the high
pressure flow. The high pressure flow must be at least
80% of free flow.
Figure 20-64-8
%=
EXAMPLE: TESTER
CONNECTION
HIGH PRESSURE FLOW (GPM)
FREE FLOW (GPM)
X 100
A low percentage may indicate a failed pump.
Reservoir
*Refer to SPECIFICATIONS Contents Page SPEC-01 for
system relief pressure and full RPM.
Hydraulic Pump
Out
In
Hydraulic Control
Valve
1
BH-196
Sample tester connection shown [Figure 20-64-8].
Start the engine and run at low idle RPM. Press the Front
Auxiliary button. Press the High Flow button. Engage the
front auxiliary with the trigger on the right handle. Make
sure the tester is connected correctly. If no flow is
indicated on the tester, the hoses are connected wrong.
With the hoses connected correctly, increase the engine
speed to full RPM*.
Warm the fluid to 140°F. (60°C.) by turning the restrictor
control (Item 1) [Figure 20-64-8] on the tester to about
1000 PSI (6895 kPa).
NOTE: DO NOT EXCEED 3300 PSI.
20-64-5
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
WARNING
High Flow Relief Adjustment Procedure
The tools listed will be needed to do the following
procedure:
MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Figure 20-64-10
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
1
W-2017-0286
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Remove the right rear tire.
2
Figure 20-64-9
P-34844
1
Disconnect the high flow pump OUTLET hose (Item 1)
from the fitting (Item 2) [Figure 20-64-10] at the control
valve.
Figure 20-64-11
2
1
P-34847
Install a jumper hose (Item 1) [Figure 20-64-9] onto the
front auxiliary quick couplers.
Raise the lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
P-34851
Connect the INLET hose (Item 1) [Figure 20-64-11] from
the tester to the OUTLET hose (Item 1) [Figure 20-6410] of the pump. Connect the OUTLET hose (Item 2)
[Figure 20-64-11] from the tester to the tubeline (Item 2)
[Figure 20-64-10] at the control valve.
Lower the cab down.
20-64-6
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
Figure 20-64-14
High Flow Relief Adjustment Procedure (Cont’d)
Figure 20-64-12
1
1
1
1
P-34919
N-23027
Remove the access cover mounting bolts (Item 1) and
the cover (Item 2) [Figure 20-64-12] from the frame.
Figure 20-64-13
Start the engine and run at low idle RPM. Press the Front
Auxiliary button. Press the High Flow button. Engage the
front auxiliary with the trigger on the right handle. Make
sure the tester is connected correctly. If no flow is
indicated on the tester, the hoses are connected wrong.
With the hoses connected correctly, increase the engine
speed to full RPM*.
Warm the fluid to 140°F. (60°C.) by turning the restrictor
control on the tester to about 1000 PSI (6895 kPa).
NOTE: DO NOT EXCEED 3300 PSI.
Turn the restrictor control clockwise on the tester to
cause more restriction on the flow. The GPM should drop
off slightly until the pressure reaches approximately 2600
PSI. At approximately 2600 PSI the flow should start
decreasing rapidly until the pressure reaches 3000 PSI.
At 3000 PSI the flow should be at 0 GPM. Turn the
restrictor counter clockwise to free flow. Shut the front
auxiliary hydraulics off.
1
If the specs from above are reached, the pump is OK.
P-34846
Remove the cap (Item 1) [Figure 20-64-13] from the
pump.
If the pump is unable to reach 3000 PSI the relief plug
(Item 1) [Figure 20-64-14] will need to be turned
clockwise a 1/4 turn and retested with the procedure
above. (1/4 turn equals about 400 PSI.)
NOTE: If the relief plug has been turned in 1/4 turn and
the pressure remains the same, go to the
relief valve removal and installation section.
(See Removal And Installation on Page 20100-2.) If relief valve has been checked and is
OK, go to the high flow pump disassembly
and assembly section. (See Disassembly on
Page 20-61-5.)
If the pump reaches 3000 PSI and there is flow, the relief
plug must be turned counter clockwise 1/4 turn and
retested with the procedure above.
20-64-7
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
Figure 20-64-16
High Flow Relief Valve Removal and Installation
1
WARNING
1
1
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-37082
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Remove the right rear tire.
Remove the access cover mount bolts (Item 1) and the
access cover (Item 2) [Figure 20-64-16] from the frame.
Figure 20-64-15
Figure 20-64-17
1
1
P-34847
P-34846
Install a jumper hose (Item 1) [Figure 20-64-15] onto the
front auxiliary quick couplers.
Remove the cap (Item 1) [Figure 20-64-17] from the
pump.
Raise the lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
20-64-8
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
Figure 20-64-19
1
High Flow Relief Valve Removal and Installation
(Cont’d)
2
Figure 20-64-18
3
1
P-34696
Inspect the relief valve (Item 1), spring (Item 2), and plug
(Item 3) [Figure 20-64-19] for damage and replace as
needed.
P-34919
Remove the Relief Plug (Item 1) [Figure 20-64-18] from
the pump.
Inspect the relief valve seat in the pump for damage or
wear.
Install the relief valve (Item 1) and spring (Item 2) [Figure
20-64-19] into the pump.
Install the plug (Item 3) [Figure 20-64-19] and turn it in
until it makes contact with the spring. Then turn the plug
one full turn clockwise. Go to the High Flow Relief
Adjustment section to finish setting the relief. (See
Checking The Output Of The High Flow Pump on Page
20-61-1.)
20-64-9
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
Figure 20-64-20
Removal And Installation
3
1
2
WARNING
P-34855
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Disconnect and cap the hoses from the outlet fitting (Item
1) of the hydraulic pump. Disconnect and cap the hoses
from the High Flow outlet fitting (Item 2) and the low
pressure return hose (Item 3) [Figure 20-64-20].
Figure 20-64-21
Raise the lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
1
Stop the engine. Raise the seat bar.
Lift and block the rear of the loader. (See LIFTING AND
BLOCKING THE LOADER on Page 10-10-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Drain the hydraulic fluid from the reservoir. (See Draining
The Fluid Reservoir on Page 20-80-1.)
Open the rear door of the loader.
Remove the hoses from the Power Bob-Tach block. If so
equipped.) (See Removal And Installation on Page 20120-1.)
P-34852
Disconnect and cap the hoses from the inlet fitting (Item
1) [Figure 20-64-21] of the hydraulic pump.
20-64-10
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
Figure 20-64-23
Removal And Installation (Cont’d)
Figure 20-64-22
1
1
P-34849
Remove the two mounting bolts (Item 1) [Figure 20-6423] from the hydraulic pump.
P-34854
Disconnect the electrical connector (Item 1) [Figure 2064-22] from the high flow solenoid.
Installation: Tighten the mounting bolts to 27-37 ft.-lbs.
(37-50 Nm) torque.
Remove the hydraulic pump from the hydrostatic pump.
Remove the coupler and the O-ring.
Reverse the removal procedure to install the hydraulic
pump.
Installation: Use a new O-ring when installing the
hydraulic pump.
20-64-11
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
Identification
1. Retaining Ring
2. Pump End Section
3. Pre-Load Seal
4. Load Seal
5. Section Seal
6. Wear Plate
7. Pins
8. Drive Gear
9. Idler Gear
10. Pump Section
11. Wear Plate
12. Section Seal
13. Spline Shaft
14. Pump Center Section
15. Pre-Load Seal
16. Load Seal
26
19
22
23
27
17
15 16
24
23
18 20 21
25
8
7
14
13
11
1
3
17. Section Seal
18. Wear Plate
19. Drive Gear
20. Idler Gear
21. Pump Section
22. Wear Plate
23. Pins
24. Section Seal
25. Pump End Section
26. Bolts (4)
27. Bolts (4)
4
5
6
7
12
9 10
2
B-16051A
20-64-12
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
Figure 20-64-25
Disassembly And Assembly
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-34693
Figure 20-64-24
Remove the valve cartridge (Item 1) [Figure 20-64-25].
1
Installation: Tighten the solenoid valve to 35-40 ft.-lbs
(47-54 Nm).
2
Figure 20-64-26
2
P-34692
Mark the pump sections for correct assembly.
1
Remove the solenoid nut (Item 1) [Figure 20-64-24].
P-34694
Remove the solenoid (Item 2) [Figure 20-64-24].
Installation: Tighten the solenoid nut to 48-72 in lbs (5-8
Nm)
Inspect the o-ring (Item 1) [Figure 20-64-26] and replace
as needed.
Inspect the o-ring and back-up ring (Item 2) [Figure 2064-26] and replace as needed.
20-64-13
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
Figure 20-64-29
1
Disassembly And Assembly (Cont'd)
2
Figure 20-64-27
3
1
P-34696
Inspect the check valve (Item 1), spring (Item 2), and plug
(Item 3) [Figure 20-64-29] for damage and replace as
needed.
P-34708
Figure 20-64-30
Remove the cap (Item 1) [Figure 20-64-27].
Installation: Tighten the cap to 13-16 ft.-lbs (18-22 Nm)
after the relief valve has been set.
Figure 20-64-28
1
2
1
P-34699
1
Remove the eight bolts (Item 1) [Figure 20-64-30].
Installation: Tighten the assembly bolts to 45-50 ft.-lbs
(60-67 Nm).
P-34695
Remove the washer (Item 1) [Figure 20-64-28].
Remove the set screw, spring and relief valve (Item 2)
[Figure 20-64-28].
Installation: See High Flow Relief Valve Adjustments.
(Pages 20-61-6.)
20-64-14
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
Figure 20-64-33
Disassembly And Assembly (Cont'd)
1
Figure 20-64-31
2
1
P-26627
Remove the pump center section (Item 1) [Figure 20-6433] & [Figure 20-64-34] from the pump center section.
P-34697
Figure 20-64-34
Remove the wear plate (Item 1) [Figure 20-64-31] and
section seal (Item 2) [Figure 20-64-31] & [Figure 20-6432] from the pump end section.
Figure 20-64-32
4
3
1
1
P-26628
NOTE: Inspect the pump center section (Item 1)
[Figure 20-64-34]. If excessive wear or
damage is visible, the pump must be
replaced.
2
P-34698
NOTE: Position wear plate (Item 1) [Figure 20-64-32]
inlets and traps as shown with bronze side
toward gears.
NOTE: Inspect the pump end section (Item 3) and
bushings (Item 4) [Figure 20-64-32]. If
excessive wear or damage is visible, the
pump must be replaced.
20-64-15
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
Figure 20-64-37
Disassembly And Assembly (Cont'd)
Figure 20-64-35
1
1
P-26631
Figure 20-64-38
P-26629
Remove the idler gear (Item 1) [Figure 20-64-35] &
[Figure 20-64-36].
1
Figure 20-64-36
P-26632
1
Remove the drive gear (Item 1) [Figure 20-64-37] &
[Figure 20-64-38].
NOTE: Inspect the drive gear (Item 1) [Figure 20-6438]. If excessive wear or damage is visible, the
pump must be replaced.
P-26630
NOTE: Inspect the idler gear (Item 1) [Figure 20-6436]. If excessive wear or damage is visible, the
pump must be replaced.
20-64-16
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
Figure 20-64-41
1
Disassembly And Assembly (Cont'd)
Figure 20-64-39
P-26636
1
1
P-26635
2
Remove the load seal (Item 1) [Figure 20-64-41].
Figure 20-64-42
P-26633
1
Figure 20-64-40
P-26638
1
1
2
P-26637
Remove the pre-load seal (Item 1) [Figure 20-64-42].
P-26634
Remove the wear plate (Item 1) [Figure 20-64-39] &
[Figure 20-64-40] and section seal (Item 2) [Figure 2064-39] & [Figure 20-64-40] from the pump center
section.
NOTE: Position wear plate (Item 1) [Figure 20-64-40]
inlets and traps as shown with bronze side
toward gears.
20-64-17
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
Figure 20-64-45
3
Disassembly And Assembly (Cont'd)
Figure 20-64-43
4
1
1
2
P-26657
NOTE: Position wear plate (Item 1) [Figure 20-64-45]
inlets and traps as shown with bronze side
toward gears.
P-26654
Remove the pump center section (Item 1) [Figure 20-6443] from the pump sections.
Figure 20-64-44
NOTE: Inspect the pump center section (Item 3) and
bushings (Item 4) [Figure 20-64-45]. If
excessive wear or damage is visible, the
pump must be replaced.
Figure 20-64-46
1
1
2
P-26655
P-26659
Remove the wear plate (Item 1) [Figure 20-64-44] &
[Figure 20-64-45] and section seal (Item 2) [Figure 2064-44] & [Figure 20-64-45] from the pump section.
Remove the pump section (Item 1) [Figure 20-64-46]
from the pump end section.
20-64-18
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
Figure 20-64-49
Disassembly And Assembly (Cont'd)
Figure 20-64-47
1
1
P-26662
NOTE: Inspect the idler gear (Item 1) [Figure 20-6449]. If excessive wear or damage is visible, the
pump must be replaced.
P-26660
NOTE: Inspect the pump section (Item 1) [Figure 2064-47]. If excessive wear or damage is visible,
the pump must be replaced.
Figure 20-64-50
Figure 20-64-48
1
P-26665
1
1
P-26664
Remove the retaining ring (Item 1) [Figure 20-64-50]
from the spline end of the drive gear.
P-26661
Remove the idler gear (Item 1) [Figure 20-64-48] &
[Figure 20-64-49].
20-64-19
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
Figure 20-64-53
Disassembly And Assembly (Cont'd)
Figure 20-64-51
1
1
P-26674
Remove the spline shaft (Item 1) [Figure 20-64-53] from
the end of the drive gear.
P-26663
Remove the drive gear (Item 1) [Figure 20-64-51] from
the pump end section.
NOTE: Inspect the spline shaft (Item 1) [Figure 20-6453]. If excessive wear or damage is visible, the
pump must be replaced.
Figure 20-64-54
Figure 20-64-52
1
1
2
P-26667
P-26666
Remove the drive gear (Item 1) [Figure 20-64-52] from
the pump end section.
Remove the wear plate (Item 1) and section seal (Item 2)
[Figure 20-64-54]
NOTE: Inspect the drive gear (Item 1) [Figure 20-6452]. If excessive wear or damage is visible, the
pump must be replaced.
20-64-20
863 Bobcat Loader
Service Manual
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
Figure 20-64-57
1
Disassembly And Assembly (Cont'd)
Figure 20-64-55
1
1
2
P-26671
Remove the pre-load seal (Item 1) [Figure 20-64-57].
Figure 20-64-58
P-26668
Inspect the wear plate (Item 1) and the section seal (Item
2) [Figure 20-64-55].
1
NOTE: Position wear plate (Item 1) [Figure 20-64-55]
inlets and traps as shown with bronze side
toward gears.
Figure 20-64-56
2
1
P-26673
P-26670
NOTE: Inspect the pump end section (Item 1) and
bushings (Item 2) [Figure 20-64-58]. If
excessive wear or damage is visible, the
pump must be replaced.
1
P-26669
Remove the load seal (Item 1) [Figure 20-64-56].
20-64-21
863 Bobcat Loader
Service Manual
20-64-22
863 Bobcat Loader
Service Manual
HYDRAULIC/HYDROSTATIC FILTER
Figure 20-70-2
Housing Removal And Installation
2
3
1
WARNING
N-19745
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Disconnect the hose clamp and hose (Item 1) [Figure
20-70-2] from the filter housing.
Disconnect the hydraulic tubeline (Item 2) [Figure 20-702].
Remove the four mounting bolts (Item 3) [Figure 20-702].
Figure 20-70-1
Installation: Tighten the mounting bolts to 25 ft.-lbls. (34
Nm) torque.
Remove the filter housing/filter assembly.
1
N-19744
Raise the lift arms and install lift arm support device.
(See LIFT ARM SUPPORT DEVICE on Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Disconnect the wires (Item 1) [Figure 20-70-1] from the
hydraulic filter sender and switch.
20-70-1
863 Bobcat Loader
Service Manual
20-70-2
863 Bobcat Loader
Service Manual
HYDRAULIC FLUID RESERVOIR
Removal And Installation
Draining The Fluid Reservoir
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Figure 20-80-1
Drain the fluid from the reservoir [Figure 20-80-1].
Remove the control panel. (See Removal And Installation
on Page 50-100-1.)
Remove the bucket position valve (if so equipped). (See
Removal And Installation on Page 20-90-2.)
Remove the select valve (if so equipped). (See Removal
And Installation on Page 20-100-2.)
1
Figure 20-80-2
N-19496
2
Remove the side cover from the loader frame. Pull the
reservoir drain hose (Item 1) [Figure 20-80-1] out the
side of the loader frame.
Remove the hose end cap and drain fluid in a container
[Figure 20-80-1].
1
N-19727
Remove the two bucket position valve mount bolts (Item
1)[Figure 20-80-2].
Remove the mount bracket.
Remove the two fill hose clamps (Item 2) [Figure 20-802].
Remove the hydraulic fill hose.
20-80-1
863 Bobcat Loader
Service Manual
HYDRAULIC FLUID RESERVOIR (CONT’D)
Figure 20-80-5
Removal And Installation (Cont’d)
1
Figure 20-80-3
2
1
N-19730
At the left motor cover hole, remove the drain hose
(Item1) [Figure 20-80-5] from the tank.
N-19728
Remove the two hydraulic hoses (Item 1) [Figure 20-803] from the reservoir.
Remove the supply hose (Item 2) [Figure 20-80-5] from
the tank.
Remove the reservoir from the loader.
Figure 20-80-4
Figure 20-80-6
1
1
N-19729
N-19731
Remove the two bolts (Item 1) [Figure 20-80-4].
Installation: Tighten the bolt to 16-20 ft.-lbs. (21-27 Nm)
torque.
Remove the rear tank bracket (Item 1) [Figure 20-80-6]
from the loader.
Remove the mounting strap.
Slide the reservoir forward.
20-80-2
863 Bobcat Loader
Service Manual
HYDRAULIC FLUID RESERVOIR (CONT’D)
Figure 20-80-8
Hydraulic Fluid Screen
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Figure 20-80-7
1
2
N-17718
1
Remove the hydraulic fluid screen (Item 1) [Figure 2080-8] from the reservoir.
Wash the screen in clean solvent and air dry, before
replacing.
N-19610
Remove the two hose clamps (Item 1) [Figure 20-80-7]
and remove the hydraulic fill hose (Item 2) [Figure 20-807] from the hydraulic reservoir.
20-80-3
863 Bobcat Loader
Service Manual
20-80-4
863 Bobcat Loader
Service Manual
BUCKET POSITION VALVE
Figure 20-90-3
Solenoid Removal And Installation
1
Disconnect the steering levers from the pump. (See
Hydraulic Pump Removal & Installation on Page 30-407.)
2
Figure 20-90-1
2
N-18191
1
Inspect the solenoid stem and replace the O-rings (Item
1) [Figure 20-90-3] and the back-up washer (Item 2)
[Figure 20-90-3].
N-23648
Disconnect the wire harness connector (Item 1) [Figure
20-90-1] from the bucket position shutoff solenoid.
Remove the solenoid nut (Item 2) [Figure 20-90-1].
Installation: Tighten the solenoid nut to 60 in.-lbs (6,78
Nm) torque.
Figure 20-90-2
1
N-23649
Remove the solenoid stem (Item 1) [Figure 20-90-2]
from the bucket position valve.
Installation: Put oil on O-rings and back-up washers and
tighten the solenoid stem to 30-35 ft.-lbs. (40,8-47,6 Nm)
torque.
20-90-1
863 Bobcat Loader
Service Manual
BUCKET POSITION VALVE (CONT’D)
Removal And Installation
Solenoid Testing
Start the engine. Raise the lift arms and install an
approved lift arm support device. (See LIFT ARM
SUPPORT DEVICE on Page 10-20-1.)
Figure 20-90-4
WARNING
P9175
Use a test meter to measure coil resistance (Item 1)
[Figure 20-90-4]. Coil wires do not have polarity.
Correct resistance for the pressure relief (small) coil is 710 ohm and the other coils 5-8 ohms.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Stop the engine.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Figure 20-90-5
1
N-23648
Disconnect the electric solenoid connector (Item 1)
[Figure 20-90-5].
20-90-2
863 Bobcat Loader
Service Manual
BUCKET POSITION VALVE (CONT’D)
Figure 20-90-8
Removal And Installation (Cont’d)
Figure 20-90-6
1
1
2
N-23652
3
Remove the tubeline (Item 1) [Figure 20-90-8] from the
B port to the control valve.
N-23650
Figure 20-90-9
Remove the solenoid nut (Item 1) [Figure 20-90-6].
Installation: Tighten the nut to 60 in.-lbs. (6,78 Nm)
torque.
Remove the solenoid (Item 2) [Figure 20-90-6] and
solenoid stem (Item 3) [Figure 20-90-6].
2
Figure 20-90-7
1
1
N-23653
1
Disconnect the tubeline (Item 1) [Figure 20-90-9] from
the C port on the bucket position valve.
C is bottom is rod end of tilt.
Disconnect the tubeline (Item 2) [Figure 20-90-9] from
the D port on the bucket position valve.
N-23651
Disconnect tubelines (Item 1) [Figure 20-90-7] from the
A port on the bucket position valve tee fitting.
D is top is base end of tilt.
20-90-3
863 Bobcat Loader
Service Manual
BUCKET POSITION VALVE (CONT’D)
Disassembly And Assembly
Removal And Installation (Cont’d)
Figure 20-90-11
Figure 20-90-10
1
1
N-19069
N-23654
Remove the solenoid nut (Item 1) [Figure 20-90-11].
Remove the mounting bolts (Item 1) [Figure 20-90-10].
Installation: Tighten the nut to 60 in.-lbs. (6,78 Nm)
torque.
Installation: Tighten the mounting bolts and nuts to 15
ft.-lbs. (20 Nm) torque.
Figure 20-90-12
Remove the bucket position valve from the loader.
2
1
N-19070
Remove the solenoid (Item 1) [Figure 20-90-12] and the
solenoid stem (Item 2) [Figure 20-90-12].
Installation: Tighten the solenoid stem to 30-35 ft.-lbs.
(40,8-47,6 Nm) torque.
20-90-4
863 Bobcat Loader
Service Manual
BUCKET POSITION VALVE (CONT’D)
Figure 20-90-15
Disassembly And Assembly (Cont’d)
Figure 20-90-13
2
1
N-18339
1
Remove the plug (Item 1) [Figure 20-90-15], and flow
control spool (Item 2) [Figure 20-90-15].
N-19072
Remove the flow adjustment valve and O-ring (Item 1)
[Figure 20-90-13].
NOTE: Always install new O-rings before any parts
are installed into the vale. Check the parts for
wear or damage and replace as needed.
Check the flow control spool for wear, check the O-ring
on the plug and replace as needed.
Figure 20-90-16
Figure 20-90-14
1
2
3
N-19042
1
N-19041
Remove the tilt cylinder check valve (Item 1) [Figure 2090-16], spring (Item 2) [Figure 20-90-16] and plug (Item
3) [Figure 20-90-16]. Check for wear, check the O-ring
and replace as needed.
Remove the plug (Item 1) [Figure 20-90-14].
20-90-5
863 Bobcat Loader
Service Manual
BUCKET POSITION VALVE (CONT’D)
Figure 20-90-18
Disassembly And Assembly (Cont’d)
Figure 20-90-17
3
2
1
N-19046
N-19045
Remove the plug [Figure 20-90-17].
Remove the plug (Item 1) [Figure 20-90-18], spring (Item
2) [Figure 20-90-18] and unloading spool (Item 3)
[Figure 20-90-18].
Check all parts and replace as needed. Install a new Oring on the plug before installing.
20-90-6
863 Bobcat Loader
Service Manual
SELECT VALVE
Figure 20-100-2
Checking The High Flow Pump Relief Valve (S/N
514450945 & Below)
3
1
IMPORTANT
2
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
WARNING
B-15551
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.
Start the engine and run at low idle RPM. Push the
mode switch (Item 1) [Figure 20-100-2] once (on the
instrument panel) to engage the front auxiliary hydraulics
momentarily, the light (Item 2) [Figure 20-100-2] will
come ON.
W-2017-0286
Push the high flow switch (Item 3) [Figure 20-100-2] for
fluid pressure to the secondary quick couplers.
Figure 20-100-1
Push the left handle rocker switch to engage the flow to
the secondary quick couplers.
2
Watch the flow meter on the hydraulic tester to make sure
the flow is correct. Increase the engine speed to full
RPM.
The free flow should be approximately 10.0 GPM (37,85
L/min..). Turn the restrictor control, on the tester, until the
main relief valve opens. The correct pressure for the
main relief is approximately 3000 PSI (20685 kPa).
1
Release the rocker switch (Item 3) [Figure 20-100-2] to
disengage the flow to the secondary quick couplers.
P-9153
The tools listed will be needed to do the following
procedure:
MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Connect the IN port of the hydraulic tester to the female
quick couplers (Item 1) [Figure 20-100-1] on the loader.
Connect the OUT port of the hydraulic tester to the male
quick coupler (Item 2) [Figure 20-100-1] on the loader.
20-100-1
863 Bobcat Loader
Service Manual
SELECT VALVE (CONT’D)
Removal And Installation
Checking The High Flow Pump Relief Valve (Cont’d)
Raise the operator cab. (See Contents, Page 10-01.)
Figure 20-100-3
Figure 20-100-4
3
1
3
2
2
2
P-9174
1
P13047
If the relief pressure is not correct, stop the engine.
Remove and inspect the relief valve (Item 1) [Figure 20100-3]. Inspect the O-rings (Item 2) [Figure 20-100-3]
and back-up ring (Item 3) [Figure 20-100-3] for damage.
Replace the relief valve if required. This relief valve is not
adjustable.
2
P-13046
Disconnect the controls harness at the left side steering
lever connectors (Item 1) [Figure 20-100-4].
Disconnect the controls harness at the select valve
connectors (Item 2) [Figure 20-100-4].
Remove the rear bolt on the left side pedal link (Item 3)
[Figure 20-100-4] and lower link.
NOTE: Steering panel brace is removed for photo
clarity.
Drain the hydraulic reservoir. (See Draining The Fluid
Reservoir on Page 20-80-1.)
20-100-2
863 Bobcat Loader
Service Manual
SELECT VALVE (CONT’D)
Figure 20-100-7
Removal And Installation (Cont’d)
1
Figure 20-100-5
1
1
3
P-13048
2
Disconnect the tubelines (Item 1) [Figure 20-100-7].
P-13047
Remove the select valve.
Loosen the clamp (Item 1) [Figure 20-100-5] and
disconnect the hose.
Disconnect the tubeline (Item 2) [Figure 20-100-5].
Installation: Connect controls harness to select valve
solenoids. See Disassembly And Assembly on page 20100-4 for solenoid identification and correct controls
harness wire color.
Disconnect the hose (Item 3) [Figure 20-100-5].
Install caps and plugs on open connections.
Figure 20-100-6
1
P-9166
Remove mounting bolts (Item 1) [Figure 20-100-6]
located on the outside left frame.
NOTE: The select valve will drop down for wrench
clearance.
20-100-3
863 Bobcat Loader
Service Manual
SELECT VALVE (CONT’D)
Figure 20-100-9
Disassembly And Assembly
IMPORTANT
1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
2
I-2003-0888
P-9177
Figure 20-100-8
Figure 20-100-10
2
1
3
1
2
4
5
2
2
P-9168
2
P-9169
Clean the select valve to remove dirt before disassembly.
Remove the solenoid valve coils in [Figure 20-100-8].
NOTE: The controls wiring harness colors are listed
below for identification during select valve
assembly installation.
Assembly: The coils largest opening (Item 1) [Figure
20-100-9] must position on the valve shoulder (Item 2)
[Figure 20-100-9]. Install the washer (Item 1) [Figure
20-100-10] between the double coils. Install the coils
and tighten the nuts (Item 2) [Figure 20-100-10] to 5 ft.lbs. (6,7 Nm) torque.
Second aux. male coupler (Item 1) [Figure 20-100-8]
Brown
Second aux. female coupler (Item 2) [Figure 20-100-8]
White
Second aux. pressure relief (Item 3) [Figure 20-100-8]
Green
High flow (Item 4) [Figure 20-100-8] Blue
Second aux. diverter (Item 5) [Figure 20-100-8] Yellow
20-100-4
863 Bobcat Loader
Service Manual
SELECT VALVE (CONT’D)
Figure 20-100-12
Disassembly And Assembly (Cont’d)
Figure 20-100-11
3
1
2
1
P-9171
2
3
P-9170
Remove the 4-way solenoid valve (Item 1) [Figure 20100-11].
Remove the 2-way solenoid valve (Item 2) [Figure 20100-11].
Remove the relief valve (Item 1) [Figure 20-100-12].
Remove the check valve (Item 2) [Figure 20-100-12].
Remove the pilot piston (Item 3) [Figure 20-100-12]
located between the check valves (Item 2) [Figure 20100-12] and (Item 3) [Figure 20-100-12].
Figure 20-100-13
Remove the 2-way solenoid valves (Item 3) [Figure 20100-11].
Inspect the solenoid valves for contamination or damage.
Wash all parts in clean solvent. Use air pressure to dry
them. Install new O-rings and back-up washers.
1
5
Assembly: Put oil on O-rings and back-up washers.
Install and tighten the solenoid valves (Items 1&3)
[Figure 20-100-11] to 25 ft.-lbs. (33,9 Nm) torque.
Tighten the solenoid valve (Item 2) [Figure 20-100-11] to
20 ft.-lbs. (27,1 Nm) torque.
4
2
3
N-0503
P-9172
Remove the load shuttle (Item 1) [Figure 20-100-13].
Remove the fitting (Item 2) [Figure 20-100-13]. Remove
the check valve (Item 3) [Figure 20-100-13].
Inspect the relief valve, check valves, piston, load shuttle
and fitting for contamination or damage. Wash all parts
in clean solvent. Use air pressure to dry them. Install
new O-rings and back-up washers.
The load shuttle (Item 1) [Figure 20-100-13] has a ball
(Item 5) [Figure 20-100-13] that must move free inside
the shuttle, the plug (Item 4) [Figure 20-100-13] can be
removed to clean the shuttle and ball.
20-100-5
863 Bobcat Loader
Service Manual
SELECT VALVE (CONT’D)
Figure 20-100-15
Disassembly And Assembly (Cont’d)
Figure 20-100-14
P-9175
P-9176
The fitting (Item 2) [Figure 20-100-13] and [Figure 20100-14] has a poppet valve. The poppet valve allows
flow out of the select valve only. Inspect the poppet for
smooth opening and closing.
Use a test meter to measure coil resistance [Figure 20100-15]. Coil wires do not have polarity. Correct
resistance for the pressure relief (small) coil is 7-10 ohms
and the other coils 5-8 ohms.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
Assembly: Put oil on O-rings and back-up washers and
pilot piston (Item 3) [Figure 20-100-12]. Install and
tighten the relief valve (Item 1) [Figure 20-100-12] to 25
ft.-lbs. (33,9 Nm) torque. Install the pilot piston (Item 3)
[Figure 20-100-12] in the port between the check valves
(Item 2) [Figure 20-100-12] and (Item 3) [Figure 20-10013]. Install the check valves and load shuttle (Item 1)
[Figure 20-100-13] and tighten to 20 ft.-lbs. (27,1 Nm)
torque. Install the fitting (Item 2) [Figure 20-100-13] and
tighten to 35 ft.-lbs. (47,4 Nm) torque.
20-100-6
863 Bobcat Loader
Service Manual
REAR AUXILIARY DIVERTER VALVE
Figure 20-110-2
Disassembly
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
1
2
I-2003-0888
N-0529
Figure 20-110-1
Remove the pilot check valves from block ports PC1 and
PC2 (Item 1) [Figure 20-110-2].
Remove the shuttle check valve from block port SH1
(Item 2) [Figure 20-110-2].
Figure 20-110-3
1
1
4
2
N-0527
3
5
Clean the diverter block to remove dirt before
disassembly.
Block ports are labeled for correct
assembly.
1
2
2
Remove the logic cartridge valves from block ports LC1
and LC2 (Item 1) [Figure 20-110-1].
3
2
1
N-0528
Remove the nuts (Item 1) [Figure 20-110-3], seal
washers (Item 2) [Figure 20-110-3] and solenoid valve
coils (Item 3) [Figure 20-110-3].
Remove the diverter control solenoid valve (Item 4)
[Figure 20-110-3] from port SV1. Remove the pressure
relieving solenoid valve (Item 5) [Figure 20-110-3] from
block port SV2.
20-110-1
863 Bobcat Loader
Service Manual
REAR AUXILIARY DIVERTER VALVE (CONT’D)
Assembly
Inspection
Put oil on O-rings and back-up washers.
Inspect cartridges, check valves, solenoid valves and
sealing washers for contamination or damage. Wash all
parts in clean solvent. Use air pressure for drying them.
Install new O-rings and back-up washers.
Tighten the logic cartridge valves (Item 1) [Figure 20110-1] to 65 ft.-lbs. (88 Nm) torque.
Inspect diverter block cavities for contamination. Wash
block in clean solvent. Use air pressure to dry.
Tighten the pilot check valves (Item 1) [Figure 20-110-2],
shuttle check valve (Item 2) [Figure 20-110-2] to 35 ft.lbs. (47 Nm) torque.
Tighten the solenoid valves (Items 4 & 5) [Figure 20-1103] to 12 ft.-lbs. (16,3 Nm) torque. Install the sealing
washers (Item 2) [Figure 20-110-3] and coils (Item 3)
[Figure 20-110-3]. Tighten the nuts (Item 1) [Figure 20110-3] to 10 in.-lbs. (1,13 Nm) torque.
Solenoid Testing
Figure 20-110-4
P-9137
Use a test meter to measure coil resistance [Figure 20110-4]. Coil wires do not have polarity. Correct
resistance is 6-9 ohms.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
20-110-2
863 Bobcat Loader
Service Manual
POWER BOB-TACH BLOCK (6676547-ALUMINUM)
Figure 20-120-1
Removal And Installation
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
1
I-2003-0888
N-23028
Disconnect the two solenoid connectors (Item 1) [Figure
20-120-1] from the loader harness.
Remove the right rear tire from the loader.
Figure 20-120-2
WARNING
1
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
2
W-2059-0598
1
1
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
N-23027
Remove the seven access cover mount bolts (Item 1)
[Figure 20-120-2] and remove the access cover (Item 2)
[Figure 20-120-2].
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Drain the hydraulic reservoir. (See Draining The Fluid
Reservoir on Page 20-80-1.)
20-120-1
863 Bobcat Loader
Service Manual
POWER BOB-TACH BLOCK (6676547-ALUMINUM)
(CONT’D)
Figure 20-120-5
Removal And Installation (Cont’d)
Figure 20-120-3
1
1
1
2
N-22660
Remove the four mounting bolts (Item 1) [Figure 20-1205].
N-23030
Disconnect the hydraulic hose (Item 1) [Figure 20-120-3]
that goes to the control valve.
Disconnect the hydraulic hose (Item 2) [Figure 20-120-3]
that goes to the hydrostatic pump.
Installation: Tighten the mounting bolts to 25-28 ft.-lbs.
(34-38 Nm) torque.
Remove the POWER BOB-TACH BLOCK (6676547Aluminum).
Figure 20-120-4
1
N-23029
Disconnect the two hydraulic hoses (Item 1) [Figure 20120-4] that go to the Bob-Tach cylinder.
20-120-2
863 Bobcat Loader
Service Manual
POWER BOB-TACH BLOCK (6676547-ALUMINUM)
(CONT’D)
Figure 20-120-7
Disassembly And Assembly
IMPORTANT
1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
N-22661
Figure 20-120-6
Figure 20-120-8
1
2
1
P-16282
N-22662
Clean the diverter block (Item 1) [Figure 20-120-6] to
remove dirt before disassembly. Block ports are labeled
for correct assembly.
Remove the plug (Item 1) [Figure 20-120-7] & [Figure
20-120-8].
Installation: Tighten until plug makes metal to metal
contact, then tighten until fully seated, (no more than 1/6
turn) or 22 ft.-lbs. (30 Nm) torque.
Remove the 0.02 screened orifice (Item 2) [Figure 20120-8].
20-120-3
863 Bobcat Loader
Service Manual
POWER BOB-TACH BLOCK (6676547-ALUMINUM)
(CONT’D)
Figure 20-120-10
Disassembly And Assembly (Cont’d)
Figure 20-120-9
1
1
P-16257
Figure 20-120-11
N-22663
Check the screened orifice (Item 1) [Figure 20-120-9]
and replace as needed.
1
Installation: Hand tighten until snug. Do Not use thread
locking agent.
P-16258
Remove the reducing valve (Item 1) [Figure 20-120-10]
& [Figure 20-120-11].
The valve is set at 2000 PSI (1379 kPa).
Installation: Put oil on O-rings and back-up washers.
Tighten to 25 ft.-lbs. (33,9 Nm).
20-120-4
863 Bobcat Loader
Service Manual
POWER BOB-TACH BLOCK (6676547-ALUMINUM)
(CONT’D)
Figure 20-120-14
Disassembly And Assembly (Cont’d)
Figure 20-120-12
1
P-16255
Remove the plug (Item 1) [Figure 20-120-14].
1
Installation: Put oil on O-ring. Tighten to 40 ft.-lbs. (54
Nm).
P-16259
Figure 20-120-13
Figure 20-120-15
1
1
P-16260
P-16251
Remove the relief valve (Item 1) [Figure 20-120-12] &
[Figure 20-120-13].
Installation: Put oil on O-rings and back-up washers.
Tighten to 25 ft.-lbs. (33,9 Nm).
Remove the P2 fitting (Item 1) [Figure 20-120-15].
Installation: Put oil on O-ring. Tighten to 40 ft.-lbs. (54
Nm).
20-120-5
863 Bobcat Loader
Service Manual
POWER BOB-TACH BLOCK (6676547-ALUMINUM)
(CONT’D)
Figure 20-120-18
Disassembly And Assembly (Cont’d)
Figure 20-120-16
1
1
P-16271
Figure 20-120-19
P-16269
1
Figure 20-120-17
1
P-16272
Remove the logic cartridge valve (Item 1) [Figure 20120-18] & [Figure 20-120-19].
P-16270
Remove the DR fitting (Item 1) [Figure 20-120-16] &
[Figure 20-120-17].
Installation: Put oil on O-rings and back-up washers.
Tighten to 25 ft.-lbs. (33,9 Nm).
20-120-6
863 Bobcat Loader
Service Manual
POWER BOB-TACH BLOCK (6676547-ALUMINUM)
(CONT’D)
Figure 20-120-22
Disassembly And Assembly (Cont’d)
Figure 20-120-20
1
1
P-16265
Remove plug (Item 1) [Figure 20-120-22].
Installation: Put oil on O-rings and back-up washers.
Tighten to 108-120 in.-lbs. (12,2-13,5 Nm).
P-16274
Figure 20-120-21
Figure 20-120-23
1
1
P-16283
P-16263
Remove the P.O. check valve (Item 1) [Figure 20-120-20]
& [Figure 20-120-21].
Installation: Put oil on O-rings and back-up washers.
Tighten to 20 ft.-lbs. (27,0 Nm).
Remove Plug (Item 1) [Figure 20-120-23].
Installation: Put oil on O-rings and back-up washers.
Tighten to 20-in.-lbs. (27,0 Nm).
20-120-7
863 Bobcat Loader
Service Manual
POWER BOB-TACH BLOCK (6676547-ALUMINUM)
(CONT’D)
Figure 20-120-26
Disassembly And Assembly (Cont’d)
Figure 20-120-24
1
1
P-16290
Remove the nut (Item 1) [Figure 20-120-26].
P-16268
Remove ROD end fitting (Item 1) [Figure 20-120-24].
Installation: Tighten to 48-60 in.-lbs. (5,4-6,8 Nm).
Figure 20-120-27
Figure 20-120-25
1
P-16276
P-16267
Remove BASE end fitting (Item 1) [Figure 20-120-25].
Use a test meter to measure coil resistance [Figure 20120-27]. Coil wires do not have polarity. Correct
resistance is approximately 9 ohms.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
20-120-8
863 Bobcat Loader
Service Manual
POWER BOB-TACH BLOCK (6676547-ALUMINUM)
(CONT’D)
Figure 20-120-29
Disassembly And Assembly (Cont’d)
Figure 20-120-28
2
1
1
P-16335
Remove the check ball (Item 1) [Figure 20-120-29].
Remove the spring (Item 2) [Figure 20-120-29].
P-16277
Remove the solenoid valve (Item 1) [Figure 20-120-28].
Installation: Put oil on O-rings and back-up washers.
Tighten the solenoid valve to 12 ft.-lbs. (16,3 Nm) torque.
20-120-9
863 Bobcat Loader
Service Manual
20-120-10
863 Bobcat Loader
Service Manual
POWER BOB-TACH BLOCK (6678554-CAST IRON)
IMPORTANT
Removal And Installation
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-121-2
WARNING
1
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
2
2
W-2059-0598
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
2
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Drain the hydraulic reservoir. (See Draining The Fluid
Reservoir on Page 20-80-1.)
P-26908
Disconnect and cap the outlet hose (Item 1) [Figure 20121-2] from block.
Disconnect and cap the hose (Item 2) [Figure 20-121-2]
from block.
Figure 20-121-1
1
P-26244
Disconnect and cap the two solenoid connectors (Item 1)
[Figure 20-121-1] from the loader harness.
20-121-1
863 Bobcat Loader
Service Manual
POWER BOB-TACH BLOCK (6678554-CAST IRON)
(CONT’D)
IMPORTANT
Removal And Installation (Cont’d)
Figure 20-121-3
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
1
1
I-2003-0888
Figure 20-121-5
1
1
P-26909
Remove the four mounting bolts (Item 1) [Figure 20-1213].
2
1
Installation: Tighten the mounting bolts to 25-28 ft.-lbs.
(34-38 Nm) torque.
3
P-26103
Remove the power Bob-Tach block.
Remove the spring (Item 1) [Figure 20-121-5] and
compensator (Item 2) [Figure 20-121-5].
Disassembly And Assembly
Figure 20-121-4
Check the O-ring (Item 3) [Figure 20-121-5] on the plug
and replace as needed.
1
Figure 20-121-6
2
P-26100
1
Clean the block (Item 1) [Figure 20-121-4] to remove dirt
before disassembly. Block ports are labeled for correct
assembly. Remove the plug (Item 2) [Figure 20-121-4].
Installation: Tighten the plug to 46 ft.-lbs. (62,4 Nm)
torque.
P-26105
Remove the plug (Item 1) [Figure 20-121-6].
Installation: Tighten the plug to 120 in.-lbs. (13,6 Nm)
torque.
20-121-2
863 Bobcat Loader
Service Manual
POWER BOB-TACH BLOCK (6678554-CAST IRON)
(CONT’D)
Figure 20-121-9
1
Disassembly And Assembly (Cont'd)
Figure 20-121-7
P-26208
3
4
2
1
5
2
1
P-26112
3
Remove the pressure reducing valve plug (Item 1)
[Figure 20-121-8] & [Figure 20-121-9].
P-26107
Remove the spring (Item 1) [Figure 20-121-7] and check
ball (Item 2) [Figure 20-121-7].
Check the O-ring (Item 3) [Figure 20-121-7] on the plug
and replace as needed.
Installation: Tighten the pressure reducing valve plug to
to 46 ft.-lbs. (62,4 Nm) torque.
Remove the relief piston (Item 2) [Figure 20-121-9],
spring (Item 3) [Figure 20-121-9], ball seat spring guide
(Item 4) [Figure 20-121-9].
Check the O-ring (Item 5) [Figure 20-121-9] on the
pressure reducing valve plug and replace as needed.
Figure 20-121-8
NOTE: The relief valve seat (Item 6) [Figure 20-121-9]
is a non-serviceable part. If seat is damaged,
order a new power Bob-Tach block from
Bobcat parts.
1
P-26109
20-121-3
863 Bobcat Loader
Service Manual
POWER BOB-TACH BLOCK (6678554-CAST IRON)
(CONT’D)
Figure 20-121-12
Disassembly And Assembly (Cont'd)
Figure 20-121-10
1
P-26116
Figure 20-121-13
1
P-26113
4
Figure 20-121-11
3
2
1
P-26117
3
2
Remove the nut (Item 1) [Figure 20-121-12] & [Figure
20-121-13].
1
P-26114
Installation: Tighten the nut to 5 ft.-lbs. (6,8 Nm) torque.
Remove the plug (Item 1) [Figure 20-121-10] & [Figure
20-121-11].
Installation: Tighten the plug to 32 in.-lbs. (3,6 Nm)
torque.
Check the O-ring (Item 2) [Figure 20-121-11] on the plug
and replace as needed.
Remove the first coil (Item 2) [Figure 20-121-13], spacer
(Item 3) [Figure 20-121-13] and the second coil (Item 4)
[Figure 20-121-13].
NOTE: Remember the coil orientation for ease of
installation.
Check the O-ring (Item 3) [Figure 20-121-11] and
replace as needed.
20-121-4
863 Bobcat Loader
Service Manual
POWER BOB-TACH BLOCK (6678554-CAST IRON)
(CONT’D)
Figure 20-121-16
Disassembly And Assembly (Cont'd)
Figure 20-121-14
1
1
P-26123
Figure 20-121-17
P-26120
Remove the stem (Item 1) [Figure 20-121-14].
Installation: Tighten the stem to 20 ft.-lbs. (27,1 Nm)
torque.
Figure 20-121-15
2
1
1
3
P-26309
Remove the plug (Item 1) [Figure 20-121-16] & [Figure
20-121-17].
Installation: Tighten the plug to 120 in.-lbs. (13,6 Nm)
torque.
2
Remove the dowel pin shuttle (Item 2) [Figure 20-12117].
P-26122
Check the O-rings and back-up washers (Item 1) [Figure
20-121-15] and replace as needed.
Check the O-ring (Item 3) [Figure 20-121-17] and
replace as needed.
Installation: Put oil on O-rings and back-up washers.
Check the O-ring (Item 2) [Figure 20-121-15] and
replace as needed.
20-121-5
863 Bobcat Loader
Service Manual
POWER BOB-TACH BLOCK (6678554-CAST IRON)
(CONT’D)
Figure 20-121-20
Disassembly And Assembly (Cont'd)
Figure 20-121-18
1
P-26128
Figure 20-121-21
1
P-26125
Figure 20-121-19
1
2
2
P-26129
1
3
Remove the plug (Item 1) [Figure 20-121-20] & [Figure
20-121-21].
P-26127
Remove the plug (Item 1) [Figure 20-121-18] & [Figure
20-121-19].
Installation: Tighten the plug to 198 in.-lbs. (22,4 Nm)
torque.
Installation: Tighten the plug to 198 in.-lbs. (22,4 Nm)
torque.
Check the O-ring (Item 2) [Figure 20-121-21] and
replace as needed.
Remove the pilot piston (Item 2) [Figure 20-121-19].
Check the O-ring (Item 3) [Figure 20-121-19] and
replace as needed.
20-121-6
863 Bobcat Loader
Service Manual
POWER BOB-TACH BLOCK (6678554-CAST IRON)
(CONT’D)
Figure 20-121-24
Disassembly And Assembly (Cont'd)
Figure 20-121-22
1
P-26133
Make sure orifice is clean and not plugged [Figure 20121-24].
P-26130
Figure 20-121-23
2
1
3
P-26132
Remove the plug (Item 1) [Figure 20-121-22] & [Figure
20-121-23].
Installation: Tighten the plug to 32 in.-lbs. (3,6 Nm)
torque.
Remove the orifice (Item 2) [Figure 20-121-23] with a 5/
32 inch allen wrench.
Installation: Tighten the orifice to 5 ft.-lbs. (6,8 Nm)
torque.
20-121-7
863 Bobcat Loader
Service Manual
POWER BOB-TACH BLOCK (6678554-CAST IRON)
(CONT’D)
Figure 20-121-27
Disassembly And Assembly (Cont'd)
Figure 20-121-25
1
P-26137
Remove the plug (Item 1) [Figure 20-121-27].
1
Installation: Tighten the plug to 120 in.-lbs. (13,6 Nm)
torque.
P-26134
Figure 20-121-26
Figure 20-121-28
3
2
1
1
4
2
P-26136
P-26139
Remove the plug (Item 1) [Figure 20-121-25] & [Figure
20-121-26].
Remove the dowel pin orifice (Item 1) [Figure 20-12128].
Installation: Tighten the plug to 198 in.-lbs. (22,4 Nm)
torque.
Check the O-ring (Item 2) [Figure 20-121-28] and
replace as needed.
Remove the relief spring (Item 2) [Figure 20-121-26].
Remove the ball seat spring guide (Item 3) [Figure 20121-26].
Check the O-ring (Item 4) [Figure 20-121-26] and
replace as needed.
20-121-8
863 Bobcat Loader
Service Manual
POWER BOB-TACH BLOCK (6678554-CAST IRON)
(CONT’D)
Figure 20-121-31
Disassembly And Assembly (Cont'd)
Figure 20-121-29
1
P-26141A
Remove the plug (Item 1) [Figure 20-121-31].
Installation: Tighten the plug to 32 in.-lbs. (3,6 Nm)
torque.
P-26140
Figure 20-121-30
Figure 20-121-32
2
1
2
1
3
P-26141
P-26143
Remove the plug (Item 1) [Figure 20-121-29] & [Figure
20-121-30].
Remove the flow control spring (Item 1) [Figure 20-12132].
Installation: Tighten the plug to 32 in.-lbs. (3,6 Nm)
torque.
Remove the flow control (Item 2) [Figure 20-121-32].
Check the O-ring (Item 2) [Figure 20-121-30] and
replace as needed.
Check the O-ring (Item 3) [Figure 20-121-32] and
replace as needed.
20-121-9
863 Bobcat Loader
Service Manual
20-121-10
863 Bobcat Loader
Service Manual
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
Disassembly And Assembly (518916011 & Above)
Removal And Installation (514449564 & Above)
Figure 20-130-2
IMPORTANT
1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
2
4
3
I-2003-0888
Figure 20-130-1
P-34661
Figure 20-130-3
2
1
1
3
4
2
6
5
3
P-34899
Disconnect the auxiliary tubelines (Item 1) [Figure 20130-1] and drain tubeline (Item 2) [Figure 20-130-1] from
the coupler block.
Remove the two mounting bolts (Item 3) [Figure 20-1301]
P-34760
Remove the male coupler (Item 1) [Figure 20-130-2] &
[Figure 20-130-3].
Installation: Tighten the male coupler (Item 1) [Figure
20-130-2] & [Figure 20-130-3] to 59 ft.-lbs. (80 Nm).
Remove the drain coupler (Item 2) [Figure 20-130-2] &
[Figure 20-130-3].
Installation: Tighten the drain coupler (Item 2) [Figure
20-130-2] & [Figure 20-130-3] to 37 ft.-lbs. (50 Nm).
Remove the female coupler (Item 3) [Figure 20-130-2] &
[Figure 20-130-3].
Installation: Tighten the female coupler (Item 3) [Figure
20-130-2] & [Figure 20-130-3] to 59 ft.-lbs. (80 Nm).
Remove the fittings (Item 4) [Figure 20-130-2] & [Figure
20-130-3] check the O-rings (Item 5) [Figure 20-130-3]
and replace as needed.
Remove the springs (Item 6) [Figure 20-130-3].
20-130-1
863 Bobcat Loader
Service Manual
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
(CONT'D)
Figure 20-130-6
1
Disassembly And Assembly (514449564 & Above)
(Cont’d)
Figure 20-130-4
1
1
P-34665
Check the O-rings (Item 1) [Figure 20-130-6] backup Orings (Item 2) [Figure 20-130-6] for damage and replace
as needed.
P-34663
Figure 20-130-7
Check the O-ring (Item 1) [Figure 20-130-4] for damage
and replace as needed.
1
Figure 20-130-5
1
2
P-34664
Check the O-rings (Item 1) [Figure 20-130-7] backup Orings (Item 2) [Figure 20-130-7] for damage and replace
as needed.
P-34701
Press center of male couplers down and check the O-ring
(Item 1) [Figure 20-130-5] for damage and replace as
needed.
20-130-2
863 Bobcat Loader
Service Manual
HYDROSTATIC SYSTEM
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Hydrostatic Charge Pressure Sender Removal And Installation 30-30-1
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-2
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Tensioner Pulley Removal And Installation . . . . . . . . . . . . . . . . 30-50-2
Tensioner Pulley Tension Spring . . . . . . . . . . . . . . . . . . . . . . . . 30-50-4
HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-8
Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-14
Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-13
Carrier Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-12
Carrier Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 30-20-11
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-7
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
HYDROSTATIC MOTOR (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . 30-21-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-12
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-4
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-11
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-16
Charge Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-8
Hydraulic Pump Removal & Installation. . . . . . . . . . . . . . . . . . . 30-40-7
Parts Identification (Left Half). . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-6
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-3
Replenishing/High Pressure Relief Valve . . . . . . . . . . . . . . . . . 30-40-1
SAFETY &
MAINTENANCE
HYDROSTATIC
SYSTEM
ELECTRICAL
SYSTEM &
ANALYSIS
ENGINE
SERVICE
SPECIFICATIONS
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . 30-10-1
Replentishing The Valve Function . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Removal And Installation With STC (Seal Tight Connector) . . . 30-60-1
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE
SPECIFICATION FOR BOLTS, SPEC-01) UNLESS OTHERWISE SPECIFIED.
30-01
863 Bobcat Loader
Service Manual
30-02
863 Bobcat Loader
Service Manual
HYDROSTATIC SYSTEM INFORMATION
WARNING
Troubleshooting Chart
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are
most common. Many of the recommended procedures
must be done by authorized Bobcat Service Personnel
only.
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
PROBLEM
No drive on one side, in one direction.
No drive on one side in both directions.
The loader does not move in a straight line.
The hydrostatic system is overheating.
Service code HP 2 appears (Warnings, low charge pressure) or the warning light
comes on.
W-2004-1285
CAUSE
1, 2
2, 3, 4, 5
2, 3, 5, 6, 7
8, 9, 10, 11
8, 11, 12, 13, 14
KEY TO CORRECT THE CAUSE
1. The hydrostatic pump replentishing valves not seating.
2. The steering linkage needs adjustment.
3. The hydrostatic pump has damage.
4. The final drive chains are broken.
5. the hydrostatic motor has damage.
6. The tires do not have the correct tire pressure.
7. The tires are not the same size.
8. The hydrostatic fluid is not at the correct level.
9. The oil cooler has a restriction.
10. The temperature sending switch is not operating correctly.
11. The loader is not being operated at the correct RPM.
12. The sender is defective.
13. Pump is defective or worn hydrostatics.
14. Hydraulic filter is plugged.
30-10-1
863 Bobcat Loader
Service Manual
HYDROSTATIC SYSTEM INFORMATION (CONT’D)
The functions of the replentishing valves are:
•
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Replentishing The Valve Function
•
To give replacement fluid to the low pressure side of
the hydrostatic circuit. Replacement fluid is needed
because of normal internal leakage and the controlled
flow to the oil cooler for cooling; Function 1 [Figure
30-10-1].
To keep high pressure fluid out of the low pressure
side of the hydrostatic circuitry; Function 2 [Figure
30-10-1].
See HYDROSTATIC MOTOR, Page 30-01 (M46 Pump)
or HYDROSTATIC MOTOR (TWO SPEED), Page 30-01
(M44 Pump) for valve location and repair information.
Figure 30-10-1
Function 1
Function 2
Valve Moves for
Charge Oil
Replacement
Valve Stays on Seat
to Hold High
Pressure for
Drive
B-2804
30-10-2
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR
Figure 30-20-1
Removal And Installation
1
2
WARNING
N-17874
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Disconnect the case drain hose (Item 1) [Figure 30-201].
Disconnect the high pressure hoses (Item 2) [Figure 3020-1].
Figure 30-20-2
Raise the lift arms and install the lift arm support device.
(See LIFT ARM SUPPORT DEVICE on Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
1
2
1
Remove the motor cover.
Mark the hoses for correct installation.
N-17876
Remove the ten mounting bolts (Item 1) [Figure 30-202].
NOTE: The two bolts (Item 2) [Figure 30-20-2] mount
the cam ring to the motor, and do not have to
be removed, to remove the motor from the
loader.
Remove the motor/cam ring section from the loader.
30-20-1
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (CONT’D)
Removal And Installation (Cont’d)
Figure 30-20-3
1
P-5405
Remove the piston/roller section (Item 1) [Figure 30-203] from the loader, if it was not removed with the motor/
cam ring.
To remove the motor carrier. (See Carrier Removal And
Installation on page 30-20-11.)
30-20-2
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (CONT’D)
Parts Identification
2
1
3
3
4
4
12
9
8
7
6
5
10
11
13
26
27
28
14
23
15
25
29
16
22
21
24
20
19
18
17
30
C-3374A
Ref.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Description
Distributor
Spring
Seal
O-Ring
Plug
O-Ring
Spring
Washer
Spool
Spring
Rear Housing
Plug
O-Ring
O-Ring
Stop Pin
Bolt
Ref.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
30-20-3
Description
Plug
O-Ring
Spring
Shim
Poppet
O-Ring
Seal
O-ring
Seal
O-ring
Cam
Roller
Piston
Block
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (CONT’D)
Figure 30-20-6
Disassembly
1
Figure 30-20-4
1
N-17863
Remove the cam ring (Item 1) [Figure 30-20-6] from the
motor housing.
N-17861
Remove the piston/roller section (Item 1) [Figure 30-204] from the motor.
Figure 30-20-7
1
Figure 30-20-5
1
1
N-17864
Remove the stop pin (Item 1) [Figure 30-20-7] from the
rear motor housing.
N-17860
Remove the two cam ring mounting bolts (Item 1)
[Figure 30-20-5].
30-20-4
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (CONT’D)
Remove the two O-rings, that are located under the
seals.
Disassembly (Cont’d)
Figure 30-20-10
1
IMPORTANT
1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1
Figure 30-20-8
N-17869
1
Remove the nine springs (Item 1) [Figure 30-20-10] from
the distributor.
2
Figure 30-20-11
N-17865
Use a brass drift punch, thru the stop pin hole (Item 1)
[Figure 30-20-8] to remove the distributor (Item 2)
[Figure 30-20-8].
1
Figure 30-20-9
N-17870
Remove the two seals (Item 1) [Figure 30-20-11] from
the distributor.
Remove the two O-rings, that are located under the
seals.
1
N-17866
Remove the two seals (Item 1) [Figure 30-20-9] from the
housing.
30-20-5
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (CONT’D)
Figure 30-20-14
Disassembly (Cont’d)
Figure 30-20-12
2
1
P-5765
1
2
4
3
Apply low air pressure to each port in the cylinder block
to remove the roller (Item 1) [Figure 30-20-14] and
piston/ring assembly (Item 2) [Figure 30-20-14].
N-17872
Remove the plug (Item 1) [Figure 30-20-12], spring (Item
2) [Figure 30-20-12], shim (Item 3) [Figure 30-20-12]
and poppet (Item 4) [Figure 30-20-12].
NOTE: Put all the roller/piston assembly in their
original position.
Figure 30-20-13
2
3
4
2
1
N-17871
Remove the plug (Item 1) [Figure 30-20-13], springs
(Item 2) [Figure 30-20-13], spool (Item 3) [Figure 30-2013] and washer (Item 4) [Figure 30-20-13].
Inspect all parts and replace as needed.
30-20-6
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (CONT’D)
Figure 30-20-17
Inspection
Clean all parts in clean solvent and use air pressure to
dry them. DO NOT use cloth or paper because small
pieces of material can get into the system and cause
damage.
Before the motor is assembled, check the following items:
Figure 30-20-15
P-5759
Check the cylinder block surface for scratches [Figure
30-20-17].
Check all the roller/piston assembly for scratches and
wear [Figure 30-20-17].
Replace the parts as needed.
N-17870
Check the distributor surface for scratches [Figure 3020-15].
Figure 30-20-16
P-5753
Check the cam ring inside surface for wear and scratches
[Figure 30-20-16].
30-20-7
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (CONT’D)
Figure 30-20-19
Assembly
IMPORTANT
1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
NOTE: Always use new O-rings and seals when
assembling the hydrostatic motor.
Figure 30-20-18
N-17870
Install new O-rings and seals (Item 1) [Figure 30-20-19]
on the distributor.
Figure 30-20-20
2
1
1
P-5765
Install the roller (Item 1) [Figure 30-20-18] in the piston
(Item 2) [Figure 30-20-18].
Dip the roller/piston assembly into oil and install into the
bore in the cylinder.
N-17869
Put grease on the springs (Item 1) [Figure 30-20-20] to
hold them in place.
Install the springs into the distributor.
Repeat for each roller/piston assembly.
30-20-8
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (CONT’D)
Install the two O-rings into the housing.
Assembly (Cont’d)
Figure 30-20-23
Figure 30-20-21
2
1
3
1
4
1
N-17866
N-17871
Install the spring (Item 1) [Figure 30-20-21], spool (Item
2) [Figure 30-20-21], washer (Item 3) [Figure 30-20-21]
and spring into the rear housing.
Replace the O-ring (Item 4) [Figure 30-20-21] on the
plug.
Install the two seals (Item 1) [Figure 30-20-23] into the
housing, over the top of the O-rings, with minimum
distortion.
Lightly smear grease over the seals.
Figure 30-20-24
Install the plug into the rear housing and tighten to 18-22
ft.-lbs. (25-30 Nm) torque.
2
3
Figure 30-20-22
1
N-17868
4
3
2
1
Install the stop pin (Item 1) [Figure 30-20-24] and tighten
to 7-9 ft.-lbs. (10-12 Nm) torque.
Install the distributor (Item 2) [Figure 30-20-24] into the
housing.
N-17872
Install the poppet (Item 1) [Figure 30-20-22], the shim
(Item 2) [Figure 30-20-22], spring (Item 3) [Figure 3020-22] into the rear housing.
Align the distributor hole (Item 3) [Figure 30-20-24] with
the stop pin. When aligned correctly, the distributor can
be depressed slightly.
Replace the O-ring (Item 4) [Figure 30-20-22] on the
plug.
Lightly smear grease on the O-ring.
Install the plug into the rear housing and tighten to 9-11
ft.-lbs. (12-15 Nm) torque.
30-20-9
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (CONT’D)
Figure 30-20-27
Assembly (Cont’d)
Figure 30-20-25
1
1
1
N-17860
Install the two cam ring mounting bolts (Item 1) [Figure
30-20-27] and tighten to 50 ft.-lbs. (67,8 Nm) torque.
N-17862
Install the O-ring (Item 1) [Figure 30-20-25] on the rear
housing.
Figure 30-20-28
Figure 30-20-26
1
N-17861
Install the piston/roller section (Item 1) [Figure 30-20-28]
in the motor.
N-17863
Install the cam ring (Item 1) [Figure 30-20-26] on the
rear housing and align the mounting bolt holes.
Install the motor on the loader and tighten the mount
bolts to 110 ft.-lbs. (149,2 Nm) torque.
NOTE: Before operating the hydrostatic motor, make
sure it is full of oil. There are several methods
to fill the motor with oil; (1) with the case drain
hose disconnected, fill the motor with oil
through the case drain port; (2) with the case
drain hose disconnected, BICS™ brake
locked, engine running, stroke the steering
until oil comes out of the case drain port.
30-20-10
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (CONT’D)
Figure 30-20-30
Carrier Removal And Installation
Figure 30-20-29
1
1
P-5467
Lift and block the loader. (See Contents Page 10-01.)
Raise the lift arm and install an approved lift arm support
device. (See LIFT ARM SUPPORT DEVICE on Page 1020-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the fluid from the chaincase. (See Replacing
The Oil on Page 10-130-1.)
Remove the front axle. (See DRIVE COMPONENTS on
Page 40-20-1.)
If the motor carrier is removed from the right side, remove
the lift arm by-pass control valve, (See Removal And
Installation on Page 20-50-1.) and remove the hydraulic
control valve. (See Removal & Installation (S/N
514447863 & Below) on Page 20-41-3.)
Remove the six mounting bolts (Item 1) [Figure 30-2029] from the carrier.
P-5489
NOTE: For easier access for the motor carrier coming
out and going into the chaincase, tie the front
drive chain to the chaincase with a wire
[Figure 30-20-30].
Slide the motor carrier out of the chaincase far enough to
install a chain and chain hoist to the carrier [Figure 3020-30].
Installation: Tighten the mounting bolts to 330 ft.-lbs.
(447 Nm) torque.
Slide the motor carrier toward the rear and remove the
rear drive chain.
30-20-11
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (CONT’D)
Carrier Parts Identification
1
2
3
4
5
5
6
7
8
TS-1227A
Ref.
1.
2.
3.
4.
5.
6.
7.
8.
Description
Shaft
Bearing
Race
Housing
Seal (2)
Race
Bearing
Snap Ring
30-20-12
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (CONT’D)
Figure 30-20-33
Carrier Disassembly
Figure 30-20-31
1
1
P-5756
Remove the snap ring (Item 1) [Figure 30-20-33] and
washer from the shaft.
P-5760
Figure 30-20-34
Remove the large O-ring from the groove (Item 1)
[Figure 30-20-31] in the housing.
Figure 30-20-32
P-5768
P-5766
Put the motor carrier in a hydraulic press [Figure 30-2032].
Use a hydraulic press, remove the shaft from the housing
[Figure 30-20-34].
Put a small amount of pressure on the shaft to release
the pre-load on the snap ring.
30-20-13
863 Bobcat Loader
Service Manual
HYDRAULIC MOTOR (CONT’D)
Carrier Assembly
Carrier Disassembly (Cont’d)
Figure 30-20-37
Figure 30-20-35
2
1
P-5764
P5761
The tool listed will be needed to the following procedure:
Install the bearing puller tool under the bearing flange,
use the hydraulic press to remove the bearing from the
shaft [Figure 30-20-35].
Figure 30-20-36
MEL1431 - Seal Driver Tool
Install the first seal (Item 1) [Figure 30-20-37] into the
housing with the seal lip facing away from you.
Use the tool (Item 2) [Figure 30-20-37] as shown in the
figure.
Figure 30-20-38
2
1
2
1
P-5763
Remove the two seals (Item 1) [Figure 30-20-36] from
the housing.
Check the bearing cup (Item 2) [Figure 30-20-36] (both
sides) and replace as needed.
P-5762
Install the second seal (Item 1) [Figure 30-20-38] into the
housing with the seal lip facing towards you.
Use the tool (Item 2) [Figure 30-20-38] as show in the
figure.
30-20-14
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (CONT’D)
Figure 30-20-40
Carrier Assembly (Cont’d)
Figure 30-20-39
2
1
1
P-5769
Install the bearing (Item 1) [Figure 30-20-40] using the
tool (Item 2) [Figure 30-20-40] (MEL1431).
P-5767
Install the bearing on the shaft [Figure 30-20-39].
Use a pipe (Item 1) [Figure 30-20-39] with O.D. that
seats on the I.D. of the bearing.
Install the shaft/bearing assembly into the housing.
After the bearing is seated. Install the washer and snap
ring on the shaft.
It may be necessary to use the tool to push the washer
and snap ring sown into position because of the pre-load
on the bearings.
30-20-15
863 Bobcat Loader
Service Manual
30-20-16
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (TWO-SPEED)
Figure 30-21-2
Removal And Installation
3
2
1
WARNING
N-22484
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the lift arms and install the lift arm support device.
(See LIFT ARM SUPPORT DEVICE on Page 10-20-1.)
Disconnect the hydraulic hose (Item 1) [Figure 30-21-2]
that goes to the two-speed port on the two-speed/brake
block.
Disconnect the hydraulic hose (Item 2) [Figure 30-21-2]
that goes to the brake port on the two-speed/brake block.
Disconnect the hydraulic hose (Item 3) [Figure 30-21-2]
that goes to the make-up port on the two-speed/brake
block.
Figure 30-21-3
Raise the operator cab. (See Contents, Page 10-01.)
Drain the hydraulic reservoir. (See Raising The Operator
Cab on Page 10-30-1.)
1
Figure 30-21-1
1
N-22485
1
Disconnect the hydraulic hose (Item 1) [Figure 30-21-3]
that goes to the case drain filter.
N-22483
Remove the motor cover mount bolts (Item 1) [Figure 3021-1].
Remove the motor cover from the loader.
30-21-1
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D)
Figure 30-21-6
Removal And Installation (Cont’d)
Figure 30-21-4
1
2
1
N-22487
2
Remove the 10 (12 mm) mount bolts (Item 1) [Figure 3021-6] from the motor.
N-22486
Remove the hydraulic fitting (Item 1) [Figure 30-21-4]
from the motor.
NOTE: The two smaller diameter bolts (8 mm), hold
the cam ring to the motor and do not have to
be removed for motor removal.
Remove the eight flange bolts (Item 2) [Figure 30-21-4]
from the high pressure hoses on the motor.
Remove the motor from the loader.
Figure 30-21-7
Installation: Install the lower collar to the motor and
connect the high pressure hoses behind the collar, then
install the upper collar and tighten the bolts to 25 ft.-lbs.
(34 Nm) torque.
Figure 30-21-5
1
1
N-22535
Installation: Replace the O-ring (item 1) [Figure 30-217] and hold it in place with a light cover of lithium base
grease. Tighten the 10 mounting bolts to 110 ft.-lbs. (149
Nm) torque.
N-22488
Remove the hydraulic fitting (Item 1) [Figure 30-21-5]
from the motor.
30-21-2
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (CONT’D)
Parts Identification
1. Motor
2. Distributor
3. Spring
4. Seal/O-Ring
5. Seal/O-Ring
6. Seal/O-Ring
7. Seal/O-Ring
8. Seal/O-Ring
9. Bushing
10. Roller
11. Piston
12. Block
13. Cam
14. Quad Ring
15. Plug
16. O-Ring
17. Locating Pin
18. Housing
19. Shim
20. O-Ring
21. Poppet
22. Spring
23. Plug
24. Bolt
25. Spring
26. Spool
27. Washer
28. O-Ring
29. Plug
30. Housing
31. Quad Ring
32. Bushing
33. Snap Ring
34. Snap Ring
35. Spool
36. Spring
37. Washer
38. Quad Ring
39. Bolt
40. Shaft
41. Brake Disc-Outer
42. Brake Disc-Inner
43. Piston
44. O-Ring
45. Washer
46. Washer
47. Gasket
48. Cover
49. Bolt
1
8
7
3
2
5
4
6
29
25 26
9
16
31
27
30
28
32 25
15
10
34
39
33
11
18
19
17
21
20
45
13
43
41
3637
38
48
23
14
12
24
22
35
47
46
49
44
42
40
B-16657A
30-21-3
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D)
Figure 30-21-10
Disassembly
Figure 30-21-8
2
1
3
N-22491
Remove the cover plate gasket (Item 1) [Figure 30-2110].
N-22489
NOTE: Mark the motor, brake and motor carrier
housings for proper alignment for ease of
assembly [Figure 30-21-8]
Remove the disc spring washer (Item 2) [Figure 30-2110] and the disk spring (Item 3) [Figure 30-21-10] from
the brake housing.
Drain the oil from the motor casing.
NOTE: Mark the top side of the disk spring for proper
installation.
Figure 30-21-9
Figure 30-21-11
1
2
1
N-22490
N-22493
Remove the twelve mounting bolts (Item 1) [Figure 3021-9] from the brake cover plate.
Remove the piston from the brake housing (Item 1)
[Figure 30-21-11].
NOTE: Unscrew the bolts alternately, one turn at a
time to release the preload in the end cap.
NOTE: The use of air pressure through the brake line
connection (Item 2) [Figure 30-21-11] will aid
in piston removal.
Remove the cover plate from the brake housing.
30-21-4
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D)
Figure 30-21-14
Disassembly (Cont’d)
Figure 30-21-12
1
2
1
N-22496
Remove the O-ring (Item 1) [Figure 30-21-14] from the
brake housing.
N-22494
Remove the eight mounting bolts (Item 1) [Figure 30-2112] from the brake housing.
Figure 30-21-15
Remove the brake housing (Item 2) [Figure 30-21-12]
from the rear housing.
1
Figure 30-21-13
2
1
N-22497
Remove the seal (Item 1) [Figure 30-21-15] from the
brake housing.
N-22495
Remove the brake disks (Item 1) [Figure 30-21-13] from
the brake shaft.
Remove the O-ring (Item 2) [Figure 30-21-13] from the
housing.
30-21-5
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D)
Figure 30-21-18
Disassembly (Cont’d)
Figure 30-21-16
1
1
2
N-22502
Remove the plug (Item 1) [Figure 30-21-18] from the
housing.
N-22499
Remove the two-sped spool (Item 1) [Figure 30-21-16]
from the housing assembly.
Installation: Tighten the plug to 18-22 ft.-lbs. (25-30 Nm)
torque.
Remove the plugs (Item 2) [Figure 30-21-18] from the
housing.
Figure 30-21-17
Installation: Tighten the plugs to 9-11 ft.-lbs. (12-15 Nm)
torque.
1
Figure 30-21-19
1
4
3
2
N-22501
Inspect the spool (Item 1) [Figure 30-21-17], the spring
(Item 2) [Figure 30-21-17], washer (Item 3) [Figure 3021-17] and the snap ring (Item 4) [Figure 30-21-17], and
replace as needed.
NOTE: The spool (Item 1) [Figure 30-21-17] is marked
with either an A or B. The spool must be
replace with a spool with the same mark.
N-22503
Remove the flushing spool assembly (Item 1) [Figure 3021-19] from the housing.
30-21-6
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D)
Figure 30-21-22
Disassembly (Cont’d)
Figure 30-21-20
1
1
2
4
3
N-22506
Remove the poppet assembly (Item 1) [Figure 30-21-22]
from the housing.
N-22504
Remove the spring (Item 1) [Figure 30-21-20], washer
(Item 2) [Figure 30-21-20] and rear spring (Item 3)
[Figure 30-21-20] from the spool (Item 4) [Figure 30-2120].
Figure 30-21-23
Inspect all parts and replace as needed.
Figure 30-21-21
1
1
3
2
N-22507
Inspect the poppet (Item 1) [Figure 30-21-23], shim
(Item 2) [Figure 30-21-23] and spring (Item 3) [Figure
30-21-23] for wear and replace as needed.
N-22505
Remove the plug (Item 1) [Figure 30-21-21] from the
housing.
Installation: Tighten the plug to 9-11 ft.-lbs. (12-15 Nm)
torque.
30-21-7
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D)
Figure 30-21-26
Disassembly (Cont’d)
Figure 30-21-24
1
1
1
N-22511
Remove the roller/piston assembly (Item 1) [Figure 3021-26] from the cylinder block.
N-22508
Loosen the two (8 mm) cam ring mount bolts (Item 1)
[Figure 30-21-24].
NOTE: Put all roller/piston assemblies back in the
original bore.
Figure 30-21-27
Turn the housing, cam ring, and rotating group assembly
over and place on a stand.
Remove the cam ring mount bolts, and remove the cam
ring from the housing.
Figure 30-21-25
1
1
2
N-22512
Remove the brake shaft (Item 1) [Figure 30-21-27] from
the housing.
N-22509
Remove the cylinder block (Item 1) [Figure 30-21-25]
from the housing.
Remove the O-ring (Item 2) [Figure 30-21-25] from the
housing.
30-21-8
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D)
Figure 30-21-30
Disassembly (Cont’d)
Figure 30-21-28
1
1
N-22516
N-22513
NOTE: The snap ring end of the shaft (Item 1) [Figure
30-21-28] goes up toward the cam ring end of
the motor.
NOTE: The distributor removal, is best accomplished
by lifting the housing (Item 1) [Figure 30-2130] 2-3 inches above a wooden surface, and
dropping the housing [Figure 30-21-30].
Figure 30-21-31
Figure 30-21-29
1
1
N-22521
Remove the locating pin (Item 1) [Figure 30-21-31] from
the distributor.
N-22515
Remove the distributor (Item 1) [Figure 30-21-29] from
the housing.
30-21-9
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D)
Figure 30-21-34
Disassembly (Cont’d)
Figure 30-21-32
2
1
1
N-22519
Remove the six seals [Figure 30-21-34] and the six
back-up O-rings (Item 2) [Figure 30-21-34] from the
distributor.
N-22522
Remove the twelve springs (Item 1) [Figure 30-21-32]
from the distributor.
Figure 30-21-33
1
N-22523
Remove the bushing (Item 1) [Figure 30-21-33] from the
distributor, if worn or scratched.
30-21-10
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D)
Figure 30-21-37
Inspection
Figure 30-21-35
1
N-22510
2
Check the cam ring inside surface for wear and scratches
[Figure 30-21-37].
N-22498
Figure 30-21-38
Clean all parts in clean solvent and use air pressure to
dry them. Do Not use cloth or paper because small
pieces of material can get into the system and cause
damage.
3
1
Before the motor is assembled, check the following items:
Check the brake piston (Item 1) [Figure 30-21-35] and
seal (Item 2).[Figure 30-21-35] and replace as needed.
Figure 30-21-36
2
N-22526
Check all rollers (Item 1) [Figure 30-21-38], pistons (Item
2) [Figure 30-21-38] and piston rings (Item 3) [Figure
30-21-38] for wear and replace as needed.
NOTE: Put all roller/piston assembly back in their
original position.
N-22520
Check the surfaces of the distributor for wear and
scratches [Figure 30-21-36].
30-21-11
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D)
Assembly
Inspection (Cont’d)
Figure 30-21-40
Figure 30-21-39
2
1
1
N-22511
N-22514
Check the brake shaft (Item 1) [Figure 30-21-39] for
wear and replace as needed.
Check the brake shaft snap ring (Item 2) [Figure 30-2139] and replace as needed.
NOTE: Always use new O-rings and seals when
assembling the motor and brake assemblies.
Dip the roller/piston assembly (Item 1) [Figure 30-21-40]
in oil and replace back in its original bore.
Repeat the procedure for each roller/piston assembly.
Figure 30-21-41
1
N-22518
Apply a small amount of grease to the locating pin (Item
1) [Figure 30-21-41] and install the locating pin in the
housing.
30-21-12
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D)
Figure 30-21-44
Assembly (Cont’d)
Figure 30-21-42
1
1
N-22515
Install the distributor (Item 1) [Figure 30-21-44] in the
housing.
N-22525
Install a new bushing (Item 1) [Figure 30-21-42] in the
distributor if the old bushing was removed.
Figure 30-21-45
Figure 30-21-43
1
1
N-22516
Align the locating pin (Item 1) [Figure 30-21-45] in the
housing with the alignment hole in the distributor, and tap
the distributor in place with a rubber mallet.
N-22522
Install new O-rings and seals on the distributor [Figure
30-21-43].
NOTE: When installing seals, apply a light coating of
oil to the seal and the mating surfaces of the
distributor. Install the O-rings and seals,
allow 30 minutes for the seals to set on the
distributor before installing the distributor in
the housing.
Using a small amount of grease, install the twelve springs
into the distributor valve [Figure 30-21-43].
30-21-13
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D)
Figure 30-21-48
Assembly (Cont’d)
Figure 30-21-46
1
1
N-22509
Install the cylinder block assembly (Item 1) [Figure 3021-48] to the brake shaft.
N-22513
Install the brake shaft (Item 1) [Figure 30-21-46] in the
housing.
Install the cam ring to the rear housing and start the
mount bolts and finger tighten.
Figure 30-21-49
Figure 30-21-47
1
1
1
N-22508
N-22512
Apply a light coating of grease, and install the O-ring
(Item 1) [Figure 30-21-47] to the housing.
Turn the motor so that it sets on the cam ring, and
cylinder block [Figure 30-21-49].
NOTE: Be careful when turning or moving the motor
so the cylinder block stays in the motor
housing.
Tighten the two cam ring mounting bolts (Item 1) [Figure
30-21-49] to 26-29 ft.-lbs. (35-39 Nm) torque.
30-21-14
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D)
Figure 30-21-52
Assembly (Cont’d)
Figure 30-21-50
2
1
N-18348
Measure the thickness of the individual brake disc’s
[Figure 30-21-52] to determine the amount of wear on
each disc.
N-22499
Install the new O-ring on the housing assembly (Item 1)
[Figure 30-21-50] and lightly smear with grease.
The normal thickness of the individual brake disc is .039
in. (1 mm).
Install the two speed spool (Item 2) [Figure 30-21-50].
If the individual disc’s thickness is .037 in. (0.95 mm) or
less, replace the complete disc pack.
Figure 30-21-51
Figure 30-21-53
1
2
1
N-22496
N-22529
Install a new O-ring on the housing assembly (Item 1)
[Figure 30-21-51] and lightly smear with grease.
Install the brake housing (Item 1) [Figure 30-21-53] on
the motor housing and align the marks.
Install the eight mounting bolts (Item 2) [Figure 30-2153] and tighten evenly to 52-57 ft.-lbs. (70-77 Nm) torque.
30-21-15
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D)
Figure 30-21-56
Assembly (Cont’d)
Figure 30-21-54
1
1
N-22533
Install the brake seal (Item 1) [Figure 30-21-56].
N-22530
Figure 30-21-57
Install the brake disc pack starting with an outer disc
(Item 1) [Figure 30-21-54] and alternating with an inner
disc, throughout the pack.
Figure 30-21-55
1
1
N-22498
Lightly coat the piston with oil and install a new piston
seal (Item 1) [Figure 30-21-57].
N-22532
End the disc pack with an outer disc (Item 1) [Figure 3021-55].
30-21-16
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D)
Figure 30-21-59
Assembly (Cont’d)
Figure 30-21-58
2
1
1
N-22534
N-22493
Install the piston (Item 1) [Figure 30-21-58] in the brake
housing.
NOTE: If the brake pack was not replaced, the
procedure described below for determining
brake washer thickness, need not be
performed.
With the motor in a hydraulic press and the
predetermined amount of pressure applied on the
piston, use a straight edge, and measure the distance
from the top of the brake housing (Item 1) [Figure 30-2159] to the top of the piston (Item 2) [Figure 30-21-59].
Record the measurement to three decimal places.
Remove the motor from the hydraulic press.
Figure 30-21-60
Install the motor assembly in a hydraulic press. Apply a
downward force of 4500 lbs. (20 Kn), on the brake piston
[Figure 30-21-58].
1
NOTE: The 4500 lbs. of force, is NOT the amount of
pressure required by the press. It is the
amount of downward force applied by the
press.
2
The amount of force applied to the brake piston, by the
press, is determined by the diameter of the piston on the
press cylinder and the PSI applied to press cylinder
piston.
Determine the diameter of the piston on the press
cylinder d and use the following formula to determine the
PSI of pressure to apply to the press cylinder piston.
(
1432
d = 6 in. 2 (Squared) = 9
2
)
1432
9
N-22492
Install the brake plate (Item 1) [Figure 30-21-60].
Install the end plate gasket (Item 2) [Figure 30-21-60].
= 159 PSI
Example: d = 6 in. (152 mm) piston diameter of the
press cylinder. Apply 159 PSI (1,096 kPa) pressure to
the press cylinder piston.
30-21-17
863 Bobcat Loader
Service Manual
HYDROSTATIC MOTOR (CONT’D)
Figure 30-21-62
Assembly (Cont’d)
Figure 30-21-61
1
N-22490
Install the brake end cover (Item 1) [Figure 30-21-62].
N-22491
Install the twelve end cover mount bolts and tighten
evenly to 10-12 ft.-lbs. (14-16 Nm) torque.
The correct washer thickness must be determined before
the washer (Item 1) [Figure 30-21-61] can be installed.
Use the recorded measurement obtained in [Figure 3021-59]. Plus the thickness of the gasket (Item 2) [Figure
30-21-60], which is 0.12 in. (0,3 mm). Minus the
thickness of the brake plate (Item 1) [Figure 30-21-60],
which is .281 in. (7,15 mm).
Select a washer, or combination of washers to suit the
calculated thickness within ± 0.6 in. (0,15 mm)
Install the proper brake washer or washers.
30-21-18
863 Bobcat Loader
Service Manual
CHARGE PRESSURE
Hydrostatic Charge Pressure Sender Removal And
Installation
Figure 30-30-1
3
1
2
N-19742
To remove and install the charge pressure sender use the
following procedure.
Disconnet the wire (Item 1) [Figure 30-30-1] from the
sender.
Remove the hydraulidcs hose (Item 2) [Figure 30-30-1]
from the charge pressure sender.
Remove the charge pressure sender from the control
valve at the connector [Figure 30-30-1].
30-30-1
863 Bobcat Loader
Service Manual
30-30-2
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP
Figure 30-40-2
Replenishing/High Pressure Relief Valve
Figure 30-40-1
1
1
2
N-17228
Remove the high pressure relief valve from the pump
[Figure 30-40-2].
N-17227
There are four replenishing/high pressure relief valves
(Item 1) [Figure 30-40-1] in the hydrostatic pump. Two
are located at the top of the pump and two at the bottom
of the pump.
See Contents, Page 30-01 for valve function.
Check the O-rings (Items 1 & 2) [Figure 30-40-2] for
damage and replace as needed.
If the high pressure relief valve must be replaced, it must
be replaced as a complete unit.
The pressure setting for a new high pressure relief valve
is:
4721 PSI
5000 PSI
30-40-1
(S/N 514441939-514446864)
(S/N 514540074-514541034)
(S/N 514446895 & Above)
(S/N 514541035 & Above)
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-40-5
Charge Pressure Relief Valve
IMPORTANT
1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
N-17232
Figure 30-40-3
There are several different thickness of shims (Item 1)
[Figure 30-40-5] and they are used to adjust the charge
pressure.
1
The charge pressure should be set at 420 PSI (2896
kPa).
N-17230
Loosen the charge relief valve plug (Item 1) [Figure 3040-3].
Figure 30-40-4
N-17231
Remove the plug, spring and poppet [Figure 30-40-4].
30-40-2
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-40-8
Removal And Installation
Figure 30-40-6
1
1
2
P-5557
1
Remove the washer and nut (Item 1) [Figure 30-40-8]
from the hydrostatic pump drive shaft.
P-5552
Remove the hydrostatic pump/engine assembly from the
loader. (See Removal And Installation on Page 70-80-1.)
Remove the belt shield clips (Item 1) [Figure 30-40-6]
and belt shield (Item 2) [Figure 30-40-6].
Installation: Tighten the nut to 175-200 ft.-lbs. (237-271
Nm) torque.
Figure 30-40-9
Figure 30-40-7
2
1
1
3
P-5657
Install the nut on the end of the pump drive shaft (without
washer.
P-5554
Loosen the stop mounting bolts (Item 1) [Figure 30-407].
Use a puller (Item 1) [Figure 30-40-9] to remove the
pulley from the pump drive shaft.
Remove the spring tension bolt (Item 2) [Figure 30-407].
Remove the drive belt (Item 3) [Figure 30-40-7].
30-40-3
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-40-12
Removal And Installation (Cont’d)
Figure 30-40-10
2
1
N-15343
1
Remove the mounting bolt (Item 1) [Figure 30-40-12] at
the hydraulic pump end of the pump.
N-15341
Remove the hydrostatic pump from the mounting bracket
and drive belt housing.
Figure 30-40-11
1
N-15342
Remove the two mounting bolts (Item 1) [Figure 30-4010] and nuts (Item 1) [Figure 30-40-11].
Installation: Tighten the mounting bolts and nuts to 6570 ft.-lbs. (89-95 Nm) torque. Make sure the key (Item 2)
[Figure 30-40-10] is installed.
30-40-4
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Parts Identification (Right Half)
8
9
5
4
3
2
7
6
1
13
14
10
15
17
11
27
12
25
19
21
23
16
18
29
20
22
24
26
3837
28
36
33
34
30
32
31
41
40
42
43
46
35
48
45
39
Ref.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Description
BOLT
END CAP
PLUG
O-RING
PLUG
O-RING
O-RING
RELIEF VALVE
BOLT
GASKET
BEARING
PLUG
O-RING
Ref.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Description
O-RING
RELIEF VALVE
PIN
VALVE PLATE
RETAINER
WASHER
SPRING
WASHER
BLOCK
RETAINER
PIN
WASHER
Ref.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
30-40-5
49
44
47
Description
RETAINER
RETAINER
PISTON ASSEMBLY
PLATE
SWASHPLATE
PIN
HOUSING
PLUG
BEARING
SEAL
O-RING
COVER
D-2427
Ref.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
Description
BOLT
SHAFT
SNAP RING
BEARING
SNAP RING
SNAP RING
PLUG
O-RING
BEARING
O-RING
PLATE
BOLT
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Parts Identification (Left Half)
16
13 11
14
6
8
4
12
10
17
23
9 7
15
18
19
21 22
32
38
26
30
37
25
27
33
35
53
60
46
56
Description
BOLT
PIN
O-RING
PLUG
BEARING
O-RING
PLATE
BOLT
SWASH PLATE
WEAR PLATE
PISTON ASSEMBLY
PISTON RETAINER
RETAINER
WASHER
PIN
RETAINER
47
45
43
42
40
50
55
54
55 54
59 58
Ref.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
29
44
51 48
52
49
39
61
62
28
34
36
31
Description
SNAP RING
WASHER
SEAL
SNAP RING
SNAP RING
BEARING
SNAP RING
KEY
SHAFT
HOUSING
PLUG
O-RING
BEARING
SEAL
O-RING
COVER
1
24
20
Ref.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
3
5
2
57
Ref.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
63
Description
BLOCK
WASHER
SPRING
WASHER
WASHER
VALVE PLATE
PIN
GASKET
BEARING
PLUG
POPPET
SPRING
SHIM
O-RING
PLUG
PLUG
30-40-6
64
65
66
Ref.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
D-2428A
Description
O-RING
O-RING
O-RING
RELIEF VALVE
PLUG
PIN
O-RINGS
PIN
GEROTOR
SPACER
O-RING
O-RING
PIN
COUPLER
BOLT
O-RING
Ref.
65.
66.
Description
O-RING
RELIEF VALVE
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-40-15
Hydraulic Pump Removal & Installation
2
Figure 30-40-13
2
2
2
1
N-17223
Remove the Hi-flow hydraulic pump (Item 1) [Figure 3040-15] (if loader is so equipped) from the hydrostatic
pumps, by removing the two mounting bolts (Item 2)
[Figure 30-40-15].
1
N-17226
Remove the standard flow hydraulic pump (Item 1)
[Figure 30-40-13] from the hydrostatic pumps, by
removing the two mounting bolts (Item 2) [Figure 30-4013].
Figure 30-40-16
Figure 30-40-14
2
1
2
1
N-17356
Remove the gasket (Item 1) [Figure 30-40-16] and
coupler (Item 2) [Figure 30-40-16] with the hydraulic
pump.
N-17229
Remove the O-ring (Item 1) [Figure 30-40-14] and
coupler (Item 2) [Figure 30-40-14] with the hydraulic
pump.
30-40-7
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-40-19
Disassembly
Pump Separation
Figure 30-40-17
1
N-17234
Separate the two hydrostatic pumps [Figure 30-40-19].
Charge Pump Disassembly
N-17230
Figure 30-40-20
Figure 30-40-18
1
1
2
1
2
N-17235
N-17233
Remove the mounting bolts (Item 1) [Figure 30-40-17] &
[Figure 30-40-18].
Remove the two O-rings (Item 1) [Figure 30-40-20] from
the grooves in the gerotor spacer on the charge pump.
Remove the O-rings (Item 2) [Figure 30-40-20] from the
charge pump housing end cap.
30-40-8
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-40-23
Disassembly (Cont’d)
2
Charge Pump Disassembly (Cont’d)
Figure 30-40-21
3
1
1
4
N-17185
Inspect the gerotor spacer (Item 1) [Figure 30-40-23] the
gerotor assembly (Item 2) [Figure 30-40-23], drive
coupling (Item 3) [Figure 30-40-23] and drive pin (Item 4)
[Figure 30-40-23] for wear and replace as needed.
N-17236
Figure 30-40-24
Figure 30-40-22
1
2
2
1
2
2
N-17186
N-17237
Remove the gerotor assembly (Item 1) [Figure 30-40-21]
& [Figure 30-40-22] from the charge pump.
Remove the locating pin (Item 1) [Figure 30-40-24] from
the pump end cap.
NOTE: The charge pump rotation is determined by the
position of the gerotor spacer and locating
pin (Item 1) [Figure 30-40-24] in the pump end
cap, and must be noted for proper installation.
Remove the four mounting bolts (Item 2) [Figure 30-4024] from the charge pump.
30-40-9
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-40-27
Disassembly (Cont’d)
1
Figure 30-40-25
1
2
N-17193
Check the valve plate [Figure 30-40-27] for wear and
remove from charge pump.
3
N-17191
Mark the charge pump (Item 1) [Figure 30-40-25] case
and the pump case (Item 2) [Figure 30-40-25] for proper
installation.
Figure 30-40-28
1
2
Mark the trunnion cover (Item 3) [Figure 30-40-25] and
pump case for proper installation.
Figure 30-40-26
N-17194
1
Check the valve plate locating pin (Item 1) [Figure 30-4028] for wear and replace if needed.
Check the needle bearing (Item 2) [Figure 30-40-28] for
wear and replace if needed.
N-17192
Remove the charge pump (Item 1) [Figure 30-40-26]
from the hydrostatic shaft end pump.
30-40-10
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-40-31
Disassembly (Cont’d)
1
Figure 30-40-29
1
N-17199
Remove the ball guide retainer (Item 1) [Figure 30-4031] from the cylinder block.
N-17197
Remove the rotating group (Item 1) [Figure 30-40-29]
from the pump.
Figure 30-40-32
3
3
Figure 30-40-30
2
1
3
2
1
3
N-17200
Check the ball guide retainer (Item 1) [Figure 30-40-32]
and washer (Item 2) [Figure 30-40-32] for wear and
replace as needed.
N-17198
Remove the slipper guide and pistons (Item 1) [Figure
30-40-30] from the cylinder block.
Remove the four slipper hold down pins (Item 3) [Figure
30-40-32] from the cylinder block.
Check the pistons (Item 2) [Figure 30-40-30] for wear
and replace as needed.
Check the cylinder block for wear and replace as needed.
30-40-11
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-40-35
Disassembly (Cont’d)
1
Figure 30-40-33
1
N-17239
Use a seal puller and remove the seal (Item 1) [Figure
30-40-35] from the pump housing.
N-17201
Remove the thrust plate (Item 1) [Figure 30-40-33] from
the pump housing.
Figure 30-40-36
Figure 30-40-34
1
1
2
N-17240
3
Remove the snap ring (Item 1) [Figure 30-40-36] from
the pump housing and remove the driveshaft and bearing
from the housing.
N-17481
Remove the driveshaft key (Item 1) [Figure 30-40-34],
the snap ring (Item 2) [Figure 30-40-34] and the support
washer (Item 3) [Figure 30-40-34] from the drive shaft
end of the pump.
30-40-12
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-40-39
Disassembly (Cont’d)
Figure 30-40-37
1
1
1
N-17243
Remove the four mount bolts (Item 1) [Figure 30-40-39]
form the lower trunnion cover. Remove the cover.
N-17241
Remove the snap ring (Item 1) [Figure 30-40-37] from
the driveshaft and remove the bearing.
Figure 30-40-40
Figure 30-40-38
2
1
1
N-17244
Remove the O-ring (Item 1) [Figure 30-40-40] and
bearing race (Item 2) [Figure 30-40-40] from the pump
housing.
N-17242
Check the bearing for wear and replace if worn.
Check the pump shaft (Item 1) [Figure 30-40-38] for
wear and replace if needed.
30-40-13
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-40-43
Disassembly (Cont’d)
Figure 30-40-41
1
1
2
N-17247
Remove the upper trunnion cover (Item 1) [Figure 30-4043].
N-17245
Check the bearing race (Item 1) [Figure 30-40-41] and
O-ring (Item 2) [Figure 30-40-41] for wear and replace
as needed.
Figure 30-40-44
Figure 30-40-42
1
2
1
N-17250
1
Inspect the seal (Item 1) [Figure 30-40-44] in the upper
trunnion cover and replace as needed.
N-17246
Remove the four mount bolts (Item 1) [Figure 30-40-42]
form the pump housing and remove the steering bracket
(Item 2) [Figure 30-40-42].
30-40-14
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-40-47
Disassembly (Cont’d)
Figure 30-40-45
1
1
N-17251
2
Slide the swashplate from the side to side and remove
the tapered roller bearing (Item 1) [Figure 30-40-47]
from the swashplate shaft.
N-17248
Remove the O-ring (Item 1) [Figure 30-40-45] and
bearing race (Item 2) [Figure 30-40-45] from the pump
housing.
Figure 30-40-48
1
Figure 30-40-46
1
N-17252
2
Tilt the swashplate (Item 1) [Figure 30-40-48] and
remove the swashplate and lower bearing from the pump
housing.
N-17249
Inspect the bearing race (Item 1) [Figure 30-40-46] and
the O-ring (Item 2) [Figure 30-40-46] and replace as
needed.
30-40-15
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-40-51
Assembly
Figure 30-40-49
1
1
2
3
N-17249
Install the tapered bearing (Item 1) [Figure 30-40-51] on
the swashplate shaft.
N-17253
Install the lower bearing (Item 1) [Figure 30-40-49] on
the swashplate.
Figure 30-40-52
Figure 30-40-50
N-17248
Install the bearing race (Item 2) [Figure 30-40-51] and Oring (Item 3) [Figure 30-40-51] as shown in [Figure 3040-52].
N-17252
Install the swashplate and bearing into the pump housing
[Figure 30-40-50].
30-40-16
863 Bobcat Loader
Service Manual
HYSROSTATIC PUMP (CONT’D)
Figure 30-40-55
Assembly (Cont’d)
Figure 30-40-53
1
2
1
N-17245
Figure 30-40-56
N-17247
Install the upper trunnion seal (Item 1) [Figure 30-40-53]
and cover.
Figure 30-40-54
1
N-17244
Install the bearing race (Item 1) [Figure 30-40-55] and Oring (Item 2) [Figure 30-40-55] at the lower trunnion as
shown in [Figure 30-40-56].
N-17246
Install the steering bracket (Item 1) [Figure 30-40-54]
and the four mounting bolts and tighten to 18-22 ft.-lbs.
(24-30 Nm) torque.
30-40-17
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-40-59
Assembly (Cont'd)
Figure 30-40-57
1
N-17241
Install the bearing and snap ring (Item 1) [Figure 30-4059] on the pump shaft.
N-17243
Figure 30-40-60
Align the marks on the lower trunnion cover and pump
housing as shown in [Figure 30-40-57].
Install the four mounting bolts and tighten to 18-22 ft.-lbs.
(24-30 Nm) torque.
Figure 30-40-58
1
1
N-17240
Install the pump shaft into the pump housing [Figure 3040-60].
Install the snap ring (Item 1) [Figure 30-40-60].
N-17242
Install the snap ring (Item 1) [Figure 30-40-58] on the
pump shaft.
30-40-18
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-40-63
Assembly (Cont'd)
Figure 30-40-61
1
1
1
2
3
1
N-17198
N-17200
Install the four slipper pins (Item 1) [Figure 30-40-61]
into the cylinder block.
Assemble the piston assemblies into the slipper guide
[Figure 30-40-63]. Lubricate the pistons and cylinder
block bores and insert the piston assemblies into the
cylinder bores [Figure 30-40-63].
Figure 30-40-64
Apply a small amount of grease to the washer (Item 2)
[Figure 30-40-61] and install into the ball guide retainer
(Item 3) [Figure 30-40-61].
Figure 30-40-62
1
N-17197
Lay the pump housing on its side and install the cylinder
block, piston assembly into the housing.
Place the pump on a work surface with the end cap
opening up [Figure 30-40-64].
N-17199
Install the ball guide retainer and washer (Item 1) [Figure
30-40-62] onto the slipper holddown pins.
30-40-19
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-40-67
Assembly (Cont'd)
Figure 30-40-65
2
1
1
N-17193
Coat the backside of the valve plate with petroleum jelly
to hold it in position and install the valve plate onto the
charge pump, bronze face up [Figure 30-40-67]-.
N-17194
Replace the needle bearing (Item 1) [Figure 30-40-65]
and valve plate locating pin (Item 2) [Figure 30-40-65] in
the charge pump.
The notch (Item 1) [Figure 30-40-67] on the valve plate
must engage the locating pin.
Figure 30-40-68
Figure 30-40-66
1
2
1
N-17192
N-17196
The bearing cage (Item 1) [Figure 30-40-66] will
protrude from 0.08-0.10 inch (2,0-2,5 mm) from the
surface of the charge pump.
Coat a new end cap gasket (Item 1) [Figure 30-40-68]
with petroleum jelly and install onto the charge pump.
The valve plate locating spring pin (Item 2) [Figure 3040-66] will protrude from 1.65-0.185 inch (4,19-4,70 mm)
from the surface of the charge pump.
30-40-20
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Charge Pump Assembly
Assembly (Cont'd)
Figure 30-40-71
Figure 30-40-69
1
N-17186
N-17191
Install the locating pin (Item 1) [Figure 30-40-71] in the
charge pump end cap.
Align the marks on the charge pump with the pump
housing and install the charge pump [Figure 30-40-69].
When the charge pump is properly installed, the cylinder
block spring will hold the charge pump end cap away
from the housing approximately .125 inch (3 mm).
NOTE: The charge pump rotation is determined by
the position of the gerotor space and locating
pin (Item 1) [Figure 30-40-71] in the pump end
cap.
Prior to assembly, lubricate the gerotor assembly with
clean hydraulic oil.
Figure 30-40-70
Figure 30-40-72
1
1
1
1
1
N-17186
N-17187
Install the four mounting bolts (Item 1) [Figure 30-40-70]
and tighten evenly to 35-45 ft.-lbs. (47-61 Nm) torque.
Install the gerotor assembly (Item 1) [Figure 30-40-72]
into the charge pump housing.
30-40-21
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-40-75
Assembly (Cont'd)
Charge Pump Assembly (Cont’d)
Figure 30-40-73
1
2
1
N-17190
1
A spanner wrench may be used in the two holes (Item 1)
[Figure 30-40-75] to slightly rotate the gerotor spacer to
align with the locating pin.
N-17188
Apply petroleum jelly to the gerotor drive pin (Item 1)
[Figure 30-40-73] and install the gerotor pin into the
drive coupler (Item 2) [Figure 30-40-73].
When the spacer is properly installed the surface of the
gerotor spacer and charge pump face are flush [Figure
30-40-75].
Figure 30-40-76
NOTE: The gerotor drive coupler (Item 2) [Figure 3040-73] must be installed with the longer
portion down toward the rear of the charge
pump.
3
2
2
Figure 30-40-74
1
3
2
N-17235
Install the two large O-rings (Item 1) [Figure 30-40-76]
into the gerotor cap.
1
Install the two smaller O-rings (Item 2) [Figure 30-40-76]
in the charge pump housing end cap.
N-17189
Install the coupler and drive pin into the gerotor, be sure
the pin engages the gerotor slot (Item 1) [Figure 30-4074].
Install the two aligning pins into the alignment holes (Item
3) [Figure 30-40-76] in the charge pump.
Install the gerotor spacer (Item 2) [Figure 30-40-74] into
the charge pump end cap.
30-40-22
863 Bobcat Loader
Service Manual
HYDROSTATIC PUMP (CONT’D)
Figure 30-40-78
Assembly (Cont'd)
1
Charge Pump Assembly (Cont’d)
Figure 30-40-77
1
N-17233
Figure 30-40-79
1
N-17234
Slide the two sections of the pumps together [Figure 3040-77].
N-17230
Install the four mounting bolts (Item 1) [Figure 30-40-78]
& [Figure 30-40-79] and tighten to 35-45 ft.-lbs. (47-61
Nm) torque.
Check for proper internal assembly by slowly rotating the
pump shaft while tightening the mount bolts.
30-40-23
863 Bobcat Loader
Service Manual
30-40-24
863 Bobcat Loader
Service Manual
DRIVE BELT
Adjustment
Shield Removal And Installation
Figure 30-50-3
Figure 30-50-1
2
1
1
P-5554
P-28478
2
Stop the engine.
Open the rear door.
Remove the three belt shield holddown clips (Item 1)
[Figure 30-50-1].
Figure 30-50-2
1
P-4681
The drive belt idler arm stop is located on the left side of
the engine below the air cleaner [Figure 30-50-3].
Loosen the two bolts (Item 1) [Figure 30-50-3] and slide
the stop against the idler arm. Tighten the bolts.
There is no adjustment for the spring, just make sure the
spring bolt (Item 2 ) [Figure 30-50-3] is tight.
P-28479
Remove the belt shield from the drive belt housing
[Figure 30-50-2].
30-50-1
863 Bobcat Loader
Service Manual
DRIVE BELT (CONT’D)
Tensioner Pulley Removal And Installation
Replacement
Figure 30-50-5
Figure 30-50-4
1
2
1
P-5552
P-7894
Remove the belt shield clips (Item 1) [Figure 30-50-5].
Remove the belt shield. (See Shield Removal And
Installation on Page 30-50-1.)
Loosen the two stop mounting bolts (Item 1) [Figure 3050-3].
Remove the belt shield (Item 2) [Figure 30-50-5].
Figure 30-50-6
Loosen the spring tension bolt (Item 2) [Figure 30-50-3].
2
Remove the fan drive belt from the tensioner pulley.
1
Remove the drive belt from the hydrostatic pump pulley
and flywheel pulley.
Remove the drive belt [Figure 30-50-4]
P-5554
Remove the two stop mounting bolts (Item 1) [Figure 3050-6].
Remove the stop.
Remove the spring tension bolt (Item 2) [Figure 30-506].
30-50-2
863 Bobcat Loader
Service Manual
DRIVE BELT (CONT’D)
Figure 30-50-9
Tensioner Pulley Removal And Installation
1
Figure 30-50-7
1
2
P-5560
Remove the pulley/arm assembly (Item 1) [Figure 30-509] from the engine housing.
P-5548
Remove the end cap (Item 1) [Figure 30-50-7] from the
tensioner pulley arm.
Remove the arm bushing (Item 2) [Figure 30-50-9].
Check for wear and replace as needed.
Figure 30-50-10
Figure 30-50-8
1
1
P-5553
P-5555
Remove the mounting bolt (Item 1) [Figure 30-50-8] from
the tensioner pulley arm.
Check the arm seal (Item 1) [Figure 30-50-10]. Replace
the seal as needed.
30-50-3
863 Bobcat Loader
Service Manual
DRIVE BELT (CONT’D)
Tensioner Pulley Tension Spring
Tensioner Pulley Removal And Installation (Cont’d)
Figure 30-50-13
Figure 30-50-11
1
P-5551
P-5561
Remove the base end bolt (Item 1) [Figure 30-50-13]
from the spring block.
Remove the pulley mounting bolt [Figure 30-50-11].
Remove the tension spring from the engine housing.
Figure 30-50-12
Figure 30-50-14
1
P-5559
P-5563
Disassemble the pulley and bearings as shown in
[Figure 30-50-12].
Remove the end block (Item 1) [Figure 30-50-14] (both
ends) from the spring.
Check parts for wear and replace as needed.
Check the spring for wear etc. Replace the spring as
needed.
Check the spring end blocks for wear and replace as
needed.
30-50-4
863 Bobcat Loader
Service Manual
OIL COOLER
Figure 30-60-3
Removal And Installation With STC (Seal Tight
Connector)
IMPORTANT
1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-24726
Open the rear door of the loader.
Figure 30-60-4
Figure 30-60-1
1
2
3
N-19346
P-24724
Slide the rubber sleeve in toward the radiator. The
connector will release [Figure 30-60-3] & [Figure 30-604].
Raise the rear grill [Figure 30-60-1].
Figure 30-60-2
Disconnect the inlet and outlet hoses (Items 1 & 2)
[Figure 30-60-1] from the oil cooler (Item 3) [Figure 3060-1]
1
NOTE: When installing the cooler hoses, the fittings
should make a clicking sound when pushed
together.
Lift up the oil cooler and remove the cooler from the
loader.
Reverse the removal procedure to install the oil cooler.
N-19345
Install tool 10 STC (Item 1) [Figure 30-60-2] to outside of
rubber sleeve (Item 1) [Figure 30-60-3].
30-60-1
863 Bobcat Loader
Service Manual
30-60-2
863 Bobcat Loader
Service Manual
DRIVE SYSTEM
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . .
Pedal Disassembly And Assembly . . . . . . . . . . . . . . . . . .
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . .
40-10-1
40-10-3
40-10-2
40-10-1
SAFETY &
MAINTENANCE
BRAKE (TWO-SPEED) (S/N 514449389 & BELOW) . . . . . . . 40-11-1
Block Disassembly And Assembly. . . . . . . . . . . . . . . . . . . 40-11-2
Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-11-1
BRAKE (TWO-SPEED) (S/N 514449390 & ABOVE) . . . . . . . 40-12-1
Block Disassembly And Assembly. . . . . . . . . . . . . . . . . . . 40-12-3
Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-12-1
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Front Chaincase Cover Removal And Installation . . . . . . . 40-30-1
Rear Chaincase Cover Removal And Installation . . . . . . . 40-30-1
DRIVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . .
Axle, Sprocket And Bearings Removal And Installation. . .
Drive Chain Removal And Installation . . . . . . . . . . . . . . . .
40-20-1
40-20-1
40-20-3
40-20-8
DRIVE
SYSTEM
ELECTRICAL
SYSTEM &
ANALYSIS
ENGINE
SERVICE
SPECIFICATIONS
40-01
863 Bobcat Loader
Service Manual
40-02
863 Bobcat Loader
Service Manual
BRAKE
Figure 40-10-3
Pedal Removal And Installation
Figure 40-10-1
1
1
1
N-19614
Disconnect the wire harness connector (Item 1) [Figure
40-10-3] from the parking brake.
N-19612
Figure 40-10-4
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the two mounting bolts (Item 1) [Figure 40-10-1]
from the foot rests.
Remove the foot rests.
1
Figure 40-10-2
1
N-19615
2
2
Remove the mounting bolts (Item 1) [Figure 40-10-4]
from the parking brake pedal.
Remove the parking brake pedal assembly from the
loader.
N-19613
Remove the two mount bolts (Item 1) [Figure 40-10-2]
from the fuse cover.
Remove the fuse cover.
Remove the four mounting bolts from the lower panel
(Item 2) [Figure 40-10-2].
Pull the lower panel toward the front of the loader.
40-10-1
863 Bobcat Loader
Service Manual
BRAKE (CONT’D)
Figure 40-10-6
Pedal Disassembly And Assembly
1
Figure 40-10-5
5
2
6
1
4
P-4156
3
Remove the harness mounting clamp (Item 1) [Figure
40-10-6] from the pedal mounting bracket (Item 2)
[Figure 40-10-6].
2
P-4189
Loosen and remove the mounting bolt (Item 1) [Figure
40-10-5] and nut from the spring mounting bracket (Item
2) [Figure 40-10-5].
Remove the brake pedal spring (Item 3) [Figure 40-10-5]
from the tension spring mounting bracket (Item 2)
[Figure 40-10-5] and from the brake pedal mounting
bracket (Item 4) [Figure 40-10-5].
Remove the two mounting bolts, washers and nuts (Item
5) [Figure 40-10-5] from the brake pedal sensor.
Remove the sensor harness from the pedal mounting
bracket.
Remove the pedal mounting bolt (Item 6) [Figure 40-105], plastic spacers and bushing nut from the brake pedal.
Remove the pedal from the pedal mounting bracket.
[Figure 40-10-6] shows the parking brake disassembled
to identify the existing parts in the brake assembly.
40-10-2
863 Bobcat Loader
Service Manual
BRAKE (CONT’D)
Figure 40-10-8
Disc Removal And Installation
5
1
4
WARNING
3
2
N-19724
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Figure 40-10-7
Remove the traction lock solenoid (Item 1) [Figure 4010-8], spring (Item 2) [Figure 40-10-8] and spring cup
(Item 3) [Figure 40-10-8].
Remove the wedge assembly (Item 4) [Figure 40-10-8]
from the guides.
Installation: Inspect the solenoid mount gasket, replace
if damaged.
See “Removal And Installation (Single Speed)” on
page 60-110-2 for complete disassembly and assembly
procedures for the traction lock assembly.
Remove the crossmember pivot bolt (Item 5) [Figure 4010-8].
Figure 40-10-9
1
N-19618
Raise the lift arms and install and approved lift arm
support device. (See Contents, Page 10-01.)
1
Raise the loader operator cab. (See Raising The
Operator Cab on Page 10-30-1.)
Remove the bolts (Item 1) [Figure 40-10-7] from traction
lock solenoid.
N-19668
Remove the bolt and nut (Item 1) [Figure 40-10-9] to
disconnect the lift pedal linkage from crossmember.
40-10-3
863 Bobcat Loader
Service Manual
BRAKE (CONT’D)
Figure 40-10-12
Disc Removal And Installation (Cont’d)
Figure 40-10-10
1
1
N-19726
Remove the center cover mounting bolts (Item 1) [Figure
40-10-12].
N-19669
Remove the chaincase cover/guides assembly.
Remove the hairpin clip and cross-pin from the control
valve lift spool (Item 1) [Figure 40-10-10].
Disconnect the crossmember from the control valve.
Installation: Replace the chaincase cover gasket.
Tighten the bolts to 190-240 in.-lbs. (21,5-27,1 Nm)
torque.
Figure 40-10-11
Figure 40-10-13
1
1
N-19725
1
P-7799
Remove the crossmember from the pivot [Figure 40-1011].
Remove the two nuts (Item 1) [Figure 40-10-13] from the
disc bolts.
Installation: Check the nylon bushing (Item 1) [Figure
40-10-11] for wear and replace as needed.
40-10-4
863 Bobcat Loader
Service Manual
BRAKE (CONT’D)
Figure 40-10-16
Disc Removal And Installation (Cont’d)
Figure 40-10-14
1
1
1
P-7865
Remove the disc (Item 1) [Figure 40-10-16] from the
shaft.
P-7801
Remove the two disc bolts (Item 1) [Figure 40-10-14 on
Page 5] from the disc.
Figure 40-10-17
3
3
Figure 40-10-15
1
1
2
P-13003
P-7800
A snap ring pliers with 90° tips are needed for removing
the brake disc snap ring.
Installation: Bolting the disc to the snap ring provides
proper disc alignment. Disc and shaft are shown
removed for photo clarity. The snap ring end gap (Item 1)
[Figure 40-10-17] must be between the disc bolts (Item
2) [Figure 40-10-17] and sprocket teeth (Item 3) [Figure
40-10-17] after the brake disc is installed on the shaft.
Pull the disc away from snap ring.
Remove the snap ring (Item 1) [Figure 40-10-15] from
the end of the carrier shaft.
40-10-5
863 Bobcat Loader
Service Manual
40-10-6
863 Bobcat Loader
Service Manual
BRAKE (TWO-SPEED) (S/N 514449389 & BELOW)
Figure 40-11-3
Block Removal And Installation
Figure 40-11-1
1
1
2
N-22538
2
Disconnect the two hydraulic hoses (Item 1) [Figure 4011-3] from the brake/two-speed block.
N-22536
Figure 40-11-4
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
1
Remove the steering shock (Item 1) [Figure 40-11-1].
2
Mark all hydraulic hoses for proper installation.
Disconnect the four hydraulic hoses (Item 2) [Figure 4011-1] from the brake/two-speed block.
Figure 40-11-2
N-22539
Disconnect the wire harness connector (Item 1) [Figure
40-11-4] from the brake solenoid.
1
Disconnect the wire harness connector (Item 2) [Figure
40-11-4] from the two-speed solenoid.
N-22537
Disconnect the two hydraulic hoses (Item 1) [Figure 4011-2] from the brake/two-speed block.
40-11-1
863 Bobcat Loader
Service Manual
BRAKE (TWO-SPEED) (S/N 514449389 & BELOW)
(CONT’D)
Block Disassembly And Assembly
Figure 40-11-7
Block Removal And Installation (Cont’d)
Figure 40-11-5
1
1
1
1
1
N-22578
Mark all hydraulic hoses for proper installation.
N-22576
Disconnect the wire harness connector (Item 1) [Figure
40-11-5] from the make-up valve solenoid.
Remove the hydraulic fittings (Item 1) [Figure 40-11-7]
from the block.
Figure 40-11-8
Figure 40-11-6
1
1
2
2
N-22579
N-22577
Turn the hydraulic fitting (Item 1) [Figure 40-11-6] to
allow for clearance to remove the mounting bolt.
Remove the two mounting bolts (Item 2) [Figure 40-11-6]
from the valve.
Remove the check valve (Item 1) [Figure 40-11-8] from
the two-speed valve.
Remove the check valve (Item 2) [Figure 40-11-8] from
the brake valve.
NOTE: The check valves (Items 1 & 2) [Figure 40-11-8]
are interchangeable.
Remove the brake/two-speed block from loader.
Remove the pedal from the pedal mounting bracket.
[Figure 40-11-6] show the parking brake disassembled
to identify the existing parts in the brake assembly.
40-11-2
863 Bobcat Loader
Service Manual
BRAKE (TWO-SPEED) (S/N 514449389 & BELOW)
(CONT’D)
Figure 40-11-11
Block Disassembly And Assembly (Cont’d)
Figure 40-11-9
1
1
2
N-22583
Use a test meter and test the solenoid [Figure 40-11-11]
for resistance.
N-22580
Check the back-up washers (Item 1) [Figure 40-11-9]
and O-rings (Item 2) [Figure 40-11-9] for wear and
replace as needed.
The resistance value for the solenoid coil can be found on
the electrical schematic. (See Solenoid Test on Page 6010-7.).
Figure 40-11-12
Figure 40-11-10
1
1
N-22582
N-22581
Loosen the electrical solenoid nut (Item 1) [Figure 40-1110] from the make-up valve solenoid.
Remove the solenoid valve (Item 1) [Figure 40-11-12]
from the block.
Assembly: Tighten the nut to 60-84 in.-lbs. (6,78-9,49
Nm) torque.
40-11-3
863 Bobcat Loader
Service Manual
BRAKE (TWO-SPEED) (S/N 514449389 & BELOW)
(CONT’D)
Figure 40-11-15
Block Disassembly And Assembly (Cont’d)
Figure 40-11-13
1
N-22586
Check the O-ring (Item 1) [Figure 40-11-15] on the plug
and replace as needed.
N-22584
Figure 40-11-16
Assembly: Always install new O-rings and back-up
washers [Figure 40-11-13]. Tighten the solenoid valve
to 20 ft.-lbs. (27,1 Nm) torque.
Figure 40-11-14
1
1
N-22587
Remove the two-speed solenoid nut (Item 1) [Figure 4011-16].
Assembly: Tighten the nut to 60-80 in.-lbs. (6,78-9,49
Nm) torque.
N-22585
Remove the plug (Item 1) [Figure 40-11-14] from the
brake/two-speed block.
40-11-4
863 Bobcat Loader
Service Manual
BRAKE (TWO-SPEED) (S/N 514449389 & BELOW)
(CONT’D)
Figure 40-11-19
Block Disassembly And Assembly (Cont’d)
Figure 40-11-17
1
N-22611
2
Assembly: Always install new O-rings. Tighten the
solenoid valve to 20 ft.-lbs. (27,1 Nm) torque.
N-22610
Use a test meter and test the solenoid (Item 1) [Figure
40-11-17] for resistance
Check the O-rings [Figure 40-11-19] and replace as
needed.
Figure 40-11-20
The resistance value for the solenoid coil can be found on
the electrical schematic. (See Solenoid Test on Page 6010-7.)
Replace the O-rings (Item 2) [Figure 40-11-17].
Figure 40-11-18
1
1
N-22587
Remove the brake solenoid nut (Item 1) [Figure 40-1120].
Assembly: Tighten the nut to 60-84 in.-lbs. (6,78-9,49
Nm) torque.
N-22588
Remove the solenoid valve (Item 1) [Figure 40-11-18]
from the block.
40-11-5
863 Bobcat Loader
Service Manual
BRAKE (TWO-SPEED) (S/N 514449389 & BELOW)
(CONT’D)
Figure 40-11-23
Block Disassembly And Assembly (Cont’d)
Figure 40-11-21
1
N-22614
Assembly: Always install new O-rings and back-up
washers. Tighten the solenoid valve to 20 ft.-lbs. (27,1
Nm) torque.
N-22613
Use a test meter and test the solenoid (Item 1) [Figure
40-11-21] for resistance.
Check the O-rings and back-up washers [Figure 40-1123] and replace as needed.
The resistance value for the solenoid can be found on the
electrical schematic. (See Solenoid Test on Page 60-107.)
Figure 40-11-22
1
N-22612
Remove the solenoid valve (Item 1) [Figure 40-11-22]
from the block.
40-11-6
863 Bobcat Loader
Service Manual
BRAKE (TWO-SPEED) (S/N 514449390 & ABOVE)
Figure 40-12-3
Block Removal And Installation
Figure 40-12-1
1
1
2
P-34092
2
Disconnect the two hydraulic hoses (Item 1) [Figure 4012-3] from the brake/two speed block.
P-34096
Figure 40-12-4
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
1
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the steering shock (Item 1) [Figure 40-12-1].
Mark all hydraulic hoses for proper installation.
Disconnect the four hydraulic hoses (Item 2) [Figure 4012-1] from the brake/two speed block.
2
Figure 40-12-2
P-34093
Disconnect the wire harness connector (Item 1) [Figure
40-12-4] from the brake solenoid.
Disconnect the wire harness connector (Item 2) [Figure
40-12-4] from the two speed solenoid.
1
1
P-34091
Disconnect the two hydraulic hoses (Item 1) [Figure 4012-2] from the brake/two speed block.
40-12-1
863 Bobcat Loader
Service Manual
BRAKE (TWO-SPEED) (S/N 514449390 & ABOVE)
(CONT’D)
Block Removal And Installation (Cont'd)
Figure 40-12-5
1
P-34094
Disconnect the wire harness connector (Item 1) [Figure
40-12-5] from the make-up valve solenoid.
Figure 40-12-6
1
1
P-34095
Remove the two mounting bolts (Item 2) [Figure 40-12-6]
from the valve.
Remove the brake/two-speed block from the loader.
40-12-2
863 Bobcat Loader
Service Manual
BRAKE (TWO-SPEED) (S/N 514449390 & ABOVE)
(CONT’D)
Figure 40-12-9
Block Disassembly And Assembly
1
Figure 40-12-7
1
2
1
N-22580
1
1
Check the back-up washers (Item 1) [Figure 40-12-9]
and O-rings (Item 2) [Figure 40-12-9] for wear and
replace as needed.
P-34097
Mark all hydraulic hoses and fittings for proper
installation.
Figure 40-12-10
Remove the hydraulic fittings (Item 1) [Figure 40-12-7]
from the block.
Figure 40-12-8
1
1
1
2
P-34099
Loosen the electrical solenoid nut (Item 1) [Figure 40-1210] from the make-up valve solenoid.
Remove the brake solenoid nut (Item 2) [Figure 40-1210] from the brake solenoid.
P-34098
Remove the check valve (Item 1 & 2) [Figure 40-12-8]
from the two-speed valve.
Assembly: Tighten the nut to 60-84 in.-lbs. (6,78-9,49
Nm) torque.
NOTE: The check valves (Items 1 & 2) [Figure 40-128] are interchangeable.
40-12-3
863 Bobcat Loader
Service Manual
BRAKE (TWO-SPEED) (S/N 514449390 & ABOVE)
(CONT’D)
Figure 40-12-13
Block Disassembly And Assembly (Cont'd)
Figure 40-12-11
1
1
2
P-34101
Remove the solenoid valve (Item 1) [Figure 40-12-13]
from the block.
P-34112
Use a test meter and test the solenoid (Item 1) [Figure
40-12-11] for resistance.
Remove the brake solenoid (Item 1) [Figure 40-12-13]
from the block.
Figure 40-12-14
The resistance value for the solenoid coil can be found on
the electrical schematic. (See Solenoid Test on Page 6010-7.)
Figure 40-12-12
N-22584
1
Assembly: Always install new O-rings and back-up
washers [Figure 40-12-14]. Tighten the solenoid valve to
20 ft.-lbs. (27,1 Nm) torque.
P-34111
Use a test meter and test the brake solenoid (Item 1)
[Figure 40-12-12] for resistance.
The resistance value for the solenoid coil can be found on
the electrical schematic. (See Solenoid Test on Page 6010-7.)
40-12-4
863 Bobcat Loader
Service Manual
BRAKE (TWO-SPEED) (S/N 514449390 & ABOVE)
(CONT’D)
Figure 40-12-17
Block Disassembly And Assembly (Cont'd)
Figure 40-12-15
1
P-34103
Check the O-rings (Item 1) [Figure 40-12-17] on the
plugs and replace as needed.
P-34105
Figure 40-12-18
Assembly: Always install new O-rings. Tighten the
solenoid valve to 20 ft.-lbs. (27,1 Nm) torque.
Check the O-rings and replace as needed [Figure 40-1215]
Figure 40-12-16
1
P-34104
Remove the two speed solenoid nut (Item 1) [Figure 4012-18].
1
Assembly: Tighten the nut to 60-84 in.-lbs. (6,78-9,49
Nm) torque.
P-34102
Remove the plugs (Item 1) [Figure 40-12-16] from the
brake/two-speed block.
40-12-5
863 Bobcat Loader
Service Manual
BRAKE (TWO-SPEED) (S/N 514449390 & ABOVE)
(CONT’D)
Figure 40-12-21
Block Disassembly And Assembly (Cont'd)
Figure 40-12-19
1
N-22611
2
Assembly: Always install new O-rings. Tighten the
solenoid valve to 20 ft.-lbs. (27,1 Nm) torque.
N-22610
Use a test meter and test the solenoid (Item 1) [Figure
40-12-19] for resistance.
Check the O-rings [Figure 40-12-21] and replace as
needed.
The resistance value for the solenoid coil can be found on
the electrical schematic. (See Solenoid Test on Page 6010-7.)
Replace the O-rings (Item 2) [Figure 40-12-19].
Figure 40-12-20
1
P-37979
Remove the solenoid valve (Item 1) [Figure 40-12-20]
from the block.
40-12-6
863 Bobcat Loader
Service Manual
DRIVE COMPONENTS
Figure 40-20-2
Axle Seal Removal And Installation
WARNING
NEVER STAND IN-LINE OF THE HUB WHEN
REMOVING A HUB FROM AN AXLE. The hub has a
tapered fit on the axle end and can come off the axle
with great force and cause serious injury.
W-2186-0395
1
Figure 40-20-1
P-4849
2
Install the puller (Item 1) [Figure 40-20-2] on the wheel
hub.
Remove the hub from the axle.
Figure 40-20-3
1
1
2
P-4850
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Remove the tire/wheel assembly.
Installation: Tighten the wheel nuts to 105-115 ft.-lbs.
(142-155 Nm) torque.
Remove the bolts (Item 1) [Figure 40-20-1] and plate.
P-4848
Remove the key (Item 1) [Figure 40-20-3] from the axle.
Installation: Tighten the bolts to 175-190 ft.-lbs. (240260 Nm) torque.
Remove the two wheel studs (Item 2) [Figure 40-20-1]
across from each other.
40-20-1
863 Bobcat Loader
Service Manual
DRIVE COMPONENTS (CONT’D)
Figure 40-20-5
Axle Seal Removal And Installation (Cont’d)
Figure 40-20-4
Taper
B-13493
1
Place the taper on the wear ring so it faces the outside
[Figure 40-20-5].
P-4817
Install a slide hammer (Item 1) [Figure 40-20-4] with a
screw tip end into the axle seal.
Place the seal with the lip facing in [Figure 40-20-5].
Figure 40-20-6
Remove the axle seal.
The tool listed will be needed to do the following
procedure:
MEL1407 - Seal Installation Tool
If the axle is damaged or worn, and axle repair sleeve kit
is available from Melroe Parts Sales in Chicago.
NOTE: If a new wear ring is being installed with new
seal, put LOCTITE sealant in the inside
diameter of the wear ring.
P-4814
Use a hammer, install the new axle seal until the tool is
flush with the edge of the axle tube [Figure 40-20-6].
40-20-2
863 Bobcat Loader
Service Manual
DRIVE COMPONENTS (CONT’D)
Axle, Sprocket And Bearings Removal And
Installation
Axle Seal Removal And Installation (Cont’d)
Figure 40-20-7
2
WARNING
1
P-10553
NOTE: S/N 514416546 & Above the axle (Item 1)
[Figure 40-20-7] finish specification was
changed to provide the correct surface for the
axle seal (Item 2) [Figure 40-20-7]. These
loaders MAY or MAY NOT have a wear ring
installed. When ordering the axle seal, check
to see of the axle uses a wear ring.
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
The tools listed will be needed to do the following
procedure:
MEL1242 - Port-a-Power
MEL1202B - Axle Bearing Service Set
NOTE: The procedure shown for removal and
installation of the axle, sprocket and bearings
is for a front axle. This procedure will be the
same for the rear axle.
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the front panel/steering lever assembly. (See
Lever Disassembly And Assembly on Page 50-110-1.)
Remove the front cover. (See Front Chaincase Cover
Removal And Installation on Page 40-30-1.)
Remove the fluid from the chaincase. (See CHAINCASE
on Page 40-30-1.)
40-20-3
863 Bobcat Loader
Service Manual
DRIVE COMPONENTS (CONT’D)
WARNING
Axle, Sprocket And Bearings Removal And
Installation
NEVER STAND IN-LINE OF THE HUB WHEN
REMOVING A HUB FROM AN AXLE. The hub has a
tapered fit on the axle end and can come off the axle
with great force and cause serious injury.
Figure 40-20-8
W-2186-0395
Figure 40-20-10
2
1
P-4810
Remove the axle sprocket bolt (Item 1) [Figure 40-20-8]
and backing washer (Item 2) [Figure 40-20-8].
1
Installation: Tighten the axle sprocket bolt to 475-525 ft.lbs. (644-710 Nm) torque.
Figure 40-20-9
P-4849
Install a puller (Item 1) [Figure 40-20-10] on the wheel
hub.
2
Remove the hub from the axle.
Figure 40-20-11
1
2
P-4850
Remove the bolts (Item 1) [Figure 40-20-9] and plate.
Installation: Tighten the bolts to 175-190 ft.-lbs. (240260 Nm) torque.
Remove the two wheel studs (Item 2) [Figure 40-20-9]
across from each other.
P-4809
Install a Port-a-Power ram between the two sprockets
[Figure 40-20-11].
40-20-4
863 Bobcat Loader
Service Manual
DRIVE COMPONENTS (CONT’D)
Figure 40-20-14
Axle, Sprocket And Bearings Removal And
Installation (Cont’d)
Figure 40-20-12
2
P-4171
Press the splined end of the axle free from the bearing
[Figure 40-20-14].
1
P-4808
Installation: Put the spline end of the axle shaft into the
bearing and press the bearing onto the axle.
Push the axle out until the ram is at the end of the stroke.
Add a spacer and push the axle out again. Repeat this
procedure until the axle is out of the sprocket.
Remove the drive chain from the sprocket.
NOTE: Hold on to the axle during installation as it will
slide freely after the bearing is pressed over
the splined end of the shaft.
Remove the sprocket (Item 1) [Figure 40-20-12] and
inner bearing (Item 2) [Figure 40-20-12].
Figure 40-20-15
Installation: Pack the inner and outer bearing with
grease before installing them.
Figure 40-20-13
1
1
P-4175
Put a piece of tubing (Item 1) [Figure 40-20-15] that
contacts inner race of the bearing only.
P-4170
A bearing puller (Item 1) [Figure 40-20-13] is needed to
do the following procedure:
Press the bearing onto the mounting surface until the
bearing is fully seated [Figure 40-20-15].
Be sure the bearing puller makes good contact with the
inner race and press the bearing off the mounting surface
of the axle [Figure 40-20-13].
NOTE: Hold onto the axle during removal as it will
slide freely after the bearing is removed from
the mounting surface.
40-20-5
863 Bobcat Loader
Service Manual
DRIVE COMPONENTS (CONT’D)
Figure 40-20-18
Axle, Sprocket And Bearings Removal And
Installation (Cont’d)
Figure 40-20-16
P-4816
Use the slide hammer and remove the bearing cup from
the axle tube [Figure 40-20-18].
P-4812
Figure 40-20-19
Use the tools provided in the MEL1202B Axle Bearing
Service Set for bearing cup removal and installation. A
slide hammer is also needed.
1
Use the long rod and bearing cup tool to remove the
inner bearing cup [Figure 40-20-16].
To remove the outer bearing cup, install a bearing cup
tool on the slide hammer.
3
Figure 40-20-17
2
P-4807
Use the bearing cup installation tools (Item 1) [Figure
40-20-19] and (Item 1) [Figure 40-20-20].
Put the inner cup (Item 2) [Figure 40-20-19] in the axle
tube.
Install the long threaded rod (Item 2) [Figure 40-20-20]
into the axle tube and through the installation tool (Item
1) [Figure 40-20-19].
P-4818
Install the nut (Item 3) [Figure 40-20-19].
Leave the bearing cup tool loose until the tool is installed
inside the tube [Figure 40-20-17].
Pull the tool against the bearing cup and tighten the nut.
40-20-6
863 Bobcat Loader
Service Manual
DRIVE COMPONENTS (CONT’D)
Figure 40-20-21
Axle, Sprocket And Bearings Removal And
Installation (Cont’d)
Figure 40-20-20
P-4813
Hit the driver handle with a hammer until the bearing cup
is seated inside the axle tube [Figure 40-20-21].
P-4811
Install the installation tool (Item 1) [Figure 40-20-20] on
the threaded rod. Install the nut.
Hold the inside nut (Item 3) [Figure 40-20-19] with a
wrench and tighten the outside nut [Figure 40-20-20].
To install the outer bearing cup, install the bearing cup
tool on the driver handle.
Install the bearing cup into the axle tube, and put the tool
into the bearing cup.
Tighten the nut until the bearing cup is seated.
Remove the installation tools and threaded rod.
40-20-7
863 Bobcat Loader
Service Manual
DRIVE COMPONENTS (CONT’D)
Figure 40-20-22
Drive Chain Removal And Installation
Rear Chain
Front Chain
WARNING
P-7866
DO NOT exceed the recommended torque of 130 ft.lbs. (176 Nm). The tool may fail under too much
torque. Put cloth around the tool to protect yourself
from flying debris.
Remove the front (or rear) drive chain from the
chaincase.
The tool listed is needed for the following procedure:
W-2233-0296
MEL1037 - Chain Link Tool
Installation: If a new chain is installed, a connector link
must be used to connect the chain together.
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
Install the new chain around the carrier shaft.
Use MEL1037 Chain Link Tool and #100 chain adapter.
Figure 40-20-23
W-2059-0598
Raise the loader lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the loader operator cab. (See Raising The
Operator Cab on Page 10-30-1.)
Drain the fluid from the chaincase. (See CHAINCASE on
Page 40-30-1.)
B-13504
Remove the front (or rear) chaincase cover. (See Front
Chaincase Cover Removal And Installation on Page 4030-1.)
Secure the tool and place the connector link and chain in
the tool as shown [Figure 40-20-23].
Remove the front (or rear) axle and sprocket. (See Axle,
Sprocket And Bearings Removal And Installation on
Page 40-20-3.)
Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-20-23]. Tighten the
threaded rod of the chain link tool to 180 ft.-lbs. (176 Nm)
torque.
40-20-8
863 Bobcat Loader
Service Manual
CHAINCASE
Figure 40-30-2
Front Chaincase Cover Removal And Installation
Figure 40-30-1
1
1
N-19956
1
Disconnect the hydraulic hoses (Item 1) [Figure 40-302].
P-4800
Figure 40-30-3
Remove the parking brake pedal. (See Pedal Removal
And Installation on Page 40-10-1.)
Remove the mounting bolts from the front cover (Item 1)
[Figure 40-30-1].
1
Remove the cover.
Rear Chaincase Cover Removal And Installation
P-7935
Remove the eight mounting bolts from the rear chaincase
cover (Item 1) [Figure 40-30-3].
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
NOTE: The auxiliary tubeline at the rear port of
hydraulic control valve may need to be
disconnected to provide clearance for cover
front bolt removal.
W-2059-0598
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
40-30-1
863 Bobcat Loader
Service Manual
40-30-2
863 Bobcat Loader
Service Manual
MAIN FRAME
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Bob-Tach Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-4
Pivot Pin Bushing And Seal Replacement . . . . . . . . . . . . . . . . 50-40-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
CONTROL HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lever Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . .
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . .
Linkage Neutral Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . .
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . .
50-110-1
50-110-1
50-110-1
50-110-5
50-110-2
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS)
ADVANCED HAND CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . 50-113-1
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-113-1
Control Handle Disassembly and Assembly . . . . . . . . . . . . . 50-113-6
Control Handle Removal And Installation . . . . . . . . . . . . . . . 50-113-5
Control Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-113-8
Control Lever Removal And Installation. . . . . . . . . . . . . . . . . 50-113-7
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . 50-113-1
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) . .
Actuators Disassembly And Assembly . . . . . . . . . . . . . . . . .
AHC Controller Removal And Installation . . . . . . . . . . . . . . .
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Handle Removal And Installation . . . . . . . . . . . . . . .
Handle Control Unit Connector . . . . . . . . . . . . . . . . . . . . . . .
50-111-1
50-111-9
50-111-4
50-111-1
50-111-8
50-111-5
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/PUSH
BUTTON FLOAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Actuators Disassembly And Assembly . . . . . . . . . . . . . . . . 50-112-11
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Control Handle Removal And Installation . . . . . . . . . . . . . . . 50-112-8
Handle Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-7
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . 50-112-5
SAFETY &
MAINTENANCE
DRIVE
SYSTEM
MAIN FRAME
ENGINE
SERVICE
SPECIFICATIONS
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS)
SELECTABLE HAND/FOOT CONTROL. . . . . . . . . . . . . . . . . . . 50-114-1
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-114-1
Control Handle Disassembly and Assembly . . . . . . . . . . . . . 50-114-6
Control Handle Removal And Installation . . . . . . . . . . . . . . . 50-114-5
Control Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-114-8
Control Lever Removal And Installation. . . . . . . . . . . . . . . . . 50-114-6
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . 50-114-1
Continued On Next Page
50-01
863 Bobcat Loader
Service Manual
MAIN FRAME (CONT’D)
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crossbar Linkage Removal And Installation . . . . . . . . . . .
Lift Foot Pedal Linkage Removal And Installation . . . . . . .
Pedal Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Tilt Foot Pedal Linkage Removal And Installation . . . . . . .
50-90-1
50-90-2
50-90-3
50-90-1
50-90-1
50-90-4
CONTROL PEDALS (ACS). . . . . . . . . . . . . . . . . . . . . . . . . . .
Foot Pedal Linkage Disassembly And Assembly. . . . . . . .
Foot Pedal Removal And Installation . . . . . . . . . . . . . . . . .
Foot Sensor Removal And Installation. . . . . . . . . . . . . . . .
50-91-1
50-91-2
50-91-2
50-91-1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Cylinder Bracket Disassembly And Assembly . . . . . .
Gas Cylinder Removal And Installation . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
50-20-1
50-20-2
50-20-1
50-20-3
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Seat Belt Removal And Installation.. . . . . . . . . . . . . . . . . . 50-30-1
OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . .
Back Removal And Installation . . . . . . . . . . . . . . . . . . . . .
Cushion Removal And Installation . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . .
Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . .
50-31-1
50-31-4
50-31-3
50-31-1
50-31-4
50-31-2
POWER BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pivot Pin Bushing And Seal Replacement . . . . . . . . . . . . .
Power Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
50-41-1
50-41-4
50-41-2
50-41-1
Continued On Next Page
50-02
863 Bobcat Loader
Service Manual
MAIN FRAME (CONT’D)
REAR DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Adjusting The Rear Door Latch (S/N 514449208 & Below) 50-70-2
Removal And Installation (S/N 514449208 & Below). . . . . 50-70-1
REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
SEAT BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling Components . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Spring Assembly And Assembly . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
50-03
50-10-1
50-10-2
50-10-4
50-10-1
863 Bobcat Loader
Service Manual
50-04
863 Bobcat Loader
Service Manual
SEAT BAR
Figure 50-10-3
Removal And Installation
Figure 50-10-1
1
1
N-18572
Remove the seat bar mounting nuts (Item 1) [Figure 5010-3] (both sides).
N-19225
Installation: Tighten the nuts to 28 ft.-lbs. (38 Nm)
torque.
Raise the seat bar (Item 1) [Figure 50-10-1].
Figure 50-10-2
Lower the operator cab. (See Lowering The Operator
Cab on Page 10-30-2.)
Figure 50-10-4
1
1
N-18463
Disconnect the seat bar sensor (Item 1) [Figure 50-10-2]
from the cab harness.
N-19224
Remove the seat bar (Item 1) [Figure 50-10-4] from the
operator cab.
Lower the seat bar.
Raise the loader operator cab. (See Raising The
Operator Cab on Page 10-30-1.)
Reverse the above procedure to install the seat bar into
the operator cab.
50-10-1
863 Bobcat Loader
Service Manual
SEAT BAR (CONT’D)
Seat Bar Mount (Item 1)
Mounting Bolt (Item 2)
Keyed Plastic Bushing (Item 3)
Seat Bar (Item 4)
Magnetic Bushing Assembly (Item 5)
Pivot Bushing (Item 6)
Sensor Bracket (Item 7)
Sensor Mounting Nut (Item 8)
Sensor Mounting Bolt (Item 9)
Mounting Nut (Item 10)
Assembling Components
Figure 50-10-5
6
5
4
7
3
2
9
1
Installation: Tighten the mounting bolt (Item 2) [Figure
50-10-5] & [Figure 50-10-6] to 50-70 in.-lbs. (5,6-7,9
Nm) torque.
8
10
N-19383
Figure 50-10-6
4
5
8
9
3
2
10
6
7
1
N-19219
Assemble the parts as shown for the left side of the seat
bar pivot assembly [Figure 50-10-5] & [Figure 50-10-6].
50-10-2
863 Bobcat Loader
Service Manual
SEAT BAR (CONT’D)
Seat Bar Mount (Item 1)
Mounting Nut (Item 2)
Pivot Bushing (Item 3)
Spacer Bushing (Item 4)
Seat Bar (Item 5)
Keyed Plastic Bushing (Item 6)
Mounting Bolt (Item 7)
Assembling Components (Cont’d)
Figure 50-10-7
5
4
3
Installation: Tighten the mounting bolt (Item 7) [Figure
50-10-7] & [Figure 50-10-8] to 50-70 in.-lbs. (5,6-7,9
Nm) torque.
6
2
7
1
N-19340
Figure 50-10-8
5
4
3
6
2
7
1
N-19220
Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-7] & [Figure 50-10-8].
50-10-3
863 Bobcat Loader
Service Manual
SEAT BAR (CONT’D)
Figure 50-10-10
Compression Spring Assembly And Assembly
6
7
Figure 50-10-9
1
5
6
4
3
2
1
N-19384
Disassemble and assemble the seat bar compression
spring and parts as shown in [Figure 50-10-10].
Bolt (Item 1)
Bushing (Item 2)
Spring (Item 3)
Clevis (Item 4)
Retaining Pin (Item 5)
Pin (Item 6)
Bushing (Item 7)
N-19222
Turn the bolt (Item 1) [Figure 50-10-9] & [Figure 50-1010] out of the clevis.
Assembly: Apply LOCTITE #518 adhesive to the bolt
threads. Adjust the compression spring by turning the
bolt in past the end of the clevis three turns.
NOTE: For procedures requiring the use of LOCTITE
#518 adhesive, thoroughly clean and dry
affected parts before the application of
LOCTITE #518.
50-10-4
863 Bobcat Loader
Service Manual
OPERATOR CAB
Figure 50-20-2
Gas Cylinder Removal And Installation
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death.
W-2113-0288
Figure 50-20-1
1
N-19621
Remove the bolts (Item 1) [Figure 50-20-2] from the gas
cylinder mounting bracket.
2
Figure 50-20-3
1
1
N-19619
Remove the operator cab stop (Item 1) [Figure 50-20-1]
(both sides).
NOTE: If the operator cab is equipped with a rear
window, the rear grill and rear grill mounts
(Item 2) [Figure 50-20-1] must be removed to
prevent window damage.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
N-19651
Use a pliers to unlock cotter pin (Item 1) [Figure 50-20-3]
& [Figure 50-20-4 on Page 2].
50-20-1
863 Bobcat Loader
Service Manual
OPERATOR CAB (CONT’D)
Gas Cylinder Bracket Disassembly And Assembly
Gas Cylinder Removal And Installation (Cont’d)
Figure 50-20-5
Figure 50-20-4
2
1
1
P-1008
N-19652
NOTE: Cotter pin (Item 1) [Figure 50-20-4] is shown in
locked position.
Remove the clevis (Item 1) [Figure 50-20-5] and washer
(Item 2) [Figure 50-20-5] from the end of the gas
cylinder.
Remove the gas cylinder from the outer housing.
Remove the cotter pin.
Remove the gas cylinder.
Assembly: Install a replacement cylinder inside the
cylinder housing.
Installation: Twist the ends of cotter pin to re-lock it.
Figure 50-20-6
P-1006
Apply a small amount of LOCTITE on the threads of the
cylinder rod [Figure 50-20-6].
Reinstall the washer and clevis on the cylinder rod.
50-20-2
863 Bobcat Loader
Service Manual
OPERATOR CAB (CONT’D)
Figure 50-20-8
Removal And Installation
Figure 50-20-7
2
1
1
N-19365
1
Remove the cab nut and holddown plate (Item 1) [Figure
50-20-7] (both sides).
Installation: Tighten the nut to 40-50 ft.-lbs. (54-68 Nm)
torque.
N-19623
Disconnect the wiring harness connectors (Item 1)
[Figure 50-20-8].
Disconnect the operator cab ground wire (Item 2) [Figure
50-20-8].
50-20-3
863 Bobcat Loader
Service Manual
OPERATOR CAB (CONT’D)
Figure 50-20-11
Removal And Installation (Cont’d)
Figure 50-20-9
1
1
P-7713
Move the operator cab forward a small amount for
clearance at the pivot mounting brackets [Figure 50-2011].
N-19647
Install a sling (Item 1) [Figure 50-20-9] on the grab
handles of the operator cab. Connect a chain hoist to the
sling.
Remove both gas cylinders. (See Gas Cylinder Removal
And Installation on Page 50-20-1.)
Install the pivot bolt, washer (one on each side) and nut
(Item 1) [Figure 50-20-11] (both sides).
Install the sling under the pivot bolt and pivot of the
operator cab [Figure 50-20-11].
Figure 50-20-12
After the gas cylinders are removed, lower the operator
cab using the chain hoist.
Figure 50-20-10
1
N-19648
Connect the slings to a chain hoist and remove the
operator cab from the loader [Figure 50-20-12].
N-19620
Remove the nut (Item 1) [Figure 50-20-10] from the pivot
bolt (both sides).
Installation: Tighten the pivot bolt and nut to 25-35 ft.lbs. (34-47 Nm) torque.
Remove the pivot bolt (both sides).
50-20-4
863 Bobcat Loader
Service Manual
OPERATOR SEAT
Seat Belt Removal And Installation.
Removal And Installation
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Figure 50-30-3
Figure 50-30-1
1
1
2
N-20729A
N-20729
Remove the seat mounting nuts (Item 1) [Figure 50-301] and washers from the operator seat mounting studs.
Locate the seat belt bolts under seat pan insulation (Item
1 & 2) [Figure 50-30-3] and peel back or cut insulation to
gain access to the head.
Figure 50-30-4
Installation: Tighten the mounting nuts to 20 ft.-lbs. (27
Nm) torque.
NOTE: Ensure the washers are installed.
Figure 50-30-2
1
2
N-20655
Remove the two nuts (Item 1 & 2) [Figure 50-30-4].
P-10564
Installation: Tighten nut (Item 1) [Figure 50-30-4] to 54
ft.-lbs. (73 Nm) torque. Tighten nut (Item 2) [Figure 5030-4] to 34 ft.-lbs. (46 Nm) torque.
P-10563
Lower the cab and install one of the mounting washer
and nut (Item 1) [Figure 50-30-2].
Repeat for the other half of seat belt and guide.
NOTE: With the seat removed the cab will raise.
Reverse the removal procedure to install the operator
seat.
50-30-1
863 Bobcat Loader
Service Manual
50-30-2
863 Bobcat Loader
Service Manual
OPERATOR SEAT (SUSPENSION)
Figure 50-31-3
Removal And Installation
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Figure 50-31-1
1
1
2
N-20974
NOTE: Assure seat tethers are securely fastened to
seatbelt studs (Item 1) [Figure 50-31-3] and
seat rail studs (Item 2) [Figure 50-31-4].
Figure 50-31-4
N-20647
Remove the four seat mounting nuts (Item 1) [Figure 5031-1] and washers from the operator seat mounting
studs.
Installation: Tighten the mounting nuts to 20 ft.-lbs. (27
Nm) torque.
Figure 50-31-2
1
N-20973
NOTE: Verify the front two seat rail studs have
washers attached (Item 1) [Figure 50-31-4].
P-10564
P-10563
Lower the cab and install one of the mounting washer
and nut (Item 1) [Figure 50-31-2].
NOTE: With the seat removed the cab will raise.
Reverse the removal procedure to install the operator
seat.
50-31-1
863 Bobcat Loader
Service Manual
OPERATOR SEAT (SUSPENSION) (CONT’D)
Slide Rail Removal And Installation
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the operator seat.
Installation on Page 50-30-1.)
(See
Removal
And
Figure 50-31-5
1
1
2
1
2
1
N-18587
Remove the two slide rail mounting bolts (Item 1) [Figure
50-31-5].
Remove the slide rail (Item 2) [Figure 50-31-5] from the
bottom of the seat frame.
Reverse the procedure to install the operator seat slide
rail.
50-31-2
863 Bobcat Loader
Service Manual
OPERATOR SEAT (SIUSPENSION) (CONT’D)
Figure 50-31-8
Cushion Removal And Installation
Figure 50-31-6
1
1
N-18581
Remove the cushion (Item 2) [Figure 50-31-7] from the
seat frame (Item 1) [Figure 50-31-8].
N-18579
Press the two buttons (Item 1) [Figure 50-31-6] &
[Figure 50-31-7] and lift the seat cushion.
Figure 50-31-9
Figure 50-31-7
2
1
N-18580
Inspect the seat ride adjustment [Figure 50-31-9].
N-18582
Reverse the removal procedure to install the operator
seat back.
50-31-3
863 Bobcat Loader
Service Manual
OPERATOR SEAT (SUSPENSION) (CONT’D)
Shock Removal And Installation
Back Removal And Installation
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Figure 50-31-10
Remove the operator seat.
Installation on Page 50-30-1.)
1
(See
Removal
And
Figure 50-31-12
1
1
N-18583
2
Pull the seatback adjustment lever (Item 1) [Figure 5031-10] and tilt the seat back all the way forward.
N-18584
Figure 50-31-11
Figure 50-31-13
1
2
1
1
N-18578
N-18585
Remove the two mounting screws (Item 1) [Figure 5031-11] from the seat back and remove the back.
Reverse the removal procedure to install the operator
seat back.
Remove the seat shock retaining pin (Item 1) [Figure 5031-12] & [Figure 50-31-13] (both ends).
Remove the seat shock (Item 2) [Figure 50-31-12] &
[Figure 50-31-13].
50-31-4
863 Bobcat Loader
Service Manual
OPERATOR SEAT (SUSPENSION) (CONT’D)
Shock Removal And Installation (Cont’d)
Figure 50-31-14
1
1
N-18586
NOTE: The seat shock mounting studs (Item 1)
[Figure 50-31-14] are replaceable.
Reverse the removal procedure to install the operator
seat shock.
50-31-5
863 Bobcat Loader
Service Manual
50-31-6
863 Bobcat Loader
Service Manual
BOB-TACH
Figure 50-40-3
Removal And Installation
Figure 50-40-1
1
P-7695
Remove the rod end pivot pin (Item 1) [Figure 50-40-3].
P-7694
Figure 50-40-4
With the lift arms all the way down, tilt the Bob-Tach
forward so it is parallel to the floor [Figure 50-40-1].
Figure 50-40-2
1
1
P-3911
Remove the tilt cylinder rod end.
Remove the seals (Item 1) [Figure 50-40-4].
P-7693
Remove the retainer bolt (Item 1) [Figure 50-40-2] from
the pivot pin.
Installation: Tighten the retainer bolt to 18-20 ft.-lbs.
(24-27 Nm) torque.
50-40-1
863 Bobcat Loader
Service Manual
BOB-TACH (CONT’D)
Figure 50-40-7
Removal And Installation (Cont’d)
Figure 50-40-5
1
P-7696
Install an adapter (Item 1) [Figure 50-40-7] into the BobTach pivot pin.
P-3910
Installation: Use two pieces of shim stock (light
cardboard), install the rod end of the tilt cylinder into the
Bob-Tach [Figure 50-40-5].
Be careful not to damage the seal during installation.
Install the slide hammer into the adapter and pull the
pivot pin from the lift arms/Bob-Tach.
NOTE: Always inspect Bob-Tach pivot pin bushings
and seals in lift arm for wear or damage.
Replace as needed.
NOTE: Removal procedure is show for the right side.
Left side procedure is the same.
Figure 50-40-6
1
P-7697
Remove the retainer bolt and nut (Item 1) [Figure 50-406] from the Bob-Tach pivot pin.
Installation: Tighten the bolt and retainer nut to 25 ft.lbs. (34 Nm) torque.
50-40-2
863 Bobcat Loader
Service Manual
BOB-TACH (CONT’D)
Figure 50-40-10
Bob-Tach Lever And Wedge
Use the following procedure to remove and install the
Bob-Tach lever, spring and wedge.
Figure 50-40-8
1
P-7681
Remove the Bob-Tach lever (Item 1) [Figure 50-40-10].
Figure 50-40-11
P-7694
With the lift arms fully down, tilt the Bob-Tach forward so
it is parallel with the floor [Figure 50-40-8].
Figure 50-40-9
1
P-7682
Remove the roll pin (Item 1) [Figure 50-40-11] from the
Bob-Tach wedge assembly.
3
2
1
P-7680
Remove the lever mounting nut (Item 1) [Figure 50-409], washer (Item 2) [Figure 50-40-9] and spring (Item 3)
[Figure 50-40-9].
Installation: Tighten the nut to 25-28 ft.-lbs. (34-38 Nm)
torque.
50-40-3
863 Bobcat Loader
Service Manual
BOB-TACH (CONT’D)
Reverse the removal procedure to install the Bob-Tach
lever and wedge assembly.
Bob-Tach Lever and Wedge (Cont’d)
Bob-Tach Stops
Figure 50-40-12
Figure 50-40-14
1
1
P-7683
P-7952
Remove the spring, bolt and clevis assembly (Item 1)
[Figure 50-40-12].
Remove the wedge from the Bob-Tach frame.
Remove and replace the Bob-Tach stop (Item 1) [Figure
50-40-14] (both sides) if worn or damaged.
NOTE: The Bob-Tach stop (Item 1) [Figure 50-40-14]
must contact the lift arm at the same time the
tilt cylinder reaches full extension. Use
available shims to adjust the Bob-Tach stop
and tilt cylinder sequence as closely as
possible.
Always replace bent or broken wedges.
Figure 50-40-13
5
2
1
4
3
P-7684
If the bolt (Item 1) [Figure 50-40-13], handle pivot (Item
2) [Figure 50-40-13] or clevis (Item 3) [Figure 50-40-13]
are damaged, put the assembly in the vise for
disassembly. Loosen and remove the bolt (Item 1)
[Figure 50-40-13] with a 5/16 inch allen wrench.
Replace the worn or damaged parts as needed.
Before installation of the parts, put grease on the handle
pivot (Item 2) [Figure 50-40-13], Bob-Tach handle pivot
(Item 5) [Figure 50-40-13] and bolt (Item 1) [Figure 5040-13].
50-40-4
863 Bobcat Loader
Service Manual
BOB-TACH (CONT’D)
Figure 50-40-17
Pivot Pin Bushing And Seal Replacement
Figure 50-40-15
1
P-7950
Use a driver to install new seals. The pivot pin can be
used to locate seal [Figure 50-40-17].
P-7948
Use a seal pick to remove seals (Item 1) [Figure 50-4015] on both sides of pivot bushing.
Figure 50-40-16
P-7949
Remove and replace bushing with a driver tool and
hammer [Figure 50-40-16].
50-40-5
863 Bobcat Loader
Service Manual
50-40-6
863 Bobcat Loader
Service Manual
POWER BOB-TACH
Figure 50-41-2
Removal And Installation
Figure 50-41-1
2
1
3
2
1
N-18545
Remove the pivot pin (Item 1) [Figure 50-41-2] from the
tilt cylinder rod end (both sides).
N-21401
Tilt the Bob-Tach forward, so it is parallel to the floor . Put
blocks (approximately 3 inches) under each side of the
Bob-Tach [Figure 50-41-1].
Remove the tilt cylinder rod end from the Bob-Tach (both
sides).
Loosen the bolt (Item 2) [Figure 50-41-2] at the BobTach pivot pin.
Lower the Bob-Tach onto the blocks.
Remove the hoses to the cylinder fittings [Figure 50-411].
NOTE: The hose with the 45° end (Item 1) [Figure 5041-1] is connected to the base end fitting on
the cylinder.
Installation: Tighten the bolt to 350 ft.-lbs. (475 Nm)
torque.
Figure 50-41-3
Remove the hose clamp on the hoses and us the bolt
(Item 2) [Figure 50-41-1] on the tilt cylinder pivot pin to
secure the clamp.
1
Remove the retainer bolt (Item 3) [Figure 50-41-1] and
nut from the tilt cylinder rod end pin (both sides).
Installation: Tighten the retainer bolt and nut to 18-20 ft.lbs (24-27 Nm) torque.
N-18547
Strike the head of the bolt (Item 1) [Figure 50-41-3] to
push the pivot pin into the Bob-Tach frame.
Remove the bolt.
50-41-1
863 Bobcat Loader
Service Manual
POWER BOB-TACH (CONT’D)
Power Bob-Tach Lever And Wedge
Removal And Installation (Cont’d)
Figure 50-41-5
Figure 50-41-4
1
1
N-21401
P-13099
Use a punch to drive the pivot pin and cap (Item 1)
[Figure 50-41-4] out of the Bob-Tach frame.
Use the following procedure to remove and install the
Bob-Tach lever (Item 1) [Figure 50-41-5], spring and
wedge.
Figure 50-41-6
Remove the Bob-Tach pivot pin (both sides).
Remove the Bob-Tach from the lift arms.
1
N-18559
Use a punch and hammer, remove the roll pin (Item 1)
[Figure 50-41-6] from the Bob-Tach Wedge and spring
clevis.
50-41-2
863 Bobcat Loader
Service Manual
POWER BOB-TACH (CONT’D)
Figure 50-41-9
Power Bob-Tach Lever And Wedge (Cont’d)
Figure 50-41-7
4
1
3
2
1
N-20625
If the bolt (Item 1) [Figure 50-41-9], handle pivot (Item 2)
[Figure 50-41-9], spring (Item 3) [Figure 50-41-9], or
clevis (Item 4) [Figure 50-41-9] are damaged, put the
assembly in a vise.
N-18560
Remove the Wedge (Item 1) [Figure 50-41-7].
Always replace bent or broken wedges.
Remove the bolt and replace the damaged parts as
needed.
Figure 50-41-8
Figure 50-41-10
2
1
1
3
4
5
N-21401
N-18563
Remove the washers and bolts (Item 1) [Figure 50-41-8].
Tighten the bolts to 25-28 ft.-lbs. (24-28 Nm) torque.
Use a punch and hammer to drive the roll pin (Item 1)
[Figure 50-41-10] flush with the face of the Bob-Tach.
Remove the cylinder off the lever points. Position the rod
end to the left with the grease fitting holes to the top
[Figure 50-41-8].
Remove the lever mounting nut (Item 2) [Figure 50-418], washer (Item 3) [Figure 50-41-8], spring (Item 4)
[Figure 50-41-8] and lever (Item 5) [Figure 50-41-8].
Installation: Tighten the nut to 25-28 ft.-lbs. (34-38 Nm)
torque.
50-41-3
863 Bobcat Loader
Service Manual
POWER BOB-TACH (CONT’D)
Pivot Pin Bushing And Seal Replacement
Power Bob-Tach Lever and Wedge (Cont’d)
Figure 50-41-12
Figure 50-41-11
2
1
1
N-18557
N-18562
Remove the power Bob-Tach. (See Removal And
Installation on Page 50-41-1.)
Reverse the removal procedure to install the Power BobTach lever and wedge [Figure 50-41-11].
Use a seal pick to remove seal (Item 1) [Figure 50-4112] on the Bob-Tach.
Remove and replace bushing (Item 2) [Figure 50-41-12]
with a driver tool and hammer.
50-41-4
863 Bobcat Loader
Service Manual
LIFT ARMS
Figure 50-50-3
Removal And Installation
The items listed are necessary for the following
procedure:
Three Lifting Straps - 7 ft. in length (with looped ends)
Chain Hoist
Install jackstands under rear of the loader.
Remove the Bob-Tach from the lift arms. (See Removal
And Installation on Page 50-40-1.)
1
Figure 50-50-1
P-7725
Remove the tubeline mounting clamp (Item 1) [Figure
50-50-3] from the back of the lift arm crossmember.
In the operator cab, turn the ignition key in the ON
position.
1
Press the PRESS TO OPERATE button.
1
Place the seat bar in the down position.
Place the loader lift pedal (Handle, with ACH) in the float
position.
P-7729
Remove the two auxiliary tubeline clamps (Item 1)
[Figure 50-50-1] from the left lift arm (if so equipped).
Figure 50-50-2
1
N-19654
Remove the two mounting bolts (Item 1) [Figure 50-50-2]
from the front auxiliary quick coupler mounting bracket (if
so equipped).
50-50-1
863 Bobcat Loader
Service Manual
LIFT ARMS (CONT’D)
Figure 50-50-5
Removal And Installation (Cont’d)
Figure 50-50-4
1
2
1
P-7730
Remove the tilt cylinder (Item 1) [Figure 50-50-5] from
the lift arms.
P-7726
Wrap the lifting strap around the lift arm crossmember as
shown in [Figure 50-50-4]. Connect both loops of the
lifting strap to a chain hoist.
Remove the tilt tubelines from the lift arms and put the tilt
cylinder on the floor.
Figure 50-50-6
Raise the lift arms enough to remove the auxiliary
tubelines (if so equipped) from the lift arms [Figure 5050-5].
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
2
Remove the nut and retainer bolt (Item 1) [Figure 50-504] from the pivot pin for the base of the tilt cylinder.
1
3
Remove the pivot pin from the base end of the cylinder
(Item 2) [Figure 50-50-4].
P-7728
Remove the lift arm support device mounting bolt and nut
(Item 1) [Figure 50-50-6].
Installation: Tighten the mounting bolt and nut to 15-17
ft.-lbs. (20-23 Nm) torque.
Remove the nut and retainer bolt (Item 2) [Figure 50-506] from the pivot pin for the lift cylinder rod end (both
sides).
Installation: Tighten the retainer bolt and nut to 15-17 ft.lbs. (20-23 Nm) torque.
50-50-2
863 Bobcat Loader
Service Manual
LIFT ARMS (CONT’D)
Figure 50-50-8
Removal And Installation (Cont’d)
Remove the pivot pin from the lift cylinder (both sides).
1
NOTE: Drive out all pivot pins from the opposite side
that the retainer bolt was removed from.
Remove the lift arm support device (Item 3) [Figure 5050-6].
2
Lower the lift arms with the chain hoist.
Figure 50-50-7
P-7732
Remove the nut and retainer bolt (Item 1) [Figure 50-508] from the loft arm pivot pin (both sides).
Installation: Tighten the retainer bolt and nut to 15-17 ft.lbs. (220-23 Nm) torque.
1
Remove the pivot pin (Item 2) [Figure 50-50-8] from the
lift arms (both sides).
Figure 50-50-9
P-7731
Install the lift strap on the lift arm as shown in [Figure 5050-7] (both sides).
Install the pivot pin (Item 1) [Figure 50-50-7] retainer bolt
and nut (both sides).
Connect the loops of the lifting straps to the chain hoist
(both lift straps).
P-7733
Raise the lift arms with the chain hoist so the lift arms are
free from the loader.
Pull the lift arms away from the loader [Figure 50-50-9].
Lower the lift arms slowly and put them on the floor.
50-50-3
863 Bobcat Loader
Service Manual
50-50-4
863 Bobcat Loader
Service Manual
REAR GRILL
Figure 50-60-3
Removal And Installation
1
Figure 50-60-1
P-7946
Remove the cotter pin and the pivot pin (Item 1) [Figure
50-60-3] (both sides).
N-19411
Figure 50-60-4
Raise the rear grill [Figure 50-60-1].
Support the rear grill.
Figure 50-60-2
1
P-7947
Remove the grill from the loader [Figure 50-60-4].
N-19412
Remove the nut (Item 1) [Figure 50-60-2] to disconnect
the gas cylinder from the rear grill.
Lower the rear grill.
50-60-1
863 Bobcat Loader
Service Manual
50-60-2
863 Bobcat Loader
Service Manual
REAR DOOR
Figure 50-70-2
Removal And Installation (S/N 514449208 & Below)
Open the rear door.
2
Figure 50-70-1
2
1
1
N-10889
Disconnect the light harness connector (Item 1) [Figure
50-70-1] from the engine harness.
Remove the light bulbs from the light housing and
remove the light housing (Item 2) [Figure 50-70-1] from
the rear door (both sides).
N-19657
Install a nylon sling (Item 1) [Figure 50-70-2] through the
holes for the light housings.
Connect a chain hoist (Item 2) [Figure 50-70-2] to the
nylon sling.
50-70-1
863 Bobcat Loader
Service Manual
REAR DOOR (CONT’D)
Adjusting The Rear Door Latch (S/N 514449208 &
Below)
Removal And Installation (S/N 514449208 & Below)
(Cont’d)
Figure 50-70-4
Figure 50-70-3
1
1
2
N-19320
The door catch (Item 1) [Figure 50-70-4] can be adjusted
side to side for alignment with the door latch.
Figure 50-70-5
1
1
N-19658
Remove the nuts from the top and bottom hinge bolts
(Item 1) [Figure 50-70-3] and remove the hinge bolts.
Installation: Tighten the mounting bolts and nuts to 25-28
ft.-lbs. (34-35 Nm) torque. The door stop (Item 2)
[Figure 50-70-3] is installed in the top hinge bolt.
N-19321
The door latch (Item 1) [Figure 50-70-5] can be adjusted
forward or backward for alignment with the door catch.
Remove the rear door from the loader frame and lay it flat
on the floor.
50-70-2
863 Bobcat Loader
Service Manual
REAR DOOR (CONT'D)
Adjusting The Striker (S/N 514449209 & Above)
Striker Removal And Installation (S/N 514449209 &
Above)
Figure 50-70-7
Figure 50-70-6
1
1
1
P-31126
1
Loosen the two striker assembly mount bolts (Item 1)
[Figure 50-70-7].
P-31126
Remove the two striker mount bolts (Item 1) [Figure 5070-6].
Align the striker assembly in the center of the mounting
holes.
Remove the striker assembly from the loader.
Tighten the striker assembly, top mount bolt only, until it
will hold the striker assembly in the enter of the mounting
slots.
Shut the rear door. (This will align the striker assembly to
the correct position.)
Open the rear door.
Tighten both striker mount bolts (Item 1) [Figure 50-707].
Close the rear door.
50-70-3
863 Bobcat Loader
Service Manual
REAR DOOR (CONT'D)
Latch Removal And Installation (S/N 516815094,
517515071, 518915872 & Above.) (Cont’d)
Latch Removal And Installation (S/N 514449209 &
Above)
Figure 50-70-10
Figure 50-70-8
1
2
P-31128
1
P-31125
Disconnect the spring (Item 1) [Figure 50-70-8] from the
tailgate.
Remove the lever (Item 1) [Figure 50-70-10] from the
rear door.
Remove the bolt and nut (Item 2) [Figure 50-70-8] from
the door latch.
Figure 50-70-9
3
2
1
P-31127
Remove the spring (Item 1) [Figure 50-70-9] from the
door handle.
Remove the spring (Item 2) [Figure 50-70-9] from the
door latch.
Remove the door latch (Item 3) [Figure 50-70-9] from the
lever.
50-70-4
863 Bobcat Loader
Service Manual
FUEL TANK
Figure 50-80-3
Removal And Installation
Figure 50-80-1
2
1
1
P-4855
Disconnect the fuel fill hose (Item 1) [Figure 50-80-3].
P-1616
Disconnect the tank vent hose (Item 2) [Figure 50-80-3].
Remove the cover (Item 1) [Figure 50-80-1] which is
installed over the drain plug.
Figure 50-80-4
Figure 50-80-2
1
1
P-7918
Remove the bolts (Item 1) [Figure 50-80-4] from the
battery hold down plate.
P-1619
Remove the drain plug (Item 1) [Figure 50-80-2].
Remove the battery hold down plate from the loader.
Drain the fuel into a container.
Check the drain plug and replace if necessary.
Remove the engine/hydrostatic pump assembly from the
loader. (See Removal And Installation on Page 70-80-1.)
50-80-1
863 Bobcat Loader
Service Manual
FUEL TANK (CONT’D)
Fuel Level Sender
Removal And Installation (Cont’d)
Figure 50-80-6
Figure 50-80-5
1
1
P-7921
P-7923
Remove the fuel level sender (Item 1) [Figure 50-80-6].
Remove the mounting plate (Item 1) [Figure 50-80-5] for
the battery hold down plate.
Figure 50-80-7
Lift the fuel tank and remove it from the loader frame.
P-7922
Check the fuel level sender with an ohmmeter as follows
[Figure 50-80-7]:
Fuel Level - 30 Seconds Delay
Full - 30 ohms
Empty - 270 ohms
Short - 0 ohms
Open - 300 + ohms
Fuel float and magnet must slide freely on the shaft
[Figure 50-80-7].
50-80-2
863 Bobcat Loader
Service Manual
CONTROL PEDALS
Pedal Adjustment
Removal And Installation
WARNING
Figure 50-90-1
AVOID INJURY OR DEATH
Adjust locking tabs on control linkage so that lift and
tilt control pedals or (Mechanical Hand Controls) are
locked in neutral when the seat bar is up.
1
W-2104-0199
After installing the pedal, adjust the pedal so that there is
clearance under the rear of the pedal. The valve spool
must travel full stroke without the pedal hitting the floor
panel.
N-19233
Remove the bolt (Item 1) [Figure 50-90-1] and nut from
the pedal linkage.
Installation: Tighten the bolt and nut to 21-25 ft.-lbs. (2834 Nm) torque.
Check the rubber bushing in the pedal for wear and
replace as needed.
Figure 50-90-2
1
N-19232
Remove the two mounting bolts (Item 1) [Figure 50-90-2]
from the pedal mounting bracket.
Remove the pedal assembly from the loader.
50-90-1
863 Bobcat Loader
Service Manual
CONTROL PEDALS (CONT’D)
Figure 50-90-4
Crossbar Linkage Removal And Installation
1
WARNING
P-24758
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
Remove the bolt and nut (Item 1) [Figure 50-90-4] to
disconnect the lift pedal linkage from crossbar.
Figure 50-90-5
W-2059-0598
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Figure 50-90-3
1
P-24757
1
Remove the hairpin clip and cross-pin from the control
valve lift spool (Item 1) [Figure 50-90-5].
Disconnect the crossbar from the control valve.
P-24756
Remove the crossbar pivot bolt (Item 1) [Figure 50-903].
50-90-2
863 Bobcat Loader
Service Manual
CONTROL PEDALS (CONT’D)
Lift Foot Pedal Linkage Removal And Installation
Crossbar Linkage Removal And Installation (Cont’d)
Figure 50-90-7
Figure 50-90-6
1
1
P-24760
P-24763
Remove the crossmember from the pivot [Figure 50-906].
Installation: Check the nylon bushing (Item 1) [Figure
50-90-6] for wear and replace as needed.
Remove the bolt and nut (Item 1) [Figure 50-90-7] to
disconnect the lift foot pedal linkage from the crossbar
linkage.
Figure 50-90-8
1
P-24759
Remove the bolt (Item 1) [Figure 50-90-8] and nut from
the pedal linkage.
Installation: Tighten the bolt and nut to 21-25 ft.-lbs. (2834 Nm) torque.
50-90-3
863 Bobcat Loader
Service Manual
CONTROL PEDALS (CONT’D)
Tilt Foot Pedal Linkage Removal And Installation
Figure 50-90-9
1
P-24761
Remove the bolt and nut (Item 1) [Figure 50-90-9] to
disconnect the tilt foot pedal linkage from the control
valve.
Figure 50-90-10
1
P-26008
Remove the bolt (Item 1) and nut from the pedal linkage.
Installation: Tighten the bolt and nut to 21-25 ft.-lbs. (2834 Nm) torque.
50-90-4
863 Bobcat Loader
Service Manual
CONTROL PEDALS (ACS)
Figure 50-91-3
Foot Sensor Removal And Installation
Figure 50-91-1
1
2
P-21936
P-21927
1
Remove the two bolts (Item 1) [Figure 50-91-3] from the
foot sensor shield.
P-21938
Pull the pin (Item 1) [Figure 50-91-1] holding the foot
pedal linkage to the sensor.
Disconnect the two connectors (Item 2) [Figure 50-91-1]
from the sensor and lock solenoid.
Installation: Tighten the bolts to 80-90- in.-lbs. (9,0-10,2
Nm) torque.
Figure 50-91-4
1
Figure 50-91-2
2
1
P-21924
Remove foot lock solenoid (Item 1) [Figure 50-91-4].
P-21935
Tilt the foot pedal up and remove the two nuts (Item 1)
[Figure 50-91-2].
Remove the foot pedal and sensor assembly from the
loader.
Installation: Apply a drop of oil to the solenoid threads
and tighten the solenoid to 35-40 ft.-lbs. (47-54 Nm)
lubed torque.
Remove the two bolts (Item 2) [Figure 50-91-4] from the
bracket and sensor assembly.
Installation: Tighten the bolts to 25-28 ft.-lbs. (34-38
Nm) torque.
Remove the sensor assembly.
50-91-1
863 Bobcat Loader
Service Manual
CONTROL PEDALS (ACS) (CONT’D)
Foot Pedal Linkage Disassembly And Assembly
Foot Sensor Removal And Installation (Cont’d)
Figure 50-91-7
NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Contents, Page 60-01.)
Foot Pedal Removal And Installation
Figure 50-91-5
1
2
P-21931
Remove the bolt (Item 1) [Figure 50-91-7] holding the
linkage (Item 2) [Figure 50-91-7] to the side of the foot
pedal.
Figure 50-91-8
1
P-21940
Remove the pin (Item 1) [Figure 50-91-5] holding the
linkage to the sensor.
2
Figure 50-91-6
1
3
P-21935
1
P-21932
Remove the spacer (Item 1) [Figure 50-91-8],linkage
(Item 2) [Figure 50-91-8] and nut (Item 3) [Figure 50-918] from the foot pedal.
P-21934
Tip the foot pedal up [Figure 50-91-6] and remove the
two nuts (Item 1) [Figure 50-91-6].
Remove the foot pedal assembly.
50-91-2
863 Bobcat Loader
Service Manual
CONTROL PANEL
Figure 50-100-1
Removal And Installation
1
WARNING
2
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
3
W-2017-0286
N-19662
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Remove the engine speed control (Item 1) [Figure 50100-1]. (See Removal And Installation on Page 70-20-1.)
Loosen the jam nut from the by-pass control knob (Item
2) [Figure 50-100-1].
Remove the control knob, jam nut and rubber washer.
Disconnect the control harness wiring connector (Item 3)
[Figure 50-100-1] from the right side steering lever.
Figure 50-100-2
1
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
N-19667
NOTE: If the loader is equipped with rear auxiliary
hydraulics, also disconnect the electrical
connectors from the left side steering lever
(Item 1) [Figure 50-100-2].
50-100-1
863 Bobcat Loader
Service Manual
CONTROL PANEL (CONT’D)
Figure 50-100-5
Removal And Installation (Cont’d)
1
Figure 50-100-3
1
2
1
2
N-19665
1
Remove the control panel mounting bolts (Item 1)
[Figure 50-100-5] from the right side of the control panel.
N-19664
Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-100-3].
Installation: Tighten the control panel mounting bolts to
25-28 ft.-lbs. (34-38 Nm) torque.
Remove the four steering linkage mounting bolts (Item 2)
[Figure 50-100-3].
Installation: Tighten the steering linkage mounting bolts
to 25-28 ft.-lbs. (34-38 Nm) torque.
Figure 50-100-4
1
1
N-19663
Remove the control panel mounting bolts (Item 1)
[Figure 50-100-4] from the right side control panel.
Installation: Tighten the control panel mounting bolts to
25-28 ft.-lbs. (34-38 Nm) torque.
50-100-2
863 Bobcat Loader
Service Manual
CONTROL PANEL (CONT’D)
Figure 50-100-7
Removal And Installation (Cont’d)
Figure 50-100-6
1
1
1
N-19667
1
N-19666
Remove the control panel mounting bolts (Item 1)
[Figure 50-100-6] & [Figure 50-100-7] from the left side
of the control panel.
Installation: Tighten the control panel mounting bolts to
25-28 ft.-lbs. (34-38 Nm) torque.
Remove the control panel from the loader.
50-100-3
863 Bobcat Loader
Service Manual
50-100-4
863 Bobcat Loader
Service Manual
CONTROL HANDLE
Lever Disassembly And Assembly
Lever Removal And Installation
Figure 50-110-2
Figure 50-110-1
1
1
3
3
2
2
N-17639
N-17643
Loosen both U-bolts (Item 1) [Figure 50-110-1] at the
steering lever (both sides).
Remove the steering cross shaft mounting bolts (Item 2)
[Figure 50-110-1] (both sides).
Installation: Tighten the mounting bolts to 25 ft.-lbs. ( 40
Nm) torque.
Disassemble the right and left steering shafts from the
cross shaft assembly.
NOTE: Some loaders may have a sleeve (Item 1)
[Figure 50-110-2] between the bearing (Item 2)
[Figure 50-110-2] and the bell crank (Item 3)
[Figure 50-110-2].
Figure 50-110-3
Remove the steering cross shaft from the control panel.
1
2
3
N-17640
Check the bearings (Item 1) [Figure 50-110-3] for wear
and replace as needed.
Check the fiber washers (Item 2) [Figure 50-110-3] for
wear and replace as needed.
Replace the wave washer (Item 3) [Figure 50-110-3] if
worn.
50-110-1
863 Bobcat Loader
Service Manual
CONTROL HANDLE (CONT’D)
Linkage Removal And Installation
Lever Disassembly And Assembly (Cont’d)
Figure 50-110-6
Figure 50-110-4
1
2
1
N-17601
2
P-13773
Check the end bearing (Item 1) [Figure 50-110-4] and
fiber washer (Item 2) [Figure 50-110-4] and replace as
needed.
Figure 50-110-5
Remove the nut (Item 1) [Figure 50-110-6] from the end
of the centering spring shoulder bolt (Item 2) [Figure 50110-6].
Remove the shoulder bolt/spring assembly.
Installation: Tighten the centering spring shoulder bolt
and a NEW lock nut to 25-28 ft.-lbs. (34-38 Nm) torque.
Drain the hydraulic reservoir. (See Draining The Fluid
Reservoir on Page 20-80-1.)
1
2
Figure 50-110-7
3
4
P-13774
NOTE: Some loaders may have a spacer (Item 1)
[Figure 50-110-5] between the bearing (Item 2)
[Figure 50-110-5] and the bell crank (Item 3)
[Figure 50-110-5].
Check the fiber washer (Item 4) [Figure 50-110-5] and
replace all worn parts.
1
2
N-19736
Remove the hydraulic hoses (Item 1) [Figure 50-110-7].
Remove the hydraulic fitting (Item 2) [Figure 50-110-7]
from the pump.
50-110-2
863 Bobcat Loader
Service Manual
CONTROL PANEL (CONT’D)
Figure 50-110-10
2
Linkage Removal And Installation (Cont’d)
5
1
Figure 50-110-8
1
3
2
2
4
3
3
N-17609
The centering plate/centering spring assembly consists
of the following parts [Figure 50-110-10]:
N-19737
Slide the plate (Item 1) [Figure 50-110-8] to the right and
remove it from the two guide pins (Item 2) [Figure 50110-8].
NOTE: The two guide bushings (Item 3) [Figure 50110-8] will be loose and can fall out of the
plate as soon as it is removed from the guide
pins.
Item
1
2
3
4
5
Description
Bolt
Washer
Sleeve
Bushing
Spring
Figure 50-110-11
Figure 50-110-9
1
1
4
2
1
N-17607
2
3
Check the wear on the centering blocks (Item 1) [Figure
50-110-11].
N-17608
The centering plate/centering spring assembly consists
of the following parts [Figure 50-110-9]:
Item
1
2
3
4
Description
Centering Spring Assembly
Guide Bushings
Lock Nut
Centering Plate
50-110-3
863 Bobcat Loader
Service Manual
CONTROL PANEL (CONT’D)
Figure 50-110-14
Linkage Removal And Installation (Cont’d)
Figure 50-110-12
1
1
N-17611
Remove the linkage bar nut (Item 1) [Figure 50-110-14]
from the torsion bushing.
N-17606
If the centering blocks need replacement, remove the
bolts (Item 1) [Figure 50-110-12]. Remove the centering
blocks.
Installation: Tighten the centering block bolts to 25-28
ft.-lbs. (34-38 Nm) torque.
The bolt is threaded into the linkage bar, remove the bolt
from underneath the pintle arm.
Installation: Tighten the bolt to 11-13 ft.-lbs. (21-25 Nm)
torque, then tighten the nut (Item 2) [Figure 50-110-16
on Page 5] to 21-25 ft.-lbs. (28-33 Nm) torque.
Figure 50-110-15
Figure 50-110-13
2
1
1
1
N-17612
N-19738
Check the surface of the four pintle cams (Item 1) [Figure
50-110-13].
Remove the linkage bar (Item 1) [Figure 50-110-15] from
the pintle arm. Remove the torsion bushing (Item 2)
[Figure 50-110-15].
Remove the nuts (Item 1) [Figure 50-110-16 on Page 5]
from both shock absorber ball joint ends.
If worn replace the cam.
Installation: Tighten the bolts to 45-50 ft.-lbs. (62-68
Nm) torque.
Installation: Tighten the nuts to 25-28 ft.-lbs. (34-38 Nm)
torque.
Disconnect the shock absorbers from the linkage bars.
50-110-4
863 Bobcat Loader
Service Manual
CONTROL HANDLE (CONT’D)
Linkage Neutral Adjustment
Linkage Removal And Installation (Cont’d)
WARNING
Figure 50-110-16
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
2
1
N-17624
Remove the nuts (Item 2) [Figure 50-110-16] from the
linkage bar mounting bolt. The bolts are threaded into
the linkage bars, remove the bolts.
Installation: Tighten the bolts to 11-13 ft.-lbs (21-25 Nm)
torque, the tighten the nuts to 21-25 ft.-lbs (28-33 Nm)
torque.
The torsion bushings can now be removed from the
steering bell cranks.
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
The linkage and the centering plate must be readjusted
for neutral after the components have been reassembled.
See “Linkage Neutral Adjustment” on Page 50-110-5 for
the neutral adjustment procedure.
Raise the lift arms and install an approve lift arm support
device. (See LIFT ARM SUPPORT DEVICE on Page 1020-1.)
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Connect the remote start switch. (See REMOTE START
on Page 10-60-1.)
Pre-load tension in the torsion bushings must be
removed before adjusting the steering linkage.
50-110-5
863 Bobcat Loader
Service Manual
CONTROL HANDLE (CONT’D)
Figure 50-110-19
Linkage Neutral Adjustment (Cont’d)
Figure 50-110-17
2
2
1
3
1
N-17619
N-17624
Loosen the nut (Item 1) [Figure 50-110-17] (three to four
turns), then loosen the bolt. The bolt is threaded into the
linkage bar (Item 2) [Figure 50-110-17]. The bolt must
be loosened enough to allow the torsion bushing to turn
freely between the steering bellcrank and the linkage bar.
Move the right side steering lever to the rear and install a
3-8 inch (10 mm) thick spacer (Item 1) [Figure 50-11019] between the pintle arm cam (Item 2) [Figure 50-11019] and the centering block (Item 3) [Figure 50-110-19].
Figure 50-110-20
Figure 50-110-18
1
3
2
1
N-17620
Move the right side steering lever forward and install a
15/16 inch (24 mm) thick spacer (Item 1) [Figure 50-11020] between the centering plate (Item 2) [Figure 50-11020] and the mounting plate (Item 3) [Figure 50-110-20].
2
N-17613
Loosen the nut (three to four turns), then loosen the bolt
at the linkage bar (Item 1) [Figure 50-110-18]. The bolt
is threaded into the linkage bar (Item 2) [Figure 50-11018]. The bolt must be loosened enough to allow the
torsion bushing to turn freely between the pintle arm and
the linkage bar.
This will allow the pintle arms to move freely while
adjusting the steering linkage for full forward travel
speed.
Remove the 3/8 inch (10 mm) thick spacer (Item 1)
[Figure 50-110-19].
50-110-6
863 Bobcat Loader
Service Manual
CONTROL HANDLE (CONT’D)
Figure 50-110-23
Linkage Neutral Adjustment (Cont’d)
Figure 50-110-21
2
1
N-17623
N-17616
Check that the pintle arm mounting bolt (Item 1) [Figure
50-110-21] is tight, 25-28 ft.-lbs. (34-38 Nm) torque and
that there is no play between the pintle arm and the
square pump shaft. Also check that the cam mounting
bolts (Item 2) [Figure 50-110-21] are tight, 45-50 ft.-lbs
(62-68 Nm) torque.
Move the left side steering lever to the full forward
position (Until the steering lever hits the stop), then pull
forward on the left side rear linkage bar until the pintle
arm is rotated to the front as far as possible. Use a
clamping plier and clamp the two linkage bars together
[Figure 50-110-23].
Tighten the nuts and bolts to 25-28 ft.-lbs. (34-38 Nm)
torque.
Check the lever movement to make sure that the pintle
arm and the steering lever are both at full stroke at the
same time. This will allow for maximum forward speed.
Figure 50-110-22
Repeat the procedure for the right side steering linkage
bar.
1
After both sides of the linkage bars have been adjusted,
the feel of both levers at full stroke should be the same.
Readjust the linkage if necessary.
Figure 50-110-24
1
N-19664
Loosen the two bolts and nuts (Item 1) [Figure 50-11022] on each steering linkage bar.
1
N-17620
Remove the spacer (Item 1) [Figure 50-110-24].
50-110-7
863 Bobcat Loader
Service Manual
CONTROL HANDLE (CONT’D)
Figure 50-110-27
Linkage Neutral Adjustment (Cont’d)
The following tool listed will be needed to so the following
procedure:
1
MEL1429A - Remote Start Switch
Connect the remote start switch to the engine harness.
(See REMOTE START on Page 10-60-1.)
Figure 50-110-25
N-19581
Move the traction lock override switch (Item 1) [Figure
50-110-27] to the OFF position so the traction function is
unlocked. The wheels are now able to turn.
Move the left hand steering lever until the tires do not turn
(neutral position).
1
Move the left side centering block to the left until it
contacts both pintle cams and the steering lever is still in
the neutral position [Figure 50-110-26].
N-19736
Loosen the four bolts (Item 1) [Figure 50-110-25] holding
the two centering blocks. Move the right side centering
block to the right as far as possible.
Tighten the bolts to 25-28 ft.-lbs. (34-38 Nm) torque.
NOTE: Bolt holes are slotted for pintle arm centering
adjustment.
Figure 50-110-26
N-17621
Adjust the left side centering block first [Figure 50-11026].
Start the engine and run at high RPM.
50-110-8
863 Bobcat Loader
Service Manual
CONTROL HANDLE (CONT’D)
Figure 50-110-29
Linkage Neutral Adjustment (Cont’d)
Figure 50-110-28
1
N-19736
N-17618
Adjust the right side centering block [Figure 50-110-28].
Tighten the two linkage bar bolts to 11-13 ft.-lbs. (15-17
Nm) torque, then tighten the two nuts to 21-25 ft.-lbs. (2833 Nm) torque at the pintle levers (Item 1) [Figure 50110-29].
Figure 50-110-30
Move the right side steering lever until the tires do not
turn (neutral position).
Move the right side centering block to the left until it
contacts both pintle cams and the steering lever is still in
the neutral position [Figure 50-110-28].
1
Tighten the bolts to 25-28 ft.-lbs. (34-38 Nm) torque.
2
Test both levers by moving them backward and forward
and letting them return to neutral by the return spring
force.
If the levers do not return to neutral and the tires do not
come to a complete stop, repeat the adjustment
procedure again.
Stop the engine.
N-17624
Tighten the two linkage bar bolts to 11-13 ft.-lbs. (15-17
Nm) torque, then tighten the two nuts to 21-25 ft.-lbs. (2833 Nm) torque at the steering cross shaft (Items 1 & 2 )
[Figure 50-110-30].
50-110-9
863 Bobcat Loader
Service Manual
50-110-10
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED HAND CONTROL)
(AHC)
Figure 50-111-3
Components Identification
Figure 50-111-1
1
1
P-13797
2
ACH controller (Item 1) [Figure 50-111-3].
N-17774
Figure 50-111-4
N-17783
Control handle (Item 1) [Figure 50-111-1].
Handle control unit (Item 2) [Figure 50-111-1] (both
sides).
1
Figure 50-111-2
1
P-28360A
ACH error indicator (Item 1) [Figure 50-111-4].
1
N-19112
NOTE: The AHC icon will illuminate when an error
occurs. The error is stored as a service code.
(See DELUXE INSTRUMENTATION SERVICE
CODES on Page 60-80-1.)
Control Valve Actuators (Item 1) [Figure 50-111-2].
50-111-1
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED HAND CONTROL) (ACH) (CONT’D)
Trouble shooting Guide
The Advanced Hand Control System (AHC) has a built-in diagnostic function which uses an icon on the right instrument
panel to indicate the condition of the AHC System. The system also records the alarm condition as a service code.
The control module continually checks the system in the order listed. The checks start with the lift handle controller and
then the lift actuator. If no problems are present, it will then check the tilt handle controller and the tilt actuator. The system
will stop its check at the first problem and then luminate the icon.
The system starts its diagnostics and calibration when the ignition key is turned ON.
The following list shows the probable causes when the icon is luminated.
Advanced
Hand
Controls
General
Warning
Fuel Level
System
Voltage
Engine Oil
Pressure
Engine
Coolant
Temperature
Air Filter
B-16640
Attachment
Control
Device
Two Speed
Glow Plugs
Seat Belt
Hydraulic
Charge
Pressure
Hydraulic Oil
Temperature
Hydraulic
Filter
Advanced Hand Controls
B-16624
Errors - lights solid with 3 beeps
32-31 - Tilt actuator fault
32-33 - Tilt actuator wiring fault
32-33 - Tilt handle wiring fault
32-34 - Tilt actuator not calibrated
32-35 - Tilt handle not calibrated
32-36 - Lift actuator fault
32-37 - Lift actuator wiring fault
32-38 - Lift handle wiring fault
32-39 - Lift actuator not calibrated
32-40 - Lift handle not calibrated
32-41 - Invalid Frequency
To see what error occurred, check the service code on the left instrument panel. (See Contents Page 60-01.)
50-111-2
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (CONT’D)
Parts Identification
C-428
C-430
C-431
C-429
TS-1957
P/N
PIN
C-430
DESCRIPTION
CONNECTOR, METRI-PACK
Orange/White
A
SWITCHED BATTERY POWER
Black
B
GROUND
C-431
Brown/Dk
Green
MALE, 10-WAY
A
SIGNAL FROM LIFT CONTROL
HANDLE INPUT
Purple/Yellow
B
FLOAT SWITCH ON/OFF
Pink/Dk. Green
C
SIGNAL FROM TILT CONTROL
HANDLE INPUT
Dk. Blue
Dk. Blue/White
D
E
TILT HIGH REFERENCE TO
RESISTIVE INPUTS
TILT LOW REFERENCE TO
RESISTIVE INPUTS
Dk Blue/White
F
LIFT LOW REFERENCE TO
RESISTIVE INPUTS
Dk. Blue
G
LIFT HIGH REFERENCE To
RESISTIVE INPUTS
Purple/White
H
BICS INPUT STATUS
Purple/Red
J
AHC STATUS OUTPUT
K
OPEN
P/N
PIN
C-428
DESCRIPTION
CONNECTOR, 8 WAY PLUG (LIFT) (TOP
ACTUATOR)
Dk. Blue/White
1
LOW REFERENCE TO RESISTIVE INPUTS
Lt. Green/White
2
SIGNAL FROM LIFT ACTUATOR
Dk. Blue
3
HIGH REFERENCE TO RESISTIVE UNITS
Brown/White
Brown/Yellow
4
OPEN
5
LIFT SPOOL ACTUATOR MOTOR (-)
6
OPEN
7
OPEN
8
C-429
LIFT SPOOL ACTUATOR MOTOR (+)
CONNECTOR, 8 WAY PLUG (TILT) (BOTTOM ACTUATOR)
Dk. Blue/White
1
LOW REFERENCE TO RESISTIVE INPUTS
Lt. Blue/White
2
SIGNAL FROM TILT ACTUATOR
Dk. Blue
Pink/White
Pink/Yellow
50-111-3
3
HIGH REFERENCE TO RESISTIVE INPUTS
4
OPEN
5
TILT SPOOL ACTUATOR MOTOR (-)
6
OPEN
7
OPEN
8
TILT SPOOL ACTUATOR MOTOR (+)
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCE HAND CONTROL)
(AHC) (CONT’D)
Figure 50-111-7
AHC Controller Removal And Installation
Figure 50-111-5
1
1
N-19643
Remove the four mounting bolts (Item 1) [Figure 50-1117] from the controller.
N-18882
Remove the controller from the loader.
Loosen the bottom bolts and remove the top bolt.
Remove the right front panel (Item 1) [Figure 50-111-5]
from the loader.
Figure 50-111-6
1
N-19642
Disconnect the wiring harness connectors from the
controller (Item 1) [Figure 50-111-6].
50-111-4
863 Bobcat Loader
Service Manual
CONTROL PANEL (ADVANCED HAND CONTROL)
(AHC) (CONT’D)
Figure 50-111-10
Handle Control Unit Connector
Figure 50-111-8
1
2
3
1
P-13733
With a pointed tool, lift the tab (Item 1) [Figure 50-11110] and pull the wire from the connector.
1
N-17392
The wire connector (Item 1) [Figure 50-111-8] can be
removed from the handle control unit wires, use the
following procedure.
Assembly: Install the wires into the connector as listed
below [Figure 50-111-10]:
Figure 50-111-9
1 - Terminal - Red
2 - Terminal - Black
3 - Terminal - Green
1
1
P-13725
P-13732
Remove the wedge (Item 1) [Figure 50-111-9] from the
connector.
50-111-5
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED HAND CONTROL)
(AHC) (CONT’D)
Figure 50-111-13
Control Handle Removal And Installation
Figure 50-111-11
3
2
1
1
P-13735
Using a pointed tool, press down on the tab (Item 1)
[Figure 50-111-13] and pull the wire from the connector.
Installation: Install the wires into the conductor as listed
below [Figure 50-111-13]:
Right Control Lever Switch Handle
1 - Terminal - Pink/Red
2 - Terminal - Pink/Black
3 - Terminal - Pink/Green
1
N-17786
Remove the handle control unit from the control lever.
(See AHC Controller Removal And Installation on Page
50-111-4.)
Left Control Lever Switch Handle
1 - Terminal - Brown/Red
2 - Terminal - Brown/Black
3 - Terminal - Brown Green
To remove the switch handle, the connector (Item 1)
[Figure 50-111-11] must be removed from the wires.
Figure 50-111-12
1
1
P-13725
P-13732
Remove the wedge (Item 1) [Figure 50-111-12] from the
connector.
50-111-6
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED HAND CONTROL)
(AHC) (CONT’D)
Installation: The wire colors of the control lever harness
are as follows:
Control Handle Removal And Installation (Cont’d)
Right Switch Handle
Figure 50-111-14
Ten-Pin Connector
A - Terminal - Orange
B - Terminal - White
C - Terminal - White/Black
D - Terminal - White/Red
E - Terminal - Dk. Green
F - Terminal - White/Lt. Green
G - Terminal - Blank
H - Terminal - Lt. Green
J - Terminal - Yellow
K - Terminal - Blank
1
2
Three-Pin Connector
A - Terminal - Pink/Red
B - Terminal - Pink/Black
C - Terminal - Pink/Lt. Green
N-17779
Disconnect the right switch handle connectors (Items 1 &
2) [Figure 50-111-14] from the loader wiring harness
connectors.
Left Switch Handle
Figure 50-111-15
1
2
3
4
Ten-Pin Connector
A - Terminal - Orange
B - Terminal - Dk. Blue
C - Terminal - White
D - Terminal - Blank
E - Terminal - Blank
F - Terminal - Yellow/Red
G - Terminal - Yellow/Green
H - Terminal - Blank
J - Terminal - Blank
K - Terminal - Blank
Three-Pin Connector
A - Terminal - Brown/Red
B - Terminal - Brown/Black
C - Terminal - Brown/Lt. Green
Two-Pin Connector
A - Terminal - Orange/Blue
B - Terminal - Orange/White
N-17772
Disconnect the left switch handle connectors (Items 1, 2,
3 & 4) [Figure 50-111-15] from the loader wiring harness
connectors.
Remove the connector locks and connectors from the
wires the remove the switch handle from the control
handle.
50-111-7
Five-Pin Connector
A - Terminal - Dk. Green
B - Terminal - Brown
C - Terminal - Blank
D - Terminal - Yellow
E - Terminal - Blank
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED HAND CONTROL)
(AHC) (CONT’D)
Figure 50-111-18
Control Handle Removal And Installation (Cont’d)
Figure 50-111-16
1
2
2
N-17471
1
Installation: When installing the switch handle and
wiring harness assembly into the control handle, route
the harness (Item 1) [Figure 50-111-18] to assure proper
return of the control handle to neutral position.
N-17382
Roll the grip handle cover (Item 1) [Figure 50-111-16]
down.
Using a small screwdriver, lift the handle tabs (Item 2)
[Figure 50-111-16] and slightly rotate the switch handle.
Figure 50-111-17
1
N-17383
Pull the switch handle and wiring harness assembly (Item
1) [Figure 50-111-17] from the control lever.
50-111-8
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED HAND CONTROL)
(AHC) (CONT’D)
Figure 50-111-21
Actuators Disassembly And Assembly
Figure 50-111-19
3
2
1
N-18941
1
Remove the rubber strap (Item 1) [Figure 50-111-21]
from the mounting shaft collar (Item 2) [Figure 50-11121].
N-18912
Remove the actuator (Item 1) [Figure 50-111-19] from
the hydraulic control valve. (See Actuator Removal And
Installation (In Loader) on Page 20-41-1.)
Installation: Tighten the mount bolts to 90-100 in.-lbs.
(130,2-11,3 Nm) torque.
Remove the mounting bracket (Item 3) [Figure 50-11121].
Check the rubber strap, mounting shaft collar and
mounting bracket for wear and replace as needed.
Figure 50-111-22
Figure 50-111-20
1
2
1
N-17742
N-17741
N-18940
Check the mounting block (Item 1) [Figure 50-111-20]
and bolts for wear and replace as needed.
Check the actuator wiring harness connector (Item 1)
[Figure 50-111-22] and replace if broken.
Installation: Install the wires into the connector as listed
on the next page. The terminal numbers are written in
the back of the connector (Item 2) [Figure 50-111-22].
50-111-9
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED HAND CONTROL
(AHC) (CONT’D)
Actuators Disassembly And Assembly (Cont’d)
Lift and Tilt Actuator
1 - Terminal - Black/Green - Larger diameter wire (16
gauge)
2 - Terminal - Green - Larger diameter wire (16
gauge)
3 - Terminal - Red/Green - Larger diameter wire (16
gauge)
4 - Terminal - Open
5 - Terminal - Red - Smaller diameter wire (18 gauge)
6 - Terminal - Open
7 - Terminal - Open
8 - Terminal - Black - Smaller diameter wire (18
gauge)
50-111-10
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED HAND CONTROL)
(AHC) (W/PUSH BUTTON FLOAT)
Figure 50-112-3
Components Identification
Figure 50-112-1
1
1
P-13797
2
ACH controller (Item 1) [Figure 50-112-3].
P-16536
N-22797
Figure 50-112-4
Control handle (Item 1) [Figure 50-112-1].
Handle sensor (Item 2) [Figure 50-112-1].
1
Figure 50-112-2
1
P-28360A
ACS error indicator (Item 1) [Figure 50-112-4].
1
N-19112
NOTE: The ACS icon will illuminate when an error
occurs. The error is stored as a service code.
(See DELUXE INSTRUMENTATION SERVICE
CODES on Page 60-80-1.)
Control Valve Actuators (Item 1) [Figure 50-112-2].
50-112-1
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED HAND CONTROL) (ACH) (W/PUSH BUTTON FLOAT) (CONT’D)
Trouble shooting Guide
The Advanced Hand Control System (AHC) has a built-in diagnostic function which uses an icon on the right instrument
panel to indicate the condition of the AHC System. The system also records the alarm condition as a service code.
The control module continually checks the system in the order listed. The checks start with the lift handle controller and
then the lift actuator. If no problems are present, it will then check the tilt handle controller and the tilt actuator. The system
will stop its check at the first problem and then luminate the icon.
The system starts its diagnostics and calibration when the ignition key is turned ON.
The following list shows the probable causes when the icon is luminated.
Advanced
Hand
Controls
General
Warning
Fuel Level
System
Voltage
Engine Oil
Pressure
Engine
Coolant
Temperature
Air Filter
B-16640A
Attachment
Control
Device
Two Speed
Glow Plugs
Seat Belt
Hydraulic
Charge
Pressure
Hydraulic Oil
Temperature
Hydraulic
Filter
Advanced Hand Controls
Errors - lights solid with 3 beeps
32-31 - Tilt actuator fault
32-32 - Tilt actuator wiring fault
32-33 - Tilt handle wiring fault
32-34 - Tilt actuator not calibrated
32-35 - Tilt handle not calibrated
32-36 - Lift actuator fault
32-37 - Lift actuator wiring fault
32-38 - Lift handle wiring fault
32-39 - Lift actuator not calibrated
32-40 - Lift handle not calibrated
32-41 - Invalid Frequency
To see what error occurred. Check the service code on the left instrument panel. (See Contents Page 60-01.)
50-112-2
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/PUSH BUTTON FLOAT ) (CONT’D)
Controller Connector and Wire Identification
C-428
C-430
C-431
C-429
TS-1957
P/N
PIN
C-430
DESCRIPTION
CONNECTOR, METRI-PACK
P/N
PIN
C-428
DESCRIPTION
CONNECTOR, 8 WAY PLUG (LIFT) (TOP
ACTUATOR)
Orange/White
A
SWITCHED BATTERY POWER
Black
B
GROUND
Dk. Blue/White
1
LOW REFERENCE TO RESISTIVE INPUTS
MALE, 10-WAY
Lt. Green/White
2
SIGNAL FROM LIFT ACTUATOR
SIGNAL FROM LIFT CONTROL
Dk. Blue
3
HIGH REFERENCE TO RESISTIVE UNITS
C-431
Brown/Dk
Green
A
HANDLE INPUT
Purple/Yellow
B
FLOAT SWITCH ON/OFF
Pink/Dk. Green
C
SIGNAL FROM TILT CONTROL
HANDLE INPUT
Dk. Blue
D
TILT HIGH REFERENCE TO
RESISTIVE INPUTS
Dk. Blue/White
E
TILT LOW REFERENCE TO
RESISTIVE INPUTS
Dk Blue/White
F
LIFT LOW REFERENCE TO
RESISTIVE INPUTS
Brown/White
Brown/Yellow
4
OPEN
5
LIFT SPOOL ACTUATOR MOTOR (-)
6
OPEN
7
OPEN
8
C-429
LIFT SPOOL ACTUATOR MOTOR (+)
CONNECTOR, 8 WAY PLUG (TILT) (BOTTOM ACTUATOR)
Dk. Blue/White
1
LOW REFERENCE TO RESISTIVE INPUTS
Lt. Blue/White
2
SIGNAL FROM TILT ACTUATOR
Dk. Blue
3
HIGH REFERENCE TO RESISTIVE INPUTS
4
OPEN
Dk. Blue
G
LIFT HIGH REFERENCE To
RESISTIVE INPUTS
5
TILT SPOOL ACTUATOR MOTOR (-)
Purple/White
H
BICS INPUT STATUS
6
OPEN
Purple/Red
J
AHC STATUS OUTPUT
7
OPEN
K
OPEN
8
TILT SPOOL ACTUATOR MOTOR (+)
Pink/White
Pink/Yellow
50-112-3
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCE HAND CONTROL)
(AHC) (W/PUSH BUTTON FLOAT) (CONT’D)
Figure 50-112-7
AHC Controller Removal And Installation
Loosen the bottom bolts and remove the top bolt.
1
Figure 50-112-5
1
N-19643
Remove the four mounting bolts (Item 1) [Figure 50-1127] from the controller.
Remove the controller from the loader.
N-22656
Remove the right front panel (Item 1) [Figure 50-112-5]
from the loader.
Figure 50-112-6
1
N-22673
Disconnect the wiring harness connectors from the
controller (Item 1) [Figure 50-112-6].
50-112-4
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCE HAND CONTROL)
(AHC) (W/PUSH BUTTON FLOAT) (CONT’D)
Figure 50-112-10
Handle Sensor Removal And Installation
Figure 50-112-8
1
1
N-22803
Remove the handle sensor connector (Item 1) [Figure
50-112-10] from the clip.
P-16581
NOTE: Pry out with a small screwdriver and push the
connector down.
Lift the boot cover (Item 1) [Figure 50-112-8].
Figure 50-112-11
Figure 50-112-9
1
1
1
N-22790
N-22801
Disconnect the harness connector (Item 1) [Figure 50112-9] from the handle sensor connector.
Use an allen wrench, remove one of the two mounting
screws (Item 1) [Figure 50-112-11] from the handle
sensor.
50-112-5
863 Bobcat Loader
Service Manual
CONTROL PANEL (ADVANCED HAND CONTROL)
(AHC) (W/PUSH BUTTON FLOAT) (CONT’D)
Figure 50-112-14
3
Handle Sensor Removal And Installation (Cont’d)
Figure 50-112-12
1
3
2
1
3
2
P-16576
Remove the handle sensor (Item 1) [Figure 50-112-14]
from the handle assembly.
P-16580
N-22793
Remove the two plastic spacers (Item 1) [Figure 50-11212] and the metal spacer (Item 2) [Figure 50-112-12]
from the handle sensor.
Figure 50-112-13
NOTE: The sensor (Item 1) [Figure 50-112-14] can
only be replaced as a complete assembly.
Check the spacers (Item 2) [Figure 50-112-14] and
screws (Item 3) [Figure 50-112-14] and replace as
needed.
Figure 50-112-15
1
1
P-16574
N-22799
Remove the top mounting bolt (Item 1) [Figure 50-11213] from the handle sensor.
Installation: When installing the handle sensor into the
control handle, check the routing of the switch handle
wire harness (Item 1) [Figure 50-112-15] to assure
proper return of the control handle to neutral.
50-112-6
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED HAND CONTROL)
(AHC) (W/PUSH BUTTON FLOAT) (CONT’D)
Figure 50-112-18
Handle Sensor Connector
Figure 50-112-16
1
2
3
1
1
P-13733
With a pointed tool, lift the tab (Items 1) [Figure 50-11218] and pull the wire from the connector.
P-16578
The wire connector (Item 1) [Figure 50-112-16] can be
removed from the handle sensor wires, use the following
procedure.
Assembly: Install the wires into the connector as listed
below [Figure 50-112-18]:
Figure 50-112-17
1
1 - Terminal - Red
2 - Terminal - Black
3 - Terminal - Green
1
P-13725
P-13732
Remove the wedge (Items 1 & 2) [Figure 50-112-17]
from the connector.
50-112-7
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED HAND CONTROL)
(AHC) (W/PUSH BUTTON FLOAT) (CONT’D)
Figure 50-112-21
Control Handle Removal And Installation
Figure 50-112-19
3
2
1
1
P-13735
1
Using a pointed tool, press down on the tab (Item 1)
[Figure 50-112-21] and pull the wire from the connector.
N-22794
To remove the switch handle, the connector (Item 1)
[Figure 50-112-19] must be removed from the wires.
Figure 50-112-20
Installation: Install the wires into the connector as listed
below [Figure 50-112-21]:
Right Control Lever Switch Handle
1 - Terminal - Red/White
2 - Terminal - Black/White
3 - Terminal - Purple/White
Left Control Lever Switch Handle
1 - Terminal - Red/White
2 - Terminal - Black/White
3 - Terminal - Purple/White
1
1
P-13725
P-13732
Remove the wedge (Item 1) [Figure 50-112-20] from the
connector.
50-112-8
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED HAND CONTROL)
(AHC) (W/PUSH BUTTON FLOAT) (CONT’D)
Installation: The wire colors of the control lever harness
are as follows:
Control Handle Removal And Installation (Cont’d)
Right Switch Handle
Figure 50-112-22
Ten-Pin Connector
A - Terminal - Orange
B - Terminal - White
C - Terminal - White/Black
D - Terminal - White/Red
E - Terminal - Dk. Green
F - Terminal - White/Lt. Green
G - Terminal - Blank
H - Terminal - Lt. Green
J - Terminal - Yellow
K - Terminal - Blank
1
Three-pin connector
A - Terminal - Pink/Red
B - Terminal - Pink/Black
C - Terminal - Pink/Lt. Green
2
N-17779
Left Switch Handle
Figure 50-112-23
1
2
3
Ten-Pin Connector
A - Terminal- Orange
B - Terminal - Dk. Blue
C - Terminal - White
D - Terminal - Purple
E - Terminal - Blank
F - Terminal - Tan
G - Terminal - Pink
H - Terminal - Blank
J - Terminal - Blank
K - Terminal - Blank
4
Three-Pin Connector
A - Terminal - Red/White
B - Terminal - Black/White
C - Terminal - Purple/White
N-17772
Disconnect the right switch handle connectors (Items 1 &
2) [Figure 50-112-22] from the loader wiring harness
connectors.
Disconnect the left switch handle connectors (Items 1, 2,
3 & 4) [Figure 50-112-23] from loader wiring harness
connectors.
Remove the connector locks and connectors from the
wires to remove the switch handle from the control
handle.
Two-Pin Connector
A - Terminal - Black
B - Terminal - Red
Five-Pin Connector
A - Terminal - Dk. Green
B - Terminal - Brown
C - Terminal - Blank
D - Terminal -Yellow
E - Terminal - Blank
50-112-9
863 Bobcat Loader
Service Manual
(CONTROL HANDLE (ADVANCED HAND CONTROL)
(AHC) (PUSH BUTTON FLOAT (CONT’D)
Figure 50-112-26
Control Handle Removal And Installation (Cont’d)
Figure 50-112-24
1
2
2
N-22794
1
Installation: When installing the switch handle and
wiring harness assembly in the control handle, route the
harness (Item 1) [Figure 50-112-26] to assure proper
return of the control handle to neutral position.
N-22783
Roll the pistol grip handle cover (Item 1) [Figure 50-11224] down.
Using a small screwdriver, lift the handle tabs (Item 2)
[Figure 50-112-24] and slightly rotate the switch handle.
Figure 50-112-25
1
N-22784
Pull the switch handle and wiring harness assembly (Item
1) [Figure 50-112-25] from the control lever.
50-112-10
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCE HAND CONTROL)
(AHC) (W/PUSH BUTTON FLOAT) (CONT’D)
Figure 50-112-29
Actuators Disassembly And Assembly
Figure 50-112-27
2
1
1
N-17742
N-17741
Check the actuator wiring harness connector (Item 1)
[Figure 50-112-29] and replace if broken.
N-18940
Remove the actuator. (See Actuator Removal And
Installation (In Loader) on Page 20-41-1.)
Installation: Install the wires into the connector as listed
below. The terminal numbers are written on the back of
the connector (Item 2) [Figure 50-112-29].
Check the mounting block (Item 1) [Figure 50-112-27]
and bolts for wear and replace as needed.
Figure 50-112-28
3
2
1
N-18941
Remove the rubber strap (Item 1) [Figure 50-112-28]
from the mounting shaft collar (Item 2) [Figure 50-11228].
Remove the mounting bracket (Item 3) [Figure 50-11228].
Check the rubber strap, mounting shaft collar and
mounting bracket for wear and replace as needed.
CONTROL HANDLE (ADVANCED HAND CONTROL)
(AHC) (W/PUSH BUTTON FLOAT) (CONT’D)
Actuators Disassembly And Assembly (Cont’d)
50-112-11
863 Bobcat Loader
Service Manual
Lift and Tilt Actuator
1 - Terminal - Black/Green - Larger diameter wire (16
gauge)
2 - Terminal -Green - Larger diameter wire (16 gauge)
3 - Terminal - Red/Green - Larger diameter wire (16
gauge)
4 - Terminal - Open
5 - Terminal - Red - Smaller diameter wire (18 gauge)
6 - Terminal - Open
7 - Terminal - Open
8 - Terminal - Black - Smaller diameter wire (18
gauge)
50-112-12
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED CONTROL
SYSTEM) (ACS) ADVANCED HAND CONTROL
Handle Sensor Removal And Installation
Figure 50-113-3
Components Identification
Figure 50-113-1
1
1
P-16581
To remove the handle sensor, slide the rubber handle
cover (Item 1) [Figure 50-113-3] up the handle.
Figure 50-113-4
2
1
P-16572
Control handle (Item 1) [Figure 50-113-1].
P-24909
Figure 50-113-2
Disconnect the loader control harness (Item 1) [Figure
50-113-4] from the handle sensor harness.
Disconnect the loader control harness (Item 2) [Figure
50-113-4] from the handle connector.
1
P-24909
Handle Sensor (Item 1) [Figure 50-113-2].
50-113-1
863 Bobcat Loader
Service Manual
CONTROL PANEL (ADVANCED CONTROL SYSTEM)
(ACS) ADVANCE HAND CONTROL (CONT’D)
Figure 50-113-7
Handle Sensor Removal And Installation (Cont’d)
Figure 50-113-5
1
1
2
1
P-24912
Using an allen wrench, remove one of the two mounting
screws (Item 1) [Figure 50-113-7] from the handle
sensor.
P-24910
Using a small screwdriver remove the handle sensor
electrical connector (Item 1) [Figure 50-113-5] from the
clip by pushing the connector down out of the connector
clip (Item 2) [Figure 50-113-5].
Installation: Tighten the handle sensor mounting screws
to 32-28 in.-lbs. (3,6-4,3 Nm) torque.
Figure 50-113-6
1
1
P-24911
Using a small screwdriver, remove the electrical
connector (Item 1) [Figure 50-113-6] from the clip by
pushing the connector down out of the connector clip
(Item 2) [Figure 50-113-6].
50-113-2
863 Bobcat Loader
Service Manual
CONTROL PANEL (ADVANCED CONTROL SYSTEM)
(ACS) ADVANCE HAND CONTROL (CONT’D)
EARLIER VERSION HAND CONTROLS ONLY;
Figure 50-113-10
Handle Sensor Removal And Installation (Cont’d)
Figure 50-113-8
1
2
2
1
P-24914
Remove the mounting bolt and nut (Item 1) [Figure 50113-10] from the control handle and shaft.
P-24915
Figure 50-113-9
NOTE: Be careful not to loose the recessed nut on the
other side of the handle.
Remove the handle sensor (Item 2) [Figure 50-113-10]
from the control handle.
Installation: Tighten the mounting bolt to 32-28 in-lbs.
(3,6-4,3 Nm) torque.
Figure 50-113-11
1
5
P-24913
Remove the spacers (Item 1) [Figure 50-113-8] &
[Figure 50-113-9] while removing the mounting pin (Item
2) [Figure 50-113-8]
1
1
3
4
3
2
P-24917
NOTE: The handle sensor (Item 1) [Figure 50-113-11]
can only be replaced as a complete assembly.
Check the spacers (Item 2) [Figure 50-113-11], screws
(Item 3) [Figure 50-113-11], mounting pin (Item 4)
[Figure 50-113-11], bolt/nut (Item 5) [Figure 50-113-11]
and replace as needed.
50-113-3
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED CONTROL
SYSTEM) (ACS) ADVANCED HAND CONTROL
(CONT’D)
Figure 50-113-14
Handle Sensor Removal And Installation (Cont’d)
CURRENT VERSION HAND CONTROLS:
1
Figure 50-113-12
P-24909
Installation: When installing the handle sensor into the
control handle, check the routing of the switch handle
wire harness (Item 1) [Figure 50-113-14] to assure
proper return of the control handle neutral.
1
P-21880
Remove one of the two mounting screws (Item 1) [Figure
50-113-12] from the handle sensor.
Installation: Tighten bolt to 32-38 in.-lbs. (3,6-4,3 Nm)
torque..
Figure 50-113-13
3
1
3
4
3
2
P-24918
Remove the handle sensor (Item 1) [Figure 50-113-13]
from the handle assembly.
NOTE: The handle sensor (Item 1) [Figure 50-113-13]
can only be replaced as a complete assembly.
Check the spacers (Item 2) [Figure 50-113-13], screws
(Item 3) [Figure 50-113-13], mounting pins (Item 4)
[Figure 50-113-13] and replace as needed.
50-113-4
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED CONTROL
SYSTEM) (ACS) ADVANCED HAND CONTROL
(CONT’D)
Figure 50-113-17
Control Handle Removal And Installation
1
Figure 50-113-15
1
N-17384
Remove the rubber handle cover (Item 1) [Figure 50113-17] from the handle.
Figure 50-113-18
P-24909
Remove the handle sensor (Item 1) [Figure 50-113-15].
(See Handle Sensor Removal And Installation on Page
50-114-1.)
1
Figure 50-113-16
2
2
1
N-17385
Using a small screwdriver, hold the handle spacer (Item
1) [Figure 50-113-18] and remove the allen head screws
(Item 2) [Figure 50-113-18] from the handle assembly.
Installation: Tighten the allen head screws to 35 in.-lbs
(4 Nm) torque.
P-16534
Remove the switch handle (Item 1) [Figure 50-113-16].
(See Switch Handle Removal And Installation on Page
60-121-8.)
50-113-5
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED CONTROL
SYSTEM) (ACS) ADVANCED HAND CONTROL
(CONT’D)
Control Handle Disassembly and Assembly
Figure 50-113-19
2
2
1
N-17394
Remove the handle sleeve (Item 1) [Figure 50-113-19]
and bushings (Item 2) [Figure 50-113-19] from the
handle.
Check all parts for wear and replace as needed.
Figure 50-113-20
1
N-22796
Check the mounting bolt (Item 1) [Figure 50-113-20] that
connects the handle to the handle sensor unit for wear,
replace as needed.
50-113-6
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED CONTROL
SYSTEM) (ACS) ADVANCED HAND CONTROL
(CONT’D)
Figure 50-113-23
Control Lever Removal And Installation
Figure 50-113-21
18.25”
1
1
1
B-16618
1
N-22667
Disconnect the electrical connectors (Item 1) [Figure 50113-21] from the control lever switch handle.
Remove the electrical connectors from the control lever
switch handle. (See Switch Handle Removal And
Installation on Page 60-121-8.)
Installation: Tighten the u-bolts so the lever can not be
moved either right or left when seated in the operator
seat. Control lever end (Item 2) [Figure 50-113-22]
should be flush with bellcrank. Be sure the control lever
does not interfere with the operator cab when lowering or
raising the cab. The distance between handles should be
18.25 inches [Figure 50-113-23].
Remove the lever from the cross shaft and control panel..
Figure 50-113-24
Figure 50-113-22
1
2
2
1
P-13734
The control lever (Item 1) [Figure 50-113-24] must be
replaced as a complete unit.
N-22658
Loosen the two u-clamps (Item 1) [Figure 50-113-22]
nuts.
The connector clip (Item 2) [Figure 50-113-24] can be
replaced separately from the control lever.
50-113-7
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED CONTROL
SYSTEM) (ACS) ADVANCED HAND CONTROL
(CONT’D)
Control Lever Boot
Figure 50-113-25
2
1
N-22659
To replace the rubber boot (Item 1) [Figure 50-113-25]
on the control panel, remove the control lever. (See
Control Lever Removal And Installation on Page 50-1137.)
Drill out the four rivets (Item 2) [Figure 50-113-25]
located on the flange of the rubber boot and remove old
boot.
Install the new boot and reinstall the control lever. (See
Control Lever Removal And Installation on Page 50-1146.)
50-113-8
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED CONTROL
SYSTEM) (ACS) SELECTABLE HAND/FOOT
CONTROL
Handle Sensor Removal And Installation
Figure 50-114-3
Components Identification
Figure 50-114-1
1
1
P-21864
Loosen the nuts (Item 1) [Figure 50-114-3].
Installation: Tighten the u-bolts so the lever can not be
moved either right or left when seated in the operator
seat. Be sure the control lever does not interfere with the
operator cab when lowering or raising the cab.
Figure 50-114-4
2
P-16572
Control handle (Item 1) [Figure 50-114-1].
1
Figure 50-114-2
P-21837
Tilt the control handle (Item 1) [Figure 50-114-4] to the
center of the loader.
1
Lift the boot cover (Item 2) [Figure 50-114-4].
P-21879
Handle Sensor (Item 1) [Figure 50-114-2].
50-114-1
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED CONTROL
SYSTEM) (ACS) SELECTABLE HAND/FOOT
CONTROL (CONT’D)
Figure 50-114-7
Handle Sensor Removal And Installation (Cont’d)
Figure 50-114-5
1
1
P-21860
Remove the handle lock solenoid connector (Item 1)
[Figure 50-114-7] from the clip.
2
NOTE: Pry out with a small screwdriver and push the
connector down.
P-21836
Disconnect the harness connector (Item 1) [Figure 50114-5] from the handle sensor connector.
Figure 50-114-8
1
Disconnect the harness connector (Item 2) [Figure 50114-5] from the handle lock solenoid.
5
Figure 50-114-6
2
4
1
3
1
P-21862
Remove one of the two mounting screws (Item 1) [Figure
50-114-8] from the handle sensor.
Installation: Tighten the screws to 32-38 in.-lbs. (3,6-4,3
Nm) torque.
P-21861
Remove the handle sensor connector (Item 1) [Figure
50-114-6] from the clip.
NOTE: Pry out with a small screw driver and push the
connector down.
While removing the mounting pin (Item 2) [Figure 50114-8] from the handle sensor, remove the one plastic
spacer (Item 3) [Figure 50-114-8], the spring (Item 4)
[Figure 50-114-8] and washer (Item 5) [Figure 50-1148].
50-114-2
863 Bobcat Loader
Service Manual
CONTROL PANEL (ADVANCED CONTROL SYSTEM)
(ACS) SELECTABLE HAND/FOOT CONTROL
(CONT’D)
Figure 50-114-10
7
Handle Sensor Removal And Installation (Cont’d)
3
EARLIER VERSION HAND CONTROLS ONLY;
1
Figure 50-114-9
4
3
5
6
8
2
P-21791
Remove the handle sensor (Item 1) [Figure 50-114-10]
from the handle assembly.
1
NOTE: The handle senor (Item 1) [Figure 50-114-10]
can only be replaced as a complete assembly.
P-21863
Remove the the top mounting bolt (Item 1) [Figure 50114-9] from the handle sensor.
NOTE: Be careful not to loose the recessed nut on the
other side of the handle.
Check the spacer (Item 2) [Figure 50-114-10] and
screws (Item 3) [Figure 50-114-10], mounting pin (Item
4) [Figure 50-114-10], spring (Item 5) [Figure 50-11410], washer (Item 6) [Figure 50-114-10], bolt/nut (Item 7)
[Figure 50-114-10], stop strap (Item 8) [Figure 50-11410] and replace as needed.
Installation: Tighten bolt to 32-38 in.-lbs. (3,6-4,3 Nm)
torque.
50-114-3
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED CONTROL
SYSTEM) (ACS) SELECTABLE HAND/FOOT
CONTROL (CONT’D)
[Figure 50-114-12], stop strap (Item 8) [Figure 50-11412] and replace as needed.
Figure 50-114-13
Handle Sensor Removal And Installation (Cont’d)
CURRENT VERSION HAND CONTROLS:
Figure 50-114-11
1
1
P-21878
Figure 50-114-14
P-21880
Remove one of the two mounting screws (Item 1) [Figure
50-114-11]from the handle sensor.
Installation: Tighten bolt to 32-38 in.-lbs. (3,6-4,3 Nm)
torque.
Figure 50-114-12
3
4
8
1
1
P-21799
Installation: When installing the handle sensor into the
control handle, check the routing of the switch handle
wire harness (Items 1) [Figure 50-114-13] & [Figure 50114-14] to assure proper return of the control handle
neutral.
4
3
5
2
6
P-21882
Remove the handle sensor (Item 1) [Figure 50-114-12]
from the handle assembly.
NOTE: The calibration procedure must be followed
when replacing handle sensor, actuator or
ACS Controller (See Actuators Disassembly
and Assembly on Page 60-122-11.)
NOTE: The handle sensor (Item 1) [Figure 50-114-12]
can only be replaced as a complete unit.
Check the spacer (Item 2) [Figure 50-114-12] and
screws (Item 3) [Figure 50-114-12], mounting pin (Item
4) [Figure 50-114-12], spring (Item 5) [Figure 50-11412], washer (Item 6) [Figure 50-114-12], bolt/nut (Item 7)
50-114-4
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED CONTROL
SYSTEM) (ACS) SELECTABLE HAND/FOOT
CONTROL (CONT’D)
Figure 50-114-17
Control Handle Removal And Installation
1
Figure 50-114-15
1
N-17384
Remove the rubber handle cover (Item 1) [Figure 50114-17] from the handle.
Figure 50-114-18
P-21879
Remove the handle sensor (Item 1) [Figure 50-114-15].
(See Handle Sensor Removal And Installation on Page
50-114-1.)
1
Figure 50-114-16
1
2
2
N-17385
Using a small screw driver, hold the handle spacer (Item
1) [Figure 50-114-18] and remove the allen head screws
(Item 2) [Figure 50-114-18] from the handle assembly.
Installation: Tighten the allen head screws to 35 in.-lbs
(4 Nm) torque.
P-16534
Remove the switch handle (Item 1) [Figure 50-114-16].
(See Switch Handle Removal on Page 60-122-6.)
50-114-5
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED CONTROL
SYSTEM) (ACS) SELECTABLE HAND/FOOT
CONTROL (CONT’D)
Control Lever Removal And Installation
Figure 50-114-21
Control Handle Disassembly and Assembly
1
Figure 50-114-19
1
1
1
2
N-22667
2
1
Disconnect the electrical connectors (Item 1) [Figure 50114-21] from the control lever switch handle.
N-17394
Remove the handle sleeve (Item 1) [Figure 50-114-19]
and bushings (Item 2) [Figure 50-114-19] from the
handle.
Remove the electrical connectors from the control lever
switch handle. (See Switch Handle Removal on Page
60-122-6.)
Check all parts for wear and replace as needed.
Figure 50-114-20
1
N-22796
Check the mounting bolt (Item 1) [Figure 50-114-20] that
connects the handle to the handle sensor for wear,
replace as needed.
50-114-6
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED CONTROL
SYSTEM) (ACS) SELECTABLE HAND/FOOT
CONTROL (CONT’D)
Figure 50-114-24
Figure 50-114-22
2
1
1
P-13734
The control lever (Item 1) [Figure 50-114-24] must be
replaced as a complete unit.
N-22658
The connector clip (Item 2) [Figure 50-114-24] can be
replaced separately from the control lever.
Figure 50-114-23
18.25”
B-16618
Loosen the two u-clamps (Item 1) [Figure 50-114-22]
nuts.
Installation: Tighten the u-bolts so the lever can not be
moved either right or left when seated in the operator
seat. Control lever end (Item 2) [Figure 50-114-22]
should be flush with bellcrank. Be sure the control lever
does not interfere with the operator cab when lowering or
raising the cab. The distance between handles should be
18.25 inches [Figure 50-114-23].
Remove the control lever from the cross shaft and control
panel.
50-114-7
863 Bobcat Loader
Service Manual
CONTROL HANDLE (ADVANCED CONTROL
SYSTEM) (ACS) SELECTABLE HAND/FOOT
CONTROL (CONT’D)
Control Lever Boot
Figure 50-114-25
2
1
N-22659
To replace the rubber boot (Item 1) [Figure 50-114-25]
on the control panel, remove the control lever. (See
Contents Page 50-01.)
Drill out the four rivets (Item 2) [Figure 50-114-25]
located on the flange of the rubber boot and remove old
boot.
Install the new boot and reinstall the control lever. (See
Control Lever Removal And Installation on Page 50-1146.)
50-114-8
863 Bobcat Loader
Service Manual
ELECTRICAL SYSTEM & ANALYSIS
ADVANCED CONTROL SYSTEM (ACS) ADVANCED HAND
CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-122-1
ACS Controller Removal And Installation . . . . . . . . . . . . 60-122-4
Actuators Disassembly and Assembly. . . . . . . . . . . . . . 60-122-11
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . 60-122-1
Controller, Connector And Wire Identification . . . . . . . . . 60-122-3
Handle Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . 60-122-5
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-122-8
Switch Handle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 60-122-6
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-122-2
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND/FOOT
CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-123-1
ACS Controller Removal And Installation . . . . . . . . . . . . 60-123-5
Actuators Disassembly and Assembly. . . . . . . . . . . . . . 60-123-12
Calibration Of The ACS System . . . . . . . . . . . . . . . . . . 60-123-15
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . 60-123-1
Controller, Connector And Wire Identification . . . . . . . . . 60-123-4
Foot Lock Solenoid Connector. . . . . . . . . . . . . . . . . . . . 60-123-20
Foot Lock Solenoid Removal And Installation . . . . . . . . 60-123-20
Foot Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . . 60-123-19
Foot Sensor Disassembly And Assembly . . . . . . . . . . . 60-123-18
Hand Controls Only Calibration Procedure . . . . . . . . . . 60-123-17
Handle Lock Solenoid Connector . . . . . . . . . . . . . . . . . 60-123-14
Handle Lock Solenoid Disassembly And Assembly. . . . 60-123-14
Handle Lock Solenoid Removal And Installation . . . . . . 60-123-13
Handle Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . 60-123-6
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-123-3
Switch Handle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 60-123-7
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-123-9
Switchable Hand/Foot Controls Calibration Procedure . 60-123-15
ADVANCED HAND CONTROL SYSTEM (AHC) . . . . . . . . .
Actuators Disassembly And Assembly . . . . . . . . . . . . . .
AHC Controller Removal And Installation . . . . . . . . . . . .
Components Identification . . . . . . . . . . . . . . . . . . . . . . . .
Handle Control Unit Connector . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch Handle Removal And Installation . . . . . . . . . . . . .
Trouble shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY &
MAINTENANCE
DRIVE
ELECTRICAL
SYSTEM AND
ANALYSIS
ENGINE
SERVICE
HVAC
SPECIFICATIONS
60-120-1
60-120-9
60-120-4
60-120-1
60-120-5
60-120-3
60-120-6
60-120-2
Continued On Next Page
60-01
863 Bobcat Loader
Service Manual
ELECTRICAL SYSTEM & ANALYSIS (CONT’D)
ADVANCED HAND CONTROL SYSTEM (AHC) (W/PUSH BUTTON
FLOAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-121-1
Actuators Disassembly And Assembly . . . . . . . . . . . . . 60-121-11
AHC Controller Removal And Installation . . . . . . . . . . . . 60-121-4
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . 60-121-1
Controller Connector and Wire Identification . . . . . . . . . . 60-121-3
Handle Control Unit Connector . . . . . . . . . . . . . . . . . . . . 60-121-7
Handle Control Unit Removal And Installation . . . . . . . . . 60-121-5
Switch Handle Removal And Installation . . . . . . . . . . . . . 60-121-8
Trouble shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . 60-121-2
ALTERNATOR (55 AMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . .
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-30-1
60-30-1
60-30-2
60-30-6
60-30-4
60-30-1
60-30-5
60-30-5
60-30-5
60-30-3
60-30-4
60-30-4
ALTERNATOR (90 AMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . .
Alternator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging System Check . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-31-1
60-31-1
60-31-1
60-31-7
60-31-3
60-31-9
60-31-2
60-31-7
60-31-4
60-31-3
60-31-6
60-31-5
60-31-8
60-31-8
60-31-8
60-31-8
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing The Electrical System . . . . . . . . . . . . . . . . . . . .
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . .
60-20-1
60-20-1
60-20-3
60-20-3
Continued On Next Page
60-02
863 Bobcat Loader
Service Manual
ELECTRICAL SYSTEM & ANALYSIS (CONT’D)
BOBCAT CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Identification Chart (S/N 514450763 & Below) . . . . . . . . . . . . . . 60-70-1
Identification Chart (S/N 514450764 & Above) . . . . . . . . . . . . . . 60-70-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-4
BICS™ SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Additional Inspection For Loaders With Advanced Hand Controls60-90-2
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine
STOPPED - Key ON). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Inspecting The BICS™ Controller (Engine STOPPED - Key ON) 60-90-1
Inspecting The Lift Arm By-Pass Control . . . . . . . . . . . . . . . . . . . 60-90-1
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . 60-90-1
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . 60-90-1
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-3
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-4
DELUXE INSTRUMENTATION SERVICE CODES . . . . . . . . . . . . . 60-80-1
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE . . . . . . . . 60-130-1
Controls Identification Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay Switches Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-10-1
60-10-4
60-10-6
60-10-6
60-10-7
60-10-3
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Changing The Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Deluxe Panel Removal And Installation (Right Side). . . . . . . . . . 60-50-9
Deluxe Panel Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Option And Field Accessory Panels. . . . . . . . . . . . . . . . . . . . . . . 60-50-7
Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Right Panel - (Deluxe) (With Keyless Start) . . . . . . . . . . . . . . . . . 60-50-3
Right Panel Setup Display Options (Deluxe) . . . . . . . . . . . . . . . . 60-50-4
Right Panel - Standard Instrument Panel (With Key Switch) . . . . 60-50-2
Standard & Deluxe Panel Removal And Installation (Left Side) 60-50-10
Standard Panel Removal And Installation (Right Side) . . . . . . . . 60-50-8
Continued On Next Page
60-03
863 Bobcat Loader
Service Manual
ELECTRICAL SYSTEM & ANALYSIS (CONT’D)
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-60-2
SEAT BAR SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BICS™ Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-100-1
60-100-4
60-100-3
60-100-2
60-100-1
STARTER (NIPPONDENSO) . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
External Pinion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-6
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-7
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-11
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
STARTER (VALEO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description Of The Control System (Two-Speed) . . . . . .
Inspecting The Control System (Two-Speed) . . . . . . . . .
Removal And Installation (Single Speed). . . . . . . . . . . . .
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-04
60-41-1
60-41-1
60-41-4
60-41-7
60-41-9
60-41-3
60-41-2
60-110-1
60-110-3
60-110-3
60-110-2
60-110-1
863 Bobcat Loader
Service Manual
SOME CONNECTOR
BODIES NOT SHOWN
FOR DRAWING CLARITY
COMMUNICATION 9000-9999 PUR
Printable Version Click Here
FUEL SENDER
20-270 ohm
TAILGATE/
WORK LIGHTS
LEFT
TAILLIGHT
2640
6330
PROTECTED POWER
COMPUTER POWER
FUSE 10
9210
9110
H
SYSTEM Tx
9300
A
CLOCK/LATCH
9310
B
DATA
9330
J
START
9320
C
BUZZER
+
-
BUZZER
C442
30A
15A
25A
2630
A B
FUSE 7
FUSE 3
FUSE 11
ATTCHMNT
REAR LT
3100
6320
GROUND
F
K
2640
SWITCH
POWER
ALT & KITS
15A
FUEL
PULL
GLOW
PLUG
FUSE 4
TRACTION
PULL
25A
FUSE 12
STARTER
HEADLIGHTS
E
FR & MK LT
REAR
LIGHT
D
G
FUSE 2
FRONT &
MARKER
LIGHT
9340
1910
FUEL PULL
3110
2610
2760
1210
FUSE 6
FUSE 8
6120
B
2910
A B
FUEL SENDER
HARNESS
6719422
B
6110
A
25A
25A
2610
2760
A
UNSWITCHED
HEATER
2600
A
FUSE 9
FUSE 1
30A
2620
A
6120
LEFT PANEL
TRACTION
2650
HARNESS 6716419
RIGHT
TAILLIGHT
FUSE 5
6110
2750
COMPUTER
ACC PLUGS
25A
25A
CONNECTS TO
C407
ON THIS PAGE
C407
A
9320
A B C
MAIN FRAME
A B C
HARNESS 6719112
6210
3700
A
3710
B
A
AIR FILTER
SWITCH
B
7100
HYD FILTER
TO OPTIONS
(BACKUP
ALARM
SWITCH)
9
4
9100
9310
B
DATA
2900
9300
A
CLOCK/LATCH
2
1
1900
9120
H
1200
9220
K
SYSTEM Rx
12
9350
1920
F
COMPUTER POWER
5
7
3900
1220
E
PROTECTED POWER
G
GROUND
D
KEY/ENTER SWITCH
3920
7
3920
2920
3910
6
6
3910
9350
2740
3
3
2740
B1
B3
B2
C1
A3
3920
SEATBAR SENSOR
GROUND
B3
OPEN
A2
A1
3900
SEATBAR
SENSOR SIGN AL
3910
B2
B1
OPEN
4320
4320
E2
4310
4310
4910
4910
J
H
H
LGN
1400
A3
4500
4940
1490
A
A
RNG
A3
4500
H
J
A
A
RNG
C
WHT
SKI
CONTROL
1450
9410
4360
9400
1480
D2
4840
4840
C2
4830
4830
C
B
B2
4820
4820
G
A2
4810
4810
G2
4430
K
K
4440
E
D
D
4200
4350
J1
4460
J2
4450
J3
4480
F2
4330
F1
4340
H1
4410
F3
4360
H2
4420
H3
4350
G3
4200
F
TO OPTIONS
(ACCESSORY
CONNECTOR)
TO OPTIONS
(ACCESSORY
CONNECTOR)
LEFT HANDLE
J
9400
D3
G1
4470
H
C3
B
DBL
G
YEL/LGN
F
SKI
CONTROL
PADDLE
MOMENTARY
YEL/RED
E
B
BRN
D
YEL
A
DGN
TURN
SIGNAL
C
E
A
B
RNG/DBL
HORN
RNG/WHT
REAR ROD
4430
A
2430
B
A
REAR BASE
ACD & REMOTE START
CONNECTOR
LOCATED AT REAR OF
MACHINE
2090
7.5 ohm nominal
at 12 VDC
B
120 ohm
WHITE TIE STRAP
4440
A
2440
B
A
7.5 ohm nominal
at 12 VDC
B
HIGH FLOW
4460
A
2460
B
A
7.5 ohm nominal
at 12 VDC
B
DIVERTER
C426
YELLOW TIE STRAP
4450
A
2450
B
D C B A G F E
A
7.5 ohm nominal
at 12 VDC
B
REAR AUX RELIEF
GREEN TIE STRAP
4480
A
2480
B
A
9.8 ohm nominal
at 12 VDC
B
FRONT ROD
B A
4330
A
2330
B
A
3.3 ohm nominal
at 10 VDC
B
2390
4340
A
2340
B
C419
FRONT BASE
A
2200
4410
A
2410
B
C420
HYD LOCK VALVE
HYDRAULIC
MAKE-UP
2350
3.3 ohm nominal
at 10 VDC
B
2360
A
9.8 ohm nominal
at 12 VDC
B
2000
BATTERY
1050
1300
100A
1030
1010
1060
+
-
1310
1040
Printed in U.S.A.
30A
FUSE 6
15A
FUSE 2
15A
FUSE 3
85
30
85
85
30
UNSW
POWER
7.7 ohm nominal
B
B
A
7.7 ohm nominal
B
25A
FUSE 4
4420
A
2420
B
A
6.7 ohm nominal
at 12 VDC
B
TWO SPEED
25A
FUSE 9
30A
FUSE 5
A
C423
30
A
BUCKET POSITION
2050
2060
1360
85
1060
2030
2040
30
1030
85
2060
30
1320
2010
2020
85
1330
2020
2030
30
1350
2040
2050
RELAY GROUNDS 2000-2060
ARE CONNECTED IN SERIES
85
1050
2000
2010
30
25A
4380
2380
C422
1150
HEATER
FUSE 1
1160
4100
4150
86 87 87A
B
4350
A
2350
B
C441
87A 87 86
A
2370
A
5.5 ohm nominal
at 12 VDC
B
SINGLE SPEED TRACTION LOCK
TWO SPEED BRAKE LOCK
4200
A
2200
C
B
4100
A
HOLD
C
B
PULL
WHT TO BLK =
0.26 ohm
RED TO BLK=
10.9 ohm
C425
87A 87 86
4110
8510
8550
8500
8210
8200
87A 87 86
TRACTION
LOCK
GLOW
PLUG
STARTER
C425
87A 87 86
1070
87A 87 86
6200
6310
6000
6300
REAR
LIGHT
MARKER
LIGHT
1130
FUEL
PULL
1120
1710
87A 87 86
6210
SWITCHED
POWER
4370
LIFT SPOOL LOCK
1110
FUSE 10
25A
6320
AHC POWER
1730
ATTACHMENT
8100
USED IN AHC
EQUIPPED
LOADERS ONLY
1140
2110
8150
1055
FUSE 12
25A
8110
FUSE 11
25A
1700
2120
8000
1800
1720
2300
2720
C421
TILT SPOOL LOCK
2730
2710
YEL
4940
2380
2740
DGN
9400
E
K
1400
4320
A2
4810
C3
D3
B3
EHC INPU T
EHC OUTPU T
F3
SPOOL LOC K
TRACTION HOL D
G3
H3
TWO SPEED
J
2410
2370
TWO
SPEED
DETENT
BRAKE SWITCH
J3
REAR BLEED
E
K
B3
K3
OPEN
F2
4330
4340
FRONT R OD
4430
4440
REAR ROD
G2
H2
4420
4410
BUCKET
POSITION
J2
4460
DIVERTER
4450
K2
FUTURE
(SERIAL RIGH T)
9600
9700
1130
9500
1120
1110
4390
4110
4150
2110
8510
2100
8550
WHT/LGN
4930
4730
6300
6600
6500
6400
1720
2720
1150
1700
1140
C458
2730
B A
2330
2100
F
PWM
G
4920
BLUE TIE STRAP
2340
2420
F
4930
1710
B A
WHT/BLK
D1
1160
C402
WHT/RED
C
K1
E3
PWM SIGN AL
4910
BRAKE SW
IN
LH AUX RIGH T
B2
4820
4920
BRAKE SW
OU T
LH AUX LEFT
C2
4930
LH SKI D OWN
4830
D2
4840
4940
LH SKI U P
E2
4310
C1
2710
C401
WHT
D
D C B A G F E
TO OPTIONS
(ACCESSORY
CONNECTOR)
B A D C
B
B
D
C
4920
K2
H2
K3
A3
K1
K2
F1
G1
H1
J1
REAR BASE
BICS LOC K
HIGH FL OW
FUTURE
(SERIAL LEFT)
A2
J3
G2
A1
E2
F1
J1
J2
D2
K1
FRONT BASE
6320
4730
9700
B2
B1
D3
6210
MARKER L T
RELAY
F3
G3
G2
RESERVED
(R TURN)
800 SERIES
H3
F2
B1
J4
WHITE
4300
PWM -
A1
B1
C1
E1
D1
RH FRON T
DETEN T
PWM +
RH SKI D OWN
E3
9340
RH SKI U P
OPEN
HEADLIGH T
SWITC H
F3
2900
GROUND
D3
9200
9350
D2
D1
9100
SYSTEM R x
E2
E1
1900
KEY/ENTER
SWITC H
F2
F1
1200
OPEN
SYSTEM Tx
PROTECTED
POWER
COMPUTER
POWER
J2
WHITE
RH TWO SPEED
C3
OPEN
C2
C1
OPEN
OPEN
1130
2100
8150
8510
8550
A3
A2
1120
UNSWITCHED
BATTERY IN (3 )
B3
B2
2110
GROUND
C3
C2
8110
FUEL PULL
FEEDBAC K
D3
D2
4110
GLOW PL U G
RELAY
E3
J4
2090
2430
CAB
2000
4300
9500
2400
SEAT
BAR
4300
9600
2440
A
E1
E3
A1
2360
2450
B
3910
K3
9800
TO OPTIONS
(ACCESSORY
CONNECTOR)
2460
C
3920
RIGHT HANDLE
9700
GROUNDS
OPEN
2910
2920
2930
J4
J3
BLACK
E2
4150
A1
1110
F1
REAR WKL T
RELAY
RESERVED
(L TURN)
G1
H1
ATTACHMEN T
KEY INPU T
8000
J1
SPARE OUTPU T 1
OPEN
C427
6000
2480
C
SYSTEM Tx
BROWN TIE STRAP
E F H G C B A D
A
GLOW PL U G
FEEDBAC K
OPEN
UNSWITCHED
BATTERY IN (2 )
UNSWITCHED
BATTERY IN (1 )
D3
STARTER
FEEDBAC K
J3
TO OPTIONS
(ACCESSORY
CONNECTOR)
C407
C2
D3
C3
3900
3910
SEATBAR SENSOR
SUPPLY
OPEN
A3
A2
A1
SPARE DIGITIAL
IN 1
B3
3300
3200
HYD TEMP
SENDER
C3
3420
SPARE
DIGITAL IN 2
B2
B1
3100
CAN HIGH
CONNECTS TO
C407
ON THIS PAGE
8250
F2
2300
2800
8200
R
C2
F3
S
ENG COOLAN T SPARE ANAL OG
TEMP SENDER
IN 2
FUEL SENDER SPARE ANAL OG
SIGNAL
IN 1
2600
K1
1800
9500
8100
A
RESERVED
(HORN)
E
U
C3
M
D
8250
EXC
1800
STARTER
1010
8200
6310
8110
6320
G
S
N
6200
A
G3
B3
S
1020
1010
BAT
8200
E
1800
D1
ALTERNATOR
RED TO BLK=
3.2 ohm
D
8100
8210
8100
8250
8500
E1
2800
T
U
G
ACCESSOR Y
RELAY OUTPU T
T
FUEL SHUT OFF
H2
D3
A2
9800
F1
6600
TRAVEL
CONTROL
6500
V
8590
H1
HR
A3
J3
P
0.4 ohm
A1
J2
6400
SPARE OUTPU T 2
W
K3
J
G
RESERVED
(ATT ACC )
8500
8250
8580
8150
HR
K2
J
8500
0.4 ohm
C3
2300
9600
B
CAN SHIELD
B
E3
2300
8000
HR
F3
G1
E1
B1
3600
GROUND
3600
X
C1
M
X
8800
M
FUEL HOLD
3600
8570
FUEL PULL RELAY
B2
D1
3200
8210
3200
BRAKE PULL
RELAY
C
STARTER REL AY
C
E1
3200
3520
HR
ENG SPEED +
(hall)
D2
E3
D1
3520
J3
3430
3500
3520
3700
B1
3500
HYD CHARGE
FILTER SIGN AL
3100
K
L
F3
F
L
C403
F
K
3520
3010
E2
3500
0.4 ohm
3900
12
5
START
G
OPEN
B3
3700
C2
3300
GLOW PLUGS
0.4 ohm
8560
9350
J2
J1
BLACK
C1
C1
C2
3400
D2
3600
E3
3420
C1
SPEED SENSOR (VR)
3430
E2
3020
F2
H
3400
HYD CHARGE
PRESSURE
SIGNAL
H
3610
HYD CHARGE
PRESSURE +
3020
3210
F2
D1
3010
3200
3500
ENG OIL
PRESSURE
SIGNAL
V
J1
ENG OIL
PRESSURE +
6600
3010
3410
3710
E1
P
7100
3600
6500
R
AIR FILTER
SIGNAL
R
W
H3
-
t
ENGINE COOLANT
SENDER
500-3000 ± 30 ohm
6400
7100
ENG SPEED
SIGNAL (vr)
6200
J1
F1
3510
3520
3920
J2
3020
3110
3310
N
S
SENSOR
GROUNDS
3500
1200
J
MAIN
FRAME
A3
F2
HYD OIL FILTER
PRESSURE SWITCH
A2
-
A1
B
2900
3410
3430
1200
9350
F
B
ENG SPEED
SIGNAL (hall )
A
C
B
2
1
9330
3900
1900
F
B
3430
3420
4730
+
ENG OIL PRESSURE
SENDER 0.5-7.5 V
4
1900
9200
HYD CHARGE PRESS
SENDER 0.5-7.5 V
F3
3410
E
A+
C
E1
F1
E2
E
3400
9340
3420
A
HARNESS 6719082
6310
2900
RIGHT PANEL
9340
10
HYD TEMP SENDER
538-1824 ±30 ohm
3310
9200
A
3300
D
9100
3400
C
E3
D
D2
D1
C
8250
7100
7100
6200
6310
6500
6400
6600
2600
3300
3310
BRAKE PULL
FEEDBAC K
B A
B F G D E C H A
ENGINE
9100
10
9
t
C404
C103
11
6100
2900
CAN L OW
B F G D E C H A
9340
9200
8
11
HARNESS 6717247
C102
6200
7100
6310
2600
2650
6210
BACKUP
ALARM
8
9800
2630
C405
LEFT WORK
LIGHT
6200
6210
3110
2620
3100
RIGHT
WORK
LIGHT
6100
C408
2930
C406
SYSTEM Rx
C409
ACCESSORIES 7000-7999 WHT
B
C410
LIGHTS 6000-6999 PNK
ENGINE 8000-8999 TAN
B
C412 C411
A
2750
C413
B
B
2760
FRONT WORKLIGHTS
C416
A
ATTACHMENT CONTROLS 5000-5999 YEL
2750
2740
C414
HYDRAULIC 4000-4999 LGN
WIRES CONNECT BY LETTER
ACROSS CONNECTORS
FRONT LIGHT
ACCESSORY
CONNECTORS
C417
S/N 514440001-45999
S/N 514540001-40999
S/N 514640001-40999
(PRINTED NOVEMBER 2002)
V-0003
CAB
HARNESS 6718870
C415
MONITORING 3000-3999 LBL
C418
863 WIRING SCHEMATIC
C435
GROUND 2000-2999 BLK
C434
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT
GREEN
DGN = DARK
GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GRAY
BATTERY FEED 1000-1999 RED, RED/WHT, RNG
A
B
9.8 ohm
C
V-0003 (10-4-02)
9210
ATTCHMNT
30A
15A
25A
9110
FUSE 7
FUSE 3
FUSE 11
9300
CONNECTS TO
C407
ON THIS PAGE
25A
FUSE 12
ACC PLUGS
+
B1
B3
B2
C2
C1
A3
3920
3920
3910
A
SEAT
BAR
4300
4300
4320
4320
4310
4310
B
D
C
9400
9410
B3
A3
C3
D3
A2
4810
BRAKE SW
IN
EHC INPUT
EHC OUTPUT
E3
PWM SIGNAL
B2
LH AUX RIGHT
4820
BRAKE SW
OUT
LH AUX LEFT
C2
4830
LH SKI DOWN
D2
LH SKI UP
4840
F3
G3
H3
J3
K3
TRACTION HOLD SPOOL LOCK
TWO SPEED
REAR BLEED
OPEN
F2
FRONT ROD
4330
4430
REAR ROD
G2
H2
4420
BUCKET
POSITION
J2
4450
DIVERTER
K2
4920
4930
4930
G
E
K
J
H
A
A
A3
4500
1480
H
J
A
H
J
A
C
1450
C
B
G
4840
4840
4830
4830
B2
A2
G2
4820
4820
4810
4810
4430
K
G1
J1
J2
J3
4440
E
D
4460
F
4480
H3
F2
F1
4350
H1
F3
H2
G3
4410
TO OPTIONS
(ACCESSORY
CONNECTOR)
4330
4340
TO OPTIONS
(ACCESSORY
CONNECTOR)
4420
4200
AHC CONNECTOR
CONNECTS TO
C433
ON THIS PAGE
ACD & REMOTE START
CONNECTOR
LOCATED AT REAR OF
MACHINE
2430
C426
4440
2440
WHITE TIE STRAP
1710
1160
2710
4460
BLUE TIE STRAP
2460
4450
2450
A
B
A
B
A
B
A
B
4480
A
2480
B
B
+
-
1310
1040
Printed in U.S.A.
BLK
RED
RED
DGN
4610
4600
4620
4710
4610
LEFT HANDLE
RNG
WHT
B
G
F
SKI
CONTROL
DBL
YEL/DGN
PADDLE
MOMENTARY
YEL/RED
B
D
A
C
BRN
TURN
SIGNAL
YEL
DGN
E
A
B
RNG/DBL
HORN
RNG/WHT
A
C
B
BRN/RED
LIFT
CONTROL
BRN/DGN
BRN/BLK
A
B
7.5 ohm nominal
at 12 VDC
REAR BASE
A
B
A
B
A
B
A
7.5 ohm nominal
at 12 VDC
HIGH FLOW
7.5 ohm nominal
at 12 VDC
DIVERTER
7.5 ohm nominal
at 12 VDC
REAR AUX RELIEF
9.8 ohm nominal
at 12 VDC
B
5.5 ohm nominal
at 12 VDC
A
B
30A
FUSE 6
15A
FUSE 2
15A
FUSE 3
4410
2410
UNSW
POWER
3.3 ohm nominal
at 10 VDC
FRONT BASE
A
B
3.3 ohm nominal
at 10 VDC
A
B
9.8 ohm nominal
at 12 VDC
BUCKET POSITION
25A
FUSE 9
25A
FUSE 4
A
B
C420
30
30A
FUSE 5
1160
1150
1130
1120
85
85
A
B
A
B
HYD LOCK VALVE
1110
30
2340
C419 C418
4100
4150
4110
8510
8550
86 87 87A
4420
A
2420
B
C423
85
TRACTION
LOCK
87A 87 86
2050
2060
1360
30
4340
GLOW
PLUG
1060
2030
2040
1320
2010
2020
85
87A 87 86
2060
30
8500
8210
8200
STARTER
87A 87 86
1030
85
6210
6200
6310
6000
6300
30
REAR
LIGHT
1330
2020
2030
85
6320
8110
8100
8150
30
87A 87 86
1350
2040
2050
RELAY GROUNDS 2000-2060
ARE CONNECTED IN SERIES
85
MARKER
LIGHT
A
B
A
6.7 ohm nominal
at 12 VDC
B
SINGLE SPEED TRACTION LOCK
TWO SPEED BRAKE LOCK
2200
A
C
4100
B
4200
A
C
B
HOLD
PULL
WHT TO BLK =
0.26 ohm
RED TO BLK=
10.9 ohm
C425
1060
30
87A 87 86
C425
1030
FUEL PULL
87A 87 86
2330
1070
1050
1300
8000
SWITCHED
POWER
1050
2000
2010
1140
4330
1055
HEATER
25A
1010
SKI
CONTROL
FRONT ROD
1800
1720
100A
LGN
RNG
TWO SPEED
A
BATTERY
DETENT
YEL
REAR ROD
4430
2350
FUSE 1
TWO
SPEED
120 ohm
GREEN TIE STRAP
2110
PWM
WHT/BLK
K
E
D
4450
4350
2710
WHT
WHT/RED
DGN
4940
YELLOW TIE STRAP
FUSE 11
25A
1700
FUSE 12
GOES TO
25A
AHC POWER
ADVANCED HAND
1730
CONTROL MODULE
FUSE 10
THIS PAGE
25A
ATTACHMENT
1710
PNK/BLK
LGN/WHT
1490
TILT
CONTROL
PNK/DGN
F
1400
2000
2720
PNK/RED
G
E
K
4940
HYDRAULIC
MAKE-UP
2120
CONNECTS TO
C433
ON THIS PAGE
B
D
C
B3
2390
2300
C433
CONNECTS TO
C432
ON THIS PAGE
A
C
B
J
H
H2
FUTURE
(SERIAL RIGHT)
9700
9600
4910
4920
D2
C2
9800
F1
FRONT BASE
4340
4440
REAR BASE
G1
H1
4410
BICS LOCK
J1
K1
4460
HIGH FLOW
FUTURE
(SERIAL LEFT)
9500
1130
1120
1110
J3
G2
A1
A2
A3
K1
K2
K3
4390
4150
F
4910
2200
2730
C A B
L HANDLE
C432
RIGHT HANDLE
AHC CONNECTOR
CONNECTS TO
C432
ON THIS PAGE
B A
2240
C A B
R HANDLE
CAB
2360
2740
BLK
C
B
2410
2350
BLK
RED
POWER FROM
FUSE 12
THIS PAGE
4600
OPEN
BRAKE SWITCH
J4
WHITE
E2
4310
PWM -
A1
4910
B1
RH TWO SPEED
4920
RH FRONT
DETENT
C1
4930
RH SKI DOWN
D1
RH SKI UP
4940
E1
9340
2900
J2
WHITE
D3
D2
9200
OPEN
E3
E2
9350
HEADLIGHT
SWITCH
F3
F2
GROUND
9100
SYSTEM Rx
1900
KEY/ENTER
SWITCH
1200
OPEN
J1
J2
D2
E2
F1
4110
2110
KEY/ENTER SWITCH
2910
2920
2930
D C B A G F E
B A
1720
2720
GROUND
A1
4730
6300
6600
6500
C402
B A
1150
1700
1140
PROTECTED POWER
D C B A G F E
TO OPTIONS
(ACCESSORY
CONNECTOR)
C458
2730
2000
SYSTEM Rx
COMPUTER POWER
BROWN TIE STRAP
2330
2100
9350
CLOCK/LATCH
9400
2090
3920
E1
F1
D1
SYSTEM Tx
COMPUTER
POWER
PROTECTED
POWER
PWM +
4300
A2
3910
SEATBAR SENSOR
GROUND
B3
B2
OPEN
C3
C2
OPEN
OPEN
3900
SEATBAR
SENSOR SIGNAL
OPEN
A1
SEATBAR SENSOR
SUPPLY
B1
OPEN
C1
OPEN
1130
A3
B3
2100
GROUND
C3
8150
D3
8510
8550
E3
F3
6320
G3
H3
J3
4730
SPARE OUTPUT 2
K3
CAN SHIELD
9700
D3
B1
B2
E3
8550
8510
F2
6210
MARKER LT
RELAY
RESERVED
(R TURN)
G2
H2
9800
J2
K2
TRAVEL
CONTROL
F1
OPEN
REAR WKLT
RELAY
G1
800 SERIES
2340
2420
2920
DATA
9410
2090
B A D C
3920
3910
SYSTEM Tx
E
G
D
C
2740
9500
2430
1220
H
K
F
C431
K H J C D E B A G F
B1
K2
C1
D1
9600
C401
2400
1920
START
A B
K1
9700
2450
9350
3900
3910
D3
C3
A3
F2
A2
9100
2900
A2
1120
UNSWITCHE D
BATTERY IN (3)
2110
B2
C2
8110
FUEL PULL
FEEDBACK
D2
4110
GLOW PLUG
RELAY
J4
9800
TO OPTIONS
(ACCESSORY
CONNECTOR)
2460
2440
6400
6000
GROUNDS
9220
J
B
A
C430
K3
2360
2480
1200
K H J C D E B A G F
A B
RIGHT PANEL
J4
J3
BLACK
E2
4150
GLOW PLUG
FEEDBACK
A1
UNSWITCHE D
BATTERY IN (2)
UNSWITCHE D
BATTERY IN (1)
1110
B1
OPEN
GROUND
C1
8800
FUEL HOLD
D1
BRAKE PULL
FUEL PULL RELAY
RELAY
STARTER RELAY
8210
E1
STARTER
FEEDBACK
8250
3430
CAN HIGH
6210
C427
E F H G C B A D
A
8110
6320
C407
8250
J3
TO OPTIONS
(ACCESSORY
CONNECTOR)
8150
CONNECTS TO
C407
ON THIS PAGE
H1
C3
C2
F3
F2
D1
2300
2800
8200
R
E1
2600
S
BRAKE PULL
FEEDBACK
E3
F3
D3
3520
ENG SPEED +
(hall)
1800
8000
M
1900
1200
9350
3900
A3
B3
3300
C3
A2
SPARE DIGITIAL
IN 1
HYD TEMP
SENDER
3200
3420
SPARE
DIGITAL IN 2
A1
B1
3100
B2
C2
FUEL SENDER SPARE ANALOG
SIGNAL
IN 1
ENG COOLANT SPARE ANALOG
TEMP SENDER
IN 2
J1
BLACK
C1
3400
HYD CHARGE
PRESSURE
SIGNAL
HYD CHARGE
PRESSURE +
RESERVED
(HORN)
8100
RESERVED
(L TURN)
E
A
H1
6310
6200
8000
N
EXC
1800
STARTER
1010
8200
8250
G
D
U
8250
8500
D
S
9600
8250
6600
G3
B3
G1
8200
E
A
6500
2100
1800
A3
F1
D3
A2
6400
ATTACHMENT
KEY INPUT
8100
3700
T
U
G
2300
HYD CHARGE
FILTER SIGNAL
T
E1
F3
C3
A1
3010
J
W
P
V
FUEL SHUT OFF
S
3600
J
G
8590
ALTERNATOR
3200
3600
2300
0.4 ohm
8100
3520
3200
8500
0.4 ohm
8500
3520
C
M
X
B
D1
D2
B2
ACCESSORY
RELAY OUTPUT
8570
3500
J3
RESERVED
(ATT ACC)
0.4 ohm
B1
3500
C
M
X
B
3600
9120
D3
C3
E1
E3
E2
J2
OPEN
3200
3520
8560
3100
K
L
F
C403
HR
F
K
L
D2
3700
E2
3300
3600
F2
3610
1020
1010
BAT
C1
B3
E2
3400
D1
3420
3500
ENG OIL
PRESSURE
SIGNAL
3430
3020
ENG OIL
PRESSURE +
H
E1
H
3600
3020
H3
C1
-
3210
3500
RED TO BLK=
3.2 ohm
F2
E3
C2
3010
GLOW PLUGS
0.4 ohm
2800
J1
3200
SPEED SENSOR (VR)
HR
3010
3410
3710
AIR FILTER
SIGNAL
V
7100
ENG SPEED
SIGNAL (vr)
6600
R
F1
R
W
P
6400
t
ENGINE COOLANT
SENDER
500-3000 ± 30 ohm
6500
7100
SENSOR
GROUNDS
3510
3520
9300
MAIN
FRAME
J1
ENG SPEED
SIGNAL (hall)
3500
E3
J2
3020
3110
3310
N
S
F3
HYD OIL FILTER
PRESSURE SWITCH
E1
F1
E2
A1
-
9340
9200
B
3410
3430
4730
+
A
C
9310
1900
HYD CHARGE PRESS
SENDER 0.5-7.5 V
C
D2
D1
A
3420
J1
3400
HARNESS 6719082
B
6
3
9100
2900
3900
SPARE OUTPUT 1
A
E
F
B
3310
K1
3430
3300
9500
3410
7100
6310
6200
7100
6400
6500
E
F
B
C
D
CAN LOW
3400
3420
6200
3
2
1
12
5
7
9330
HYD TEMP SENDER
538-1824 ±30 ohm
8210
6310
6200
7100
2600
6600
2600
C
D
A
3300
3310
C102
t
B A
6310
6
2740
9
4
9200
2900
B F G D E C H A
ENGINE
3910
BUZZER
9340
HARNESS 6717247
C404
C103
+
-
6100
4620
3900
3920
B F G D E C H A
ENG OIL PRESSURE
SENDER 0.5-7.5 V
12
5
7
9350
HYD FILTER
8
11
10
4700
9100
AIR FILTER
SWITCH
TO BACKUP
ALARM
SWITCH
6674804 rev. B
BUZZER
4710
A
B
ADVANCED HAND CONTROL MODULE
START
4700
C405
A
B
2650
8580
11
10
9
4
2
1
2900
7100
BACKUP
ALARM
HR
9340
1200
3700
CLOCK/LATCH
4720
HARNESS 6719113
3710
HR
8
9200
6210
2630
DATA
SYSTEM Rx
9400
MAIN FRAME
6100
1900
LEFT WORK
LIGHT
BLK
9320
2930
3110
6200
6210
2620
3100
RIGHT
WORK
LIGHT
SYSTEM Tx
B
J
C
7 8
COMPUTER POWER
4720
A
A B C
H
A
1 2 3 4 5 6
C407
25A
A B C
C406
C429
1 2 3 4 5 6 7 8
PROTECTED POWER
9410
25A
9320
GROUND
4580
COMPUTER
9330
G
E
F
K
LIFT ACTUATOR
C432
STARTER
LIFT ACTUATOR
TILT ACTUATOR
C409
FUSE 4
FUSE 8
TRACTION
PULL
HEADLIGHTS
C410
GLOW
PLUG
1 2 3 4 5 6 7 8
C428
C433 C412 C411
FUEL SENDER
HARNESS
6719422
FUEL
PULL
1 2 3 4 5 6 7 8
2240
15A
C408
3100
3110
2610
9310
ALT & KIT S
4500
6330
1910
1400
2640
25A
FUSE 10
4320
LEFT
TAILLIGHT
SWITCH
POWER
4360
6320
FR & MK LT
REAR
LIGHT
1210
REAR LT
2620
2910
UNSWITCHED
4200
2610
FUEL PULL
A B
2600
2630
HARNESS 6716419
RIGHT
TAILLIGHT
C442
2650
2640
FRONT &
MARKER
LIGHT
D
9340
4350
TAILGATE/
WORK LIGHTS
25A
FUSE 2
2760
TILT ACTUATOR
FUSE 9
HEAT ER
30A
FUSE 6
6120
LEFT PANEL
FUSE 1
TRACTION
A B
6110
A
B
C413
FUSE 5
2760
A
C414
Printable Version Click Here
M
C415
FUEL SENDER
20-270 ohm
M
C416
COMMUNICATION 9000-9999 PUR
A
B
2750
C417
ENGINE 8000-8999 TAN
6120
B
C441
SOME CONNECTOR
BODIES NOT SHOWN
FOR DRAWING CLARITY
6110
B
A
RED
LIGHTS 6000-6999 PNK
ACCESSORIES 7000-7999 WHT
2750
DGN
ATTACHMENT CONTROLS 5000-5999 YEL
B
A
A
B
2760
FRONT WORKLIGHTS
1740
HYDRAULIC 4000-4999 LGN
2750
2740
1730
WIRES CONNECT BY LETTER
ACROSS CONNECTORS
FRONT LIGHT
ACCESSORY
CONNECTORS
C435
MONITORING 3000-3999 LBL
HARNESS 6718870
4470
WITH ADVANCED HAND CONTROL OPTION
S/N 514440001-43831
S/N 514540001-40110
S/N 514640001-40215
(PRINTED NOVEMBER 2002)
V-0004
CAB
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT
GREEN
DGN = DARK
GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GRAY
BATTERY FEED 1000-1999 RED, RED/WHT, RNG
GROUND 2000-2999 BLK
C434
863 WIRING SCHEMATIC
A
B
9.8 ohm
C
V-0004 (10-4-02)
ATTCHMNT
9300
CONNECTS TO
C407
ON THIS PAGE
C407
A
2930
+
2920
9350
2740
B1
B3
B2
C2
C1
3920
A3
3920
1400
A3
9400
9410
B3
4500
C3
D3
4320
A2
4810
BRAKE SW
IN
EHC INPUT
EHC OUTPUT
E3
PWM SIGNAL
B2
LH AUX RIGHT
4820
BRAKE SW
OUT
LH AUX LEFT
C2
4830
LH SKI DOWN
D2
LH SKI UP
4840
F3
G3
H3
J3
K3
TRACTION HOLD SPOOL LOCK
TWO SPEED
REAR BLEED
OPEN
F2
FRONT ROD
G2
4430
REAR ROD
H2
4420
BUCKET
POSITION
J2
K2
4450
DIVERTER
FUTURE
(SERIAL RIGHT)
F1
FRONT BASE
4340
G1
REAR BASE
4440
H1
4410
BICS LOCK
J1
K1
4460
HIGH FLOW
FUTURE
(SERIAL LEFT)
4730
4330
J4
WHITE
E2
4310
PWM -
A1
4910
B1
RH TWO SPEED
4920
RH FRONT
DETENT
C1
4930
RH SKI DOWN
D1
RH SKI UP
4940
E1
9340
2900
J2
WHITE
D3
D2
9200
OPEN
E3
E2
9350
HEADLIGHT
SWITCH
F3
F2
GROUND
PWM +
4300
A2
3910
SEATBAR SENSOR
GROUND
B3
B2
OPEN
C3
C2
OPEN
3900
SEATBAR
SENSOR SIGNAL
OPEN
OPEN
9100
SYSTEM Rx
1900
KEY/ENTER
SWITCH
1200
OPEN
E1
F1
D1
SYSTEM Tx
COMPUTER
POWER
PROTECTED
POWER
6320
F3
J3
G3
H3
SPARE OUTPUT 2
K3
CAN SHIELD
9700
F2
6210
MARKER LT
RELAY
G2
F1
REAR WKLT
RELAY
KEY/ENTER SWITCH
C
3920
3910
A
AHC CONNECTOR
CONNECTS TO
C432
ON THIS PAGE
4300
4320
4310
4310
4920
4930
4930
G
E
K
J
4940
4940
B3
1400
1490
A3
4500
1450
4640
BRAKE SWITCH
D2
C2
4840
4840
4830
4830
B2
A2
G2
4820
4820
4810
4810
TO OPTIONS
(ACCESSORY
CONNECTOR)
4340
TO OPTIONS
(ACCESSORY
CONNECTOR)
4200
H2
4430
2430
BROWN TIE STRAP
4440
2440
WHITE TIE STRAP
2090
1710
1160
2710
4460
BLUE TIE STRAP
2460
4450
2450
A
B
A
B
A
B
A
B
GREEN TIE STRAP
2390
4480
A
2480
B
HYDRAULIC
MAKE-UP
4350
A
2000
2350
B
1060
1310
1040
Printed in U.S.A.
BLK
WHT
B
G
F
SKI
CONTROL
DBL
PNK
PADDLE
MOMENTARY
TAN
K
E
H
B
D
A
C
BRN
TURN
SIGNAL
YEL
DGN
E
A
B
A
C
B
BLK
HORN
RED
RED/WHT
LIFT
CONTROL
PUR/WHT
BLK/WHT
A
B
7.5 ohm nominal
at 12 VDC
REAR BASE
A
B
A
B
A
B
A
7.5 ohm nominal
at 12 VDC
HIGH FLOW
7.5 ohm nominal
at 12 VDC
DIVERTER
7.5 ohm nominal
at 12 VDC
REAR AUX RELIEF
9.8 ohm nominal
at 12 VDC
B
5.5 ohm nominal
at 12 VDC
A
B
30A
FUSE 6
15A
FUSE 2
15A
FUSE 3
4410
2410
UNSW
POWER
3.3 ohm nominal
at 10 VDC
FRONT BASE
A
B
3.3 ohm nominal
at 10 VDC
A
B
9.8 ohm nominal
at 12 VDC
BUCKET POSITION
25A
FUSE 9
25A
FUSE 4
A
B
C420
30
30A
FUSE 5
1160
1150
1130
1120
85
85
A
B
A
B
HYD LOCK VALVE
1110
30
2340
C419 C418
4100
4150
4110
8510
86 87 87A
4420
A
2420
B
C423
85
8550
8500
8210
8200
30
TRACTION
LOCK
87A 87 86
2050
2060
1360
85
4340
GLOW
PLUG
1060
2030
2040
30
2060
85
87A 87 86
1030
30
6210
6200
6310
6000
6300
8110
8100
8150
85
STARTER
A
B
A
6.7 ohm nominal
at 12 VDC
B
SINGLE SPEED TRACTION LOCK
TWO SPEED BRAKE LOCK
2200
A
C
4100
B
4200
A
C
B
HOLD
PULL
WHT TO BLK =
0.26 ohm
RED TO BLK=
10.9 ohm
C425
1030
1010
30
REAR
LIGHT 87A 87 86
C425
1050
1300
100A
RELAY GROUNDS 2000-2060
ARE CONNECTED IN SERIES
85
87A 87 86
2330
1070
BATTERY
30
MARKER
LIGHT
1320
2010
2020
FUSE 1
87A 87 86
1350
2040
2050
HEATER
25A
FUEL PULL
87A 87 86
1330
2020
2030
SWITCHED
POWER
6320
4330
1055
8000
FUSE 11
25A
1700
FUSE 12
GOES TO
25A
AHC POWER
ADVANCED HAND
1730
CONTROL MODULE
FUSE 10
THIS PAGE
25A
ATTACHMENT
1710
1050
2000
2010
1140
2110
-
2710
+
2720
2120
FLOAT
SIGNAL
PUR
RNG
FRONT ROD
1800
1720
2300
SKI
CONTROL
TWO SPEED
2200
2730
DETENT
YEL
REAR ROD
2360
2740
TWO
SPEED
LEFT HANDLE
ACD & REMOTE START
CONNECTOR
LOCATED AT REAR OF
MACHINE
YELLOW TIE STRAP
2240
DGN
120 ohm
9800
9700
9600
9500
1130
1120
1110
J3
G2
A1
A2
A3
K1
K2
K3
4390
4150
J1
J2
D2
E2
F1
4110
2110
E3
D3
B1
B2
8510
8550
G3
B3
G1
2100
AHC CONNECTOR
CONNECTS TO
C433
ON THIS PAGE
2410
2350
WHT/LGN
D
J
A
C
4480
4420
F
G
E
K
D
J
A
F
PWM
WHT/BLK
LGN
E
H
4410
WHT
WHT/RED
RNG
4440
H1
F3
H2
G3
PNKBLK
A
C
B
G
TILT
CONTROL
PNK/DGN
A
4450
4330
B
D
C
PNK/RED
H
K
4460
A
C
B
J
H
4430
B A
1720
2720
1150
1700
1140
2730
F
4910
C426
C458
2100
B
D
C
4920
D C B A G F E
B A
RED
RIGHT HANDLE
4320
4350
C433
CONNECTS TO
C433
ON THIS PAGE
CAB
2000
4300
H3
F2
F1
C A B
L HANDLE
CONNECTS TO
C432
ON THIS PAGE
4910
G1
J1
J2
J3
C A B
R HANDLE
C432
SEAT
BAR
A1
4730
6300
6600
B A
2330
2420
BLK
OPEN
D C B A G F E
2340
RED
POWER FROM
FUSE 12
THIS PAGE
GROUND
9400
2090
B A D C
DGN
SYSTEM Rx
PROTECTED POWER
9410
9500
C402
BLK
SYSTEM Tx
COMPUTER POWER
B1
K2
C1
D1
9600
2430
C401
RED
CLOCK/LATCH
2910
2920
2930
B
4610
3920
3910
E
G
D
C
4600
1220
4620
3900
4710
1920
DATA
1480
9700
2400
TO OPTIONS
(ACCESSORY
CONNECTOR)
K H J B C D E A G F
4700
9350
K1
9800
2450
TO OPTIONS
(ACCESSORY
CONNECTOR)
6500
6400
6000
GROUNDS
2460
2440
9220
3910
D3
C3
A3
F2
A1
SEATBAR SENSOR
SUPPLY
B1
OPEN
C1
OPEN
1130
A3
B3
2100
GROUND
C3
8150
D3
8510
E3
8550
A2
1120
UNSWITCHE D
BATTERY IN (3)
2110
B2
C2
8110
FUEL PULL
FEEDBACK
D2
4110
GLOW PLUG
RELAY
J4
2360
2480
1200
H
K
F
START
J4
J3
BLACK
E2
4150
GLOW PLUG
FEEDBACK
A1
UNSWITCHE D
BATTERY IN (2)
UNSWITCHE D
BATTERY IN (1)
1110
B1
OPEN
GROUND
C1
8800
FUEL HOLD
D1
BRAKE PULL
FUEL PULL RELAY
RELAY
STARTER RELAY
8210
E1
STARTER
FEEDBACK
8250
3430
OPEN
C427
E F H G C B A D
A
8210
C407
6210
8250
J3
TO TOPTIONS
(ACCESSORY
CONNECTOR)
8110
6320
CONNECTS TO
C407
ON THIS PAGE
8150
2300
2800
8200
R
H1
C3
C2
F3
F2
D1
S
E1
M
9120
J
B
A
2600
8000
1010
BRAKE PULL
FEEDBACK
E3
F3
D3
3520
ENG SPEED +
(hall)
CAN HIGH
STARTER
A2
E3
A3
B3
3300
C3
A2
SPARE DIGITIAL
IN 1
HYD TEMP
SENDER
3200
3420
SPARE
DIGITAL IN 2
A1
B1
3100
B2
C2
FUEL SENDER SPARE ANALOG
SIGNAL
IN 1
ENG COOLANT SPARE ANALOG
TEMP SENDER
IN 2
1800
RESERVED
(R TURN)
8100
9800
E
A
EXC
1800
H2
8250
S
G
6310
6200
C431
B A
K3
800 SERIES
TRAVEL
CONTROL
ALTERNATOR
1020
1010
BAT
D
U
8200
N
J2
8200
D
S
8250
RED TO BLK=
3.2 ohm
E
A
8250
8500
K2
1800
T
U
G
9600
8100
6600
G1
8100
2800
6500
RESERVED
(HORN)
FUEL SHUT OFF
A3
F1
D3
A2
6400
RESERVED
(L TURN)
T
2300
J
W
P
V
H1
8590
E1
F3
C3
A1
8000
0.4 ohm
3600
ATTACHMENT
KEY INPUT
B
J
G
3200
3600
ACCESSORY
RELAY OUTPUT
8500
8500
3520
3200
J1
2300
0.4 ohm
3520
C
M
X
B
D1
D2
B2
J3
RESERVED
(ATT ACC)
8570
C
M
X
3500
3700
3600
B1
3500
F
HYD CHARGE
FILTER SIGNAL
3200
3520
8560
3100
K
L
3010
HR
0.4 ohm
F
K
L
C403
3500
OPEN
3700
GLOW PLUGS
0.4 ohm
1900
D3
C3
E1
E3
E2
J2
J1
BLACK
3300
D2
3600
C1
B3
E2
E2
3610
3400
F2
3420
HYD CHARGE
PRESSURE +
3430
3020
D1
H
3500
ENG OIL
PRESSURE
SIGNAL
H
ENG OIL
PRESSURE +
3020
3210
SPEED SENSOR (VR)
F2
E3
C2
3010
3200
C1
J1
3400
HYD CHARGE
PRESSURE
SIGNAL
3010
3410
3710
E1
7100
H3
C1
-
t
ENGINE COOLANT
SENDER
500-3000 ± 30 ohm
R
P
V
3600
6600
R
W
AIR FILTER
SIGNAL
6500
ENG SPEED
SIGNAL (vr)
6400
9300
MAIN
FRAME
J1
F1
7100
3020
3110
3310
SENSOR
GROUNDS
3510
3520
N
S
9100
2900
HYD OIL FILTER
PRESSURE SWITCH
1900
1200
9350
3900
-
F3
B
3430
ENG SPEED
SIGNAL (hall)
B
9310
HYD CHARGE PRESS
SENDER 0.5-7.5 V
C
E1
F1
E2
A1
3410
A
9340
9200
3420
D2
D1
3400
SPARE OUTPUT 1
3430
A
E
F
B
4730
+
ENG OIL PRESSURE
SENDER 0.5-7.5 V
6200
3
6
3
9330
3900
J2
6310
3500
2740
2
1
12
5
7
9200
9100
2900
HYD TEMP SENDER
538-1824 ±30 ohm
3310
K1
3410
7100
6310
6200
7100
6400
6500
6600
2600
E
F
B
3420
3300
9500
3400
C
D
CAN LOW
6310
7100
2600
6200
B A
C102
t
C
D
A
3300
3310
HARNESS 6719082
A
C
9
4
2900
B F G D E C H A
ENGINE
6
C430
RIGHT PANEL
9340
HARNESS 6717247
C404
C103
3910
3900
HYD FILTER
TO
OPTIONS
(BACKUP
ALARM
SWITCH)
3920
12
5
7
9350
K H J B C D E A G F
B A
BUZZER
4610
AIR FILTER
SWITCH
-
4600
A
B
+
6100
4620
3710
C405
A
B
8
11
10
4720
3110
9100
2900
1200
B F G D E C H A
HR
11
10
9
4
2
1
1900
2650
8580
9340
9200
HARNESS 6727131
7100
HR
8
4710
MAIN FRAME
3700
HR
9320
6100
BUZZER
4700
25A
ADVANCED HAND CONTROL MODULE
START
4720
25A
CLOCK/LATCH
4640
ACC PLUGS
9320
7 8
SYSTEM Rx
9400
COMPUTER
9330
1 2 3 4 5 6
COMPUTER POWER
9410
STARTER
C429
LIFT ACTUATOR
1 2 3 4 5 6 7 8
PROTECTED POWER
4580
25A
FUSE 12
LIFT ACTUATOR
TILT ACTUATOR
C432
FUSE 4
FUSE 8
TRACTION
PULL
9310
C408
3110
3100
ALT & KIT S
6210
BACKUP
ALARM
DATA
9210
4360
2630
SYSTEM Tx
B
J
C
1910
4200
LEFT WORK
LIGHT
3100
6200
6210
2620
H
A
25A
FUSE 10
9110
A B C
RIGHT
WORK
LIGHT
GROUND
25A
C406
6330
G
E
F
K
1210
FUSE 11
6320
2640
2910
UNSWITCHED
A B C
LEFT
TAILLIGHT
HEADLIGHTS
15A
GLOW
PLUG
1 2 3 4 5 6 7 8
C428
C409
SWITCH
POWER
D
FUSE 3
FUEL
PULL
1 2 3 4 5 6 7 8
C410
REAR
LIGHT
9340
30A
15A
FUEL SENDER
HARNESS
6719422
2760
TILT ACTUATOR
REAR LT
2610
6120
FUSE 7
2620
M
C433 C412 C411
FR & MK LT
6110
A
B
C413
FRONT &
MARKER
LIGHT
A
LEFT PANEL
4350
2610
25A
FUSE 2
A
B
FUSE 9
HEAT ER
30A
FUSE 6
FUEL PULL
A B
2600
2630
HARNESS 6716419
RIGHT
TAILLIGHT
C442
2640
2760
4470
TAILGATE/
WORK LIGHTS
6120
FUSE 1
TRACTION
A B
2650
M
C414
FUSE 5
2760
C415
FUEL SENDER
20-270 ohm
Printable Version Click Here
6110
2750
C416
COMMUNICATION 9000-9999 PUR
B
C417
ENGINE 8000-8999 TAN
B
A
C441
ACCESSORIES 7000-7999 WHT
SOME CONNECTOR
BODIES NOT SHOWN
FOR DRAWING CLARITY
2750
BLK
LIGHTS 6000-6999 PNK
FRONT WORKLIGHTS
RED
A
2750
2740
DGN
B
B
FRONT LIGHT
ACCESSORY
CONNECTORS
HARNESS 6718870
2240
1740
A
ATTACHMENT CONTROLS 5000-5999 YEL
CAB
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT
GREEN
DGN = DARK
GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GRAY
HYDRAULIC 4000-4999 LGN
1730
BATTERY FEED 1000-1999 RED, RED/WHT, RNG
GROUND 2000-2999 BLK
MONITORING 3000-3999 LBL
WIRES CONNECT BY LETTER
ACROSS CONNECTORS
C434 C435
863 WIRING SCHEMATIC
WITH ADVANCED HAND CONTROL OPTION
S/N 514443832-45999
S/N 514540111-40999
S/N 514640216-40999
(PRINTED NOVEMBER 2002)
V-0119
A
B
C
9.8 ohm
V-0119 (10-4-02)
A
2460
B
4350
A
B
H1
K3
4410
F3
G2
4360
G1
4440
4420
A
2420
B
4830
A2
B3
4810
A3
4500
D1
C1
4940
B1
A1
4920
E2
4310
E3
E1
4320
4820
1400
SEE CAB CONNECTOR
THIS PAGE
B
SEE
CONTROL
MODULE
J1 THIS
PAGE
4930
4910
C
4300
E
6400
TWO
SPD
DETENT
FLOW
RNG
LGN
RNG
SIDE
SHIFT
RIGHT HANDLE
A
B
J
2650
2600
2620
C488
2610
TO OPTIONS
(BACKUP
ALARM SWITCH)
9410
4640
4840
B A
A
ACS
JUMPER
6600
6500
L
F
D
4235
R
C
4275
9400
8560
8570
B A
C473
C407
2730
P
M
2640
8580
8590
SEE CAB
CONNECTOR
THIS PAGE
6600
2650
BRN
7100
4730
E
4550
N
6300
S
1700
A
1140
H
B
1150
E B A D D
B A
C411
C412
TO OPTIONS
(ACCESSORY
CONNECTOR)
6400
TO OPTIONS
(ACCESSORY
CONNECTOR)
SINGLE SPEED TRACTION LOCK
TWO SPEED BRAKE LOCK
2200
A
C
4100
B
4200
A
HOLD
C
B
PULL
WHT TO BLK =
0.26 ohm
RED TO BLK=
10.9 ohm
C425
6500
G
C
HORN
TURN SIGNAL
9420
D
SKI
CTRL
LEFT HANDLE
9420
C
SKI
CTRL
HR HR HR HR
2600
6310
C425
7100
BACKUP
ALARM
YEL
PWM
6000
E
D
G
E H J A F G B C K D
RNG/DBL
6200
4830
E H J A F G B C K D
C410
E K J H A
DGN
WHT
TWO-SPEED
MAKE-UP
WHT/LGN
2360
4390
B D C G F
DBL
9410
4200
4820
9400
D3
G3
RNG/WHT
H
A
C413
4840
C2
B2
YEL
F
B
H
A
C414
4460
4420
DGN
F
B
C404
6310
C416
4450
4350
GLOW PLUGS
1.0 ohms Each
C103
6200
6.7 ohm
12V
B
4480
J1
H3
H2
D2
5 ohm
12V
6200
A
4430
A B
8200
5.5 ohm
12V
BUCKET POSITION
B D C G F E K J H A
A B
A
B
C423
4330
C458
FUEL SHUTOFF
8250
C417
C421
F2
2350
C441
TWO SPEED
4340
WHT/BLK
8100
7.5 ohm
12V
B
2340
F1
WHT/RED
2800
2
7200
6510
9700
9600
9500
9800
1110
1120
1130
4150
4110
2100
2110
8110
8150
8210
8250
8510
8550
6210
6320
8000
4
3
1
A
WHT
F1
K3
G1
K2
K1
H2
A1
A2
A3
E2
D2
B3
B2
C2
C1
C3
E1
D1
D3
E3
F2
J2
J1
F3
H3
4730
C101
C110
S
4460
4810
BLACK
C102
BLUE TIE STRAP
4340
K1
C3
J3 BLACK
H1
+
-
R
2
9.8 ohm
12V
YEL/LGN
A1
RH TWO SPEED
3
1
A
B
YEL/RED
RH FRONT
DETENT
J1
RH SKI DOWN
A2
4910
LH AUX RIGHT
C107
RH SKI UP
B1
4920
LH AUX LEFT
C1
4930
LH SKI DOWN
C106
PWM +
D1
4940
A3
1130
LH SKI UP
B3
2100
E1
C3
8150
PWM -
D3
8510
A3
E3
8550
4500
F3
6320
4300
G3
4810
H3
B2
J3
C2
K3
D2
UNSWITCHED
BATTERY IN (3 )
E2
GROUND
1400
C104
FRONT BASE
J4
WHITE
FUEL PULL
FEEDBACK
A2
BRAKE SW
IN
GLOW PLU G
RELAY
B3
1120
GLOW PLU G
FEEDBACK
B2
4820
2110
MARKER L T
RELAY
BRAKE SW
OUT
8110
OPEN
C3
A1
1110
UNSWITCHED
BATTERY IN (2 )
GROUND
4830
B1
9400
C2
EHC INPUT
4110
TRAVEL
CONTROL
4730
C1
8800
D2
D3
9410
4150
TWO SPEED
MAKE-U P
9800
D1
8210
BRAKE PULL
FUEL PULL RELAY
RELAY
E2
4840
6210
CAN SELECT
8250
BRAKE PULL
FEEDBACK
J3
BLACK
EHC OUTPUT
F2
E3
4320
F1
REAR WKL T
RELAY
G2
4310
A1
SPARE
ANALOG 1
G1
OPEN
H2
PWM SIGNAL
FUEL SENDER
SIGNAL
FUEL HOLD
OPEN
ATTACHMEN T
KEY INPU T
8000
E1
UNSWITCHED
BATTERY IN (1 )
A
B
J2
J3
REAR BASE
F1
4340
FRONT ROD
F2
F3
4330
4360
SPOOL LOCK
HYD CHARGE
PRESSURE +
STARTER REL AY
2330
K2
HYD LOCK
SOLENOID
G1
4440
REAR ROD
G2
G3
4430
ENG OIL
PRESSURE +
OPEN
B2
3200
4200
ENG SPEED
SIGNAL
B
3210
TRACTION HOLD
RESERVED
(hall)
3200
3.2 ohm
12V
6320
2630
A2
B
A
4
6210
6330
H1
STARTER
FEEDBACK
J2
K2
9600
1800
6210
2640
SPARE
ANALOG 2
2610
LEFT
TAILLIGHT
B1
RIGHT
TAILLIGHT
3100
2630
C1
LEFT
WORKLIGHT
J1
OPEN
4330
C409
2600
2620
3400
B
A
TAILGATE / WORKLIGHTS 6716419
RIGHT
WORKLIGHT
HYD CHARGE ENG COOLANT
PRESS SIGNAL
TEMP
B
K1
9500
CAN LOW
C3
2015
M
CAN HIGH
ACCESSORY
RELAY OUTPU T
9700
A
STARTER
1015
D1
B
A
B
CONTROL MODULE
SPARE
OUTPUT 2
7.5 ohm
12V
HIGH FLOW / 900 LOAD SENSE
A
B
SUPPLY
1020
G
3500
ALTERNATOR
E1
E1
3600
3600
B
3610
AIR FILTER
SIGNAL
3600
3510
A3
A
B2
D2
C2
3520
4640
t
C
B
3520
HANDLE
FLOAT
ENGINE
COOLANT
SENDER
500-3000 ohm
D1
B3
B
3500
3200
B
A
SPEED
SENSOR
3500
3300
C
A
HYDRAULIC
TEMP
C
B
A
C3
2350
A
3420
ENGINE OIL
PRESSURE
SENDER
0.5-7.5 V
2710
RESERVED
(AC INPUT)
2120
2720
F1
A3
4640
D2
2730
C
2480
4240
A3
J1
BLACK
HYDRAULIC FILTER HARNESS - 6717247
2740
E3
3430
SEE LEFT
HANDLE
CONNECTOR
THIS PAGE
SENSOR
GROUNDS
3410
ENG OIL
PRESS SIGNAL
F
B
E2
3420
A
B
4480
1480
B3
3910
F2
F
B
3430
E
C1
C2
D3
3410
B3
3400
3310
OPEN
E
3300
A
3520
3420
C
D
E3
D
A
3430
-
HYD OIL FILTER
PRESSURE SWITCH
2110
3400
3700
2600
C
B
C
3310
HYD CHARGE
FILTER SIGNAL
HYD CHARGE PRESS
SENDER 0.5-7.5 V
2300
3300
F3
3610
3510
+A
3010
2800
SPARE
DIGITAL 2
HYD TEMP SENDER
500-3000 ohm
H1
C3
t
2240
4410
D3
3920
BUCKET
POSITION
A2
SEATBAR SENSOR
GROUND
HIGH FLOW /
900 LOAD SENSE
SEATBAR
SENSOR SIGNAL
B2
OPEN
A
B
3.3 ohm
PWM
900 FLOW
CONTROL
OPEN
C2
OPEN
A
B
FRONT BASE
OPEN
CAB HARNESS - 6727178
3900
OPEN
J2
WHITE
OPEN
A
B
2520
C
GREEN TIE STRAP
2410
4940
MAIN
FRAME
2000
C422
6120
2760
2750
6110
CAB
7.5 ohm
12V
REAR AUX RELIEF
4410
1490
2740
A
B
A
B
C415
GROUND
2380
2530
2770
2750
2760
B3
C2
C1
A3
A2
E2
A1
G
B
J1
C405
2920
A
4460
E3
9340
2900
4380
B
FRONT ROD
3.3 ohm
PWM
DIVERTER
F3
2900
RUN/ENTER SWITCH
PROTECTED POWER
H3
2000
D
4350
D3
2200
9200
9350
H2
3010
3710
D2
9350
F
E
COMPUTER POWER
1220
1920
J2
B
9100
SYSTEM R x
E2
HEADLIGHT
SWITCH
SEAT BAR
SENSOR
2910
2920
2930
K2
1900
KEY/ENTER
SWITCH
F2
GROUND
SYSTEM Tx
4420
2370
F1
A1
1200
E2
F2
3700
D3
E1
B1
H
TWO SPEED
A
B
AIR FILTER
SWITCH
F2
C1
9120
A
B
9.8 ohm
12V
J3
2390
D1
D1
OPEN
2410
D2
F3
E3
E1
SYSTEM Rx
DATA
4450
3700
2420
F1
CLOCK/LATCH
K
4470
A
F1
F3
A
9220
REAR AUX
RELIEF
3110
9300
A
HYD. LOCK VALVE
K3
B
OPEN
START
7.5 ohm
12V
DIVERTER
4920
A
OPEN
J
B
B
2450
YELLOW TIE STRAP
4930
B
3910
B
A
2440
4450
2370
4230
3920
N
A
7.7 ohm
PWM
RIGHT PANEL
4440
4370
4910
G
K
A
B
LIFT SPOOL LOCK
(NOT Used With AHC or ACS)
BUZZER
-
A
B
7.7 ohm
PWM
4310
G
K
N
SYSTEM Tx
+
9310
C
3900
SEATBAR SENSOR
SUPPLY
BUZZER
DATA
4320
B
J2 WHITE
START
C
9330
9350
L
COMPUTER
POWER
J
9320
2930
1930
BRAKE
SWITCH
2770
L
PROTECTED
POWER
9330
WHITE TIE STRAP
TILT SPOOL LOCK
(NOT Used With AHC or ACS)
4220
3110
B1
3100
CLOCK/LATCH
C420
1200
A
B
C418
1900
SYSTEM Rx
9300
C419
P
R
B
3910
3920
3900
9350
1200
P
SYSTEM Tx
K
9320
4500
R
B
COMPUTER POWER
H
9210
A
B
REAR BASE
4300
A
B
3100
9200
9100
F
9110
PROTECTED POWER
K1
2490
A
B
C
A
9340
2740
1910
9310
6100
A
B
2430
BROWN TIE STRAP
J3
C
A
1340
2900
F
S
D
E
HEADLIGHTS
6410
2100
C442
FUEL SENDER
30-270 ohm
A B
GROUND
B1
3100
2520
C406
2330
C3
B1
B2
2340
B A
G
9340
1210
C434 C435
LIFT ARM
RELEASE
SWITCH
4030
E
FUEL SENDER
HARNESS - 6719422
2430
2380
F
S
2740
A B
4430
2910
G2
2400
1900
9110
2450
2440
4500
SEE ACS
CONNECTOR D
THIS PAGE
9100
GROUNDS
D
E
SEE CONTROL
B
MODULE J4
THIS PAGE
E
*
*
C
D
C408
SEE ACS
CONNECTOR
THIS PAGE
BATTERY FEED 1000-1999 RED, RED/WHT, RNG
GROUND 2000-2999 BLK
MONITORING 3000-3999 LBL
HYDRAULIC 4000-4999 LGN
ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK
ACCESSORIES 7000-7999 WHT
ENGINE 8000-8999 TAN
COMMUNICATION 9000-9999 PUR
2460
J
A
M
A
M
6100
C
SOME CONNECTOR
BODIES NOT SHOWN
FOR DRAWING CLARITY
2480
A
9200
A
9340
B
B
C407
A
SEE FUSE/RELAY
CENTER
(EUROPEAN
LIGHTING)
THIS PAGE
H
H
J
2900
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GRAY
Printable Version Click Here
2530
*
WIRES CONNECT BY LETTER
ACROSS CONNECTORS
REAR ROD
LEFT PANEL
FRONT
WORKLIGHTS
B A
9210
S/N 514446001 - 514450763
S/N 514541001 - 514541103
S/N 514641001 - 514641254
(PRINTED NOVEMBER 2002)
V-0120
RIGHT
G3
863 WIRING SCHEMATIC
(WITHOUT ACS OPTION)
LEFT
MACHINES.
J4 WHITE
ARE NOT
* NOTE: THESE
FOUND ON ALL
A
B
9.8 ohm
C
G
FUSE 2
15A
FUSE 3
15A
85
30
SWITCH
POWER
ATTCHM NT
1120
1130
4100
4150
4110
8110
1110
R
G
9520
2240
C
H
S
9110
F
1740
B
A
25A
TRACTION
PULL
STARTER
25A
FUSE 12
ACS
25A
25A
2710
ALT & KITS
FUEL
PULL
9710
FUSE 11
GLOW
PLUG
COMPUTER
1050
1300
1060
100A
1010
1030
1310
Printed in U.S.A.
D
9210
25A
FUSE 10
9610
FUSE 8
9620
1170
(ACS)
L
K
E
UNSWITCHED
REAR
LIGHT
REAR LT
15A
FUSE 4
FUSE 12
25A
9510
FUSE 3
FUSE 9
25A
(UNSWITCHED
POWER)
9800
FUSE 7
1070
FUSE / RELAY CENTER
SEE CONTROL
MODULE J2
E
THIS PAGE
SEE CONTROL
MODULE J2
D
THIS PAGE
1160
1730
15A
120
OHM
RESISTOR
1160
FR & MK LT
30A
4550
1080
FUEL PULL
FRONT &
MARKER
LIGHT
-
25A
4275
9720
FUSE 5
30A
1040
HEATER
FUSE 2
30
J
P
N
M
FUSE 9
FUSE 1
30A
+
TRACTION
85
1140
RELAY GROUNDS 2000-2060
ARE CONNECTED IN SERIES
FUSE 5
85
FUSE 6
30A
1150
FUSE 6
8150
8100
30
85
4220
(COMPUTER)
25A
FUSE 4
30
8210
8200
8510
8500
8550
87A 87 86
TRACTION
LOCK
86 87 87A
2050
2060
1360
85
1350
2040
2050
30
FUEL
PULL
87A 87 86
2060
85
6210
6200
6320
6310
30
STARTER
87A 87 86
C492
(HEATER)
FUSE 1
25A
MAINFRAME HARNESS 6729057 or 6730297
85
GLOW
PLUG
1030
30
1710
REAR
LIGHT
87A 87 86
1330
2020
2030
(ATTACHMENT)
FUSE 10
25A
TO OPTIONS
(ACCESSORY
CONNECTOR)
MARKER
LIGHT
87A 87 86
1060
2030
2040
SWITCHED
POWER
87A 87 86
1720
1720
1320
2010
2020
2720
6000
1055
1050
2000
2010
C489
B
A
TO OPTIONS
(ACS
CONNECTOR)
(ALTERNATOR
& KITS)
FUSE 11
25A
1700
6300
1800
8000
K
TO OPTIONS
(ACCESSORY CONNECTOR)
1040
BATTERY
1080
F E D A B C G
TO OPTIONS
(ATTACHMENT
CONTROL)
ACD & REMOTE
START CONNECTOR
C426
V-0120 (10-4-02)
4330
H1
K3
4410
F3
G2
4360
G1
4440
4830
A2
B3
4810
A3
4500
D1
C1
4940
B1
A1
4920
E2
4310
E3
E1
4320
SEE CAB CONNECTOR
THIS PAGE
B
4910
C
4300
R
G
FUSE / RELAY CENTER
FUSE 9
25A
(UNSWITCHED
POWER)
FUSE 12
25A
C
2240
C
H
G
H
F
B
1740
B
A
F
P
4550
9720
9620
25A
FUSE 6
FUSE 2
FUEL PULL
FR & MK LT
ATTCHM NT
30A
15A
25A
FUSE 7
FUSE 3
FUSE 10
2240
1080
SWITCH
POWER
FUSE 12
COMPUTER
ACS
25A
25A
ACS HARNESS 6726925 OR
6733292 (6726925 Shown,
2710
9710
9610
9510
9800
1730
STARTER
25A
1050
-
TRACTION
PULL
+
FUEL
PULL
1160
ALT & KITS
GLOW
PLUG
1300
1060
100A
1010
1030
1310
G
H
2280
1500
J1
G
K
B
TO OPTIONS
(ATTACHMENT
CONTROL)
ACD & REMOTE
START CONNECTOR
C426
TILT
PEDAL
J
C
D
H
F
3
1
2
3
1
1
3
2
C471
V-0216 (10-4-02)
2
4640
PUR
WHT
DBL
RED
BLK
BLK
DGN
RED
RED
E
1
3
2
LIFT
PEDAL
2670
4670
1530
4680
J2
BLACK
A
YEL
BRN
DGN
BLK
F
4690
2770
4770
D
ADVANCED HYDRAULIC CONTROL MODULE
B
A
PNK
TAN
RNG
RNG/BLK
BLK/WHT
BLK
RED
DGN
RED
1630
H
E
D
2250
4840
4830
4820
4810
4240
1480
2520
4940
1490
1510
1610
2750
A
GRAY
J3
C470
1080
J
See Schematic - S/N & Above
for 6733292)
F E D A B C G
1040
BATTERY
C B G E
C
F
9520
1740
FUSE 11
REAR LT
K
S
J
S
UNSWITCHED
REAR
LIGHT
C429
8 7 6 5 4 3 2 1
R
9110
1170
(ACS)
8 7 6 5 4 3 2 1
C428
8 7 6 5 4 3 2 1
4680
D
9210
8 7 6 5 4 3 2 1
4690
1070
K
E
D
9620
9520
SEE CONTROL
MODULE J2
D
THIS PAGE
1160
L
K
E
4220
4275
1170
4780
120
OHM
RESISTOR
FUSE 5
30A
1040
FRONT &
MARKER
LIGHT
25A
LIFT ACTUATOR
2270
4550
9720
SEE CONTROL
MODULE J2
E
THIS PAGE
M
L
A
N
TO OPTIONS
(ACCESSORY
CONNECTOR)
M
4780
1120
1110
(COMPUTER)
25A
FUSE 4
1130
4100
4150
4110
8110
1350
2040
2050
30
4275
J
P
N
M
FUSE 9
HEATER
Printed in U.S.A.
85
FUSE 6
30A
1150
FUSE 8
85
2050
2060
1360
30
85
4220
1140
RELAY GROUNDS 2000-2060
ARE CONNECTED IN SERIES
15A
FUSE 4
8150
8100
8210
8200
30
2060
8500
8550
8510
85
TRACTION
LOCK
86 87 87A
C468
1 3 2
2660
FUSE 3
15A
30
FUEL
PULL
87A 87 86
C467
1 3 2
1180
FUSE 2
15A
85
STARTER
87A 87 86
1030
30
87A 87 86
1060
2030
2040
85
6210
6200
6320
6310
6000
30
GLOW
PLUG
C492
C492
(HEATER)
FUSE 1
25A
MAINFRAME HARNESS 6729057 or 6730297
85
REAR
LIGHT
87A 87 86
1320
2010
2020
30
MARKER
LIGHT
87A 87 86
1330
2020
2030
(ATTACHMENT)
FUSE 10
25A
1710
TO OPTIONS
(ACCESSORY
CONNECTOR)
6300
SWITCHED
POWER
87A 87 86
1720
1050
2000
2010
C489
1055
2720
1720
TO OPTIONS
(ACS
CONNECTOR)
(ALTERNATOR
& KITS)
FUSE 11
25A
8000
1800
1700
FUSE 1
TO OPTIONS
(ACCESSORY
CONNECTOR)
TILT ACTUATOR
K
30A
C472
A C B
M
TO OPTIONS
(ACCESSORY CONNECTOR)
B
A
C412
1520
1150
B A
C411
4660
H
B
E B A D D
A C B
BLK
1140
2260
1700
A
FOOT PEDAL
LOCK - TILT
2760
S
FOOT PEDAL
LOCK - LIFT
4220
6300
4260
4550
13 ohm
at 12V
13 ohm
at 12V
2500
E
1 3 2
A C B
A C B
4730
N
C449
1 3 2
C469
6400
HORN
1 3 2
C450
9.8 ohm
G
TRACTION
2530
1 3 2
TWO SPEED BRAKE LOCK
B
C
FLOAT
2650
A
4750
4275
PULL
4790
R
C
B
SKI
CTRL
TURN
SIGNAL
4790
4235
A
C
AHC LIFT
HALL
SENSOR
PUR/WHT
B
SIDE
SHIFT
HANDLE
LOCK LEFT HANDLE
RED/WHT
A
C
4100
6600
L
F
D
C465
2 1 3
AHC TILT
HALL
SENSOR
WHT TO BLK =
0.26 ohm
RED TO BLK=
10.9 ohm
RED/WHT
8560
8570
2200
HOLD
1190
C488
2610
2 1 3
C466
1 3 2
4650
9420
1 3 2
PWM
RIGHT
SKI
ROCKER
UP DETENTCTRL
FLOW
ACS
JUMPER
SINGLE SPEED TRACTION LOCK
4200
A
6500
E H J A F G B C K D
YEL/RED
B A
E J H A G K
RNG/BLK
C473
4270
2620
C410
C409
B D C F
2510
2600
E H J A F G B C K D
H A
B D C G F E K J
B A
TWO-SPEED
MAKE-UP
4930
9410
4200
4920
9400
D3
G3
C407
2730
P
M
2640
FUSE 5
SEE
CONTROL
MODULE
J1 THIS
PAGE
4930
1620
J
2650
C413
1400
4760
A
B
2650
TO OPTIONS
(BACKUP
ALARM SWITCH)
C414
4820
HANDLE
RIGHT HANDLE LOCK
SEE CAB
CONNECTOR
THIS PAGE
6600
C416
4840
C2
B2
4280
6500
7100
C417
4460
4420
C425
C
6400
G
C
6.7 ohm
12V
B
4450
C425
7100
BACKUP
ALARM
E
D
8580
E
D
G
6310
A
4350
HR HR HR HR
2600
B
6200
8590
H
A
A
2420
4480
J1
H3
H2
D2
6000
F
B
H
A
C404
F
B
4420
4430
GLOW PLUGS
1.0 ohms Each
C103
6310
5.5 ohm
12V
BUCKET POSITION
2360
4390
A B
A
B
C423
F2
2350
C441
TWO SPEED
4340
5 ohm
12V
6200
A
B
7.5 ohm
12V
B
2340
F1
A B
8200
6200
4350
A
4340
C458
FUEL SHUTOFF
8250
B
BLK/WHT
8100
A
2460
PUR/WHT
2800
2
7200
6510
9700
9600
9500
9800
1110
1120
1130
4150
4110
2100
2110
8110
8150
8210
8250
8510
8550
6210
6320
8000
C110
4
3
1
9.8 ohm
12V
YEL/RED
F1
K3
G1
K2
K1
H2
A1
A2
A3
E2
D2
B3
B2
C2
C1
C3
E1
D1
D3
E3
F2
J2
J1
F3
H1
+
-
H3
A
B
K1
C3
J3 BLACK
4730
C101
2
A
B
RNG
A1
RH TWO SPEED
3
1
4460
LGN
BLACK
C102
BLUE TIE STRAP
4230
RH FRONT
DETENT
J1
RH SKI DOWN
C107
RH SKI UP
A2
4910
LH AUX RIGHT
C106
PWM +
B1
4920
LH AUX LEFT
C1
4930
LH SKI DOWN
A3
1130
D1
B3
2100
4940
C3
8150
LH SKI UP
D3
8510
A3
E3
8550
4500
F3
6320
E1
G3
PWM -
H3
4300
J3
4810
K3
B2
UNSWITCHED
BATTERY IN (3 )
C2
GROUND
D2
FUEL PULL
FEEDBACK
A2
E2
GLOW PLU G
RELAY
1400
C104
FRONT BASE
J4
WHITE
1120
GLOW PLU G
FEEDBACK
B2
BRAKE SW
IN
2110
MARKER L T
RELAY
B3
A1
1110
UNSWITCHED
BATTERY IN (2 )
GROUND
4820
8110
OPEN
BRAKE SW
OUT
B1
C3
C2
4830
4110
TRAVEL
CONTROL
4730
C1
8800
D2
9400
4150
TWO SPEED
MAKE-U P
9800
D1
8210
BRAKE PULL
FUEL PULL RELAY
RELAY
E2
EHC INPUT
6210
CAN SELECT
8250
BRAKE PULL
FEEDBACK
J3
BLACK
D3
9410
F2
4840
REAR WKL T
RELAY
G2
EHC OUTPUT
F1
OPEN
H2
E3
4320
G1
ATTACHMEN T
KEY INPU T
J2
8000
E1
FUEL HOLD
OPEN
4310
STARTER REL AY
UNSWITCHED
BATTERY IN (1 )
PWM SIGNAL
A1
SPARE
ANALOG 1
OPEN
2330
J2
J3
REAR BASE
F1
4340
FRONT ROD
F2
F3
4330
4360
SPOOL LOCK
FUEL SENDER
SIGNAL
STARTER
FEEDBACK
4330
K2
HYD LOCK
SOLENOID
G1
4440
REAR ROD
G2
G3
4430
HYD CHARGE
PRESSURE +
H1
OPEN
B2
3200
4200
ENG OIL
PRESSURE +
B
3210
TRACTION HOLD
ENG SPEED
SIGNAL
R
S
6210
2630
RESERVED
(hall)
3200
3.2 ohm
12V
6210
6330
A2
B
A
4
6320
2640
SPARE
ANALOG 2
LEFT
TAILLIGHT
B1
2610
3100
2630
RIGHT
TAILLIGHT
C1
LEFT
WORKLIGHT
J1
K2
9600
1800
2600
2620
3400
B
A
TAILGATE / WORKLIGHTS 6716419
RIGHT
WORKLIGHT
HYD CHARGE ENG COOLANT
PRESS SIGNAL
TEMP
M
K1
9500
CAN LOW
C3
2015
B
CAN HIGH
ACCESSORY
RELAY OUTPU T
9700
A
STARTER
1015
D1
B
A
B
CONTROL MODULE
SPARE
OUTPUT 2
7.5 ohm
12V
HIGH FLOW / 900 LOAD SENSE
A
B
SUPPLY
1020
G
3500
ALTERNATOR
E1
E1
3600
3600
B
3610
AIR FILTER
SIGNAL
3600
3510
A3
A
B2
D2
C2
3520
4640
t
C
B
3520
HANDLE
FLOAT
ENGINE
COOLANT
SENDER
500-3000 ohm
D1
B3
B
3500
3200
B
A
SPEED
SENSOR
3500
3300
C
A
HYDRAULIC
TEMP
C
B
A
C3
2350
A
3420
ENGINE OIL
PRESSURE
SENDER
0.5-7.5 V
2710
RESERVED
(AC INPUT)
2120
2720
F1
A3
4640
D2
2730
C
C421
6120
A3
J1
BLACK
HYDRAULIC FILTER HARNESS - 6717247
2740
E3
3430
SEE LEFT
HANDLE
CONNECTOR
THIS PAGE
SENSOR
GROUNDS
3410
ENG OIL
PRESS SIGNAL
F
B
E2
3420
2480
4910
B3
3910
F2
F
B
3430
E
C1
C2
D3
3410
B3
3400
3310
OPEN
E
3300
A
3520
3420
C
D
E3
D
A
3430
-
HYD OIL FILTER
PRESSURE SWITCH
2110
3400
3700
2600
C
B
C
3310
HYD CHARGE
FILTER SIGNAL
HYD CHARGE PRESS
SENDER 0.5-7.5 V
2300
3300
F3
3610
3510
+A
3010
2800
SPARE
DIGITAL 2
HYD TEMP SENDER
500-3000 ohm
H1
C3
t
2240
4410
D3
3920
BUCKET
POSITION
A2
SEATBAR SENSOR
GROUND
HIGH FLOW /
900 LOAD SENSE
SEATBAR
SENSOR SIGNAL
B2
OPEN
A
B
3.3 ohm
PWM
900 FLOW
CONTROL
OPEN
C2
OPEN
A
B
FRONT BASE
OPEN
CAB HARNESS - 6727178
3900
OPEN
J2
WHITE
OPEN
A
B
4480
GREEN TIE STRAP
2410
4310
C
A
B
DGN
MAIN
FRAME
2000
C422
2750
6110
CAB
7.5 ohm
12V
REAR AUX RELIEF
4410
4320
2740
A
B
A
B
C415
GROUND
2380
WHT/LGN
2770
2750
2760
B3
C2
C1
A3
A2
E2
A1
G
B
J1
C405
2920
A
4460
E3
9340
2900
4380
B
FRONT ROD
3.3 ohm
PWM
DIVERTER
F3
2900
RUN/ENTER SWITCH
PROTECTED POWER
H3
2000
D
4350
D3
2200
9200
9350
H2
3010
3710
D2
9350
F
E
COMPUTER POWER
1220
1920
J2
B
9100
SYSTEM R x
E2
HEADLIGHT
SWITCH
SEAT BAR
SENSOR
2910
2920
2930
K2
1900
KEY/ENTER
SWITCH
F2
GROUND
SYSTEM Tx
4420
2370
F1
A1
1200
E2
F2
3700
D3
E1
B1
H
TWO SPEED
A
B
AIR FILTER
SWITCH
F2
C1
9120
A
B
9.8 ohm
12V
J3
2390
D1
D1
OPEN
2410
D2
E1
SYSTEM Rx
DATA
4450
3700
2420
F1
CLOCK/LATCH
K
4470
A
F1
F3
A
9220
REAR AUX
RELIEF
3110
OPEN
9300
A
HYD. LOCK VALVE
K3
B
OPEN
START
7.5 ohm
12V
DIVERTER
2450
YELLOW TIE STRAP
4300
A
SYSTEM Tx
J
B
B
4450
2370
WHT
B
3910
B
A
2440
WHT/BLK
3920
N
A
7.7 ohm
PWM
RIGHT PANEL
4440
4370
WHT/RED
G
K
A
B
LIFT SPOOL LOCK
(NOT Used With AHC or ACS)
4220
G
K
N
A
B
7.7 ohm
PWM
BUZZER
-
9310
C
3900
SEATBAR SENSOR
SUPPLY
+
DATA
9410
B
J2 WHITE
BUZZER
9330
9350
L
COMPUTER
POWER
START
C
2930
1930
BRAKE
SWITCH
2770
L
PROTECTED
POWER
J
9320
J3
3110
B1
3100
9330
WHITE TIE STRAP
TILT SPOOL LOCK
(NOT Used With AHC or ACS)
B1
A
B
3100
CLOCK/LATCH
K1
2490
A
B
C
A
A
B
9400
1200
SYSTEM Rx
9300
9420
1900
SYSTEM Tx
K
A
B
REAR BASE
C420
C408
P
R
B
3910
3920
3900
9350
1200
1900
P
COMPUTER POWER
H
9210
9320
4500
R
B
F
9110
PROTECTED POWER
G2
C
A
9200
9100
1910
2430
BROWN TIE STRAP
6410
2100
C442
FUEL SENDER
30-270 ohm
9340
2740
D
E
HEADLIGHTS
9310
6100
F
S
GROUND
G3
3100
2520
C406
2330
C3
B1
B2
2340
A B
1340
E
FUEL SENDER
HARNESS - 6719422
2430
2380
9100
9110
2400
F
S
2740
SEE ACS
CONNECTOR D
THIS PAGE
2450
2440
4500
B A
2900
C
D
D
E
SEE CONTROL
B
MODULE J4
THIS PAGE
E
*
*
C434 C435
LIFT ARM
RELEASE
SWITCH
4030
G
9340
1210
A
B
4430
2910
C418
C407
SEE ACS
CONNECTOR
THIS PAGE
BATTERY FEED 1000-1999 RED, RED/WHT, RNG
GROUND 2000-2999 BLK
MONITORING 3000-3999 LBL
HYDRAULIC 4000-4999 LGN
ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK
ACCESSORIES 7000-7999 WHT
ENGINE 8000-8999 TAN
COMMUNICATION 9000-9999 PUR
2460
J
A
M
A
M
6100
C
SOME CONNECTOR
BODIES NOT SHOWN
FOR DRAWING CLARITY
2480
A
9200
GROUNDS
A
F3
E3
2530
B
B
9340
Printable Version Click Here
A
2900
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GRAY
SEE FUSE/RELAY
CENTER
(EUROPEAN
LIGHTING)
THIS PAGE
H
H
J
9210
S/N 514446001 - 514450763
S/N 514541001 - 514541103
S/N 514641001 - 514641254
(PRINTED NOVEMBER 2002)
V-0216
*
WIRES CONNECT BY LETTER
ACROSS CONNECTORS
A B
2760
863 WIRING SCHEMATIC
WITH ACS OPTION
B A
REAR ROD
LEFT PANEL
FRONT
WORKLIGHTS
YEL
RIGHT
C419
LEFT
MACHINES.
J4 WHITE
ARE NOT
* NOTE: THESE
FOUND ON ALL
25
39
42
19
12
36 9
32 40
30
38
10
44 14 24 34 16
33 28 13
22
4320
4640
36
26
4840
16
4820
4830
4810
B
C
A
A
B
C
B
A
TO OPTIONS
(ATTACHMENT
CONTROL)
V-0214 (11-26-03)
120
C
C
C404
A
B
C489
A
1080
C450
B
C
+
C477
C102
-
1040
BATTERY
C426
ACD & REMOTE
START CONNECTOR
C
A
B
G
1030
AHC TILT
HALL SENSOR
B
2710
1010
1310
+
-
-
25A
Printed in U.S.A.
1300
1060
100A
A
FUSE 12
1050
ACS
25A
C
25A
9710
STARTER
9610
TRACTION
PULL
E
COMPUTER
FUEL
PULL
9510
GLOW
PLUG
F
ALT & KITS
D
FUSE 11
REAR LT
9800
FUSE 3
1730
25A
FUSE 7
ATTCHM NT
1160
15A
A
B
1040
25A
FR & MK LT
30A
FUSE 10
RGN
A
F
A
B
B
9110
1080
SWITCH
POWER
K
H
C
1170
DETENT
FLOW
G
2240
1740
D
R
9210
9520
SKI CTRL
1070
FUSE 12
25A
(ACS)
E
D
S
LGN
K
C492
FUSE / RELAY CENTER
N
4550
G 9410
F 9400
1160
FUSE 9
25A
(UNSWITCHED
POWER)
6510
9620
E
1150
P
9720
FUSE 5
30A
FUSE 6
30A
J
L
6410
HANDLE
LOCK
TWO SPD
30
1360
2050
2060
2040
2050
1350
2060
1030
FUSE 4
(COMPUTER)
85
25A
85
87
UNSWITCHED
REAR
LIGHT
FUEL PULL
FUSE 4
1110
86
M
4275
FUSE 9
FRONT &
MARKER
LIGHT
HEATER
25A
FUSE 8
1120
86
TRACTION
87A LOCK
1140
RELAY GROUNDS 2000-2060
ARE CONNECTED IN SERIES
15A
1130
30
4100
87A 87
85
4150
30
86
4220
7200
FUEL
PULL
STARTER
87A 87
4110
8110
85
2030
2040
1060
2010
2020
1320
FUSE 3
15A
30
86
8150
85
87A 87
8100
86
8210
30
2020
2030
1330
FUSE 2
15A
GLOW
PLUG
REAR
LIGHT
87A 87
8200
85
8510
86
8550
30
2000
2010
1050
(HEATER)
FUSE 1
25A
85
87A 87
8500
30
6210
(ATTACHMENT)
FUSE 10
25A
86
6200
87A 87
6320
MARKER
LIGHT
SWITCHED
POWER
1720
MAINFRAME HARNESS
6732061
6310
1055
6000
1720
6300
2720
A
8010
B
YEL
C412
1740
(ALTERNATOR
& KITS)
FUSE 11
25A
DGN
1150
WHT/LGN
H
H
J
1140
F
A
E
1700
C466
A
B
B
4550
S
1730
FUSE 2
G
A
H
J
WHT/BLK
RNG/DBL
RNG/WHT
C411
RIGHT
HANDLE
4275
E
1700
FUSE 1
K
F
E
WHT
WHT/RED
FLOAT
6300
C
D
4235
N
A
D
B
PUR
SKI CTRL
4730
C
WHT
F
C472
C
6400
YEL
6500
6000
6600
L
E
2730
P
M
C449
A
D
K
D
DBL
C407
BRN
SEE CAB
CONNECTOR
TO OPTIONS
(BACKUP ALARM
SWITCH)
1800
30A
G
A
4930
C
C
YEL/LGN
HORN
TURN SIGNAL
DGN
A
B
K
TRACTION
1490
4920
D
B
SIDE
SHIFT
AHC LIFT
HALL SENSOR
-
PWM
B
FUSE 5
2530
4910
B
G
YEL/RED
+
HANDLE LOCK
LEFT HANDLE
G
FUSE 6
4230
4310
F
A
B
RGN
C465
A
PULL 0.3 ohm
R
TO OPTIONS
(ACCESSORY
CONNECTOR)
4940
4320
K
D
C
A
B
B
J
4300
4640
B
G
4840
4820
F
4830
4810
1480
HOLD 10.9 ohm
A
B
4100
C409
C410
A
C
J
A
C
HR HR HR HR
7100
C488
4300
H
E
C103
4310
9
43
Traction Lock
4200
BACKUP ALARM
TO OPTIONS
(ACCESSORY
HARNESS
CONNECTOR)
4920
19
29
J
6600
2900
4940
E
6500
4930
9100
9340
H
6400
40
30
20
4500
4240
E
9200
8200
2600
D
46
5
15
44
4
8250
6310
G
C
1900
J2
C425
6200
SEE FUSE/RELAY
CENTER
(EUROPEAN
LIGHTING)
A
2520
1400
H
A
H
C407
4910
4200
6410
7200
6510
9700
9600
9500
9800
1110
1120
1130
4150
2100
H
A
2900
2770
2750
2760
J1
2200
F
B
1200
24
41 4
8 48 17
LEFT
50
RIGHT
49
3520
1.0 ohm each
F
B
C
48
7200
4110
7100
ENG OIL
RESERVED
PRESS SIGNAL (FAN OUTPUT )
47
3420
8110
6330
30
2910
2920
2930
2740
9350
14
3300
A
B
See C492
3920
6
2015
E
D
G
HORN
3900
FRONT
WORKLIGHTS
8110
2910
6320
GROUND
2100
LEFT PANEL
3500
9340
8550
1210
9700
E
1130
G
D
8150
HEADLIGHTS
4350
PROTECTED POWER
40
HYD CHARGE
PRESS SIGNAL
3910
25
34
C434
39
46
50
35
45
C435
38
1910
37
9110
36
F
H
35
SPARE
OUTPUT 2
49
SYSTEM Tx
34
45
OPEN
OPEN
48
COMPUTER POWER
33
+5V
SUPPLY
40
B
6100
32
44
RH SKI
UP
4940
HYDRAULIC
TEMP
9210
31
9800
39
K
FUEL PULL
RELAY
ATTACHMENT
KEY INPUT
OPEN
38
2750
A
C408
2900
MARKER
LT RELAY
43
GROUND
A
6100
GROUND
42
47
F
G
2900
8210
ENG OIL
PRESS +8v
8000
46
4500
9400
9410
9340
4450
GLOW PLUG
FEEDBACK
SWITCH PWR / RESERVED
ACC RELAY (CAN SHIELD)
45
3920
23
42
6110
B
B R P S F E D C M A J H
9340
28
1120
OPEN
41
OPEN
44
9340
8150
2640
2650
29
27
CAN
SELECT
1400
BRAKE SW
IN
43
4640
8210
LEFT
TAILLIGHT
6210
26
3010
4470
30
4930
20
8800
STARTER
RELAY
8250
6320
19
6210
DIVERT ER
8510
2610
18
4460
D3
2630
RIGHT
TAILLIGHT
17
RH SKI
DOWN
29
4320
A
N K G L B R P S F E D C M A J
N K G L
8500
LEFT
WORKLIGHT
1800
FUEL RELAY
HOLD
4200
PWM
SIGNAL
28
3100
8560
6310
A
REAR WKLT
RELAY
RESERVED
UNSWIT CHED
(SENSOR GRND) BATTERY (2)
8570
6200
1020
10
4110
UNSWIT CHED
BATTERY (3)
8580
6200
6210
B
B
A
25
4730
F&R AUX
RELIEF
8590
2620
A
24
9600
16
6510
J1
P01
9
8510
HIGH FLOW /
900 LOAD
8550
2600
RIGHT
WORKLIGHT
B
15
6210
BAT
ALTERNATOR
TAILGATE / WORKLIGHTS 6716419
TRAVEL
CONTROL
6320
A
3400
CAN
LOW
8000
1015
14
9500
4730
B
G
R
S
C109
M
C110
1020
13
1110
TRACTION
LOCK HOLD
RIGHT
BLINKER
8
6410
4150
STARTER
1015
HYD CHARGE
PRESS +8V
12
23
7
E3
C101
8100
CAN
HIGH
8250
22
6
4390
FUEL PULL
FEEDBACK
HANDLE
POWER
2800
UNSWIT CHED
BATTERY (1)
TRACTION LOCK SENSOR
PULL FEEDBACK GROUNDS
21
J1
5
SEATBAR
SIGNAL
42
9410
E
9200
SPARE
DIGITAL 2
4
4910
HEADLIGHT
SWIT CH
41
FLOAT
FUEL
SENDER
2110
4410
9210
GLOW PLUG TRACTION LOCK
RELAY
PULL / 963
LEFT
BLINKER
SPARE
OUTPUT 1
37
D
7
9200
11
3510
3
3430
TWO SPEED
MAKE-UP
36
4840
20
4920
9100
49
STARTER
FEEDBACK
RESERVED
(hall)
RESERVED
(BOOTSTRAP)
OPEN
35
3910
19
4310
9100
37
3520
2
TWO SPEED
SWIT CH
LH SKI
UP
34
9350
33
18
3700
4500
3500
3520
OPEN
1
HYD FILT ER
SIGNAL
27
3100
9110
4500
3500
C
B
RESERVED
(AC INPUT )
STATUS
OUT
OPEN
26
RH FRONT
DETENT
2740
A
2
SEATBAR
GROUND
LH SKI
DOWN
4830
3600
PWM -
2740
3
1
KEY/ENT ER
SWIT CH
HYD LOCK
SOLENOID
SEE J2
TWO SPEED
SOLENOID
2
OPEN
32
4420
B
C
23
1
BUCKET
POSIT ION
31
2710
FUEL
SHUTOFF
3.2 ohm 12V
OPEN
4820
J2
P05
9
4300
B
6120
2770
B
25
3900
28
11
10
8
2760
+8
1900
C
B
24
1900
-
1200
A
C
23
9400
FUEL
SENDER
30-270 ohm
1900
3430
SEAT BAR
+8v
22
4430
B
A
1200
B
COMPUT ER
POWER
21
4340
3100
C
B
A
9350
23
17
15
9200
3110
9350
3010
16
14
B
A
6719422
3200
AIR FILT ER
SIGNAL
SEAT
BAR
C
3410
3310
STATUS
IN
9210
SPARE
DIGITAL 1
C
AIR FILTER
SWITCH
3900
3420
F
D
C
C107
2120
2720
REAR
ROD
4810
LH AUX
LEFT
1200
4440
7
9100
SYSTEM
Rx
B
A
B
A
3900
3420
15
47
3300
3110
ENG SPEED
SIGNAL
PWM +8V
SUPPLY
SYSTEM Rx
A
3920
3400
SEE J2
ENGINE OIL
PRESSURE
SENDER
0.5-7.5 V
2740
2730
13
6
COOLANT
TEMP SIGNAL
9300
B
3700
ENGINE
COOLANT
SENDER
500-3000 ohm
t
3910
B
3400
HYDRAULIC FILTER 6717247
2110
12
5
PROTECTED
POWER
L HAND
SERIAL IN
CLOCK/LATCH
3710
A
B
3920
2600
11
4
2900
4330
LH AUX
RIGHT
9310
B
3910
3510
3
SPARE
ANALOG 2
SYSTEM
Tx
9330
A
A
C
3430
A
E
2300
2300
2
REAR
BASE
4360
COMPUT ER
GROUND
9320
3200
3210
MAIN
FRAME
B
3300
18
A
B
SPEED
SENSOR
CAB
A
HYDRAULIC OIL
FILTER SWITCH
3610
8
J
C
3.3 ohm
PWM
C476
F
D
48
DATA
1
2
A
B
C406
E
3410
3310
3700
3210
3420
B
3200
B
B
A
A
3300
HYDRAULIC
TEMPERATURE
SENDER
500-3000 ohm
2800
1
FRONT
ROD
R HAND
SERIAL IN
FRONT
BASE
3400
2100
C
10 38
3600
A
C
4410
2240
A
B
4340
B
2000
2350
SPARE
ANALOG 1
9110
A
C
4360
HYDRAULIC CHARGE
PRESSURE SENDER
0.5 - 7.5 V
2200
4330
2390
2370
4430
2380
4440
11
SPOOL
LOCK
32 12 22 1 41 3 21
START
B
J2
J2
BUZZER
3610
B
J1
9320
9.8 ohm
12V
J1
29 26
2930
A
C
A
B
BUZZER
2470
1
2
3600
1930
BRAKE
SWITCH
A
B
RIGHT PANEL
FRONT BASE
7.5 ohm
12V
4420
2410
18
9330
C417
2100
2360
31
J
A
B
4470
2520
2420
6
4450
2330
4460
2400
2340
4350
2440
2430
4390
UNSWITCHED POWER 1000-1999 RED
FUSED, UNSWITCHED POWER 1000-1999 RED/WHT
SWITCHED POWER 1000-1999 RNG
GROUND 2000-2999 BLK
MONITORING 3000-3999 LBL
HYDRAULIC 4000-4999 LGN
ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK
ACCESSORIES 7000-7999 WHT
ENGINE 8000-8999 TAN
COMMUNICATION 9000-9999 PUR
7
START
2
9.8 ohm
12V
B
2480
2450
9310
A
B
4470
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GRAY
B
2
REAR AUX RELIEF
2460
DATA
2330
3.3 ohm
PWM
9300
2420
2450
GREEN TIE
STRAP
9220
B
1
DIVERTER
SOME CONNECTOR
BODIES NOT SHOWN
FOR DRAWING CLARITY
GROUNDS
A
K
1
A
2000
A
SYSTEM Rx
B
C104 C104
B
B
CLOCK/LATCH
4330
C416
A
9120
4420
4450
Printable Version Click Here
H
A
YELLOW TIE STRAP
SYSTEM Tx
A
FRONT ROD
2340
WIRES CONNECT BY LETTER
ACROSS CONNECTORS
1920
B
F
2360
4410
2410
9350
B
B
COMPUTER POWER
BICS HYDRAULIC LOCK
WHITE TIE STRAP
CAB 6727178
A
5 ohm
12V
1220
2440
4340
TWO SPEED
MAKE-UP
2920
4440
C419 C106
2350
4390
A
9.8 ohm
12V
E
A
B
C418
B
A
4350
C423
A
C437
B
C441
863 (S/N 514450764 AND ABOVE)
(S/N 514541104 AND ABOVE)
(S/N 514641255 AND ABOVE)
(PRINTED DECEMBER 2003)
V-0214
A
7.5 ohm
12V
D
G
BLUE TIE STRAP
GROUND
2460
B
RUN/ENTER SWITCH
A
7.5 ohm
12V
4460
C420
A
B
BUCKET POSITIONING
TWO SPEED
SOLENOID
1
2
4370
2370
BROWN TIE STRAP
C
2430
OPEN
4430
C421
2460
A
B
C414
4460
C415
A
B
A
B
A
B
REAR BASE
HIGH FLOW
7.5 ohm
12V
C413
6733137
WIRING SCHEMATIC
(Without ACS Option)
2530
B
PROTECTED POWER
TILT SPOOL LOCK
(NOT Used With AHC or ACS)
REAR ROD
A
7.5 ohm
12V
C469
C423
C416
C417
8550
3500
2100
6320
8110
25
39
42
19
12
36 9
20 32 40
30
38
10
44 14 24 34 16
33 28 13
22
4300
4320
4640
36
26
4840
16
4820
4830
4810
B
A
A
C404
C
B
C
B
C
A
A
C477
C102
C488
B
C
1520
C
4660
B
2660
2760
ACS HARNESS 6733292
V-0215 (11-26-03)
120
2750
4760
A
1610
4770
C
B
1620
4750
4670
LIFT
PEDAL
A
C
B
B
4650
A
C471
ACD & REMOTE
START CONNECTOR
TO OPTIONS
(ATTACHMENT
CONTROL)
C
B
C470
B
1080
C426
A
TILT
PEDAL
C469
C
A
E
C
H
A
F
B
G
A
J2
BLACK
J
C450
B
C
ACS Controller
Advanced Control System
K
C
A
A
AHC TILT
HALL SENSOR
B
1500
A
B
F
RGN
F
A
B
9110
J1
DETENT
FLOW
B
SKI CTRL
1740
LGN
2670
P
HANDLE
LOCK
TWO SPD
4670
A
YEL
1
1170
DGN
2
H
B
WHT/LGN
WHT/BLK
1
1740
B
H
J
WHT
WHT/RED
2
G
2280
C466
A
B
BLK
D
2250
F
C
RNG/DBL
RNG/WHT
DGN
9520
2240
E
B
D
FLOAT
D
B
YEL
C489
K
H
J
G
A
F
E
K
4930
C
G
A
4920
D
1490
4910
B
PUR
SKI CTRL
9520
H
G
+
-
BATTERY
2530
4310
K
D
DBL
WHT
YEL/LGN
B
C
G
4680
1530
C
H
2710
1040
A
1310
C
+
-
-
25A
9710
25A
1030
9610
ACS
1010
E
FUSE 12
COMPUTER
1060
100A
9510
25A
F
ALT & KITS
STARTER
D
1300
9800
FUSE 11
1730
1050
FUSE 3
TRACTION
PULL
4230
4320
K
D
C
4
4690
4680
4690
F
5
6
7
8
2770
4770
C
A B C D
1160
25A
FUSE 7
FUSE 10
ATTCHM NT
REAR LT
4940
4300
4640
B
G
4840
6
7
8
1
2
D
4750
1040
15A
Printed in U.S.A.
A
E
9620
G
2240
1080
FR & MK LT
30A
FUEL
PULL
K
GREY
J3
25A
FUEL PULL
GLOW
PLUG
J H
1630
F
4780
G
C
4780
D
C B G E
4550
9720
9210
9520
1740
(ACS)
9420
3
1070
FUSE 12
25A
R
S
R
4
5
S
4790
G 9410
F 9400
4550
9720
9620
4790
D
6
7
8
E
2270
E
D
FUSE 9
SWITCH
POWER
25A
FUSE 2
FUSE 4
K
C429
UNSWITCHED
REAR
LIGHT
30A
FUSE 6
FUSE 8
N
K
2260
FUSE / RELAY CENTER
A
N
4550
9720
1160
FUSE 9
25A
(UNSWITCHED
POWER)
P
6510
9620
E
1150
RELAY GROUNDS 2000-2060
ARE CONNECTED IN SERIES
1170
6410
C492
1140
4275
4220
1360
2050
2060
2040
2050
1350
2060
1030
FUSE 5
30A
FUSE 6
30A
J
L
4260
30
2500
87
J
L
1190
85
4220
7200
4275
1180
86
85
2510
86
FUSE 4
(COMPUTER)
30
M
M
4270
4280
87A 87
85
4220
25A
86
TRACTION
87A LOCK
1110
30
1120
87A 87
1130
FUEL
PULL
STARTER
4100
85
4150
86
4110
30
2030
2040
1060
2010
2020
1320
FUSE 3
15A
87A 87
8110
85
8150
86
8100
30
2020
2030
1330
FUSE 2
15A
GLOW
PLUG
REAR
LIGHT
87A 87
8210
85
8200
86
8510
30
8550
87A 87
8500
85
2000
2010
1050
(HEATER)
FUSE 1
25A
86
6210
30
1730
6200
87A 87
(ATTACHMENT)
FUSE 10
25A
MAINFRAME HARNESS
6732061
MARKER
LIGHT
SWITCHED
POWER
1720
6320
1055
6310
1720
6000
2720
A
6300
B
8010
(ALTERNATOR
& KITS)
1800
FUSE 11
25A
1700
15A
4830
A B
C428
K
3
C468
1
2
A B
C467
3
4
5
6
7
8
A B
A B
G
FRONT &
MARKER
LIGHT
LIFT ACTUATOR
3
1150
TO OPTIONS
(ACCESSORY
CONNECTOR)
M
M
4
5
H
TILT ACTUATOR
RIGHT
HANDLE
1740
RED
1140
13 ohm
12V
FOOT PEDAL LOCK
RED
1700
A
A
S
4650
4550
1510
4275
E
HORN
C412
TO OPTIONS
(ACCESSORY
CONNECTOR)
BLK
6300
C
2650
4235
N
DGN
D
BLK
4730
RED
F
C411
C472
RED
6400
BLK
6500
6000
6600
L
E
2730
P
M
C449
A
C
C407
BRN
SEE CAB
CONNECTOR
TO OPTIONS
(BACKUP ALARM
SWITCH)
-
PWM
TURN SIGNAL
DGN
A
B
B
HEATER
SIDE
SHIFT
AHC LIFT
HALL SENSOR
BACKUP ALARM
FUSE 1
+
HANDLE LOCK
R
TRACTION
4820
C465
RGN
PULL 0.3 ohm
YEL/RED
B
J
B
A
4100
HOLD 10.9 ohm
F
2200
C409
C410
A
C
LEFT HANDLE
J
FUSE 5
J
Traction Lock
A
C
4200
7100
TO OPTIONS
(ACCESSORY
CONNECTOR)
F
6600
A
6500
H
6400
4240
E
4810
8200
2600
D
1480
8250
A
B
C103
4310
9
43
6310
G
C
TO OPTIONS
(ACCESSORY
HARNESS
CONNECTOR)
4920
19
29
A
B
C
2900
4940
H
E
E
D
G
4930
9100
9340
E
6200
40
30
20
4500
J2
C425
H
A
9200
2520
1400
H
A
46
5
15
44
4
4910
4200
6410
7200
6510
9700
9600
9500
9800
F
B
SEE FUSE/RELAY
CENTER
(EUROPEAN
LIGHTING)
C407
J1
2015
F
B
1200
1900
41 4
8 48 17
2900
2770
2750
2760
9350
24
6
1110
7100
50
1120
6330
49
3520
1130
2640
2650
ENG OIL
RESERVED
PRESS SIGNAL (FAN OUTPUT )
48
7200
4150
LEFT
TAILLIGHT
6210
HORN
47
3420
2100
6320
HYD CHARGE
PRESS SIGNAL
4110
2610
46
8110
2630
RIGHT
TAILLIGHT
SPARE
OUTPUT 2
LEFT
9700
45
30
2910
2920
2930
2740
H
A
3920
14
3300
RIGHT
1130
+5V
SUPPLY
3900
FRONT
WORKLIGHTS
8150
2910
4350
GROUND
40
LEFT PANEL
39
9340
38
1210
37
E
36
G
D
35
HEADLIGHTS
34
PROTECTED POWER
33
44
3910
25
34
C434
32
9800
50
35
45
C435
31
ATTACHMENT
KEY INPUT
OPEN
49
1910
FUEL PULL
RELAY
43
40
OPEN
48
9110
MARKER
LT RELAY
42
RH SKI
UP
4940
HYDRAULIC
TEMP
F
H
8210
GROUND
8000
47
SYSTEM Tx
4450
ENG OIL
PRESS +8v
SWITCH PWR / RESERVED
ACC RELAY (CAN SHIELD)
46
4500
COMPUTER POWER
28
1120
GLOW PLUG
FEEDBACK
41
45
3920
8150
LEFT
WORKLIGHT
29
27
OPEN
1400
39
20
8800
STARTER
RELAY
CAN
SELECT
4470
44
9340
8800
6310
19
6210
DIVERT ER
8210
6200
18
4460
8250
6200
6210
1800
17
8510
2620
A
FUEL RELAY
HOLD
4200
8550
2600
RIGHT
WORKLIGHT
1020
26
REAR WKLT
RELAY
HIGH FLOW /
900 LOAD
RESERVED
UNSWIT CHED
(SENSOR GRND) BATTERY (2)
6210
BAT
ALTERNATOR
TAILGATE / WORKLIGHTS 6716419
B
B
A
25
4730
F&R AUX
RELIEF
10
4110
3010
6320
A
A
24
9600
16
6510
J1
P01
9
8510
UNSWIT CHED
BATTERY (3)
8000
1015
B
23
15
OPEN
38
A
B
6100
22
4730
B
G
R
S
C109
M
C110
1020
TRAVEL
CONTROL
8
6410
4150
STARTER
1015
3400
CAN
LOW
GROUND
B
A
See C492
2900
8100
14
9500
43
4640
F
G
2750
6100
2800
B
13
1110
TRACTION
LOCK HOLD
OPEN
42
9410
9400
9410
2900
C
B
12
RIGHT
BLINKER
BRAKE SW
IN
41
23
42
A
C408
9340
8120
HYD CHARGE
PRESS +8V
30
4930
6110
B
B R P S F E D C M A J H
9200
A
CAN
HIGH
8250
TRACTION LOCK SENSOR
PULL FEEDBACK GROUNDS
7
D3
A
J1
8800
UNSWIT CHED
BATTERY (1)
6
4390
E3
?? ohm
HOLD PULL
KUBOTA
FUEL
SHUTOFF
A
C
5
FUEL PULL
FEEDBACK
HANDLE
POWER
A
4
4910
SEATBAR
SIGNAL
RH SKI
DOWN
29
4320
GLOW PLUG TRACTION LOCK
RELAY
PULL / 963
LEFT
BLINKER
SPARE
OUTPUT 1
HEADLIGHT
SWIT CH
PWM
SIGNAL
28
3100
2110
4410
FLOAT
FUEL
SENDER
A
N K G L B R P S F E D C M A J
N K G L
9100
11
SPARE
DIGITAL 2
3
3430
TWO SPEED
MAKE-UP
37
E
9340
49
3510
RESERVED
(BOOTSTRAP)
36
4840
9210
9200
37
3520
STARTER
FEEDBACK
RESERVED
(hall)
TWO SPEED
SWIT CH
OPEN
35
3910
D
7
9100
3500
3520
2
HYD FILT ER
SIGNAL
STATUS
OUT
LH SKI
UP
34
9350
33
20
4920
4500
3500
C
B
OPEN
1
21
8820
SEATBAR
GROUND
27
19
4310
4500
A
RESERVED
(AC INPUT )
TWO SPEED
SOLENOID
B
KEY/ENT ER
SWIT CH
OPEN
26
18
3700
2740
3
23
B
OPEN
32
4420
HYD LOCK
SOLENOID
SEE J2
2710
?? ohm
BUCKET
POSIT ION
31
LH SKI
DOWN
4830
3100
9110
1900
C
B
OPEN
4820
J2
P05
RH FRONT
DETENT
1200
A
B
25
3900
B
C
SEE J2
C
24
1900
3600
PWM -
2740
3430
3300
23
9400
9
4300
B
6120
+8
1900
B
SEAT BAR
+8v
22
4430
-
1200
23
COMPUT ER
POWER
21
4340
3100
C
FUEL
SENDER
30-270 ohm
B
A
2760
2770
3010
17
15
9200
B
A
9350
3410
3310
16
14
28
11
10
8
3200
AIR FILT ER
SIGNAL
3110
9350
3420
F
D
C
STATUS
IN
9210
SPARE
DIGITAL 1
1200
4440
REAR
ROD
4810
LH AUX
LEFT
B
A
3900
3420
15
47
7
9100
SYSTEM
Rx
SEAT
BAR
6719422
ENG SPEED
SIGNAL
PWM +8V
SUPPLY
C
AIR FILTER
SWITCH
3920
3400
B
A
3110
B
A
3910
B
3400
C107
2120
2720
13
6
COOLANT
TEMP SIGNAL
9210
A
3900
C
3430
ENGINE OIL
PRESSURE
SENDER
0.5-7.5 V
2740
2730
12
5
PROTECTED
POWER
L HAND
SERIAL IN
K
B
3700
ENGINE
COOLANT
SENDER
815-1696 ohm
t
3920
3300
A
E
HYDRAULIC FILTER 6717247
2110
11
4
2900
4330
LH AUX
RIGHT
SYSTEM Rx
3710
A
B
3910
2600
SPARE
ANALOG 2
SYSTEM
Tx
9300
B
A
3510
3
REAR
BASE
4360
2300
2300
2
R HAND
SERIAL IN
COMPUT ER
GROUND
9310
A
C
A
HYDRAULIC OIL
FILTER SWITCH
3610
1
FRONT
ROD
9330
3200
3210
MAIN
FRAME
B
F
D
18
A
B
SPEED
SENSOR
CAB
E
3410
3310
8
DATA
A
B
C476
3210
3420
B
48
START
B
C406
B
B
A
A
3700
HYDRAULIC
TEMPERATURE
SENDER
500-3000 ohm
2800
SPARE
ANALOG 1
FRONT
BASE
3400
3200
C
3300
A
C
2100
2240
A
B
10 38
3600
B
2000
2350
SPOOL
LOCK
32 12 22 1 41 3 21
9110
A
C
4410
HYDRAULIC CHARGE
PRESSURE SENDER
0.5 - 7.5 V
2200
4340
2390
2370
4360
2380
4330
11
4430
2410
J2
CLOCK/LATCH
A
3610
J2
J1
9320
1
2
3600
C
J1
29 26
9320
9.8 ohm
12V
B
J
C
A
BUZZER
B
BUZZER
A
2470
2930
FRONT BASE
1930
BRAKE
SWITCH
4470
RIGHT PANEL
2
7.5 ohm
12V
4440
2100
2360
18
9330
A
B
4420
2520
2420
31
9310
A
B
4470
2330
6
4450
2400
2340
4460
2440
2430
4350
UNSWITCHED POWER 1000-1999 RED
FUSED, UNSWITCHED POWER 1000-1999 RED/WHT
SWITCHED POWER 1000-1999 RNG
GROUND 2000-2999 BLK
MONITORING 3000-3999 LBL
HYDRAULIC 4000-4999 LGN
ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK
ACCESSORIES 7000-7999 WHT
ENGINE 8000-8999 TAN
COMMUNICATION 9000-9999 PUR
7
4390
2450
J
2
B
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GRAY
B
2330
9.8 ohm
12V
B
2480
2460
DATA
2420
3.3 ohm
PWM
REAR AUX RELIEF
SOME CONNECTOR
BODIES NOT SHOWN
FOR DRAWING CLARITY
GROUNDS
START
B
1
9300
1
2450
GREEN TIE
STRAP
CLOCK/LATCH
A
9220
4330
A
2000
B
B
9120
B
C104 C104
A
1920
4420
4450
Printable Version Click Here
F
A
DIVERTER
YELLOW TIE STRAP
A
K
A
FRONT ROD
2340
WIRES CONNECT BY LETTER
ACROSS CONNECTORS
H
2360
SYSTEM Tx
B
SYSTEM Rx
B
B
BICS HYDRAULIC LOCK
4410
2410
9350
A
5 ohm
12V
COMPUTER POWER
2
4340
TWO SPEED
MAKE-UP
1220
2380
WHITE TIE STRAP
CAB 6727178
2350
4390
A
9.8 ohm
12V
E
2440
2370
C419 C106
B
A
4350
RUN/ENTER SWITCH
4440
C418
A
C437
B
C441
863 (S/N 514450764 AND ABOVE)
(S/N 514541104 AND ABOVE)
(S/N 514641255 AND ABOVE)
(PRINTED DECEMBER 2003)
V-0215
A
7.5 ohm
12V
PROTECTED POWER
A
B
1
BUCKET POSITIONING
TWO SPEED
SOLENOID
2920
BLUE TIE STRAP
D
G
2460
B
GROUND
A
7.5 ohm
12V
4460
4380
1
2
4370
LIFT SPOOL LOCK
(NOT Used With AHC or ACS)
BROWN TIE STRAP
C420
A
B
C
2430
C421
4430
C422
2460
A
B
C414
4460
C415
A
B
A
B
A
B
REAR BASE
HIGH FLOW
7.5 ohm
12V
C413
6733137
WIRING SCHEMATIC
(With ACS Option)
2530
B
OPEN
TILT SPOOL LOCK
(NOT Used With AHC or ACS)
REAR ROD
A
7.5 ohm
12V
863 WIRING SCHEMATIC
6200
2600
THERMOSTAT
F E D C B A
LEFT WORK
39 K
ohm
RIGHT WORK
7000
DELUXE EUROPEAN
TAILLIGHT HARNESS - 6718198
RIGHT TAILLIGHT
C
1000
1700
1740
2730
2740
5
6530
2750
7010
3
4
4
5
7220
6
TO MAINFRAME
A
B
G
E
C
F
H
D
2780
6300
6300
6440
6400
6540
6500
6600
TO LEFT HANDLE CONNECTOR
6510
6000
TO EUR0. LIGHTS
CONNECTOR
C411
D
A
B
C
E
6410
4700
2
4
5
6
4
1110
2
1
1750
4700
2715
4
5
6
6
2790
C
F
A
D
E
B
7210
2735
TO OPTIONS
(HVAC OR HVAC/ACCESSORY)
1140
1700
1740
2730
2740
6420
2
1130
2
2
6430
TO OPTIONS
(EXTERIOR CAB)
5
6
D
A
C
B
7010
3
4
5
2
6
TO MAINFRAME
6300
A
B
G
E
C
F
6440
6400
6540
6500
6000
2
BLK
B
A
2710
1110
2
1
1
1750
B
A
M
A
B
2790
B A
B A
AIR CONDITIONER
HARNESS 6719630 OR 6726888
C
F
G
E
A
D
H
B
RNG
RNG/DGN
4700
2715
BLK
TO OPTIONS (FRONT WIPER)
C
F
A
D
E
B
LEFT
TAILLIGHT
RIGHT
TAILLIGHT
LEFT
WORK
LIGHT
RNG
RNG/DGN
BACK-UP
ALARM
BACK-UP ALARM
HARNESS - 6715659
TO ATTACHMENT
2775
6440
6540
E
A
C
D
F
B
EXTERIOR CAB HARNESS 6718872
E
A
C
F
D
B
1
5
6700
6
2760
A
B
C606
3
6430
A
B
7010
B
B
2770
A
7000
TO MAINFRAME
1720
A
TO MAINFRAME
6440
G
E
D
F
A
B
C
H
6400
2780
6540
6500
STANDARD ACCESSORY HARNESS - 6715365
3200
A
B
C
1300
7200
2110
2130
A
B
C
10
8
7
RED
WHT
BLK
M
3
2
1
4
5
6
5000
1200
1010
2210
TO OPTIONS
(HVAC ADAPTER)
TO OPTIONS
(HVAC ADAPTER)
2200
A
7010
HVAC HARNESSES - 6717877 OR 6725275
Printed in U.S.A.
7020
POWER RELAY
1740
85
87
87A
86
30
TO OPTIONS
(HVAC/ACCESSORY)
2210
1190
2740
A
B
C
A
2320
7020
B
A
B
A
1740
AIR CONDITIONER
CLUTCH SOLENOID
HVAC ADAPTER HARNESSES - 6726357
A
B
C
D
1
2
3
9500
9600
9700
9800
1710
1160
2710
TO
MAINFRAME
A
B
C
D
E
F
G
BOOM HARNESS - 6718426
RED
YEL
RNG
RNG
7160
7210
2765 or BRN
2755
B
C
A
1720
2720
ALARM
HORN
2730
7200
B
C
A
WIPER HARNESS - 6718295
or 6729739
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GRAY
WIRES CONNECT BY LETTER
ACROSS CONNECTORS
A
B
B
A
SOME CONNECTOR
BODIES NOT SHOWN
FOR DRAWING CLARITY
A
B
TO HANDLE CONNECT0R
FRONT HORN HARNESS 6719151 or 6727498
7310
2735
A
B
TO MAINFRAME
(ACCESSORY CONNECTOR)
2745
C
B
E
A
D
F
C610
1140
C642
C
B
A
TO ATTACHMENT
(BOOM
CONNECTOR)
C666
1010
M
BLK
C640
2
1
4
6
5
TO OPTIONS
(DELUXE ACCESSORY)
TO OPTIONS
(DELUXE ACCESSORY)
2740
HVAC/ACCESSORY
HARNESS 6725390 OR 6807266
BLOWER MOTOR
YEL
RED
RNG
TO OPTIONS
(HVAC HARNESS)
C636
BLOWER SWITCH
1200
C640
H
3
C634
M
5000
3
2
1
4
5
6
C
B
A
C667
2200
B
L
THERMOSTAT
C426
A
B
C
3100
DBL
GRADER HARNESS 6707303
1730
V
M
TO OPTIONS
(HVAC)
C
B
A
B
A
FRONT WIPER
MOTOR
C636
C634
A
B
C
C
B
A
2205
7010
C641
1000
BLK
POTENTIOMETER
1110
C635
DBL
WHT
7000
C
C637
HEATER VALVE
6
5
4
3
2
1
C639
TO OPTIONS (HVAC)
2100
C638
7000
1740
LT
TM
CENTER
GD
RT
BLK
2740
3100
HIGH
ADDITIONAL POWER
CONNECTOR
S
BRN
1740
M
L X
MEDIUM
A
B
C
E
F
G
H
L
K
TO OLDER
MODEL ATTACHMENTS
WHT
ADDITIONAL POWER CONNECTOR
C622
LOW
2720
M
A
D
FRONT WIPER
BOTTLE AND TANK
AIR CONDITIONER SWITCH
OFF
1730
BACK-UP ALARM
SWITCHES HARNESS 6718820 OR 6807152
POWER BOB-TACH
SOLENOID
POWER BOB-TACH HARNESS 6718652 or 6730770
6
6530
2750
C506
7110
4
5
3
4
7010
C601
7000
2
A
D
C
B
E
B
A
BACK-UP ALARM
SWITCHES
POWER BOB-TACH
SOLENOID
TO OPTIONS
C601
2760
1
1700
E
D
A
C
B
2770
B
J
N
P
TO MAINFRAME
7200 or YEL
4 WAY FLASHER
HARNESS - 6718873
6700
2780
2785
C668
2
1
3
2
6010
L
X
C
F
G
E
A
D
H
B
RIGHT
WORK
LIGHT
7150 or DGN
1130
1180
2
EVAPORATOR (AC)
PRESSURE SWITCH
TO ENGINE OR MAINFRAME
REAR LIGHT HARNESS - 6714350
C427
6540
C669
2785
TO OPTIONS
(4 WAY FLASHER)
POWER BOB-TACH
SWITCH
HAZARD SWITCH
4
3
1
TO OPTIONS
(EXTERIOR CAB)
C668 OR C670
1
2
3
C669
2795
2790
TO OPTIONS
(EXTERIOR CAB)
6440
TO OPTIONS
(POWER BOB-TACH)
2730
6
TO
STROBE/BEACON
TO OPTIONS
B
A
C
D
C607
C609
2 1
C401
TO MAINFRAME
5
DIODE
2700
2735
2745
B
A
2300
7030
C632
7100
RIGHT
FLASHER
LIGHT
B
C
1190
1760
LEFT
FLASHER
LIGHT
2310
BLK
DBL/WHT
6
DELUXE ACCESSORY HARNESS - 6725273
FLASHER
B
A
DOME LIGHT
SWITCH
DOME LIGHT
6
4710
BEACON SWITCH
A
1190
RED
PNK
3
4
7210
2 1
TO OPTIONS
(DELUXE ACCESSORY)
2210
2740
5
7310
5
TO OPTIONS
(DOME LIGHT)
POWER
PLUG
STROBE OR
BEACON
87A
30
AIR CONDITIONER
CLUTCH SOLENOID
1
2
1730
3
4
6
C411
6510
4700
TO EUR0. LIGHTS
CONNECTOR
D
A
B
C
E
6410
10
8
7
RED
WHT
TRAVEL CONTROL
LOCKOUT SWITCH
FRONT WIPER
SWITCH
4
5
H
D
6600
TO LEFT HANDLE CONNECTOR
2130
A
B
C
BACK-UP
ALARM
1720
1
6
6300
87
HVAC JUMPER HARNESS 6725934 OR 6725936
1710
3
2780
86
85
TO ENGINE OR MAINFRAME
REAR WIPER
SWITCH
7220
2725
6700
7200
V
M
4
5
6530
2750
2760
6520
3
3
4
E
7000
2
HAZARD SWITCH
1
6010
L
X
1180
1
2770
POWER RELAY
1740
HEATER VALVE
A
B
C
1300
TO OPTIONS
C608
1
5
6
4
3
1
C670
POWER BOB-TACH
SWITCH
REAR WIPER
MOTOR
C601
LIGHT SWITCH
BEACON SWITCH
2745
E
D
C
F
A
B
B
A
C
1140
C427
C401
TO MAINFRAME
TO OPTIONS
(POWER BOB-TACH)
M
BLK
C617 OR C642
DELUXE ACCESSORY HARNESS - 6715366
FLASHER
BLOWER MOTOR
YEL
RED
RNG
TO OPTIONS (FRONT WIPER)
1160
1150
M
B
E
F
2700
4710
A
D
B
C
A
D
C
B
E
F
1190
POWER
PLUG
BLK
TO OPTIONS (HVAC)
TO OPTIONS (HVAC)
3
7310
5
TO OPTIONS
(DOME LIGHT)
B
A
3
2
1
4
5
6
10
8
7
RED
WHT
1
2
1730
1
3
2710
B
E
F
HEATER VALVE
A
D
C
TRAVEL CONTROL
LOCKOUT SWITCH
FRONT WIPER
SWITCH
3
6
2725
6700
1720
1
2
2130
2110
C404
5
6520
3
6430
C633
E
D
C
F
A
B
3
4
6
C608
C670
TO OPTIONS
(EXTERIOR CAB)
2
1700
BLK
DBL/WHT
HAZARD SWITCH
1
6010
L
X
REAR WIPER
SWITCH
7200
HVAC HARNESS - 6725933
PNK
BLK
1180
2
7000
V
M
C614
1130
3
1
1
2
2200
PNK
BLK
2
2760
1010
BLOWER SWITCH
C667
5
E
D
A
C
B
2770
3
2
1
4
5
6
1200
H
C608
6
4
6420
C601
1
2745
REAR WIPER
MOTOR
C427
BEACON SWITCH
POWER BOB-TACH
SWITCH
A
D
C
1300
BLK
TO OPTIONS
(POWER BOB-TACH)
LIGHT SWITCH
3200
POTENTIOMETER
5000
M
C667
FLASHER
1120
B
A
C
BLK
HERE OR TO OPTIONS
(HVAC JUMPER)
A
B
C
B
C617 OR C642
1140
1150
C401
1140
WHT
1110
L
TO OPTIONS
(HVAC OR HVAC/ACCESSORY)
TO MAINFRAME
A
B
C
DBL
10 K
ohm
7020
LEFT TAILLIGHT
RIGHT TAILLIGHT
TO OPTIONS (AC)
HIGH
C617
E F C A B D
REGISTRATION
LAMP
A
B
C
C612
C605
6210
C614
C604
C612
2620
6340
6320
6610
2610
2640
6330
6620
BLK
RIGHT WORK
2630
2205
2310
C402
F E D C B A
LEFT WORK
F E D C B A
REAR TAILLIGHT HARNESS - 6714546
A
D
B
C
A
B
C
7010
C491
E F C A B D
REGISTRATION
LAMP
E F C A B D
A
B
C631
C603
2100
MEDIUM
DBL/WHT
C613
C602
LOW
C103
F E D C B A
LEFT TAILLIGHT
AIR CONDITIONER SWITCH
OFF
C611
E F C A B D
BLK
PNK
BLK
6500
3100
PNK
DGN/YEL
BLK
PNK
DGN/YEL
BLK
A
D
H
B
6310
C103
Printable Version Click Here
BLK/WHT
6400
BACK-UP
ALARM
C623
PNK
DGN
6600
C490
YEL
BACK-UP
ALARM
C
F
G
E
7100
C402
F
G
E
A
D
H
B
BATTERY FEED 1000-1999 RED, RED/WHT, RNG
GROUND 2000-2999 BLK
MONITORING 3000-3999 LBL
HYDRAULIC 4000-4999 LGN
ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK
ACCESSORIES 7000-7999 WHT
ENGINE 8000-8999 TAN
COMMUNICATION 9000-9999 PUR
V-0020 (10-4-02)
B
A
C412
RNG/DGN
2650
C630
C
7010
RNG
DGN/YEL
(PRINTED NOVEMBER 2002)
V-0020
TO ENGINE OR MAINFRAME
TO ENGINE OR MAINFRAME
C103
EUROPEAN ONLY
C103
OPTIONS
S/N 514440001 AND ABOVE
S/N 514540001 AND ABOVE
S/N 514640001 AND ABOVE
To
Mainframe
863 WIRING SCHEMATIC
4640
4840
4820
4650
AHC TILT
HALL
SENSOR
PUR
WHT
PNK
DBL
HORN
1 3 2
1 3 2
A C B
A C B
C449
C495
DGN
YEL
B A
E B A D D
C412
C411
TO OPTIONS
(ACCESSORY
CONNECTOR)
TO OPTIONS
(ACCESSORY
CONNECTOR)
4610
4710
A C B
4600
C494
A C B
RED
1 3 2
BRN
PUR/WHT
BLK/WHT
RED/WHT
PNK/BLK
PNK/DGN
1 3 2
FLOAT
LEFT HANDLE
TURN SIGNAL
4620
To
Mainframe
9400
B A
SKI
CTRL
BLK
AHC LIFT
HALL
SENSOR
PNK/RED
C473
9410
TAN
RNG
YEL
LGN
DGN
RNG
SIDE
SHIFT
RIGHT HANDLE
4720
2750
SKI
CTRL
4700
C496
1750
B
WHT/LGN
TWO
SPD
DETENT
FLOW
C450
Extra Power
Connector
A
E H J A F G B C K D
E K J H A
PWM
BATTERY FEED 1000-1999 RED, RED/WHT, RNG
GROUND 2000-2999 BLK
MONITORING 3000-3999 LBL
HYDRAULIC 4000-4999 LGN
ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK
ACCESSORIES 7000-7999 WHT
ENGINE 8000-8999 TAN
COMMUNICATION 9000-9999 PUR
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GRAY
WHT/BLK
WHT
WHT/RED
WIRES CONNECT BY LETTER
ACROSS CONNECTORS
C410
C409
B D C G F
SOME CONNECTOR
BODIES NOT SHOWN
FOR DRAWING CLARITY
4830
1480
E H J A F G B C K D
To
Mainframe
B
A
4810
OPTIONS
S/N 514446001-46746
S/N 514541001-41027
S/N 514641001-41068
(PRINTED NOVEMBER 2002)
V-0121
A
B
C410
E H J A F G B C K D
ADVANCED
HAND
CONTROL
HIBBING
HARNESS 6729054
M
4645
4620
4610
4600
4720
4710
C493
8 7 6 5 4 3 2 1
C428
8 7 6 5 4 3 2 1
BLK
DGN
RED
RED
BLK
BLK
RED
K H J D C E G A F B
BLK
B A
LIFT ACTUATOR
M
K H J D C E G A F B
DGN
C474
TILT ACTUATOR
RED
B A
4700
2740
4580
1740
B
1720
A
2720
C489
To
Mainframe
8 7 6 5 4 3 2 1
C429
8 7 6 5 4 3 2 1
HIBBING AHC CONTROLLER
Printed in U.S.A.
V-0121 (10-4-02)
To
Mainframe
863 WIRING SCHEMATIC
4640
4840
4820
4650
AHC TILT
HALL
SENSOR
PUR
WHT
PNK
DBL
HORN
1 3 2
1 3 2
A C B
A C B
C449
C495
DGN
YEL
B A
E B A D D
C412
C411
TO OPTIONS
(ACCESSORY
CONNECTOR)
TO OPTIONS
(ACCESSORY
CONNECTOR)
4610
4710
A C B
4600
C494
A C B
RED
1 3 2
BRN
PUR/WHT
BLK/WHT
RED/WHT
PNK/BLK
PNK/DGN
1 3 2
FLOAT
LEFT HANDLE
TURN SIGNAL
4620
To
Mainframe
9400
B A
SKI
CTRL
BLK
AHC LIFT
HALL
SENSOR
PNK/RED
C473
9410
TAN
RNG
YEL
LGN
DGN
RNG
SIDE
SHIFT
RIGHT HANDLE
4720
2750
SKI
CTRL
4700
C496
1750
B
WHT/LGN
TWO
SPD
DETENT
FLOW
C450
Extra Power
Connector
A
E H J A F G B C K D
E K J H A
PWM
BATTERY FEED 1000-1999 RED, RED/WHT, RNG
GROUND 2000-2999 BLK
MONITORING 3000-3999 LBL
HYDRAULIC 4000-4999 LGN
ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK
ACCESSORIES 7000-7999 WHT
ENGINE 8000-8999 TAN
COMMUNICATION 9000-9999 PUR
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GRAY
WHT/BLK
WHT
WHT/RED
WIRES CONNECT BY LETTER
ACROSS CONNECTORS
C410
C409
B D C G F
SOME CONNECTOR
BODIES NOT SHOWN
FOR DRAWING CLARITY
4830
1480
E H J A F G B C K D
To
Mainframe
B
A
4810
OPTIONS
S/N 514446001-46746
S/N 514541001-41027
S/N 514641001-41068
(PRINTED NOVEMBER 2002)
V-0121
A
B
C410
E H J A F G B C K D
ADVANCED
HAND
CONTROL
HIBBING
HARNESS 6729054
M
4645
4620
4610
4600
4720
4710
C493
8 7 6 5 4 3 2 1
C428
8 7 6 5 4 3 2 1
BLK
DGN
RED
RED
BLK
BLK
RED
K H J D C E G A F B
BLK
B A
LIFT ACTUATOR
M
K H J D C E G A F B
DGN
C474
TILT ACTUATOR
RED
B A
4700
2740
4580
1740
B
1720
A
2720
C489
To
Mainframe
8 7 6 5 4 3 2 1
C429
8 7 6 5 4 3 2 1
HIBBING AHC CONTROLLER
Printed in U.S.A.
V-0121 (10-4-02)
863 WIRING SCHEMATIC
OPTIONS
S/N 514446001 AND ABOVE
S/N 514541001 AND ABOVE
S/N 514641001 AND ABOVE
(PRINTED NOVEMBER 2002)
V-0123
FLASHER
1
HAZARD SWITCH
C670
B
A
SOME CONNECTOR
BODIES NOT SHOWN
FOR DRAWING CLARITY
E
D
6700
B
F
A
C
6540
2
1180
L
X
2
1
5
3
4
5
4
6
6530
2750
6
7010
3
6430
TO MAINFRAME
ACS SWITCH
1
2755
2780
2
2745
2755
6440
E
4550
3
R
4
D
C
K
G
B
J
4235
4275
5
6
2730
S
L
M
H
N
P
F
A
1700
6400
6500
BATTERY FEED 1000-1999 RED, RED/WHT, RNG
GROUND 2000-2999 BLK
MONITORING 3000-3999 LBL
HYDRAULIC 4000-4999 LGN
ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK
ACCESSORIES 7000-7999 WHT
ENGINE 8000-8999 TAN
COMMUNICATION 9000-9999 PUR
1150
STANDARD ACCESSORY HARNESS - 6727468
TO OPTIONS
(HVAC OR HVAC/ACCESSORY)
1140
1740
2740
FLASHER
TO OPTIONS
(POWER BOB-TACH)
5
3
1
2
1180
X
L
6010
HAZARD SWITCH
1
2
B
F
A
6540
C
6300
6
5
7000
7010
3
4
6
E
D
A
C
B
V
M
REAR WIPER
SWITCH
7220
2
4
5
6530
2750
2760
6520
3
6430
2770
1710
1720
1
6
5
2725
2
4
2710
1110
TO LEFT HANDLE
CONNECTOR
6510
6000
D
A
B
C
E
POWER
PLUG
7310
1770
2755
2
4550
E
R
4235
4275
D
C
K
G
B
J
L
M
H
N
P
3
4
5
TO MAINFRAME
6
2730
6400
6500
1150
6300
6600
TO EUR0. LIGHTS
CONNECTOR
4730
1140
1700
4730
2715
3
4
5
6
6
1190
2700
2790
TO OPTIONS
(FRONT WIPER)
1760
C
F
A
D
E
2735
B
7210
ACS SWITCH
1
1
4710
C488
6410
2
1
B
A
2
1730
1750
5
TO OPTIONS
(DOME LIGHT)
6440
1
3
4
6
2780
TRAVEL CONTROL
LOCKOUT SWITCH
FRONT WIPER
SWITCH
3
C411
C670
6700
5
1
2
3
4
E
D
6420
2
1130
TO OPTIONS
(EXTERIOR CAB)
POWER BOB-TACH
SWITCH
1
6
4
C608
2745
C601
LIGHT SWITCH
BEACON SWITCH
REAR WIPER
MOTOR
B
A
C
C667
A
B
3
1
TO OPTIONS
(EXTERIOR CAB)
6010
C617 OR C642
1130
WIRES CONNECT BY LETTER
ACROSS CONNECTORS
7000
C488
Printable Version Click Here
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GRAY
2760
2
BEACON SWITCH
6
5
4
E
D
A
C
B
2770
C601
TO OPTIONS
(POWER BOB-TACH)
POWER BOB-TACH
SWITCH
F
A
S
DELUXE ACCESSORY HARNESS - 6727190
Printed in U.S.A.
V-0123 (10-4-02)
ELECTRICAL SYSTEM INFORMATION
863 WIRING SCHEMATIC
S/N 514440001-45999
S/N 514540001-40999
S/N 514640001-40999
(PRINTED OCTOBER 2002)
V-0003
863 WIRING SCHEMATIC
WITH ADVANCED HAND CONTROL OPTION
S/N 514440001-43831
S/N 514540001-40110
S/N 514640001-40215
(PRINTED OCTOBER 2002)
V-0004
863 WIRING SCHEMATIC
WITH ADVANCED HAND CONTROL OPTION
S/N 514443832-45999
S/N 514540111-40999
S/N 514640216-40999
(PRINTED OCTOBER 2002)
V-0119
863 WIRING SCHEMATIC
WITHOUT ACS OPTION
S/N 514446001-514450763
S/N 514541001-514541103
S/N 514641001-514641254
(PRINTED OCTOBER 2002)
V-0120
863 WIRING SCHEMATIC
WITH ACS OPTION
S/N 514446001-514450763
S/N 514541001-514541103
S/N 514641001-514641254
(PRINTED OCTOBER 2002)
V-0216
863 WIRING SCHEMATIC
WITHOUT ACS OPTION
S/N 514450764 AND ABOVE
S/N 514541104 AND ABOVE
S/N 514641255 AND ABOVE
(PRINTED OCTOBER 2002)
V-0214
863 WIRING SCHEMATIC
WITH ACS OPTION
S/N 514450764 AND ABOVE
S/N 514541104 AND ABOVE
S/N 514641255 AND ABOVE
(PRINTED OCTOBER 2002)
V-0215
60-10-1
863 Bobcat Loader
Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
OPTIONS
863 WIRING SCHEMATIC
OPTIONS
S/N 514440001 AND ABOVE
S/N 514540001 AND ABOVE
S/N 514640001 AND ABOVE
(PRINTED OCTOBER 2002)
V-0020
863 WIRING SCHEMATIC
OPTIONS
S/N 514440001 AND ABOVE
S/N 514540001 AND ABOVE
S/N 514640001 AND ABOVE
(PRINTED OCTOBER 2002)
V-0021
863 WIRING SCHEMATIC
OPTIONS
S/N 514446001-46746
S/N 514541001-41027
S/N 514641001-41068
(PRINTED OCTOBER 2002)
V-0121
863 WIRING SCHEMATIC
OPTIONS
S/N 514446001 AND ABOVE
S/N 514541001 AND ABOVE
S/N 514641001 AND ABOVE
(PRINTED OCTOBER 2002)
V-10123
60-10-2
863 Bobcat Loader
Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
WARNING
Troubleshooting Chart
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are
most common. Many of the recommended procedures
must be done by authorized Bobcat Service Personnel
only.
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0903
PROBLEM
Battery will not take charge.
Alternator will not charge.
Starter will not turn the engine.
CAUSE
1, 2, 3, 4, 5
1, 2, 5
2, 3, 4, 6, 7, 8, 9
KEY TO CORRECT THE CAUSE
1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connector is not making good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or solenoid is damaged.
9. Check the fuses.
60-10-3
863 Bobcat Loader
Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Figure 60-10-2
Description
Figure 60-10-1
1
P-28473
1
Figure 60-10-3
P-13849
The loader has a 12 volt, negative ground alternator
charging system. The electrical system is protected by a
100 amp master fuse (Item 1) [Figure 60-10-1] to protect
against serious overloads that could lead to burned up
harness or loader damage.
1
P-28475
the fuse holder is located in the engine compartment,
below the engine harness connector (Item 1) [Figure 6010-2] & [Figure 60-10-3].
60-10-4
863 Bobcat Loader
Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Figure 60-10-5
Description (Cont’d)
IMPORTANT
Do Not use silicone base sprays and/or sealants on
harness connectors or components.
I-2123-0397
1
Figure 60-10-4
N-19659
The fuse panel cover (Item 1) [Figure 60-10-5] & [Figure
60-10-7] has a decal inside to show the location and amp
ratings.
1
N-19659
The electrical system is also protected by fuses and
relays under the fuse panel cover (Item 1) [Figure 60-104] located in the cab on the steering control panel.
60-10-5
863 Bobcat Loader
Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Fuse Location
The location and sizes are shown in [Figure 60-10-6] &
[Figure 60-10-7].
Ref
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
Figure 60-10-6
Description
Heater
Front & Marker Lights
Rear Lights
Bobcat Controller
Traction
Fuel Shutoff
Not Used
Not Used
Unswitched Attachment
Switched Attachment
Alternator & Kits
AHC Power
Amp
25
15
15
25
30
30
--25
25
25
25
Relay Switches Location
Remove the cover to check or replace the relays.
N-19660
F5
F1
F6
F2
F7
F3
F8
F4
Fuses
E
D
C
B
F9
The location is shown in [Figure 60-10-6] & [Figure 6010-7].
Ref
B
C
D
E
F10
F
G
H
F11
J
Description
Switch Power
Rear Lights
Front & Marker Lights
Not Used
Ref
F
G
H
J
Description
Glow Plugs
Fuel Shutoff
Traction
Starter
F12
Relays
Fuses
N-18465A
Figure 60-10-7
1
N-19661
Remove the cover to check or replace the fuses.
60-10-6
863 Bobcat Loader
Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Solenoid Test
Figure 60-10-8
P-9175
Use a test meter to measure coil resistance [Figure 6010-8]. Coil wires do not have polarity. Correct resistance
for the pressure relief (small) coil is 7-10 ohm and the
other coils 5-8 ohms.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
60-10-7
863 Bobcat Loader
Service Manual
60-10-8
863 Bobcat Loader
Service Manual
BATTERY
Figure 60-20-2
Removal And Installation
WARNING
1
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-1296
P-28431
Remove the bolt from the cable clamp (Item 1) [Figure
60-20-2] and loader frame.
Figure 60-20-3
Open the rear door.
Figure 60-20-1
2
1
1
P-28429
Disconnect the positive (+) cable (Item 1) [Figure 60-203]from the battery.
P-28429
Disconnect the negative (-) cable (Item 1) [Figure 60-201] from the battery.
Remove the battery holddown clamp (Item 2) [Figure 6020-3].
Remove the battery from the loader.
60-20-1
863 Bobcat Loader
Service Manual
BATTERY (CONT’D)
Figure 60-20-6
Removal And Installation (Cont’d)
Figure 60-20-4
1
P-28431
Installation: The short negative cable must be
connected at the cable clamp and ground bolt (Item 1)
[Figure 60-20-6] to insure proper system ground and
cable routing.
P-9589
Figure 60-20-5
Connect and tighten the battery cables.
negative (-) cable last to prevent sparks.
Connect the
P-9590
Installation: Always clean the terminals and cable ends
when installing a new battery as shown in [Figure 60-204] & [Figure 60-20-5].
When installing the battery in the loader, do not touch any
metal parts with the battery terminal posts.
60-20-2
863 Bobcat Loader
Service Manual
BATTERY (CONT’D)
Using A Booster Battery (Jump Starting)
Servicing The Electrical System
WARNING
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-1296
W-2065-1296
WARNING
Figure 60-20-7
Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at engine frame.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F (16°C) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Battery gas can explode and cause serious injury.
W-2066-1296
P-9588
The battery cables must be clean and the connections
tight. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate (baking soda) and
water solution as shown in [Figure 60-20-7].
Clean the terminals and cable ends as shown in [Figure
60-20-4] and [Figure 60-20-5].
Check the electrolyte level in the battery, add distilled
water as needed.
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
Put Battery Saver P/N 6664458 or grease on the battery
terminals and cable ends to prevent corrosion.
I-2023-1285
If it is necessary to use a booster battery to start the
engine, BE CAREFUL! There must be one person in the
operator’s seat and one person to connect and
disconnect the battery cables.
60-20-3
863 Bobcat Loader
Service Manual
BATTERY (CONT’D)
Using A Booster Battery (Jump Starting) (Cont’d)
The ignition must be in the OFF position. The booster
battery to be used must be 12 volt.
Figure 60-20-8
2
4
P-10813
3
1
P-7661
Connect the end of the first cable (Item 2) [Figure 60-208] to the positive (+) terminal of the booster battery.
Connect the other end of the second cable (Item 2)
[Figure 60-20-8] to the positive terminal on the starter.
Connect the end of the second cable (Item 3) [Figure 6020-8] to the negative (-) terminal of the bootser battery.
Connect the other end of the same cable (Item 4) [Figure
60-20-8] to the engine.
Keep cables away from moving parts. Start the engine.
After the engine has started, remove the ground (-) cable
(Item 4) [Figure 60-20-8] first.
Remove the cable from the starter.
60-20-4
863 Bobcat Loader
Service Manual
ALTERNATOR (55 AMP)
If the reading is low, remove the screws and pull the
regulator cover away from the alternator and continue
testing (below).
Alternator Output Test
Rectifier (Diode) Test
IMPORTANT
NOTE: The alternator is removed from the loader for
clarity purposes.
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
Disconnect the negative (-) cable from the battery.
Install the wires in their original location on the back of
the alternator.
W-2017-0286
Figure 60-30-2
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Output
Terminal
Disconnect the negative (-) cable from the battery.
Figure 60-30-1
1
Regulator
Terminal
P-1304
Connect a jumper wire (Item 1) [Figure 60-30-2] to the
alternator output terminal and the regulator terminal.
1
Connect the battery negative (-) cable.
N-19696
Start the engine and run at 2600 RPM.
Disconnect the red wire (Item 1) [Figure 60-30-1] from
the alternator. Connect the wire to the negative (-) side of
the ammeter.
Connect the positive (+) side of the ammeter to the
output terminal on the alternator (Item 1) [Figure 60-301].
If the reading is within 45-55 amps @ 2600 RPM replace
the rectifier (diode) assembly or replace the alternator.
If the reading is low, do the Alternator Regulator Test.
Disconnect the fuel stop solenoid connector.
Connect the negative (-) cable to the battery.
Turn on the lights for 3 minutes to discharge the battery.
Connect the fuel stop solenoid, start the engine and run
at 2600 RPM.
If ammeter reading is between 45-55 amps @ 2600 RPM
the alternator is good and no further testing is needed.
60-30-1
863 Bobcat Loader
Service Manual
ALTERNATOR (55 AMP) (CONT’D)
Figure 60-30-4
Alternator Regulator Test
WARNING
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
Ground
Stud
Brush
Terminal
W-2050-1285
1
Figure 60-30-3
P-1364
Connect the jumper wire (Item 1) [Figure 60-30-4] from
the brush terminal to the ground stud.
Connect the negative (-) battery cable and start the
engine. Run at 1500 RPM.
If the voltmeter reading is 14.5 or above, replace the
regulator.
If the voltmeter reading is below 14.5, repair or replace
the alternator.
N-19695
Connect the positive (+) voltmeter lead to the positive (+)
battery terminal [Figure 60-30-3].
Connect the negative (-) voltmeter lead to the negative (-)
battery terminal [Figure 60-30-3].
Start the engine and run at 1500-2000 RPM.
The voltmeter should read between 13.9-14.7 volts.
If the reading is low, stop the engine and disconnect the
battery negative (-) cable.
NOTE: The alternator is removed from the loader for
clarity purposes.
Remove the wires from the back of the alternator.
Remove the regulator cover from the back of the
alternator.
Install the wires on the back of the alternator.
60-30-2
863 Bobcat Loader
Service Manual
ALTERNATOR (55 AMP) (CONT’D)
Figure 60-30-6
Removal And Installation
2
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
1
N-19698
I-2023-1285
Loosen the adjustment bolt (Item 1) [Figure 60-30-6].
Figure 60-30-5
Remove the alternator belt.
Remove the adjustment bolt (Item 1) [Figure 60-30-6].
Remove the mounting bolt (Item 2) [Figure 60-30-6] and
nut.
Remove the alternator.
1
2
N-19696
Open the rear door.
Disconnect the negative (-) battery cable.
Disconnect the red wire (Item 1) [Figure 60-30-5] at the
alternator.
Disconnect the wiring harness connectors (Item 2)
[Figure 60-30-5].
60-30-3
863 Bobcat Loader
Service Manual
ALTERNATOR (55 AMP) (CONT’D)
Stator Continuity Test
Disassembly
Figure 60-30-8
Figure 60-30-7
1. Nut
2. Pulley
3. Fan
4. Bolt
5. Case Half (Front)
6. Bearing
7. Rotor
8. Stator
9. Rectifier (Diode)
10. Case Half (Rear)
11. Condenser Assembly
12. Strap
13. Regulator
14. Brush
15. Cover
3
2
1
5
8
7
P-1369
6
4
Use an ohmmeter to test the stator.
Touch the probes to two of the bare stator wires [Figure
60-30-8].
12
13
Move one of the probes to the third wire.
The readings should be the same.
9
10
11
14
If there is no continuity, replace the stator.
Stator Ground Test
15
Figure 60-30-9
C-3312
Disassemble the alternator (See Parts Identification
[Figure 60-30-7]).
Remove the regulator cover and regulator.
Remove the four bolts holding halves together.
Pry the halves apart.
Use a soft jaw vise to hold rotor while removing pulley
nut.
Remove front case half from the rotor using a plastic
hammer.
Unsolder the stator leads from the rectifier. Remove the
stator.
P-1386
Touch one probe to a bare stator lead and the other
probe to the bare metal surface of the stator [Figure 6030-9].
There should be no continuity.
Replace the stator if there is continuity.
60-30-4
863 Bobcat Loader
Service Manual
ALTERNATOR (55 AMP) (CONT’D)
Rectifier Continuity (Diode) Test
Rotor Continuity Test
NOTE: In the diode tests there should be continuity in
one direction only. If the diode being tested
shows no continuity or continuity in both
directions, replace the rectifier assembly.
Figure 60-30-10
Figure 60-30-12
P-1365
Touch the probes to the slip rings (Item 1) [Figure 60-3010].
The ohmmeter should read between 3.0-33.0 ohms.
P-1373
Touch the probes to the terminals of each diode and read
the meter [Figure 60-30-12].
If there is no continuity, replace the rotor.
Rotor Ground Test
Reverse the probes to check the diode in the other
direction.
Figure 60-30-11
There should be continuity in one direction only.
Figure 60-30-13
P-1378
P-1370
Touch one probe to one of the slip rings and the other
probe to the rotor shaft [Figure 60-30-11].
There should be no continuity.
Touch one probe to the diode and the other to the
connected heat sink and read the meter [Figure 60-3013].
Replace the rotor if there is continuity.
Reverse the probes to check the diode in the other
direction.
There should be continuity in one direction only.
60-30-5
863 Bobcat Loader
Service Manual
ALTERNATOR (55 AMP) (CONT’D)
Assembly
Figure 60-30-14
1
P-1808
Reverse the order of disassembly.
Place the rotor in soft jaws when tightening the shaft nut.
Tighten to 50 ft.-lbs. (68 Nm) torque [Figure 60-30-14].
Install the rear case half and the remaining parts.
60-30-6
863 Bobcat Loader
Service Manual
ALTERNATOR (90 AMP)
Alternator Identification
Adjusting The Alternator Belt
Figure 60-31-2
Stop the engine.
Open the rear door.
2
1
Figure 60-31-1
P-24416A
2
4
1
1
3
P-24417
Figure 60-31-3
P-24611
4
P-24614
Loosen the alternator mounting bolt (Item 1) [Figure 6031-1].
3
Loosen the adjustment bolt (Item 2) [Figure 60-31-1].
Move the alternator until the belt has 5-16 inch (8,0 mm)
movement at the middle of the belt span with 15 lbs. (66
N) of force.
1
Tighten the adjustment bolt and mounting bolt.
2
1
1
P-24542
Close the rear door.
The black cover has been removed to show alternator
rectifier/regulator assembly. The alternator contains field
coil diodes (low current) (Item 1) [Figure 60-31-2],
grounded heat sink (Item 2) [Figure 60-31-2] & [Figure
60-31-3], B+ power heat sink (Item 3) [Figure 60-31-2] &
[Figure 60-31-3], regulator (Item 4) [Figure 60-31-2] &
[Figure 60-31-3], and four pair of large power diodes
(Item 1) [Figure 60-31-3] on the underside of the rectifier.
.
NOTE: The rectifier/regulator assembly has been
removed from the alternator and flipped over
for component identification [Figure 60-31-3]
60-31-1
863 Bobcat Loader
Service Manual
ALTERNATOR (90 AMP) (CONT’D)
If the charging system malfunctions check the following:
Charging System Check
Check the condition of the alternator belt. (See Adjusting
The Alternator Belt on Page 60-31-1) If belt is worn or
deteriorated replace.
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
Inspect the alternator wiring harness and connectors at
alternator. Harness and connectors must be clean and
tight.
Check the fuse for the alternator in the fuse panel. If fuse
is burned, fond the cause and repair/replace. If fuse is in
doubt, remove it and check for continuity.
Check the electrolyte level in the battery. Add distilled
water as needed. (Does not apply to maintenance free
batteries.)
Verify the charge of the battery. Make sure the battery is
fully charged.
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-1296
Disconnect the battery cables (negative first, then
positive). Inspect the cable clamps and battery posts for
corrosion. Remove acid or corrosion from the battery
and cables with a sodium bicarbonate and water solution.
Put grease on the cable ends and battery terminals to
prevent corrosion. Reconnect the cable to the positive
terminal.
With the key off, connect a test light between the negative
battery post and the disconnected negative cable clamp.
1. If the test light does not light up, reattach the clamp
and proceed to alternator voltage test.
(See
Alternator Voltage Test on Page 60-31-3.)
2. If the test light lights up, there is a short (drain) in the
electrical system of the loader. The short must be
repaired before the charging system can be checked.
WARNING
Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at engine frame.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F (16°C) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Battery gas can explode and cause serious injury.
W-2066-1296
60-31-2
863 Bobcat Loader
Service Manual
ALTERNATOR (90 AMP) (CONT’D)
Figure 60-31-5
Charging System Check (Cont’d)
Figure 60-31-4
1
2
P-24616
Turn the engine on with the remote start tool and run at
idle. With a voltmeter, check the voltage between the B+
terminal and ground at the starter [Figure 60-31-5].
P-24621
3. Disconnect the alternator B+ terminal (Item 1) [Figure
60-31-4] and L & S terminal connector (Item 2)
[Figure 60-31-4] and if the test light goes out, the
alternator is faulty. If the test light stays on, find the
short in the system and repair it.
The voltage must be higher than 13.5 volts but lower than
n 14.7 volts at 70° F (Alternator Temperature).
Alternator Voltage Test
If the voltage is lower than 13.5 volts, run engine at high
idle and recheck voltage. If voltage is still below 13.5
volts, proceed with the See Low Voltage Test on Page 6031-3.
Open the rear door. (See REAR DOOR on Page 50-701.)
If the voltage is higher than 14.7 volts proceed to See
High Voltage Test on Page 60-31-4.
Connect the remote start tool to the loader. (See
REMOTE START on Page 10-60-1.)
60-31-3
863 Bobcat Loader
Service Manual
ALTERNATOR (90 AMP) (CONT’D)
High Voltage Test
Low Voltage Test
Turn engine off and remove the L & S Terminal connector
(Item 1) [Figure 60-31-6 on Page 3] off the alternator.
Figure 60-31-6
Figure 60-31-8
1
P-24568
1
2
P-24617
P-24569
Turn engine OFF and remove the L & S terminal
connector (Item 1) [Figure 60-31-6] off the alternator.
Turn the remote start tool key to the ON position.
Figure 60-31-7
P-24619
Check the continuity between the “S” terminal (Item 1)
[Figure 60-31-8] and the positive (+) terminal on the
battery or starter terminal (Item 2) [Figure 60-31-8].
There should be continuity. If no continuity, replace wire
harness.
If voltage is still above 14.7 volts at 70° F (Alternator
Temperature), then remove alternator for replacement or
repair. To repair, See Rectifier Continuity (Diode) Test on
Page 60-31-6 for further component testing.
2
1
P-24618
Check the voltage across the “L” terminal (Item 1) [Figure
60-31-7] and the ground (Item 2) [Figure 60-31-7]. The
voltage should be what the battery voltage is. If not,
check wire harness, relay and fuses. If the wire harness,
relay and fuses are ok then remove the alternator for
replacement or repair. To repair, See Rectifier Continuity
(Diode) Test on Page 60-31-6 for further component
testing.
60-31-4
863 Bobcat Loader
Service Manual
ALTERNATOR (90 AMP) (CONT’D)
IMPORTANT
Removal And Installation
Place jackstands under the rear of the loader.
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
Figure 60-31-10
WARNING
1
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
2
W-2059-0598
3
Figure 60-31-9
P-24611
Remove the adjustment bolt (Item 1) [Figure 60-31-10]
from the mounting bracket.
1
Remove the alternator belt (Item 2) [Figure 60-31-10]
from the alternator pulley.
2
Remove the mounting bolt (Item 3) [Figure 60-31-10].
P-24621
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Open the rear door.
Disconnect the negative (-) cable from the battery.
Disconnect the red wire (Item 1) [Figure 60-31-9] from
the alternator which comes from the battery.
Disconnect the wiring harness connector (Item 2)
[Figure 60-31-9] from the alternator.
60-31-5
863 Bobcat Loader
Service Manual
ALTERNATOR (90 AMP) (CONT’D)
Figure 60-31-13
Rectifier Continuity (Diode) Test
1
Figure 60-31-11
1
2
1
3
1
P-24527
1
Touch the probes to the terminals (Item 1) [Figure 60-3113] of each diode and read the meter.
P-24416
Remove the two screws (Item 1) [Figure 60-31-11], nut/
washer (Item 2) [Figure 60-31-11] and the plastic cover
(Item 3) [Figure 60-31-11] from the alternator.
NOTE: In the diode tests there should be continuity in
one direction only. Meter readings should be
different when robes are reversed. If the
diode being tested shows no continuity or
continuity in both directions, replace the
rectifier assembly.
Reverse the probes to check the diode in the other
direction.
Meter readings should be different when probes are
reversed.
Figure 60-31-14
Figure 60-31-12
1
1
P-24558
Touch one probe to the diode (Item 1) [Figure 60-31-14]
and the other probe to each heat sink and read the
meter.
P-24532
NOTE: Use the diode function (Item 1) [Figure 60-3112] on the multimeter.
Reverse the probes to check the diode in the other
direction.
Meter readings should be different when probes are
reversed.
60-31-6
863 Bobcat Loader
Service Manual
ALTERNATOR (90 AMP) (CONT’D)
Disassembly
Alternator Regulator Test
Figure 60-31-17
1. Alternator
2. Nut
3. Pulley
4. Spacer
5. Bolt
6. Bracket
7. Bolt
8. Bearing
9. Retainer
10. Rotor
Figure 60-31-15
2
11. Bearing
12. Stator
13. Bracket
14. Sleeve
15. Regulator
16. Rectifier
17. Cover
18. Spacer
19. Nut
7
1
6
1
4 7
13
14
P-24533
2
Touch one probe to the “L” terminal (Item 1) [Figure 6031-15] and the other probe to the ground (Item 2) [Figure
60-31-15].
3
10
8
Figure 60-31-16
12
5
11
9
19
18
15
16
17
C-3529
Disassemble the alternator.
[Figure 60-31-17].)
(See Parts Identification
Remove the rear cover.
P-24535
Remove the four bolts holding halves together.
Reverse the probes to check in the other direction
[Figure 60-31-16].
There should be continuity in one direction only. Meter
readings should be different when probes are reversed.
If there is no continuity or continuity in both directions,
replace regulator.
Pry the halves apart (Use a press if needed).
Use a soft jaw vise to hold rotor while removing pulley
nut.
Remove front case half from the rotor using a plastic
hammer or press.
Unsolder the stator leads from the rectifier. Remove the stator.
Unsolder the two leads between the rectifier and
regulator. Remove the regulator from rectifier.
60-31-7
863 Bobcat Loader
Service Manual
ALTERNATOR (90 AMP) (CONT’D)
Rotor Continuity Test
Stator Continuity Test
Figure 60-31-20
Figure 60-31-18
P-24524
P-24537
Touch the probes the slip rings [Figure 60-31-20].
Use and ohmmeter to test the stator
The ohmmeter should read between 2.5-3.5 ohms.
Touch the probes of two of the bare stator wires [Figure
60-31-18].
If there is no continuity replace the rotor.
Rotor Ground Test
Move one of the probes to the third wire.
Figure 60-31-21
The readings should be the same.
If there is no continuity, replace the stator.
Stator Ground Test
Figure 60-31-19
P-24525
Touch one probe to one of the slip rings and the other
probe to the rotor shaft [Figure 60-31-21].
There should be no continuity.
P-24538
Replace the rotor if there is continuity.
Touch one probe to a bare stator lead and the other
probe to the bare metal surface of the stator [Figure 6031-19].
There should be no continuity.
Replace the stator if there is continuity.
60-31-8
863 Bobcat Loader
Service Manual
ALTERNATOR (90 AMP) (CONT’D)
Assembly
Reverse the order of disassembly.
Do not assemble the rear case half.
Figure 60-31-22
1
P-24557
Place the rotor in soft jaws when tightening the shaft nut
(Item 1) [Figure 60-31-22]. Tighten to 72 ± 14.5 ft.-lbs.
(98 ± 20 Nm) torque.
Install the rear case half and the remaining parts.
60-31-9
863 Bobcat Loader
Service Manual
60-31-10
863 Bobcat Loader
Service Manual
STARTER (NIPPONDENSO)
Figure 60-40-3
Removal And Installation
Figure 60-40-1
1
1
N-20399
Remove the lower mounting bolt (Item 1) [Figure 60-403].
N-19699
Figure 60-40-4
Open the rear door.
Disconnect the negative (-) cable from the battery.
Disconnect the wires and positive (+) cable (Item 1)
[Figure 60-40-1] from the starter solenoid.
Figure 60-40-2
1
N-19702
1
Remove the two top mounting bolts (Item 1) [Figure 6040-4].
1
Remove the starter.
N-19700
Disconnect the wires (Item 1) [Figure 60-40-2] from the
starter solenoid.
60-40-1
863 Bobcat Loader
Service Manual
STARTER (NIPPONDENSO) (CONT'D)
Parts Identification
1. Felt Washer
2. Bearing
3. Armature
4. Bearing
5. Field Windings
Housing Assy.
6. Cover
7. Brush Holder
8. Cover
9. Bolt
10. Bolt
8
6
10
9
7
11. Brushes
12. Cover
13. Gasket
14. Screw
15. Pinion Shaft
16. Nut
17. Washer
18. Nut
19. Washer
20. Roller
5
4
3
1
2
11
13
17
12
16
18
14
15
22
21
20
19
11
18
25
16
24
17
23
35
34
33
31
27
26
28
30
32
21. Retainer
22. Pinion
23. Ball
24. Spring
25. Housing
26. Screw
27. Washer
28. O-ring
29. Housing
30. Gear
31. Spring
32. O-ring
33. Drive
34. Spring
35. Shaft
29
D-2297A
60-40-2
863 Bobcat Loader
Service Manual
STARTER (NIPPONDENSO) (CONT'D)
Figure 60-40-7
Disassembly And Assembly
Figure 60-40-5
B-14442
Remove the field windings housing from the magnetic
switch [Figure 60-40-7].
B-14441
Disconnect the wire from the magnetic switch [Figure 6040-5].
Figure 60-40-8
Assembly: Tighten the nut to 52-86 in.-lbs. (5,9-9,7 Nm)
torque. Securely put the rubber boot over the terminal.
1
Figure 60-40-6
B-14468
Assembly: When installing the field windings housing to
the magnetic switch, engage the tab (Item 1) [Figure 6040-8] on the field windings housing with the notch in the
magnetic switch.
B-14474
Remove the through bolts from the drive end frame
[Figure 60-40-6].
Assembly: Tighten the through bolts to 60-104 in.-lbs.
(6,8-11,8 Nm) torque.
60-40-3
863 Bobcat Loader
Service Manual
STARTER (NIPPONDENSO) (CONT'D)
Figure 60-40-11
Disassembly And Assembly (Cont'd)
Figure 60-40-9
B-14444
Remove the armature from the field windings [Figure 6040-11].
B-14443
NOTE: Use a plastic hammer to tap the field windings
housing, when necessary to remove the
armature.
Remove the screws from the cover over the brushes.
Remove the cover over the brushes.
Figure 60-40-12
Use a long nose pliers, to remove the brushes from the
brush holder [Figure 60-40-9].
Remove the brush holder.
Figure 60-40-10
Positive Brush
Insulator
Negative
Brush
B-14445
Positive Brush
Holder Hole
Remove the screws from the drive end frame [Figure 6040-12].
Negative Brush Holder Hole
Assembly: Tighten the screws to 60-104 in.-lbs. (6,811,8 Nm) torque.
B-14466
Assembly: Install the negative brushes (brush holder
side) to the brush holders (not insulated), and the positive
brushes to the brush holders (separated from plate with
insulator). Make sure that the positive brush wires are not
grounded when assembling the brush holder to the field
windings, take care not to damage and get oil on the
brushes [Figure 60-40-10].
60-40-4
863 Bobcat Loader
Service Manual
STARTER (NIPPONDENSO) (CONT'D)
Figure 60-40-15
Disassembly And Assembly (Cont'd)
Figure 60-40-13
B-14448
Remove the steel ball from the overrunning clutch
[Figure 60-40-15].
B-14446
Figure 60-40-16
Remove the drive end frame from the magnetic switch
[Figure 60-40-13].
Figure 60-40-14
1
B-14449
Remove the pinion (Item 1) [Figure 60-40-16] from the
drive end frame.
B-14447
Remove the overrunning clutch from the drive end frame
[Figure 60-40-14].
NOTE: If the pinion is installed on the drive end frame
(externally attached to the overrunning clutch
shaft), it will be necessary to remove the
pinion before removing the overrunning
clutch. (See External Pinion on Page 60-40-6.)
60-40-5
863 Bobcat Loader
Service Manual
STARTER (NIPPONDENSO) (CONT'D)
External Pinion
Disassembly And Assembly (Cont'd)
Figure 60-40-19
Figure 60-40-17
B-14452
B-14450
Remove the retainer and rollers from the drive end frame
[Figure 60-40-17].
If the pinion is installed on the drive end frame (externally
attached to overrunning clutch shaft), it will be necessary
to remove the pinion prior to removing the overrunning
clutch.
Figure 60-40-18
Push down on the drive end frame [Figure 60-40-19].
Figure 60-40-20
1
Collar
B-14451
B-14453
Remove the return spring from the magnetic switch
[Figure 60-40-18].
Assembly: Reverse the order of disassembly. Before
reassembling, put grease on the following parts:
While pressing down on the starter pinion, tap the collar
using a pipe (Item 1) [Figure 60-40-20].
Overrunning Clutch
Retainer and Rollers
Steel Ball
Return Spring
Armature Bearing
Felt Washer
60-40-6
863 Bobcat Loader
Service Manual
STARTER (NIPPONDENSO) (CONT’D)
Figure 60-40-23
External Pinion (Cont’d)
Figure 60-40-21
1
B-14456
Armature Winding Ground Test: Use a circuit tester,
touch one probe to a commutator segment and the other
probe to the armature core [Figure 60-40-23]. There
should be no continuity. If there is continuity, the armature
is grounded and must be replaced.
B-14454
Remove the snap ring (Item 1) [Figure 60-40-21].
After the snap ring is removed, the pinion, overrunning
clutch, shaft, washer, and spring can be removed.
Figure 60-40-24
Inspection And Repair
ARMATURE:
Figure 60-40-22
B-14457
Armature Winding Continuity Test: Use a circuit tester,
touch the probes to two commutator segments [Figure
60-40-24]. There should be continuity at any point. If
there is no continuity, the winding is open-circuited,
replace the armature.
B-14455
Armature Short-Circuit Test: Use a growler tester, put the
armature on the growler and hold a hack saw blade
against the armature core while slowly rotating the
armature [Figure 60-40-22]. A short circuited armature
causes the blade to vibrate and be attracted to the core.
An armature which is short-circuited must be replaced.
60-40-7
863 Bobcat Loader
Service Manual
STARTER (NIPPONDENSO) (CONT'D)
Figure 60-40-27
Inspection And Repair (Cont'd)
ARMATURE (Cont'd)
1
Figure 60-40-25
B-14460
Measure the segment mica depth (Item 1) [Figure 60-4027].
Service Limit - 0.008 inches (0,2 mm)
B-14458
If it is worn, undercut the segment mica.
Commutator Run-Out Test: Check the commutator runout as shown in [Figure 60-40-25].
Service Limit - 0.02 inches (0,5 mm)
If the commutator exceeds the service limit, repair as
needed.
Check the commutator surface for burned spots which
usually indicates an open-circuit, and correct it using
#400 sand paper.
Figure 60-40-28
Figure 60-40-26
B-14461
Check the bearings for wear and damage [Figure 60-4028].
B-14459
Measure the commutator outer diameter [Figure 60-4026].
If the bearings are worn or damaged, they should be
replaced.
Service Limit - 1.38 inches (35 mm)
If it is worn, replace the armature.
60-40-8
863 Bobcat Loader
Service Manual
STARTER (NIPPONDENSO) (CONT'D)
Figure 60-40-31
Inspection And Repair (Cont'd)
ARMATURE (Cont’d)
Figure 60-40-29
Press
Bearing
B-14463
Field Windings Continuity Test: Use a circuit tester, touch
one probe to the wire and the other probe to the brush
[Figure 60-40-31]. There should be continuity. If there is
no continuity, the field windings are open-circuited.
Armature
B-14439
Use a press as shown in [Figure 60-40-29], replace the
worn or damaged bearing(s).
Replace the field windings.
BRUSH AND BRUSH HOLDER:
Figure 60-40-32
FIELD WINDINGS:
Figure 60-40-30
B-14464
B-14462
Measure the brush length.
Check the field windings for wear and damage.
Service Limit - 0.512 inches (13 mm)
Check all the connections for clean and tight solder joints.
If it exceeds the limit, replace the brush holder or field
windings assembly.
Field Winding Ground Test: Use a circuit tester, touch
one probe to the field winding end of the brush and the
other probe to the surface of the field windings housing
[Figure 60-40-30]. There should be no continuity. If there
is continuity, the field windings are grounded.
Replace the field windings.
Check brush springs, for damage or rust. Replace as
needed.
Brush Holder Insulation Test: Use a circuit tester, touch
one probe to the positive brush holder plate and the other
probe to the holder plate [Figure 60-40-32]. There
should be no continuity. If there is continuity, replace or
repair.
60-40-9
863 Bobcat Loader
Service Manual
STARTER (NIPPONDENSO) (CONT'D)
Figure 60-40-35
Inspection And Repair (Cont'd)
C
OVERRUNNING CLUTCH:
50
Figure 60-40-33
M.T.
B-14470
Hold-In Test: With the same conditions as in the pull-in
test, open the connecting Terminal C [Figure 60-40-35].
The pinion should remain in the engaged position.
B-14465
Figure 60-40-36
Inspect the pinion, it must rotate freely in the direction of
the starter rotation and locked in the opposite rotation
[Figure 60-40-33].
C
50
Figure 60-40-34
C
50
M.T.
B-14469
M.T.
Return Test: With the same conditions as in the hold-in
test, open the connecting Terminal 50 [Figure 60-40-36].
The pinion should return immediately.
B-14471
M.T....Main Terminal to which the main cable from the
battery is connected.
The following tests should be done without the armature
assembly:
NOTE: Each test should be performed a short time (3
to 5 seconds) to prevent the magnetic switch
winding from burning. Each test should be
performed with 12 volts.
C....C-Terminal to which the wire from the field windings
is connected.
50....50-Terminal to which the wire from the starting
switch or stator relay is connected.
Pull-In Test: Connect the wires as shown in [Figure 6040-34]. When connecting Terminal C and M.T. are
closed, the pinion should engage.
60-40-10
863 Bobcat Loader
Service Manual
STARTER (NIPPONDENSO) (CONT’D)
No Load Test
Figure 60-40-37
Ammeter
50
M.T.
C
Starter
B-14440
The following test should be done after reassembling the
starter:
Clamp the starter in a vise. Use a 12 volt battery and
ammeter, connect the positive wire of the battery, and the
ammeter to the 50 Terminal [Figure 60-40-37]. Connect
the negative wire to the starter body.
The starter should show smooth and steady rotation
immediately after the pinion is engaged, it should draw
less than the specified current.
Service Limit - 200 Amp. Maximum Draw
60-40-11
863 Bobcat Loader
Service Manual
60-40-12
863 Bobcat Loader
Service Manual
STARTER (VALEO)
Figure 60-41-3
Checking
Figure 60-41-1
2
1
Bat
S
M
Cranking
Motor
P-34673
Disconnect the negative cable from the battery. (See
Removal And Installation on Page 60-20-1.)
A-1992
Disconnect the S terminal on the starter (Item 1) [Figure
60-41-3].
The key switch must be in the OFF position.
The battery must be at full charge.
The cable connections on the battery must be clean and
tight.
Connect a jumper wire between S terminal and BAT
terminal [Figure 60-41-1].
Hold-In Test: Use circuit tester, touch one probe to the S
terminal (Item 1) [Figure 60-41-3] and one probe to the
mounting bolt (Item 2) [Figure 60-41-3] on the magnetic
switch (solenoid). If there is no continuity replace the
magnetic switch (solenoid).
Figure 60-41-4
If the starter turns but does not turn the engine, the
starter drive has a defect.
2
Figure 60-41-2
1
P-34675
1
Bat
S
M
2
Cranking
Motor
P-34674
Disconnect the negative cable from the battery. (See
Removal And Installation on Page 60-20-1.)
A-1991
Disconnect the S terminal on the starter (Item 1) [Figure
60-41-4].
Connect a jumper wire between the M terminal and the
BAT terminal [Figure 60-41-2].
If the starter turns, the defect is in the solenoid.
Pull-In Test: Use circuit tester, touch one probe to the S
terminal (Item 1) and one probe to the starter motor
terminal (Item 2) [Figure 60-41-4]. If there is no
continuity replace the magnetic switch (solenoid).
If the starter does not turn, the starter is defective.
60-41-1
863 Bobcat Loader
Service Manual
STARTER (VALEO) (CONT’D)
Removal And Installation
Figure 60-41-5
4
2
5
3
1
P-34385
Stop the engine and open the rear door.
Remove the negative (-) and positive (+) cables from the
battery.
Disconnect the ground wire (Item 1) [Figure 60-41-5]
from the starter.
Disconnect the engine harness power wire and positive
(+) battery cable from the starter solenoid terminal (Item
2) [Figure 60-41-5].
Installation: Tighten the nut to 18-24 ft. lbs. (24,4-32,5
Nm) torque.
Disconnect the tan wire (Item 3) [Figure 60-41-5] from
the R terminal on the starter solenoid.
Disconnect the brown wire (Item 4) [Figure 60-41-5] from
the S terminal on the starter solenoid.
Remove the mounting bolts (Item 5) [Figure 60-41-5]
from the starter.
Remove the starter from the engine.
Installation: Tighten the three mounting bolts to 25-28
ft.-lbs. (34-38 Nm) torque.
Reverse the removal procedure to install the starter.
60-41-2
863 Bobcat Loader
Service Manual
STARTER (VALEO) (CONT’D)
Parts Identification
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
30
Starter
Shaft
Gear
Washer
Shaft
Stop Ring
Lever
Holder
Spring
Spring
Plate
Seal
33
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
34
13
36
8*
10*
9*
11*
Lever
Gear
Bracket
Spring
Gear
Stop
Stop Ring
Ball
Armature
Washer
Seal
Yoke
31
7*
32
21
15
14
16
19 18
19
20
17
5
8
14
6
1
29
4
3
28
2
27
35
22
23
25
23
24
* Not serviceable parts
26
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
Holder
Bracket
Ring
Bolt
Bolt
Switch
Seal
Bolt
Washer
Nut
Boot
Bracket
B-16488
60-41-3
863 Bobcat Loader
Service Manual
STARTER (VALEO) (CONT’D)
Figure 60-41-8
Disassembly and Assembly
Figure 60-41-6
2
1
1
1
2
P-34596
Remove the bolts (Item 1) [Figure 60-41-8] from the
brush cover (Item 2) [Figure 60-41-8].
P-34594
Remove the cable (Item 1) [Figure 60-41-6] from the
magnetic switch.
Remove the cover (Item 2) [Figure 60-41-8].
Figure 60-41-9
Remove the bolts (Item 2) [Figure 60-41-6].
2
Installation: Tighten the bolts to 63-129 ft.lbs. (7,1-14,6
Nm) torque.
Figure 60-41-7
1
1
2
4
3
3
N-00980
Using a needle nose pliers, pull the brush springs (Item
1) [Figure 60-41-9] back and remove the brushes (Item
2) [Figure 60-41-9].
P-34595
Remove the armature, yoke, brush holder and rear
bracket assemblies (Item 1) [Figure 60-41-7] from the
front assembly (Item 2) [Figure 60-41-7].
NOTE: When separating the parts there will be a steel
ball (Item 3) [Figure 60-41-7] located at the end
of the armature shaft (Item 4) [Figure 60-41-7].
NOTE: The brushes are non-replaceable. If the
brushes are worn order a new brush holder
(for the negative brushes) and yolk (for the
positive brushes).
Remove the brush holder (Item 3) [Figure 60-41-9] from
the end of the armature.
Installation: Apply grease to the steel ball (Item 3)
[Figure 60-41-7] and install into the end of the armature
shaft (Item 4) [Figure 60-41-7] .
60-41-4
863 Bobcat Loader
Service Manual
STARTER (VALEO) (CONT’D)
Figure 60-41-12
Disassembly and Assembly (Cont'd)
1
Figure 60-41-10
2
3
1
2
P-34600
P-34598
Remove the armature (Item 1) [Figure 60-41-10] from
the frame.
Inspect the magnetic switch (Item 1) [Figure 60-41-12],
the spring (Item 2) [Figure 60-41-12],and the plunger
(Item 3) [Figure 60-41-12] for wear and replace as
needed.
Figure 60-41-13
Remove the bearing (Item 2) [Figure 60-41-10] from the
end of the armature.
Figure 60-41-11
3
2
1
1
P-34601
Remove the center bracket (Item 1) [Figure 60-41-13]
P-34599
Remove the bolts (Item 1) [Figure 60-41-11] from the
magnetic switch.
Installation: Tighten bolts to 34-69 ft.-lbs. ( 3,8-7,8 Nm)
torque.
Remove the front assembly (Item 2) [Figure 60-41-11]
from the magnetic switch (Item 3) [Figure 60-41-11].
60-41-5
863 Bobcat Loader
Service Manual
STARTER (VALEO) (CONT’D)
Figure 60-41-16
Disassembly and Assembly (Cont'd)
Figure 60-41-14
1
3
2
2
2
4
P-34604
Remove the snap ring (Item 3) [Figure 60-41-15] &
[Figure 60-41-16]
1
P-34602
Remove the rubber retainer (Item 1) [Figure 60-41-14].
Remove the planetary gears (Item 2) [Figure 60-41-14]
and inspect for damage.
Figure 60-41-15
Remove the retainer (Item 2) [Figure 60-41-15] &
[Figure 60-41-16] and pinion (Item 1) [Figure 60-41-15]
& [Figure 60-41-16].
Remove the spring (Item 4) [Figure 60-41-16].
Installation: Inspect all parts for wear and replace as
needed.
3
2
1
P-34603
Press down on the pinion (Item 1) [Figure 60-41-15] &
[Figure 60-41-16] and retainer (Item 2) [Figure 60-4115] & [Figure 60-41-16].
60-41-6
863 Bobcat Loader
Service Manual
STARTER (VALEO) (CONT’D)
Figure 60-41-19
Inspection And Repair
Figure 60-41-17
N-00997
B-14455
Inspect the brush cover for discoloration, indication the
starter has been overheated.
Armature Winding Continuity Test: Use a circuit tester,
touch the probes to two commutator segments [Figure
60-41-19]. There should be continuity at any point. If
there is no continuity, the winding is open-circuited,
replace the armature.
Figure 60-41-20
Inspect the pinion teeth for wear and damage.
Armature Short-Circuit Test: Use a growler tester, put the
armature on the growler and hold a hack saw blade
against the armature core while slowly rotating the
armature [Figure 60-41-17]. A short circuited armature
causes the blade to vibrate and be attracted to the core.
An armature which is short-circuited must be replaced.
Figure 60-41-18
B-14458
Commutator Run-Out Test: check the commutator runout as shown in [Figure 60-41-20].
Service Limit - 0.003 inch (0,07 mm)
If the commutator exceeds the service limit, repair as
needed.
N-00996
Armature Winding Ground Test: Use a circuit tester,
touch one probe to a commutator segment and the other
probe to the armature core [Figure 60-41-18]. There
should be no continuity. If there is continuity, the armature
is grounded and must be replaced.
60-41-7
863 Bobcat Loader
Service Manual
STARTER (VALEO) (CONT’D)
Figure 60-41-22
Inspection And Repair (Cont'd)
Figure 60-41-21
1
N-00999
Check the field windings for wear and damage.
B-14460
Check all the connections for clean and tight solder joints.
Measure the segment mica depth (Item 1) [Figure 60-4121].
Service Limit - 0.012 inch (0,3 mm)
Field Winding Ground Test: Use a circuit tester, touch
one probe to the field winding end of the brush and the
other probe to the surface of the frame [Figure 60-4122]. There should be no continuity. If there is continuity,
the field windings are grounded.
If it is worn, replace the armature.
Replace the frame.
Check the commutator surface for burned spots which
usually indicates an open-circuit, and correct it using
#400 sand paper.
Figure 60-41-23
N-15005
Field Windings Continuity Test: Use a circuit tester, touch
one probe to the wire and the other probe to the brush
[Figure 60-41-23]. There should be continuity. If there is
no continuity, the field windings are open-circuited.
Replace the frame.
60-41-8
863 Bobcat Loader
Service Manual
STARTER (VALEO) (CONT’D)
No Load Test
Inspection and Repair (Cont'd)
Figure 60-41-25
Ammeter
Figure 60-41-24
M.T.
S
Starter
B-14440
N-15006
The following test should be done after reassembling the
starter:
Inspect the brushes for wear and damage.
Replace the brush holder and yoke if the brushes need
replacement.
Check brush spring, for damage or rust. Replace as
needed.
Brush Holder Insulation Test: Use a circuit tester, touch
one probe to the positive brush holder plate and the other
probe to the holder plate [Figure 60-41-24]. There
should be no continuity. If there is continuity, replace or
repair.
Clamp the starter in a vise. Using a 12 volt battery and
ammeter, connect the positive wire of the battery, and the
ammeter to the terminal [Figure 60-41-25]. Connect the
negative wire to the starter body. Using a jumper wire,
connect the S terminal to the main terminal.
The starter should show smooth and steady rotation
immediately after the pinion is engaged, it should draw
less than the specified current.
Service Limit - 1150 Amp. Maximum @ Stall Condition
Clean all parts and apply high temperature grease to the
armature bearing, return spring, steel ball, over running
clutch, and idler gear rollers.
60-41-9
863 Bobcat Loader
Service Manual
60-41-10
863 Bobcat Loader
Service Manual
INSTRUMENT PANEL
Figure 60-50-1
Left Panel
2
The left instrument panel is the same for both Standard
and the Deluxe Instrument Panels [Figure 60-50-1].
1
3
4
6
5
7
8
The table below shows the DESCRIPTION and
FUNCTION/OPERATION for each of the components of
the left panel.
Press and hold LIGHTS Button (Item 4) [Figure 60-50-1]
for two seconds to view SERVICE CODES in the
HOURMETER/CODE DISPLAY (Item 2) [Figure 60-501]. If more than one SERVICE CODE is present, the
codes will scroll on the HOURMETER/CODE DISPLAY.
Ref No
1
2
3
4
5
6
7
8
13
14
9
10 11 12
B-15551
Description
TEMPERATURE GAUGE
HOURMETER / CODE DISPLAY /
GLOWPLUG COUNTDOWN
Function / Operation
Shows the engine coolant temperature.
HOURMETER - Records operating hours of loader. CODE DISPLAY - Displays
numeric SERVICE CODES* relating to the loader monitoring system.
COUNTDOWN - Glow Plug time remaining.
FUEL GAUGE
Shows the amount of fuel in the tank.
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)
[Figure 60-50-1]. (CODES* show only when there is an error found by
loader monitoring system.)
BUCKET POSITIONING (Option)
Press to engage the BUCKET POSITIONING function. Press again to
disengage. Press and hold 2 seconds to view BASE or SHTDN
( SHUTDOWN) feature in HOURMETER/CODE DISPLAY.
ATTACHMENT AUXILIARY HYDRAULICS
HIGH FLOW (Option)
Press to engage the HIGH FLOW auxiliary hydraulics. Press again to
disengage.
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.]
AUXILIARY PRESSURE RELEASE
Press and hold for two seconds. The engine will stop. Hydraulic pressure will
be released in the auxiliary circuit.
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
(See BICS™ SYSTEM, page 60-01 Troubleshooting Guide for troubleshooting)
*
9
PRESS TO OPERATE LOADER
Press to activate BICS™ System when the Seat Bar is down and operator is
seated in operating position.
The light comes ON when the seat bar is down.
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.
The light comes ON when the seat bar is down, engine is running, and the
parking brake is released. The loader can be moved forward or backward when
the light is ON.
10
11
SEAT BAR
LIFT & TILT VALVE
12
TRACTION
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
Page 60-01). Press a second time to lock the brakes.
14
ALARM
The ALARM beeps when there is an Error, WARNING or
condition.
SHUTDOWN
See ELECTRICAL SYSTEM SERVICE MANUAL for further description of SERVICE CODES.
SHUTDOWN feature only in Deluxe Right Panel or Factory Option with Standard Panel.
60-50-1
863 Bobcat Loader
Service Manual
INSTRUMENT PANEL IDENTIFICATION (CONT’D)
Figure 60-50-2
Right Panel - Standard Instrument Panel (With Key
Switch)
15 17 19 21 23 25 27
The right instrument panel shown [Figure 60-50-2] is the
Standard Panel.
16 18 20 22 24 26 28
or
The table below shows the Icons and other components
of the Right Standard Panel.
B-15552
REF.
FUNCTION
OPTION
OR STD.
Advanced Hand Opt.
15 Controls (AHC)
ICON/
LIGHT
ALARM
CODE
CONDITION
DESCRIPTION
ON
3 Beeps *
Error
Error with Advanced Hand Controls (AHC).
Opt.
ON
3 Beeps *
Error
Error with Advanced Control System (ACS).
Attachment Control
Device (ACD)
Std.
Std.
ON
FLASHING
--3 Beeps
*
--Error
Electrical controlled attachment is present.
Error with Attachment Control Device (ACD).
General
Warning
Std.
Std.
Std.
ON
ON
FLASHING
3 Beeps
3 Beeps
Continuous
*
*
*
Error
WARNING
◆SHUTDOWN
Error with one or more engine or hydraulic functions.
Engine speed high or in shutdown.
Engine speed very high. Engine will stop in 10 seconds.
High
Range
Std.
Std.
ON
ON
--3 Beeps
*
--Error
Light is ON when High Range is activated.
Solenoid error.
Fuel
Level
Std.
Std.
ON
FLASHING
3 Beeps
3 Beeps
*
*
Error
WARNING
Fuel level sender system fault.
Fuel level low.
Glow
Plugs
Std.
Std.
ON
FLASHING
--3 Beeps
*
--Error
Glow plugs are energized.
Error with glow plugs.
System Voltage
Std.
ON
3 Beeps
*
WARNING
Voltage low, high or very high.
Seat Belt
Std.
ON
---
-
---
Light stays on for 45 seconds to remind operator to fasten seat belt.
Engine
Oil Pressure
Std.
Std.
Std.
ON
ON
FLASHING
3 Beeps
3 Beeps
Continuous
*
*
*
Error
WARNING
◆SHUTDOWN
Engine Oil Pressure sender out of range.
Engine oil level low.
Engine oil pressure very low. Engine will shutdown in 10 seconds.
24
Hydrostatic
Charge
Pressure
Std.
Std.
Std.
ON
ON
FLASHING
3 Beeps
3 Beeps
Continuous
*
*
*
Error
WARNING
◆SHUTDOWN
Hydraulic oil pressure sender out of range.
Hydraulic oil pressure low.
Hydraulic charge pressure very low. Engine will stop in 10 seconds.
25
Engine
Coolant
Temperature
Std.
Std.
Std.
ON
ON
FLASHING
3 Beeps
3 Beeps
Continuous
*
*
*
Error
WARNING
◆SHUTDOWN
Engine coolant sender out of range.
Engine coolant temperature high.
Engine coolant temperature very high. Engine will stop in 10 seconds.
26
Hydraulic
Oil
Temperature
Std.
Std.
Std.
ON
ON
FLASHING
3 Beeps
3 Beeps
Continuous
*
*
*
Error
WARNING
◆SHUTDOWN
Hydraulic oil temperature out of range.
Hydraulic oil temperature high.
Hydraulic oil temperature very high. Engine will stop in 10 seconds.
Engine
Air Filter
Std.
Std.
ON
FLASHING
3 Beeps
3 Beeps
*
*
Error
WARNING
Air filter switch not connected.
Air filter with high restriction.
Hydraulic
Filter
Std.
Std.
ON
FLASHING
3 Beeps
3 Beeps
*
*
Error
WARNING
Hydraulic filter switch not connected.
Hydraulic filter with high restriction.
Key Switch
-
-
-
-
-
Used to start and stop the engine.
or
Advanced
Control System
(ACS)
16
17
18
19
20
21
22
23
27
28
29
(Early Models) ACD Icon will also be On when the 7 pin / 14 pin Connector Harness (Opt./Acc) is installed and the selector switch is in the 14 pin position.
◆ SHUTDOWN feature only in Deluxe Right Panel or Factory Option with Standard Panel. (Engine can be restarted to move or relocate loader.)
* These functions are monitored and have SERVICE CODES associated with them. See DELUXE INSTRUMENTATION SERVICE CODES on Page 60-80-1 for descriptions
of SERVICE CODES.
60-50-2
863 Bobcat Loader
Service Manual
INSTRUMENT PANEL (CONT’D)
Figure 60-50-4
Right Panel - (Deluxe) (With Keyless Start)
1. Display Panel: The Display Panel is where all system
setup, monitoring, troubleshooting, and error
conditions are displayed.
2. Function Icons: The lower left area of the Deluxe
Panel has the same Icons as the Standard Panel (See
Right Panel - Standard Instrument Panel (With Key
Switch) on Page 60-50-2). These Icons are only
visible when the monitoring system has detected an
error.
3. Selection Buttons: The four Selection Buttons allow
you to select items from the Display Panel and scroll
through screens.
B-16656
The first screen you will see on your new loader will be as
shown in [Figure 60-50-4].
Figure 60-50-3
When this screen is on the display you can enter the
password and start the engine or change the Display
Panel setup features.
3
1
NOTE: Your new loader (with Deluxe Instrument
Panel) will have a Owner Password. Your
dealer will provide you with this password.
Change the password to one that you will
easily remember to prevent unauthorized use
of your loader. (See ELECTRICAL SYSTEM
SERVICE MANUAL.) Keep your password in a
safe place for future needs.
2
4
6
5
B-15553
4. Keypad: The numeric keypad (Item 4) [Figure 60-503] has two functions:
(a) To enter a number code (password) to allow
starting the engine (Keyless Start).
Start Engine: Use the Keypad to enter the numbers
(letters) of your password and press the RUN/ENTER key
(Item 5)[Figure 60-50-3]
Press and hold the START Button (Item 6) [Figure 6050-3] until the engine starts.
Change Language: Press the Selection Button at the end
of the arrow [Figure 60-50-4]to go to the next screen.
(b) To enter a number as directed for further use of
the Display Panel.
60-50-3
863 Bobcat Loader
Service Manual
INSTRUMENT PANEL (CONT’D)
Right Panel Setup Display Options (Deluxe)
Right Panel - (Deluxe) (With Keyless Start)
Icon Identification
Figure 60-50-5
Make selection by pressing SELECTION BUTTON
opposite the Icon.
Icon
B-16655
Description
LOCK / UNLOCK: Allows machine to be
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 the Keypad to select the number of the language
[Figure 60-50-5].
Press EXIT. The screen will return to [Figure 60-50-4].
You can then enter the password and start the engine.
?
EXIT
11:23
0.0
Use to set clock, check system warnings,
select language, set passwords, etc.
HELP: Access help on current menu
item.
EXIT returns you to previous level menu.
CLOCK / JOB CLOCK: Press to clear or
lock job clock; TOOL /SETUP to set time.
UP ARROW: Goes backward one screen.
DOWN ARROW: Goes forward one
screen.
OUTLINE ARROWS: No screen available
(backward / forward).
NEXT
INFO
YES/NO
CLEAR
SET
60-50-4
SELECTION ARROW: Use to select
menu item.
Goes to the NEXT screen series.
EXAMPLE: The next Active Warning
screen.
Goes to more information about an
attachment.
Answer yes/no to current setup question.
Removes previously installed password.
Set accepts current installed password.
863 Bobcat Loader
Service Manual
INSTRUMENT PANEL (CONT’D)
Passwords
Deluxe Panel Setup
Display Options
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.
Owner Password:
Allows for the full use of the loader and to setup the
Deluxe Panel. Owner can select a password to
allow starting & operating the loader and modify the
setup if the Deluxe Panel. Owner should change the
password as soon as possible for security of the
loader.
Press
TOOL/SETUP
User Password:
Allows starting and operating the loader; cannot
change password or any of the other setup
features.
Press
LOADER FEATURES
Changing The Password
Right Instrument Panel
Display Screen
Press
DISPLAY OPTIONS
Press
TOOL / SETUP
Press PASSWORD
UTILITIES
Press
ADJUST CONTRAST
Press
UP or Down
Arrow to
change contrast.
Press
MODIFY OWNER
or
MODIFY USER
Press EXIT to
return to
previous level
menu.
All new machines with Deluxe Instrumentation arrive at
Bobcat Dealerships with the panel in locked mode. This
means that a password must be used to start the engine.
60-50-5
863 Bobcat Loader
Service Manual
INSTRUMENT PANEL (CONT’D)
Changing The Password (Cont’d)
Vitals (Monitor engine, hydraulic / hydrostatic,
electrical functions when engine is running.)
TOOL / SETUP
LOADER FEATURES
VITALS
Press SELECTION ARROW to select METRIC
or ENGLISH (M/E) readouts
You can monitor real-time readouts of:
Engine Oil Pressure
Engine Coolant Temperature
Hydraulic Charge Pressure
Hydraulic Oil Temperature
System Voltage
Engine Speed
Enter Password on
Keypad
Press Enter to
Continue
The Display Panel is easy to use. Continue to set
your own preferences for running / monitoring your
Bobcat Loader.
Re-enter new
password. Press
Enter to Continue
(See left)
Press Enter to
Continue
(See left)
More EXAMPLES:
Clocks
TOOL / SETUP
LOADER FEATURES
DISPLAY OPTIONS
CLOCKS
SET CLOCK
Use the keypad to set time.
Press RUN / ENTER to set clock.
Press EXIT to return to previous level menu.
RESET JOB CLOCK (Password required).
Press CLEAR to reset job clock to zero.
Press LOCK / UNLOCK to unlock.
Enter Password and press RUN / ENTER.
Languages
TOOL / SETUP
LOADER FEATURES
DISPLAY OPTIONS
LANGUAGES
Select the language, press RUN / ENTER.
Press EXIT to return to previous level menu.
60-50-6
863 Bobcat Loader
Service Manual
INSTRUMENT PANEL (CONT’D)
2
3
4
5
6
FRONT
WIPER
REAR
WIPER
NOT
USED
NOT
USED
SIDE
CONSOLE
POWER
PLUG
1
NOT
USED
Option And Field Accessory Panels
9
7
POWER
BOB-TACH
8
TURN SIGNAL
INDICATORS
NOT USED
10
11
HAZARD
LIGHTS
ROTATING
BEACON
Early Models
FRONT
CENTER
PANEL
12
9
POWER
BOB-TACH
TURN SIGNAL
INDICATORS
8
Later Models
13
10
ROTATING
BEACON
HAZARD
LIGHTS
PARKING
BRAKE
NOT USED
11
7
14
ADVANCED
CONTROL
SYSTEM (ACS)
Side Console
Ref.
No.
Description
1
POWER PLUG
2
NOT USED
3
FRONT WIPER
4
REAR WIPER
5
NOT USED
6
NOT USED
Front Center Panel
7
ADVANCED CONTROL
SYSTEM (ACS)
8
NOT USED
9
TURN SIGNAL
INDICATORS
10
HAZARD LIGHTS
11
ROTATING BEACON
12
POWER BOB-TACH
13
14
PARKING BRAKE
NOT USED
NOT USED
b-16642
b-16641
b-15891 updated
Function / Operation
Provides a 12V receptacle for accessories.
--Press the top of the switch to start the front wiper (press and hold for wiper
fluid). Press the bottom of the switch to stop the 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.
-----
Press the top to select Hand Controls; bottom to select Foot Controls.
--Indicates left or right TURN SIGNALS are ON.
Press the left side to turn the HAZARD LIGHTS ON; right side to turn OFF.
Press the left side to turn the ROTATING BEACON ON; right side to turn OFF.
Press and hold the left side to disengage the Bob-Tach wedges. Press and
hold the right side to engage the wedges into the mounting frame holes.
Press the top to engage the PARKING BRAKE; bottom to disengage.
---
60-50-7
863 Bobcat Loader
Service Manual
INSTRUMENT PANEL (CONT’D)
Standard Panel Removal And Installation (Right Side)
Ignition Switch Removal And Installation (Standard
Panel)
Figure 60-50-8
Figure 60-50-6
1
1
N-20140
P-21769
Remove the three mounting bolts (Item 1) [Figure 60-506].
Disconnect the key switch wiring harness (Item 1)[Figure
60-50-8] from the back of the control panel.
Figure 60-50-9
Installation: Be careful not to overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
holes in the panels.
Figure 60-50-7
2
1
1
P-21769
Remove the ignition key (Item 1) [Figure 60-50-9] from
the switch. Remove the ignition switch retaining nut (Item
2) [Figure 60-50-9] from the switch.
N-20158
Pull the right instrument panel down and disconnect the
wire harness connector (Item 1) [Figure 60-50-7] from
the panel.
Remove the panel from the loader cab.
60-50-8
863 Bobcat Loader
Service Manual
INSTRUMENT PANEL (CONT’D)
Figure 60-50-12
Standard Panel Removal And Installation (Right Side)
(Cont’d)
Ignition Switch Removal And Installation (Standard
Panel) (Cont’d)
Figure 60-50-10
1
1
N-20163
Pull the right instrument panel down and disconnect the
wire harness connector (Item 1) [Figure 60-50-12] from
the panel.
Remove the panel from the loader cab.
N-20141
Figure 60-50-13
Remove the ignition switch (Item 1) [Figure 60-50-10]
from the control panel.
Deluxe Panel Removal And Installation (Right Side)
1
Figure 60-50-11
1
N-20142
NOTE: The instrument panel (Item 1) [Figure 60-50-13]
must be replaced as a complete unit.
N-20103
Remove the three mounting bolts (Item 1) [Figure 60-5011].
Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
holes in the panels.
60-50-9
863 Bobcat Loader
Service Manual
INSTRUMENT PANEL (CONT’D)
Alarm Removal and Installation
Standard & Deluxe Panel Removal And Installation
(Left Side)
Remove the left side instrument panel.
Figure 60-50-16
Figure 60-50-14
1
1
N-20144
N-18409
Remove the three mounting bolts (Item 1) [Figure 60-5014].
Remove the retaining nut (Item 1) [Figure 60-50-16] from
the loader alarm.
Remove the alarm from the loader instrument panel.
Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
holes in the panels.
Bulb Removal And Installation
Figure 60-50-15
Remove the left side instrument panel. (See Standard &
Deluxe Panel Removal And Installation (Left Side) on
Page 60-50-10)
Figure 60-50-17
3
2
1
1
N-20165
Pull the left instrument panel down and disconnect the
wire harness connector (Item 1) [Figure 60-50-15] from
the loader alarm.
Disconnect the wire harness connector (Item 2) [Figure
60-50-15] from the loader instrument panel.
N-20145
Remove the two light bulb covers (Item 1) [Figure 60-5017] from the back of the instrument panel.
NOTE: The wiring harness (Item 3 ) [Figure 60-50-15]
is an optional accessory harness.
Remove the instrument panel from the loader.
60-50-10
863 Bobcat Loader
Service Manual
INSTRUMENT PANEL (CONT’D)
Figure 60-50-19
Standard & Deluxe Panel Removal And Installation
(Left Side) (Cont’d)
Figure 60-50-18
N-20147
To install the bulbs, place them in the sockets and turn
clockwise [Figure 60-50-19].
N-20146
With a flat blade screwdriver, turn the light bulb
counterclockwise [Figure 60-50-18] and remove from
panel.
60-50-11
863 Bobcat Loader
Service Manual
60-50-12
863 Bobcat Loader
Service Manual
LIGHTS
Figure 60-60-3
Front Removal And Installation
Open the rear door.
Disconnect the negative (-) cable from the battery. (See
Removal And Installation on Page 60-20-1.)
Figure 60-60-1
1
1
N-19351
Remove the bulb (Item 1) [Figure 60-60-3] from the
socket.
Reverse the above procedure to install the bulb.
N-19348
Remove the light housing (Item 1) [Figure 60-60-1] from
the operator cab.
Figure 60-60-2
1
N-19349
Remove the bulb assembly (Item 1) [Figure 60-60-2]
from the light housing by turning bulb assembly a 1/4
turn.
60-60-1
863 Bobcat Loader
Service Manual
LIGHTS (CONT’D)
Figure 60-60-5
Rear Removal And Installation
Figure 60-60-4
1
2
3
N-19339
Using care press the rear light and housing from the door
[Figure 60-60-5].
N-19655
Remove the bulb assembly (Item 1 & 2) [Figure 60-60-4]
from the light housing (Item 3) [Figure 60-60-4] by
turning bulb assembly 1/4 turn.
Reverse this procedure for installation.
60-60-2
863 Bobcat Loader
Service Manual
BOBCAT CONTROLLER
Identification Chart (S/N 514450763 & Below)
TS-01941
60-70-1
863 Bobcat Loader
Service Manual
BOBCAT CONTROLLER (CONT’D)
Identification Chart (S/N 514450764 & Above)
41
31
50
40
30
20
10
21
11
1
9 8 7 6
41
31
21
11
1
50
40
30
20
10
9 8 7 6
5 4 3 2
J1
5 4 3 2
J2
Controller
Harness Connector View
Harness Connector View
50
41
40
31
21
30
21
30
11
20
11
20
41
J1
31
1 2 3 4 5
J2
1 2 3 4 5
6 7 8 9 10
50
40
6 7 8 9 10
V-171/V-172
60-70-2
863 Bobcat Loader
Service Manual
BOBCAT CONTROLLER (CONT’D)
Identification Chart (S/N 514450764 & Above) (Cont’d)
Harness Connector View
41
3420
7200
3520
X
8550
3500
2100
6320
8110
40
4730
4470
X
1120
4450
8210
30
9500
3400
6510
4200
4460
6210
8800
3430
4910
X
X
X
6410
8510
4110
3
4
8
9 10
8000
X
9800
X
31
X
8150
1130
9700
X
21
X
4150
3010
9600
X
8250
1110
X
X
2
11
1
J1
50
X
1400
5
6
7
20
Harness Connector View
41
4410
9410
4640
9340
3920
J2
X
3300
X
X
4840
X
2110
X
4940
40
30
31
X
4420
X
9350
3910
21
4340
4430
9400
1900
3900
4830
X
3100
4320
4930
9110
4440
X
1200
9200
4820
X
3700
4310
4920
4360
X
4330
2900
9100
4810
9210
3200
4300
3600
1
2
3
4
5
6
7 8
11
50
4500
20
9 10
V-172
60-70-3
863 Bobcat Loader
Service Manual
BOBCAT CONTROLLER (CONT’D)
Figure 60-70-2
Removal And Installation
1
1
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
1
W-2059-0598
S/N 514450763 & Below
N-19958
Figure 60-70-1
Loosen the harness connector mounting bolts (Item 1)
[Figure 60-70-2] from the Bobcat controller.
Installation: Tighten the connector bolts to 30-35 in.-lbs.
(3,39-3,96 Nm) torque.
1
1
Unplug the individual harness connectors from the
controller.
1
NOTE: The connectors are keyed and will only plug
in one way.
Figure 60-70-3
N-19957
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
1
1
Stop the engine. Raise the seat bar.
Lift and block the rear of the loader. (See LIFTING AND
BLOCKING THE LOADER on Page 10-10-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
S/N 514450764 & Above
Remove the left front side panel mount bolts (Item
1)[Figure 60-70-1].
Remove the left front side panel.
P-34842
Loosen the harness connectors mounting bolts (Item 1)
[Figure 60-70-3] from the Bobcat controller.
Remove the connectors.
NOTE: The connectors are keyed and will only plug
in one way.
60-70-4
863 Bobcat Loader
Service Manual
BOBCAT CONTROLLER (CONT'D)
Removal And Installation (Cont’d)
Figure 60-70-4
1
P-34843
Loosen the three mounting bolts (Item 1) [Figure 60-704] of the system controller.
Installation: Tighten the nuts to 12-14 ft.-lbs. (17-19,2
Nm) torque.
Remove the system controller.
Reverse the above procedure to install the system
controller.
60-70-5
863 Bobcat Loader
Service Manual
60-70-6
863 Bobcat Loader
Service Manual
DELUXE INSTRUMENTATION SERVICE CODES
The hourmeter display on the Left Instrument Panel can
change from engine hours to SERVICE CODES (See at
right.). These CODES help your dealership analyze
monitored functions of your Bobcat loader. Some service
procedures mus be performed ONLY BY QUALIFIED
BOBCAT SERVICE PERSONNEL.
The Prefix, in the left two columns, followed by a Suffix, in
the right two columns, will indicate a Function Error.
EXAMPLE: 01-17 Plugged Air Filter
Press and hold LIGHTS Button (Item 5) [Figure 60-50-1
on Page 1] (See DELUXE INSTRUMENTATION
SERVICE CODES on Page 60-80-1.) for two seconds to
view SERVICE CODES in the HOURMETER/CODE
DISPLAY display (Item 6) [Figure 60-50-1 on Page 1]
(See DELUXE INSTRUMENTATION SERVICE CODES
on Page 60-80-1.). If more than one SERVICE CODE is
present, the codes will scroll on the HOURMETER/CODE
DISPLAY.
The following word errors may also be displayed:
REPLY One or both instrument panel(s) not
communicating with the controller.
INPUT The controller not communicating with the
left instrument panel.
CODE
The controller is asking for a password.
(Deluxe Panel Only)
ERROR The wrong password was entered.
(Deluxe Panel Only)
SERVICE CODESS
PREFIX FUNCTION
SUFFIX
01
02
03
04
05
06
07
08
09
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
31
32
Air filter
Hydraulic Charge Filter
Battery Voltage
Engine Oil Pressure
Hydraulic Charge Pressure
Engine Speed
Hydraulic Oil Temperature
Engine Coolant Temperature
Fuel Level
Seat Bar Sensor
Front Auxiliary PWM Switch (Proportional Control)
Fuel Shutoff Solenoid - Secondary
Fuel Shutoff Solenoid - Primary
Traction Lock Solenoid - Primary
Traction Lock Solenoid - Secondary
Lift and Tilt Vlave Solenoid
Spool Lock Solenoid
Bucket Positioning Solenoid
Two-Speed Solenoid (If Equipped)
Glow Plugs
Starter Output
Solenoid for Rear Female Coupler
Solenoid for Rear Male Coupler
Rear Auxiliary Relief Solenoid
Solenoid for Front Female Coupler
Solenoid for Front Male Coupler
Diverter Valve Solenoid
High Flow Auxiliary Solenoid
Recovery Mode Failure (Loss of Power)
Advanced Hand Controls (AHC)
Advanced Control System(ACS)
(Selectable Foot/Hand Controls
33
Constant Data (Stored Loader Information)
34
Deluxe Panel Not Downgraded in Error
35
Two Speed Fan
36
Attachment Control Device (ACD) Controller
80
ACD Output A
81
ACD Output B
82
ACD Output C
83
ACD Output D
84
ACD Output E
85
ACD Output F
86
ACD Output G
87
ACD Output H
Multiple SERVICE CODES and /or Abnormal Symptoms can be caused by
corroded or loose ground connection. Flashing instrument panel lights, alarm
beeping, front & rear lights flashing, low battery voltage, loose battery
connectors, could also indicate a poor ground. Check all grounds before
performing other diagnostics
60-80-1
02
03
04
05
06
07
09
10
11
13
14
15
16
17
18
21
22
23
28
31
32
33
34
35
36
37
38
39
40
41
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
ERROR DESCRIPTION
Error ON (Detects ON when should be OFF)
Error OFF (Detects OFF when should be ON)
In Error
Short to Battery (Detects 12V & should not be)
Short To Ground
Open Circuit (Not Grounded)
Low
High
Exteremely High
No Signal
Extremely Low
In Shutdown
Not Connected
Plugged
Out Of Range
Out of Range High
(Above detectable range of sensor)
Out Of Range Low
(Below detectable range of sensor)
Not Calibrated
Failure
Tilt Actuator Fault
Titl Actuator Wiring Fault
Tilt Handle Wiring Fault
Tilt Actuator Not Calibrated
Tilt Handle Not Calibrated
Lift Actuator Fault
Lift Actuator Wiring Fault
Lift Handle Wiring Ffault
Lift Actuator Not Calibrated
Lift Handle Not Calibrated
Invalid Frequency From Advanced Hand Controls (AHC)
Multiple Controllers Present -Error
Lift Actuator Short To Ground
Tilt Actuator Short To Ground
Lift Actuator Short To Battery
Tilt Actuator Short To Battery
Lift Handle/Pedal Short To Ground
Tilt Handle/Pedal Short To Ground
Lift Handle/Pedal Short To Battery
Tilt Handle/Pedal Short to Battery
Lift Actuator Reduced Performance
Tilt Actuator Reduced Performance
Lift Actuator Wrong Direction
Tilt Actuator Wrong Direction
Handle Lock Short To Ground
Handle Lock Short To Battery
Pedal Lock Short To Ground
Pedal Lock Short To Battery
Sensor Supply Voltage Out Of Range
Battery Out Of Range
Switch Moved While Operating
863 Bobcat Loader
Service Manual
60-80-2
863 Bobcat Loader
Service Manual
BICS™ SYSTEM
2. Raise the Seat Bar fully. All four BICS lights (Items 1,
2, 3, & 4) [Figure 60-90-1] [PRESS TO OPERATE
LOADER, SEAT BAR, LIFT & TILT VALVE and
TRACTION*] on left instrument panel should be OFF
[Figure 60-90-1].
Inspecting The BICS™ Controller (Engine STOPPED Key ON)
Figure 60-90-1
NOTE: Record what lights are blinking (if any) and
number of light flashes. See Troubleshooting
Guide on Page 60-90-4.
Inspecting Deactivation Of The Auxiliary Hydraulics
System (Engine STOPPED - Key ON)
3. Sit in the operator's seat, lower the Seat Bar, and
press the PRESS TO OPERATE LOADER Button.
Press the auxiliary hydraulics FLOW Button. The
auxiliary FLOW Button light will come ON. Raise the
Seat Bar. The light should be OFF.
Inspecting The Seat Bar Sensor (Engine RUNNING)
N-18409
4. Sit in the operator's seat, lower the seat bar, engage
the parking brake pedal and fasten the seat belt.
5. Start the engine and operate at low idle. Press the
PRESS TO OPERATE LOADER Button. While
raising the lift arms, raise the Seat Bar fully. The lift
arms should stop. Repeat using the tilt function.
1
2
3
Inspecting The Traction Lock (Engine RUNNING)
4
B-15551G
6. Fasten the seat belt, disengage the parking brake
pedal, press the PRESS TO OPERATE LOADER
Button and raise the Seat Bar fully. Move the steering
levers slowly forward and backward. The TRACTION
lock should be engaged. Lower the Seat Bar. Press
the PRESS TO OPERATE LOADER Button.
WARNING
AVOID INJURY OR DEATH
The Bobcat Interlock Control System (BICS™) must
deactivate the lift, tilt and traction drive functions. If it
does not, contact your dealer for service. DO NOT
modify the system.
W-2151-0394
1. Sit in the operator's seat. Turn key ON (Standard
Panel), press RUN / ENTER Button (Deluxe Panel,
lower the Seat Bar and disengage the parking brake
pedal. Press the PRESS TO OPERATE LOADER
Button. Three BICS lights (Items 1, 2, & 3) [Figure 6090-1] [PRESS TO OPERATE LOADER, SEAT BAR,
and LIFT & TILT VALVE] on left instrument panel
should be ON [Figure 60-90-1].
7. Engage the parking brake pedal and move the
steering levers slowly forward and backward. The
TRACTION lock should be engaged.
NOTE: * The TRACTION light on the left instrument
panel will remain OFF until the engine is
started, the PRESS TO OPERATE LOADER
Button is pressed and the parking brake is
disengaged.
Inspecting The Lift Arm By-Pass Control
8. Raise the lift arms 6 feet (2 meters) off the ground.
Stop the engine.
Turn the lift arm by-pass control knob clockwise 1/4 turn.
Pull up and hold the lift arm by-pass control knob until the
lift arms slowly lower.
60-90-1
863 Bobcat Loader
Service Manual
BICS™ SYSTEM (CONT'D)
Additional Inspection For Loaders With Advanced
Hand Controls
9. Sit in the operator's seat and fasten the Seat Belt.
Lower the Seat Bar, start the engine and press the
PRESS TO OPERATE LOADER Button.
Inspecting The BICS™ Controller (Engine STOPPED Key ON)
10. Raise the lift arms about 6 feet (2 meters) off the
ground.
11. Turn key OFF (Standard Panel), press the STOP
Button (Deluxe Panel), and wait for the engine to
come to a complete stop.
12. Turn key ON (Standard Panel), press RUN /ENTER
Button (Deluxe Panel). Press the PRESS TO
OPERATE LOADER Button, move the left hand
control toward the operator. The lift arms should not
lower.
13. Move the right hand control away from the operator.
The bucket (or attachment) should not tilt forward.
60-90-2
863 Bobcat Loader
Service Manual
BICS™ SYSTEM (CONT'D)
WARNING
Troubleshooting Chart
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system
problems. It is recommended that these procedures be
done by authorized Bobcat Service Personnel only.
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM
SOLUTION#
All indicator lights flashing.
One of the indicator lights flashing.
Intermittent indicator lights.
5
1
2, 3, 4
SOLUTION SUGGESTIONS
1. Refer to BICS™ troubleshooting guide.(See Page 60-90-4)
2. Check wire connections on Bobcat controller to make sure connectors are locked into
place.
3. Check pins in connectors for pins pushed back or bent.
4. Use seatbar sensor tester MEL1428 to isolate problem between sensor and controller
and wiring.
5. Possible low or high voltage.
60-90-3
863 Bobcat Loader
Service Manual
BICS™ SYSTEM (CONT'D)
Figure 60-90-2
Troubleshooting Guide
The following chart shows the effects which can happen
to the loader, and the probable causes when the BICS
Instrument Panel lights are off. See [Figure 60-90-2] for
location of BICS™ lights and Icons. Have service
procedures performed ONLY BY QUALIFIED BOBCAT
SERVICE PERSONNEL.
6
5
Press and hold LIGHTS Button (Item 5) [Figure 60-90-2]
for two seconds to view SERVICE CODES in the
HOURMETER / CODE DISPLAY (Item 6) [Figure 60-902]. If more than one SERVICE CODE is present, the
codes will scroll on the HOURMETER / CODE DISPLAY.
Indicator
Light
Light ON
Light OFF
Effect on
Operation of
Loader When
Light is OFF
2
1
3
4
B-15551
SERVICE CODES Means System Error
(See Your Bobcat Dealer for Service)
No. of Service
Flashes Code
Causes
PRESS TO
OPERATE
LOADER Button
is pressed.
PRESS TO
OPERATE
LOADER Button
is not pressed.
Lift, tilt and
traction
functions will
not operate.
----
----
Seat Bar is
down.
Seat Bar is up.
Lift and tilt
functions will
not operate.
2
11-05
3
11-06
Seat Bar sensor circuit shorted to battery
voltage*.
Seat Bar sensor circuit shorted to ground.
3
Control valve can Control valve
Lift, tilt and
be used.
cannot be used. traction
functions will
not operate.
1
2
3
3
17-07
17-05
17-06
17-06
Valve output circuit is open.
Valve output circuit shorted to battery voltage*.
Valve output circuit shorted to ground.
Controller not grounded or intermittent ground.
4
Loader can be
Loader cannot
moved forward & be moved
backward
forward and
backward.
1
2
16-07
16-05
3
16-06
5
15-02
6
15-03
Traction lock hold solenoid circuit is open.
Traction lock hold solenoid circuit shorted to
battery voltage*.
Traction lock hold solenoid circuit shorted to
ground.
Traction lock pull solenoid circuit is shorted to
battery voltage* - ERROR ON (Should be OFF).
Traction lock pull solenoid circuit ERROR OFF
(Should be ON).
System voltage low
System voltage high
1
2
SEAT BAR
2
LIFT & TILT VALVE
3
Loader cannot
be moved
forward and
backward.
TRACTION
4
03-09
Flashing 03-10
Continuous
----
NOTES:
Multiple SERVICE CODES and/or Abnormal Symptoms can be caused by corroded or loose ground. Check grounds and
both battery connections.
ERROR OFF = shorted to ground or bad fuse, faulty wiring, faulty open relay, no voltage from relay to controller.
ERROR ON = shorted to battery voltage, faulty wiring, faulty closed relay.
*Normal BICS operating voltage is less than the electrical system voltage.
60-90-4
863 Bobcat Loader
Service Manual
SEAT BAR SENSOR
WARNING
Troubleshooting Chart
The following troubleshooting chart is provided for
assistance in locating and correcting BICS system
problems. It is recommended that these procedures be
done by authorized Bobcat Service Personnel only.
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM
SOLUTION #
Indicator light does not come ON when seat bar is lowered.
1, 2, 3, 4, 5
SOLUTION SUGGESTIONS
1. Check sensor wire connection.
2. Use the BICS™ sensor tester MEL 1428 with seat bar adapter MEL1567 to check
sensor and controller.
3. Check for loose hardware.
4. Check keyed bushing to make sure magnet collar rotates with seat bar.
5. Check magnet collar magnets for contamination such as metal particles.
60-100-1
863 Bobcat Loader
Service Manual
SEAT BAR SENSOR (CONT'D)
Figure 60-100-3
Test
Figure 60-100-1
2
1
1
P-4698
If there is no power light (Item 1) [Figure 60-100-3] on
the sensor tester, check the tester or wiring harness.
N-18463
Figure 60-100-4
Use Sensor Tester (MEL1428) and seat bar sensor tester
adapter (MEL1567) for the following procedure:
Connect the seat bar adapter sensor leads (MEL1567) to
the sensor tester.
1
Disconnect the seat bar sensor connector (Item 1)
[Figure 60-100-1].
Figure 60-100-2
P-4699
1
Lower the seat bar. The Sensor Test light (Item 1)
[Figure 60-100-4] should illuminate.
N-19557
Raise the seat bar. The Sensor Test light (Item 1) [Figure
60-100-4] should go off.
If the above test fails, there is a problem with the seat bar
sensor.
N-19558
Connect the Sensor Tester (Item 1) [Figure 60-100-2]
inline, to the seat bar sensor connectors. See inset
[Figure 60-100-2].
Turn the key to the ON position. DO NOT START THE
ENGINE.
Disconnect the Sensor Tester.
Replace the Seat Bar Sensor. (See Removal And
Installation on Page 60-100-3.)
If the above test passes, run the seat bar sensor BICS
circuit test. (See BICS™ Circuit Test on Page 60-100-4.)
The toggle switch (Item 2) [Figure 60-100-3] can be in
either the Absent or Present position.
60-100-2
863 Bobcat Loader
Service Manual
SEAT BAR SENSOR (CONT'D)
Figure 60-100-7
Removal And Installation
1
Figure 60-100-5
2
3
1
N-19383
Remove the keyed plastic bushing (Item 1) [Figure 60100-7], magnetic bushing assembly (Item 2) [Figure 60100-7] and sensor bracket (Item 3) [Figure 60-100-7].
N-19224
Remove the seat bar (Item 1) [Figure 60-100-5] from the
loader. (See Removal And Installation on Page 50-10-1.)
IMPORTANT
Figure 60-100-6
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095
Installation: Be sure the tabs on the pivot bushing are
positioned in the slotted hole (Item 1) [Figure 60-100-7]
of the seat bar
3
Inspect all parts for damage and wear and replace if
necessary.
1
Reverse the removal procedure to install the seat bar
sensor.
2
N-19219
Remove the mounting bolt (Item 1) [Figure 60-100-6]
from the seat bar mount (Item 2) [Figure 60-100-6].
Installation: Tighten the mounting bolt to 50-70 in.-lbs.
(5,6-7,9 Nm) torque.
Remove the sensor mounting bolt (Item 3) [Figure 60100-6] and nut.
60-100-3
863 Bobcat Loader
Service Manual
SEAT BAR SENSOR (CONT'D)
When the power light is illuminated, move the toggle
switch (Item 2) [Figure 60-100-9] on the sensor tester to
the Present position.
BICS™ Circuit Test
Figure 60-100-8
NOTE: The sensor test light (Item 3) [Figure 60-100-9]
is only activated by the seat bar. It will be off
with the seat bar up or on with the seat bar
down.
Figure 60-100-10
1
N-18463
1
Use Sensor Testers (MEL1428) and seat bar sensor
tester adapter (MEL1567) for the following procedure:
N-18409
Connect the seat bar sensor tester adapter MEL1567 to
the sensor tester.
Disconnect the seat bar sensor connector (Item 1)
[Figure 60-100-8].
The BICS™ seat bar indicator light (Item 1) [Figure 60100-10] should illuminate.
Figure 60-100-11
Figure 60-100-9
3
1
2
1
P-4699
P-4703
Connect Sensor Tester (Item 1) [Figure 60-100-9] inline
to the seat bar sensor connectors.
Turn the key to the ON position. DO NOT START THE
ENGINE.
If there is no power light on the sensor tester, check the
tester or wiring harness.
Move the toggle switch (Item 1) [Figure 60-100-11] on
the sensor tester to the Absent position.
The Seat Bar light (Item 1) [Figure 60-100-10] should go
off.
If the above test fails, there is a problem with the Bobcat
controller or the wiring harness.
60-100-4
863 Bobcat Loader
Service Manual
TRACTION LOCK
WARNING
Troubleshooting Chart
The following troubleshooting chart is provided for
assistance in locating and correcting BICS™ system
problems. It is recommended that these procedures be
done by authorized Bobcat Service Personnel only.
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM
SOLUTION #
Traction lock stays engaged.
Intermittent activation of traction lock.
1, 2, 3, 4, 5, 6, 7
8, 9, 10
SOLUTION SUGGESTIONS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Make sure brake pedal is not engaged.
Maneuver loader to allow brake discs to move and remove pressure on the brake wedge so it
can retract.
If all lights indicate the brake should be released, but it doesn’t, check the brake 25 amp fuse.
When checking fuse, also check other fuses. Check the fuse block for correct orientation and
location of fuses. (See Electrical System Information, Page 60-01.)
To test the solenoid, the pull coil should be .4 to .5 ohms and the hold coil 10.5 to 11.0 ohms .
Check brake solenoid and cover mounting hardware for the correct torque.
Remove brake cover and check wedges for binding in the wedge guides.
Check wire connections for loose connector body.
Check for loose or bent pins in connectors.
Check for loose spade connectors in fuse holder.
60-110-1
863 Bobcat Loader
Service Manual
TRACTION LOCK (CONT’D)
Figure 60-110-2
Removal And Installation (Single Speed)
WARNING
2
1
AVOID INJURY OR DEATH
Do not modify the electrical wiring connected to the
traction lock solenoid or any part of the traction lock
system. The traction lock provides the locking
function of the parking brake. Service work on the
traction lock system should only be performed by a
qualified technician. Use only genuine Bobcat
Company parts if repair is necessary.
3
N-19724
W-2165-0100
Remove the electric solenoid and bracket assembly from
the chaincase cover (Item 1) [Figure 60-110-2].
Figure 60-110-1
Remove the traction lock assembly (Item 2) [Figure 60110-2] from the chaincase.
The spring and collar (Item 3) [Figure 60-110-2] may
stay with the shaft when the electric solenoid and bracket
are removed from the chaincase.
Figure 60-110-3
1
2
1
4
N-19618
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
3
Remove the two mounting bolts (Item 1) [Figure 60-1101] from the electric solenoid mounting bracket.
Installation: Tighten the mounting bolts to 25-28 ft.-lbs.
(34-38 Nm) torque.
N-20148
Remove and inspect the compression spring (Item 1)
[Figure 60-110-3], collar (Item 2) [Figure 60-110-3] and
snap ring (Item 3) [Figure 60-110-3] for wear or damage.
Replace if necessary.
Installation: Install the snap ring (Item 3) [Figure 60110-3] on the traction lock shaft (Item 4) [Figure 60-1103]. Install the collar (Item 2) [Figure 60-110-3] and
compression spring (Item 1) [Figure 60-110-3]
60-110-2
863 Bobcat Loader
Service Manual
TRACTION LOCK (CONT’D)
Description Of The Control System (Two-Speed)
Removal And Installation (Single Speed) (Cont’d)
The Traction Lock Control System will lock the traction
drive system when the engine stops. The Traction Lock
Control System is incorporated into the BICS™ System.
IMPORTANT
Inspecting The Control System (Two-Speed)
Failure to use LOCTITE may allow the traction lock
assembly to loosen up which can cause damage to
the traction lock system.
Figure 60-110-5
I-2090-1095
Figure 60-110-4
4
2
2
3
1
1
N-18409
5
N-20211
Remove the shaft mounting bolt (Item 1) [Figure 60-1104], spring (Item 2) [Figure 60-110-4] and washer (Item 3)
[Figure 60-110-4] from the assembly shaft (Item 4)
[Figure 60-110-4]. Remove the wedge (Item 5) [Figure
60-110-4] and inspect all; parts for damage or wear.
Replace if necessary.
Installation: Thoroughly clean and dry the shaft
mounting bolt (Item 1) [Figure 60-110-4], the shaft (Item
4) [Figure 60-110-4] and wedge (Item 5) [Figure 60110-4]. Use LOCTITE 242 when assembling these parts
to the traction lock assembly.
1
2
3
4
B-15551G
Fasten the seat belt, disengage the parking brake pedal,
press the PRESS TO OPERATE LOADER Button (Item
1) [Figure 60-110-5] and raise the Seat Bar fully. Move
the steering levers slowly forward and backward. The
TRACTION lock (Item 2) [Figure 60-110-5] should be
engaged. Lower the Seat Bar. Press the PRESS TO
OPERATE LOADER Button (Item 1) [Figure 60-110-5].
Engage the parking brake pedal and move the steering
levers slowly forward and backward. The TRACTION
lock should be engaged.
NOTE: *The TRACTION light on the left instrument
panel will remain OFF until the engine is
started, the PRESS TO OPERATE LOADER
Button is pressed and the parking brake is
disengaged.
60-110-3
863 Bobcat Loader
Service Manual
TRACTION LOCK (CONT’D)
Inspecting The Control System (Two-Speed) (Cont’d)
Figure 60-110-6
1
P-9440
Check the wire connections at the engine speed sensor
(Item 1) [Figure 60-110-6].
NOTE: When the Traction Lock Override Button is
activated, the Traction Lock Override Control
System will NOT engage the Traction Lock if
the engine stops.
60-110-4
863 Bobcat Loader
Service Manual
ADVANCED HAND CONTROL SYSTEM (AHC)
Figure 60-120-3
Components Identification
Figure 60-120-1
1
1
P-13797
2
ACH/PWM Controller (Item 1) [Figure 60-120-3].
N-17774
N-17783
Figure 60-120-4
Steering Lever/Handle Control (Item 1) [Figure 60-1201].
1
Handle Control Unit (Item 2) [Figure 60-120-1] (both
sides).
Figure 60-120-2
1
P-28360A
ACH error indicator (Item 1) [Figure 60-120-4].
NOTE: The AHC icon will illuminate when an error
occurs. The error is stored as a service code.
(See Contents, Page 60-01.)
1
N-19112
Control Valve Actuators (Item 1) [Figure 60-120-2].
60-120-1
863 Bobcat Loader
Service Manual
ADVANCED HAND CONTROL SYSTEM (ACH) (CONT’D)
Trouble shooting Guide
The Advanced Hand Control System (AHC) has a built-in diagnostic function which uses an icon on the right instrument
panel to indicate the condition of the AHC System. The system also records the alarm condition as a service code.
The control module continually checks the system in the order listed. The checks start with the lift handle controller and
then the lift actuator. If no problems are present, it will then check the tilt handle controller and the tilt actuator. The system
will stop its check at the first problem and then luminate the icon.
The system starts its diagnostics and calibration when the ignition key is turned ON.
The following list shows the probable causes when the icon is luminated.
Advanced
Hand
Controls
General
Warning
Fuel Level
System
Voltage
Engine Oil
Pressure
Engine
Coolant
Temperature
Air Filter
B-16640
Attachment
Control
Device
Two Speed
Glow Plugs
Seat Belt
Hydraulic
Charge
Pressure
Hydraulic Oil
Temperature
Hydraulic
Filter
Advanced Hand Controls
Errors - lights solid with 3 beeps
32-31 - Tilt actuator fault
32-32 - Tilt actuator wiring fault
32-33 - Tilt handle wiring fault
32-34 - Tilt actuator not calibrated
32-35 - Tilt handle not calibrated
32-36 - Lift actuator fault
32-37 - Lift actuator wiring fault
32-38 - Lift handle wiring fault
32-39 - Lift actuator not calibrated
32-40 - Lift handle not calibrated
32-41 - Invalid Frequency
To see what error occurred. Check the service code on the left instrument panel. (See DELUXE INSTRUMENTATION
SERVICE CODES on Page 60-80-1.)
60-120-2
863 Bobcat Loader
Service Manual
ADVANCED HAND CONTROL SYSTEM (AHC) (CONT’D)
Parts Identification
C-428
C-430
C-431
C-429
TS-1957
P/N
PIN
C-430
DESCRIPTION
CONNECTOR, METRI-PACK
P/N
PIN
C-428
DESCRIPTION
CONNECTOR, 8 WAY PLUG (LIFT) (TOP
ACTUATOR)
Orange/White
A
SWITCHED BATTERY POWER
Black
B
GROUND
Dk. Blue/White
1
LOW REFERENCE TO RESISTIVE INPUTS
MALE, 10-WAY
Lt. Green/White
2
SIGNAL FROM LIFT ACTUATOR
SIGNAL FROM LIFT CONTROL
Dk. Blue
C-431
Brown/Dk
Green
A
Purple/Yellow
B
FLOAT SWITCH ON/OFF
Pink/Dk. Green
C
SIGNAL FROM TILT CONTROL
HANDLE INPUT
HANDLE INPUT
Brown/White
Brown/Yellow
3
HIGH REFERENCE TO RESISTIVE INPUTS
4
OPEN
5
LIFT SPOOL ACTUATOR MOTOR (-)
6
OPEN
7
OPEN
8
LIFT SPOOL ACTUATOR MOTOR (+)
Dk. Blue
D
TILT HIGH REFERENCE TO
RESISTIVE INPUTS
Dk. Blue/White
E
TILT LOW REFERENCE TO
RESISTIVE INPUTS
Dk. Blue/White
1
LOW REFERENCE TO RESISTIVE INPUTS
LIFT LOW REFERENCE TO
RESISTIVE INPUTS
Lt. Blue/White
2
SIGNAL FROM TILT ACTUATOR
Dk. Blue
Dk Blue/White
Dk. Blue
Purple/White
Purple/Red
F
G
H
J
K
C-429
CONNECTOR, 8 WAY PLUG (TILT) (BOTTOM ACTUATOR)
3
HIGH REFERENCE TO RESISTIVE INPUTS
4
OPEN
5
TILT SPOOL ACTUATOR MOTOR (-)
BICS INPUT STATUS
6
OPEN
AHC STATUS OUTPUT
7
OPEN
8
TILT SPOOL ACTUATOR MOTOR (+)
LIFT HIGH REFERENCE To
RESISTIVE INPUTS
OPEN
Pink/White
Pink/Yellow
60-120-3
863 Bobcat Loader
Service Manual
ADVANCE HAND CONTROL SYSTEM (AHC)
(CONT’D)
Figure 60-120-6
AHC Controller Removal And Installation
This procedure may be done with the lift arms in the
raised or lowered position, if lift arms are raised, install
the approved lift arm support device. (See LIFT ARM
SUPPORT DEVICE on Page 10-20-1.)
WARNING
1
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
N-23236
Disconnect the wiring harness connectors from the
controller (Item 1) [Figure 60-120-6].
Figure 60-120-7
Figure 60-120-5
1
2
3
1
N-23235
N-23234
Loosen the three bottom bolts (Item 1) [Figure 60-1205].
Remove the four mounting bolts (Item 1) [Figure 60-1207] from the controller.
Remove the two top bolts (Item 2) [Figure 60-120-5], lift
and remove the right front panel (Item 3)[Figure 60-1205] from the loader.
60-120-4
863 Bobcat Loader
Service Manual
ADVANCED HAND CONTROL SYSTEM (AHC)
(CONT’D)
Figure 60-120-10
AHC Controller Removal And Installation (Cont’d)
Figure 60-120-8
1
1
1
P-13732
P-13725
Remove the wedge (Item 1) [Figure 60-120-10] from the
connector.
N-23237
Figure 60-120-11
Remove the controller from the loader (Item 1) [Figure
60-120-8].
Handle Control Unit Connector
3
Figure 60-120-9
2
1
1
P-13733
With a pointed tool, lift the tab (Item 1) [Figure 60-12011] and pull the wire from the connector.
1
Assembly: Install the wires into the connector as listed
below [Figure 60-120-11]:
N-17392
The wire connector (Item 1) [Figure 60-120-9] can be
removed from the handle control unit wires, use the
following procedure.
60-120-5
1 - Terminal - Red
2 - Terminal - Black
3 - Terminal - Green
863 Bobcat Loader
Service Manual
ADVANCED HAND CONTROL SYSTEM (AHC)
(CONT’D)
Figure 60-120-13
Switch Handle Removal And Installation
Remove the handle control unit from the steering lever.
(See Control Handle Removal And Installation on Page
50-112-8.)
Figure 60-120-12
1
1
P-13732
P-13725
Remove the wedge (Item 1) [Figure 60-120-13] from the
connector.
Figure 60-120-14
3
1
2
1
1
P-13735
N-23243
To remove the switch handle the connector (Item 1)
[Figure 60-120-12] must be removed from the wires, use
the following procedure.
Using a pointed tool, press down on the tab (Item 1)
[Figure 60-120-14] and pull the wire from the connector.
Installation: Install the wires into the conductor as listed
below [Figure 60-120-14]:
Right Control Lever Switch Handle
1 - Terminal - Pink/Red
2 - Terminal - Pink/Black
3 - Terminal - Pink/Green
Left Control Lever Switch Handle
1 - Terminal - Brown/Red
2 - Terminal - Brown/Black
3 - Terminal - Brown Green
60-120-6
863 Bobcat Loader
Service Manual
ADVANCED HAND CONTROL SYSTEM (AHC)
(CONT’D)
Installation: The wire colors of the control lever harness
are as follows:
Switch Handle Removal And Installation (Cont’d)
Right Switch Handle
Figure 60-120-15
1
Ten-Pin Connector
A - Terminal - Orange
B - Terminal - White
C - Terminal - White/Black
D - Terminal - White/Red
E - Terminal - Dk. Green
F - Terminal - White/Lt. Green
G - Terminal - Blank
H - Terminal - Lt. Green
J - Terminal - Yellow
K - Terminal - Blank
2
Three-Pin Connector
A - Terminal - Pink/Red
B - Terminal - Pink/Black
C - Terminal - Pink/Lt. Green
N-23244
Disconnect the right switch handle connectors (Items 1 &
2) [Figure 60-120-15] from the loader wiring harness
connectors.
Left Switch Handle
Figure 60-120-16
4
1
2
Ten-Pin Connector
A - Terminal - Orange
B - Terminal - Dk. Blue
C - Terminal - White
D - Terminal - Blank
E - Terminal - Blank
F - Terminal - Yellow/Red
G - Terminal - Yellow/Green
H - Terminal - Blank
J - Terminal - Blank
K - Terminal - Blank
Three-Pin Connector
A - Terminal - Brown/Red
B - Terminal - Brown/Black
C - Terminal - Brown/Lt. Green
3
Two-Pin Connector
A - Terminal - Orange/Blue
B - Terminal - Orange/White
N-23245
Disconnect the left switch handle connectors (Items 1, 2,
3 & 4) [Figure 60-120-16] from the loader wiring harness
connectors.
Remove the connector locks and connectors from the
wires the remove the switch handle from the control
handle.
60-120-7
Five-Pin Connector
A - Terminal - Dk. Green
B - Terminal - Brown
C - Terminal - Blank
D - Terminal - Yellow
E - Terminal - Blank
863 Bobcat Loader
Service Manual
ADVANCED HAND CONTROL SYSTEM (AHC)
(CONT’D)
Figure 60-120-19
Switch Handle Removal And Installation (Cont’d)
Figure 60-120-17
1
2
2
N-17471
1
Installation: When installing the switch handle and
wiring harness assembly into the control handle, route
the harness (Item 1) [Figure 60-120-19] to assure proper
return of the control handle to neutral position.
N-17382
Roll the grip handle cover (Item 1) [Figure 60-120-17]
down.
Using a small screwdriver, lift the handle tabs (Item 2)
[Figure 60-120-17] and slightly rotate the switch handle.
Figure 60-120-18
1
N-17383
Pull the switch handle and wiring harness assembly (Item
1) [Figure 60-120-18] from the steering lever.
60-120-8
863 Bobcat Loader
Service Manual
ADVANCED HAND CONTROL SYSTEM (AHC)
(CONT’D)
Figure 60-120-22
Actuators Disassembly And Assembly
Remove the actuator. (See Actuator Removal And
Installation (In Loader) on Page 20-41-1.)
2
Figure 60-120-20
1
1
N-17742
N-17741
Check the actuator wiring harness connector (Item 1)
[Figure 60-120-22] and replace if broken.
Installation: Install the wires into the connector as listed
on the next page. The terminal numbers are written in
the back of the connector (Item 2) [Figure 60-120-22].
N-18940
Check the mounting block (Item 1) [Figure 60-120-20]
and bolts for wear and replace as needed.
Figure 60-120-21
3
2
1
N-18941
Remove the rubber strap (Item 1) [Figure 60-120-21]
from the mounting shaft collar (Item 2) [Figure 60-12021].
Remove the mounting bracket (Item 3) [Figure 60-12021].
Check the rubber strap, mounting shaft collar and
mounting bracket for wear and replace as needed.
60-120-9
863 Bobcat Loader
Service Manual
ADVANCED HAND CONTROL SYSTEM (AHC)
(CONT’D)
Actuators Disassembly And Assembly (Cont’d)
Lift and Tilt Actuator
1 - Terminal - Black/Green - Larger diameter wire (16
gauge)
2 - Terminal - Green - Larger diameter wire (16
gauge)
3 - Terminal - Red/Green - Larger diameter wire (16
gauge)
4 - Terminal - Open
5 - Terminal - Red - Smaller diameter wire (18 gauge)
6 - Terminal - Open
7 - Terminal - Open
8 - Terminal - Black - Smaller diameter wire (18
gauge)
60-120-10
863 Bobcat Loader
Service Manual
ADVANCED HAND CONTROL SYSTEM (AHC) (W/
PUSH BUTTON FLOAT)
Figure 60-121-3
Components Identification
Figure 60-121-1
1
1
P-13797
2
ACH controller (Item 1) [Figure 60-121-3].
P-16536
Figure 60-121-4
N-22797
Steering Lever/Control Handle (Item 1) [Figure 60-1211].
Handle Control Unit (Item 2) [Figure 60-121-1].
1
Figure 60-121-2
1
P-28360A
ACS error indicator (Item 1) [Figure 60-121-4].
NOTE: The ACS icon will illuminate when an error
occurs. The error is stored as a service code.
(See Contents, Page 60-01.)
1
N-19112
Control Valve Actuators (Item 1) [Figure 60-121-2].
60-121-1
863,863H Bobcat Loader
Service Manual
(ADVANCED HAND CONTROL SYSTEM (ACH) (W/PUSH BUTTON FLOAT) (CONT’D)
Trouble shooting Guide
The Advanced Hand Control System (AHC) has a built-in diagnostic function which uses an icon on the right instrument
panel to indicate the condition of the AHC System. The system also records the alarm condition as a service code.
The control module continually checks the system in the order listed. The checks start with the lift handle controller and
then the lift actuator. If no problems are present, it will then check the tilt handle controller and the tilt actuator. The system
will stop its check at the first problem and then luminate the icon.
The system starts its diagnostics and calibration when the ignition key is turned ON.
The following list shows the probable causes when the icon is luminated.
Advanced
Hand
Controls
General
Warning
Fuel Level
System
Voltage
Engine Oil
Pressure
Engine
Coolant
Temperature
Air Filter
B-16640A
Attachment
Control
Device
Two Speed
Glow Plugs
Seat Belt
Hydraulic
Charge
Pressure
Hydraulic Oil
Temperature
Hydraulic
Filter
Advanced Hand Controls
B-16299
Errors - lights solid with 3 beeps
32-31 - Tilt actuator fault
32-32 - Tilt actuator wiring fault
32-33 - Tilt handle wiring fault
32-34 - Tilt actuator not calibrated
32-35 - Tilt handle not calibrated
32-36 - Lift actuator fault
32-37 - Lift actuator wiring fault
32-38 - Lift handle wiring fault
32-39 - Lift actuator not calibrated
32-40 - Lift handle not calibrated
32-41 - Invalid Frequency
To see what error occurred. Check the service code on the left instrument panel. (See DELUXE INSTRUMENTATION
SERVICE CODES on Page 60-80-1.)
60-121-2
863,863H Bobcat Loader
Service Manual
ADVANCED HAND CONTROL SYSTEM (AHC) (W/PUSH BUTTON FLOAT ) (CONT’D)
Controller Connector and Wire Identification
C-428
C-430
C-431
C-429
TS-1957
P/N
PIN
C-430
DESCRIPTION
CONNECTOR, METRI-PACK
P/N
PIN
C-428
DESCRIPTION
CONNECTOR, 8 WAY PLUG (LIFT) (TOP
ACTUATOR)
Orange/White
A
SWITCHED BATTERY POWER
Black
B
GROUND
Dk. Blue/White
1
LOW REFERENCE TO RESISTIVE INPUTS
MALE, 10-WAY
Lt. Green/White
2
SIGNAL FROM LIFT ACTUATOR
SIGNAL FROM LIFT CONTROL
Dk. Blue
C-431
Brown/Dk
Green
A
Purple/Yellow
B
FLOAT SWITCH ON/OFF
Pink/Dk. Green
C
SIGNAL FROM TILT CONTROL
HANDLE INPUT
HANDLE INPUT
Brown/White
Brown/Yellow
3
HIGH REFERENCE TO RESISTIVE INPUTS
4
OPEN
5
LIFT SPOOL ACTUATOR MOTOR (-)
6
OPEN
7
OPEN
8
LIFT SPOOL ACTUATOR MOTOR (+)
Dk. Blue
D
TILT HIGH REFERENCE TO
RESISTIVE INPUTS
C-429
Dk. Blue/White
E
TILT LOW REFERENCE TO
RESISTIVE INPUTS
Dk. Blue/White
1
LOW REFERENCE TO RESISTIVE INPUTS
LIFT LOW REFERENCE TO
RESISTIVE INPUTS
Lt. Blue/White
2
SIGNAL FROM TILT ACTUATOR
Dk. Blue
Dk Blue/White
Dk. Blue
Purple/White
Purple/Red
F
G
H
J
K
CONNECTOR, 8 WAY PLUG (TILT) (BOTTOM ACTUATOR)
3
HIGH REFERENCE TO RESISTIVE INPUTS
4
OPEN
5
TILT SPOOL ACTUATOR MOTOR (-)
BICS INPUT STATUS
6
OPEN
AHC STATUS OUTPUT
7
OPEN
8
TILT SPOOL ACTUATOR MOTOR (+)
LIFT HIGH REFERENCE To
RESISTIVE INPUTS
OPEN
Pink/White
Pink/Yellow
60-121-3
863,863H Bobcat Loader
Service Manual
ADVANCE HAND CONTROL SYSTEM (AHC) (W/PUSH
BUTTON FLOAT) (CONT’D)
Figure 60-121-6
AHC Controller Removal And Installation
This procedure may be done with the lift arms in the
raised or lowered position, if lift arms are raised, install
the approved lift arm support device. (See LIFT ARM
SUPPORT DEVICE on Page 10-20-1.)
WARNING
1
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
N-23236
Disconnect the wiring harness connectors from the
controller (Item 1) [Figure 60-121-6].
Figure 60-121-7
Figure 60-121-5
1
2
3
1
N-23235
N-23234
Loosen the three bottom bolts (Item 1) [Figure 60-1215].
Remove the four mounting bolts (Item 1) [Figure 60-1217] from the controller.
Remove the two top bolts (Item 2) [Figure 60-121-5], lift
and remove the right front panel (Item 3)[Figure 60-1215] from the loader.
60-121-4
863,863H Bobcat Loader
Service Manual
Figure 60-121-9
ADVANCED HAND CONTROL SYSTEM (AHC) (W/
PUSH BUTTON FLOAT) (CONT’D)
AHC Controller Removal And Installation (Cont’d)
Figure 60-121-8
1
1
P-16581
Lift the boot cover (Item 1) [Figure 60-121-9].
Figure 60-121-10
N-23237
Remove the controller from the loader (Item 1) [Figure
60-121-8].
Handle Control Unit Removal And Installation
This procedure may be done with the lift arms in the
raised or lowered position, if lift arms are raised, install
the approved lift arm support device. (See LIFT ARM
SUPPORT DEVICE on Page 10-20-1.)
1
WARNING
P-18142
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
Disconnect the harness connector (Item 1) [Figure 60121-10] from the handle control unit connector.
W-2059-0598
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
60-121-5
863,863H Bobcat Loader
Service Manual
ADVANCED HAND CONTROL SYSTEM (AHC) (W/
PUSH BUTTON FLOAT) (CONT’D)
Figure 60-121-13
Handle Control Unit Removal And Installation
Figure 60-121-11
2
1
1
P-16580
P-18138
Remove the two plastic spacers (Item 1) [Figure 60-12113] and the metal spacer (Item 2) [Figure 60-121-13]
from the control unit.
P-18143
Remove the handle control unit connector (Item 1)
[Figure 60-121-11] from the clip.
Figure 60-121-14
NOTE: Pry out with a small screwdriver and push the
connector down.
Figure 60-121-12
1
1
P-16574
1
Remove the top mounting bolt (Item 1) [Figure 60-12114] from the control unit.
P-18136
Use an allen wrench, remove one of the two mounting
screws (Item 1) [Figure 60-121-12] from the control unit.
60-121-6
863,863H Bobcat Loader
Service Manual
ADVANCED HAND CONTROL SYSTEM (AHC) (W/
PUSH BUTTON FLOAT) (CONT’D)
Handle Control Unit Connector
Figure 60-121-17
Handle Control Unit Removal And Installation
Figure 60-121-15
3
1
1
3
P-16578
3
2
P-16576
Remove the handle control unit (Item 1) [Figure 60-12115] from the handle assembly.
The wire connector (Item 1) [Figure 60-121-17] can be
removed from the handle control unit wires, use the
following procedure.
Figure 60-121-18
NOTE: The sensor (Item 1) [Figure 60-121-15] can only
be replaced as a complete assembly.
Check the spacers (Item 2) [Figure 60-121-15] and
screws (Item 3) [Figure 60-121-15] and replace as
needed.
Figure 60-121-16
1
1
P-13725
1
P-13732
Remove the wedge (Items 1) [Figure 60-121-18] from
the connector.
P-18141
Installation: When installing the control unit into the
control handle, check the routing of the switch handle
wire harness (Item 1) [Figure 60-121-16] to assure
proper return of the control handle to neutral.
60-121-7
863,863H Bobcat Loader
Service Manual
ADVANCED HAND CONTROL SYSTEM (AHC) (W/
PUSH BUTTON FLOAT) (CONT’D)
Figure 60-121-21
Handle Control Unit Connector (Cont’d)
Figure 60-121-19
1
3
2
1
1
1
P-13725
P-13732
Remove the wedge (Item 1) [Figure 60-121-21] from the
connector.
P-13733
Figure 60-121-22
With a pointed tool, lift the tab (Item 1) [Figure 60-12119] and pull the wire from the connector.
Assembly: Install the wires into the connector as listed
below [Figure 60-121-19]:
1 - Terminal - Red
2 - Terminal - Black
3 - Terminal - Green
3
2
1
Switch Handle Removal And Installation
1
Remove the handle control unit from the steering lever.
(See Control Handle Removal And Installation on Page
50-112-8.)
P-13735
Figure 60-121-20
Using a pointed tool, press down on the tab (Item 1)
[Figure 60-121-22] and pull the wire from the connector.
Installation: Install the wires into the connector as listed
below [Figure 60-121-22]:
Right Steering Lever Switch Handle
1 - Terminal - Pink/Red
2 - Terminal - Pink/Black
3 - Terminal - Pink/Green
Left Steering Lever Switch Handle
1 - Terminal - Red/White
2 - Terminal - Black/White
3 - Terminal - Purple/White
1
P-18137
To remove the switch handle the connector (Item 1)
[Figure 60-121-20] must be removed from the wires, use
the following procedure:
60-121-8
863,863H Bobcat Loader
Service Manual
ADVANCED HAND CONTROL SYSTEM (AHC) (W/
PUSH BUTTON FLOAT) (CONT’D)
Installation: The wire colors of the control lever harness
are as follows:
Switch Handle Removal And Installation (Cont’d)
Right Switch Handle
Figure 60-121-23
Ten-Pin Connector
A - Terminal - Orange
B - Terminal - White
C - Terminal - White/Black
D - Terminal - White/Red
E - Terminal - Dk. Green
F - Terminal - White/Lt. Green
G - Terminal - Blank
H - Terminal - Lt. Green
J - Terminal - Yellow
K - Terminal Blank
1
2
Three-pin connector
A - Terminal - Pink/Red
B - Terminal - Pink/Blank
C - Terminal - Pink/Lt. Green
N-23244
Left Switch Handle
Figure 60-121-24
Ten-Pin Connector
A - Terminal- Orange
B - Terminal - Dk. Blue
C - Terminal - White
D - Terminal - Purple
E - Terminal - Blank
F - Terminal - Tan
G - Terminal - Pink
H - Terminal - Blank
J - Terminal - Blank
K - Terminal Blank
4
1
2
3
Three-Pin Connector
A - Terminal - Red/White
B - Terminal - Black/White
C - Terminal - Purple/White
N-23245
Disconnect the right switch handle connectors (Items 1 &
2) [Figure 60-121-23] from the loader wiring harness.
Disconnect the left switch handle connectors (Items 1, 2,
3 & 4) [Figure 60-121-24] from loader wiring harness
connectors.
Remove the connector locks and connectors from the
wires to remove the switch handle from the steering
handle.
Two-Pin Connector
A - Terminal - Black
B - Terminal - Black
Five-Pin Connector
A - Terminal - Dk. Green
B - Terminal - Brown
C - Terminal - Blank
D - Terminal -Yellow
E - Terminal - Blank
60-121-9
863,863H Bobcat Loader
Service Manual
ADVANCED HAND CONTROL SYSTEM (AHC) (PUSH
BUTTON FLOAT (CONT’D)
Figure 60-121-27
Switch Handle Removal And Installation (Cont’d)
Figure 60-121-25
1
2
2
P-18139
1
Installation: When installing the switch handle and
wiring harness assembly into the steering handle, route
the harness (Item 1) [Figure 60-121-27] to assure proper
return of the control handle to neutral position.
N-22783
Roll the pistol grip handle cover (Item 1) [Figure 60-12125] down.
Using a small screwdriver, lift the handle tabs (Item 2)
[Figure 60-121-25] and slightly rotate the switch handle.
Figure 60-121-26
1
N-22784
Pull the switch handle and wiring harness assembly (Item
1) [Figure 60-121-26] from the control lever.
60-121-10
863,863H Bobcat Loader
Service Manual
ADVANCE HAND CONTROL SYSTEM (AHC) (W/PUSH
BUTTON FLOAT) (CONT’D)
Figure 60-121-30
Actuators Disassembly And Assembly
Remove the actuator. (See Actuator Removal And
Installation (In Loader) on Page 20-41-1.)
2
Figure 60-121-28
1
1
N-17742
N-17741
Check the actuator wiring harness connector (Item 1)
[Figure 60-121-30] and replace if broken.
Installation: Install the wires into the connector as listed
below. The terminal numbers are written on the back of
the connector (Item 2) [Figure 60-121-30].
N-18940
Check the mounting block (Item 1) [Figure 60-121-28]
and bolts for wear and replace as needed.
Figure 60-121-29
3
2
1
N-18941
Remove the rubber strap (Item 1) [Figure 60-121-29]
from the mounting shaft collar (Item 2) [Figure 60-12129].
Remove the mounting bracket (Item 3) [Figure 60-12129].
Check the rubber strap, mounting shaft collar and
mounting bracket for wear and replace as needed.
60-121-11
863,863H Bobcat Loader
Service Manual
ADVANCED HAND CONTROL SYSTEM (AHC) (W/
PUSH BUTTON FLOAT) (CONT’D)
Actuators Disassembly And Assembly (Cont’d)
Lift and Tilt Actuator
1 - Terminal - Black/Green - Larger diameter wire (16
gauge)
2 - Terminal -Green - Larger diameter wire (16 gauge)
3 - Terminal - Red/Green - Larger diameter wire (16
gauge)
4 - Terminal - Open
5 - Terminal - Red - Smaller diameter wire (18 gauge)
6 - Terminal - Open
7 - Terminal - Open
8 - Terminal - Black - Smaller diameter wire (18
gauge)
60-121-12
863,863H Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) ADVANCED
HAND CONTROL
Figure 60-122-3
Components Identification
Figure 60-122-1
1
2
1
P-21767
ACS Controller (Item 1) [Figure 60-122-3].
NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Calibration Of The ACS System on Page 60123-15.)
P-24909
P-16536
Control Handle (Item1) [Figure 60-122-1].
Handle Sensor (Item 2) [Figure 60-122-1].
NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Calibration Of The ACS System on Page 60123-15.)
Figure 60-122-4
1
Figure 60-122-2
1
P-21769A
ACS error indicator (Item 1) [Figure 60-122-4].
NOTE: The ACS icon will illuminate when an error
occurs. The error is stored as a service code.
(See DELUXE INSTRUMENTATION SERVICE
CODES on Page 60-80-1.)
1
P-24203
Control Valve Actuators (Item 1) [Figure 60-122-2].
NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Calibration Of The ACS System on Page 60123-15.)
60-122-1
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) ADVANCED
HAND CONTROL (CONT'D)
Troubleshooting Guide
The Advanced Control System (ACS) has a built-in diagnostic function which uses an icon on the right instrument panel
to indicate the condition of the ACS SYSTEM. The system also records the alarm condition as a service code.
The control module continually checks the system in the order listed. The checks start with the lift handle sensor and then
the lift actuator. If no problems are present, it will then check the tilt handle sensor and the tilt actuator. The system will
stop its check at the first problem and then luminate the icon.
The system starts its diagnostics and calibration when the ignition key is turned ON.
The following list shows the probable causes when the icon is luminated.
Advanced
Control
System
Attachment
Control
Device
General
Warning
Fuel Level
Two Speed
Glow Plugs
System
Voltage
Seatbelt
Engine Oil
Pressure
Hydraulic
Charge
Pressure
Engine
Coolant
Temperature
Hydraulic Oil
Temperature
Air Filter
Hydraulic
Filter
Advanced Control System
Errors - lights soild with 3 beeps
32-04 - ACS in error
32-23 - ACS not calibrated
32-31 - Tilt actuator fault
32-34 - Tilt actuator not calibrated
32-35 - Tilt handle/pedal not calibrated
32-36 - Lift actuator fault
32-39 - Lift actuator not calibrated
32-40 - Lift handle/pedal not calibrated
32-49 - Lift actuator short to ground
32-50 - Tilt actuator short to ground
32-51 - Lift actuator short to battery
32-52 - Tilt actuator short to battery
32-53 - Lift handle/pedal short to ground
32-54 - Tilt handle/pedal short to ground
32-55 - Lift handle/pedal short to battery
32-56 - Tilt handle/pedal short to battery
32-57 - Lift actuator reduced performance
32-58 - Tilt actuator reduced performance
32-59 - Lift actuator wrong direction
32-60 - Tilt actuator wrong direction
32-61 - Handle lock short to ground
32-62 - Handle lock short to battery
32-63 - Pedal lock short to ground
32-64 - Pedal lock short to battery
32-65 - Sensor supply voltage out of range
32-66 - Battery out of range
32-67 - Switch flipped while operating
To see what error occurred. Check the service code on the left instrument panel. (See DELUXE INSTRUMENTATION
SERVICE CODES on Page 60-80-1.)
60-122-2
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) ADVANCED
HAND CONTROL (CONT'D)
Controller, Connector And Wire Identification
G
F
H
J
K
E
D
A
B
C
J3
J1
F
F
E
D
C
PIN
J1
E
D
G
H
A
B
C
J2
B
A
J3
J2
DESCRIPTION
P/N
CONNECTOR, METRI-PACK
J3
A
5V HALL EFFECT SUPPLY
Red
Orange
B
SWITCHED AHC POWER
Green
c
HAND/FOOT INPUT
Purple
D
CAN SIGNAL HIGH AHC
Purple
E
Purple
F
Black
G
Black
H
CONNECTOR, METRI-PACK
A
OPEN
B
OPEN
C
OPEN
D
OPEN
Orange
J2
J2
J1
J1
P/N
H
J
K
G
J3
PIN
DESCRIPTION
CONNECTOR, METRI-PACK
A
TILT ACTUATOR FORWARD
Red/White
B
UNSWITCHED AHC POWER
Red/White
C
UNSWITCHED AHC POWER
Black
D
LIFT ACTUATOR REVERSE
CAN SIGNAL LOW AHC
Green
E
HANDLE LOCK POWER
CAN SHEILD AHC
Red
F
LIFT ACTUATOR FORWARD
AHC GROUND
Green
G
PEDAL LOCK POWER
AHC GROUND
Black
H
AHC GROUND
Black
J
AHC GROUND
Black
K
TILT ACTUATOR REVERSE
Green
E
TILT SPOOL SIGNAL
Green
F
LIFT HANDLE SIGNAL
Green
G
TILT HANDLE SIGNAL
Green
H
LIFT SPOOL SIGNAL
Green
J
LIFT PEDAL SIGNAL
Green
K
TILT PEDAL SIGNAL
60-122-3
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) ADVANCED
HAND CONTROL (CONT'D)
Figure 60-122-7
ACS Controller Removal And Installation
Figure 60-122-5
1
1
P-21840
Remove the two mounting bolts (Item 1) [Figure 60-1227] from the controller.
P-21839
Remove the controller from the loader.
Loosen the bottom bolts and remove the top bolt.
Remove the right front panel (Item 1) [Figure 60-122-5]
from the loader.
NOTE: The calibration procedure must be followed
when replacing handle sensor, actuator or
ACS Controller. (See Calibration Of The ACS
System on Page 60-123-15.)
Figure 60-122-6
1
P-21843
Disconnect the wiring harness connectors (Item 1)
[Figure 60-122-6] from the controller.
60-122-4
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) ADVANCED
HAND CONTROL (CONT'D)
Figure 60-122-10
Handle Sensor Connector
Figure 60-122-8
1
1
1
2
3
P13733
With a pointed tool, lift the tab (Item 1) [Figure 60-12210] and pull the wire from the connector.
P16578
The wire connector (Item 1) [Figure 60-122-8] can be
removed from the handle sensor wires, use the following
procedure.
Assembly: Install the wires into the connector as listed
below [Figure 60-122-10]:
Figure 60-122-9
1-Terminal - Red
2-Terminal - Black
3-Terminal - Green
1
1
P13725
P13732
Remove the wedge (Item 1) [Figure 60-122-9] from the
connector.
60-122-5
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) ADVANCED
HAND CONTROL (CONT'D)
Figure 60-122-13
Switch Handle Removal
NOTE: Switch handle can be removed and installed
while in loader.
Figure 60-122-11
1
3
2
1
P-13735
2
1
Using a pointed tool, press down on the tab (Item 1)
[Figure 60-122-13] and pull the wire from the connector.
Figure 60-122-14
P-24909
Disconnect the harness connector (Item 1) [Figure 60122-11] from the handle sensor connector.
Disconnect the harness connector (Item 2) [Figure 60122-11] from the blank handle connector.
1
Figure 60-122-12
1
P-13725
P-13732
Remove the wedge (Item 1) [Figure 60-122-14] from the
harness connector (Black) that connects to the blank
handle connector (Item 2) [Figure 60-122-11].
1
1
P-13725
P-13732
Remove the wedge (Item 1) [Figure 60-122-12] from the
harness connector (Gray) that connects to the handle
sensor connector.
60-122-6
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) ADVANCED
HAND CONTROL (CONT'D)
Figure 60-122-17
Switch Handle Removal (Cont'd)
Figure 60-122-15
2
1
3
1
3
4
2
P-34035
1
Disconnect the left switch handle connectors (Items 1, 2,
3 & 4) [Figure 60-122-17] from the loader wiring harness
connectors.
P-13735
Use a pointed tool, press down on the tab (Item 1)
[Figure 60-122-15] and pull the wire from the connector.
Figure 60-122-16
1
2
P-34034
Disconnect the right switch handle connectors (Items 1 &
2) [Figure 60-122-16] from the loader wiring harness
connectors.
60-122-7
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) ADVANCED
HAND CONTROL (CONT'D)
Figure 60-122-20
Switch Handle Removal (Cont'd)
Figure 60-122-18
2
2
P-24234
1
Pull harness (Item 1) [Figure 60-122-20] out the bottom
of the control lever tube.
N-22783
Switch Handle Installation
Roll the pistol grip handle cover (Item 1) [Figure 60-12218] down.
Figure 60-122-21
Using a small screwdriver, lift the handle tabs (Item 2)
[Figure 60-122-18] and slightly rotate the switch handle.
Figure 60-122-19
Tape back 1/2 of Wires
Tape 1/2 of Wires
2
P-24233
P-21699
1
When installing the new switch handle, tape the wire
terminals together.
N-22784
Pull the switch handle and wiring harness assembly (Item
1) [Figure 60-122-19] from the control lever.
Cut the wires (Item 2) [Figure 60-122-19] below the
switch handle and remove switch handle.
NOTE: Only cut the wires if the switch handle is bad
and needs replacement. If the switch handle is
good and just needs to be removed for control
handle or lever replacement, then remove the
connectors on the end of the harness and pull
switch handle up out of lever tube.
The switch handle comes with a 6 inch piece of heat
shrink tube side on the end of the wires. Remove the
heat shrink tube from the end of the wires before routing
through handle and control lever tube.
NOTE: Leave all the other heat shrink tube on the
wires for protection.
Tape half of the wires back and half forward [Figure 60122-21] to keep the harness small enough to route
through the control lever tube.
60-122-8
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) ADVANCED
HAND CONTROL (CONT'D)
Inspect the wire terminal tabs (Item 2) [Figure 60-12223] and re-bend tabs if necessary.
Switch Handle Installation (Cont'd)
Install the wires into the connectors as listed below:
Figure 60-122-22
Right Switch Handle
Ten-Pin Connecter
A-Terminal - Orange
B-Terminal - White
C-Terminal - White/Black
D-Terminal - White/Red
E-Terminal - Dk. Green
F-Terminal - White/Lt. Green
G-Terminal - Yellow/Red
H-Terminal - Lt. Green
J-Terminal - Yellow
K-Terminal - Orange/Black
1
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White
P-21700
Install the new switch handle and wires from the top of
the control lever.
Left Switch Handle
Route wire (Item 1) [Figure 60-122-22] through the
casting, along side the handle sensor and into the control
lever tube.
NOTE: Do not pull the wire harness tight, allow a
small amount of slack or slight bend at the
handle pivot area. Verify the control handle
returns to neutral position.
Figure 60-122-23
Ten-Pin Connector
A-Terminal - Orange
B-Terminal - Dk. Blue
C-Terminal - White
D-Terminal - Purple
E-Terminal - Yellow/Red
F-Terminal - Tan
G-Terminal - Pink
H-Terminal - Orange/Black
J-Terminal - Blank
K-Terminal - Blank
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White
2
Two-Pin Connector
A-Terminal - Black
B-Terminal - Red
1
P-21695
Remove tape from wires for installation and install the 6
inches of heat shrink tube (Item 1) [Figure 60-122-23]
approximately 3 inches into the control lever. Apply heat
to the exposed heat shrink tube.
60-122-9
Five-Pin Connector
A-Terminal - Dk. Green
B-Terminal - Brown
C-Terminal - Blank
D-Terminal - Yellow
E-Terminal - Blank
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) ADVANCED
HAND CONTROL (CONT'D)
Figure 60-122-26
Switch Handle Installation (Cont'd)
Figure 60-122-24
1
3
1
2
P-13735
Install the wires into the connectors as listed below:
2
Left and Right Control Lever Switch Handle [Figure 60122-26]
1-Terminal - Red/White
2-Terminal - Black/White
3-Terminal - Purple/White
P-34034
Figure 60-122-25
Figure 60-122-27
1
3
1
2
P-34035
Connect the handle harness connectors (Item 1) [Figure
60-122-24] & [Figure 60-122-25] to the loader harness
connectors.
P-13735
Left and Right Control Lever Switch Handle [Figure 60122-27]
1-Terminal - Yellow/Red
2-Terminal - Open
3-Terminal - Orange/Black
60-122-10
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) ADVANCED
HAND CONTROL (CONT'D)
Actuators Disassembly and Assembly
Switch Handle Installation (Cont'd)
Remove the actuator. (See Actuator Removal And
Installation (In Loader) on Page 20-41-1.)
Figure 60-122-28
Figure 60-122-29
1
P-21804
N-18940
Connect the handle harness connector to the sensor and
blank handle connector [Figure 60-122-28].
Check the mounting block (Item 1) [Figure 60-122-29]
and bolts for wear and replace as needed.
60-122-11
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) ADVANCED
HAND CONTROL (CONT’D)
Actuators Disassembly And Assembly (Cont’d)
Figure 60-122-30
1
N-17742
N-17741
Check the actuator wiring harness connector (Item 1)
[Figure 60-122-30] and replace if broken.
Installation: Install the wires into the connector as listed
below. The terminal numbers are written on the back of
the connector (Item 2) [Figure 60-122-30].
Lift and Tilt Actuator
1 - Terminal-Black/Green-Larger diameter wire (16
gauge)
2 - Terminal-Green-Larger diameter wire (16 gauge)
3 - Terminal-Red/Green-Larger diameter wire (16
gauge)
4 - Terminal-Open
5 - Terminal-Red-Smaller diameter wire (18 gauge)
6 - Terminal-Open
7 - Terminal-Open
8 - Terminal-Black-Smaller diameter wire (18 gauge)
NOTE: The calibration procedure must be followed
when replacing a handle sensor, actuator or
ACS controller. (See Calibration Of The ACS
System on Page 60-123-15.)
60-122-12
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL
Components Identification
The Advanced Control System (ACS) is a selectable foot/
hand control system.
NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Calibration Of The ACS System on Page 60123-15.)
Figure 60-123-3
The ACS system allows the operator to quickly switch
between foot and hand control modes.
1
Figure 60-123-1
1
1
2
P16536
P-24203
Control Valve Actuators (Item 1) [Figure 60-123-3].
NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Calibration Of The ACS System on Page 60123-15.)
P-21879
Control Handle (Item 1) [Figure 60-123-1].
Handle sensor (Item 2) [Figure 60-123-1].
NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Calibration Of The ACS System on Page 60123-15.)
Figure 60-123-4
Figure 60-123-2
2
1
P-21767
1
P-21938
ACS Controller (Item 1) [Figure 60-123-4].
P-21939
Foot control/sensor assembly (Item 1) [Figure 60-123-2].
NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Calibration Of The ACS System on Page 60123-15.)
Foot sensor (Item 2) [Figure 60-123-2].
60-123-1
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT'D)
Components Identification (Cont'd)
Figure 60-123-5
1
P-21769A
ACS error indicator (Item 1) [Figure 60-123-5].
NOTE: The ACS icon will illuminate when an error
occurs. The error is stored as a service code.
(See Calibration Of The ACS System on Page
60-123-15.)
60-123-2
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT'D)
Troubleshooting Guide
The Advanced Control System (ACS) has a built-in diagnostic function which uses an icon on the right instrument panel
to indicate the condition of the ACS SYSTEM. The system also records the alarm condition as a service code.
The control module continually checks the system in the order listed. The checks start with the lift handle sensor and then
the lift actuator. If no problems are present, it will then check the tilt handle sensor and the tilt actuator. The system will
stop its check at the first problem and then luminate the icon.
The system starts its diagnostics and calibration when the ignition key is turned ON.
The following list shows the probable causes when the icon is luminated.
Advanced
Control
System
Attachment
Control
Device
General
Warning
Fuel Level
Two Speed
Glow Plugs
System
Voltage
Seatbelt
Engine Oil
Pressure
Hydraulic
Charge
Pressure
Engine
Coolant
Temperature
Hydraulic Oil
Temperature
Air Filter
Hydraulic
Filter
Advanced Control System
Errors - lights soild with 3 beeps
32-04 - ACS in error
32-23 - ACS not calibrated
32-31 - Tilt actuator fault
32-34 - Tilt actuator not calibrated
32-35 - Tilt handle/pedal not calibrated
32-36 - Lift actuator fault
32-39 - Lift actuator not calibrated
32-40 - Lift handle/pedal not calibrated
32-49 - Lift actuator short to ground
32-51 - Lift actuator short to battery
32-50 - Tilt actuator short to ground
32-52 - Tilt actuator short to battery
32-53 - Lift handle/pedal short to ground
32-54 - Tilt handle/pedal short to ground
32-55 - Lift handle/pedal short to battery
32-56 - Tilt handle/pedal short to battery
32-57 - Lift actuator reduced performance
32-58 - Tilt actuator reduced performance
32-59 - Lift actuator wrong direction
32-60 - Tilt actuator wrong direction
32-61 - Handle lock short to ground
32-62 - Handle lock short to battery
32-63 - Pedal lock short to ground
32-64 - Pedal lock short to battery
32-65 - Sensor supply voltage out of range
32-66 - Battery out of range
32-67 - Switch moved while operating
To see what error occurred. Check the service code on the left instrument panel. (See DELUXE INSTRUMENTATION
SERVICE CODES on Page 60-80-1.)
60-123-3
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL(CONT'D)
Controller, Connector And Wire Identification
G
F
H
J
K
E
D
A
B
C
J3
J1
F
F
E
D
C
PIN
J1
E
D
G
H
A
B
C
J2
B
A
J3
J2
DESCRIPTION
P/N
CONNECTOR, METRI-PACK
J3
A
5V HALL EFFECT SUPPLY
Red
Orange
B
SWITCHED AHC POWER
Green
c
HAND/FOOT INPUT
Purple
D
CAN SIGNAL HIGH AHC
Purple
E
Purple
F
Black
G
Black
H
CONNECTOR, METRI-PACK
A
OPEN
B
OPEN
C
OPEN
D
OPEN
Orange
J2
J2
J1
J1
P/N
H
J
K
G
J3
PIN
DESCRIPTION
CONNECTOR, METRI-PACK
A
TILT ACTUATOR FORWARD
Red/White
B
UNSWITCHED AHC POWER
Red/White
C
UNSWITCHED AHC POWER
Black
D
LIFT ACTUATOR REVERSE
CAN SIGNAL LOW AHC
Green
E
HANDLE LOCK POWER
CAN SHEILD AHC
Red
F
LIFT ACTUATOR FORWARD
AHC GROUND
Green
G
PEDAL LOCK POWER
AHC GROUND
Black
H
AHC GROUND
Black
J
AHC GROUND
Black
K
TILT ACTUATOR REVERSE
Green
E
TILT SPOOL SIGNAL
Green
F
LIFT HANDLE SIGNAL
Green
G
TILT HANDLE SIGNAL
Green
H
LIFT SPOOL SIGNAL
Green
J
LIFT PEDAL SIGNAL
Green
K
TILT PEDAL SIGNAL
60-123-4
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT'D)
Figure 60-123-8
ACS Controller Removal And Installation
Figure 60-123-6
1
1
P-21840
Remove the two mounting bolts (Item 1) [Figure 60-1238] from the controller.
P-21839
Remove the controller from the loader.
Loosen the bottom bolts and remove the top bolt.
Remove the right front panel (Item 1) [Figure 60-123-6]
from the loader.
NOTE: The calibration procedure must be followed
when replacing handle sensor, actuator or
ACS Controller. (See Calibration Of The ACS
System on Page 60-123-15.)
Figure 60-123-7
1
P-21843
Disconnect the wiring harness connectors (Item 1)
[Figure 60-123-7] from the controller.
60-123-5
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT'D)
Figure 60-123-11
Handle Sensor Connector
Figure 60-123-9
1
2
3
1
1
P-13733
With a pointed tool, lift the tab (Item 1) [Figure 60-12311] and pull the wire from the connector.
P-16578
The wire connector (Item 1) [Figure 60-123-9] can be
removed from the handle sensor wires, use the following
procedure.
Installation: Install the wires into the connector as listed
below [Figure 60-123-11]:
Figure 60-123-10
1
1-Terminal - Red
2-Terminal - Black
3-Terminal - Green
1
P-13725
P-3732
Remove the wedge (Item 1) [Figure 60-123-10] from the
connector.
60-123-6
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT'D)
Figure 60-123-14
Switch Handle Removal
NOTE: Switch handle can be removed and installed
while in loader.
Figure 60-123-12
1
3
2
1
P-13735
Using a pointed tool, press down on the tab (Item 1)
[Figure 60-123-14] and pull the wire from the connector.
1
2
Figure 60-123-15
P-21879
Disconnect the harness connector (Item 1) [Figure 60123-12] from the handle sensor connector.
Disconnect the harness connector (Item 2) [Figure 60123-12] from the handle lock solenoid connector.
Figure 60-123-13
1
1
P-13725
P-13732
Remove the wedge (Item 1) [Figure 60-123-15] from the
harness connector (Black) that connects to the handle
lock solenoid connector.
1
1
P-13725
P-13732
Remove the wedge (Item 1) [Figure 60-123-13] from the
harness connector (Gray) that connects to the handle
sensor connector.
60-123-7
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT'D)
Figure 60-123-18
Switch Handle Removal (Cont'd)
Figure 60-123-16
2
1
3
4
1
3
2
P-34035
1
Disconnect the left switch handle connectors (Items 1, 2,
3 & 4) [Figure 60-123-18] from the loader wiring harness
connectors.
P-13735
Use a pointed tool, press down on the tab (Item 1)
[Figure 60-123-16] and pull the wire from the connector.
Figure 60-123-17
1
2
P-34034
Disconnect the right switch handle connectors (Items 1 &
2) [Figure 60-123-17] from the loader wiring harness
connectors.
60-123-8
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT'D)
Figure 60-123-21
Switch Handle Removal (Cont'd)
1
Figure 60-123-19
2
2
P-24234
1
Pull harness (Item 1) [Figure 60-123-21] out the bottom
of the control lever tube.
N-22783
Switch Handle Installation
Roll the pistol grip handle cover (Item 1) [Figure 60-12319] down.
Figure 60-123-22
Using a small screwdriver, lift the handle tabs (Item 2)
[Figure 60-123-19] and slightly rotate the switch handle.
Tape 1/2 of Wires
Figure 60-123-20
Tape back 1/2 of Wires
2
P-24233
1
P-21699
When installing the new switch handle, tape the wire
terminals together.
N-22784
Pull the switch handle and wiring harness assembly (Item
1) [Figure 60-123-20] from the control lever.
Cut the wires (Item 2) [Figure 60-123-20] below the
switch handle and remove switch handle.
NOTE: Only cut the wires if the switch handle is bad
and needs replacement. If the switch handle is
good and just needs to be removed for control
handle or lever replacement, then remove the
connectors on the end of the harness and pull
switch handle up out of lever tube.
The switch handle comes with a 6 inch piece of heat
shrink tube side on the end of the wires. Remove the
heat shrink tube from the end of the wires before routing
through handle and control lever tube.
NOTE: Leave all the other heat shrink tube on the
wires for protection.
Tape half of the wires back and half forward [Figure 60123-22] to keep the harness small enough to route
through the control lever tube.
60-123-9
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT'D)
Inspect the wire terminal tabs (Item 2) [Figure 60-12324] and re-bend tabs if necessary.
Switch Handle Installation (Cont'd)
Install the wires into the connectors as listed below:
Figure 60-123-23
Right Switch Handle
Ten-Pin Connector
A-Terminal - Orange
B-Terminal - White
C-Terminal - White/Black
D-Terminal - White/Red
E-Terminal - Dk. Green
F-Terminal - White/Lt. Green
G-Terminal - Yellow/Red
H-Terminal - Lt. Green
J-Terminal - Yellow
K-Terminal - Orange/Black
1
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White
P-21700
Install the new switch handle and wires from the top of
the control lever.
Left Switch Handle
Route wire (Item 1) [Figure 60-123-23] through the
casting, along side the handle sensor and into the control
lever tube.
NOTE: Do not pull the wire harness tight, allow a
small amount of slack or slight bend at the
handle pivot area. Verify the control handle
returns to neutral position.
Figure 60-123-24
Ten-Pin Connector
A-Terminal - Orange
B-Terminal - Dk. Blue
C-Terminal - White
D-Terminal - Purple
E-Terminal - Yellow/Red
F-Terminal - Tan
G-Terminal - Pink
H-Terminal - Orange/Black
J-Terminal - Blank
K-Terminal - Blank
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White
2
Two-Pin Connector
A-Terminal - Black
B-Terminal - Red
1
P-21695
Remove tape from wires for installation and install the 6
inches of heat shrink tube (Item 1) [Figure 60-123-24]
approximately 3 inches into the control lever. Apply heat
to the exposed heat shrink tube.
60-123-10
Five-Pin Connector
A-Terminal - Dk. Green
B-Terminal - Brown
C-Terminal - Blank
D-Terminal - Yellow
E-Terminal - Blank
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT'D)
Figure 60-123-27
Switch Handle Installation (Cont'd)
Figure 60-123-25
1
1
3
2
P13735
1
Install the wires into the connectors as listed below:
Left and Right Control Lever Switch Handle [Figure 60123-27]
1-Terminal - Red/White
2-Terminal - Black/White
3-Terminal - Purple/White
P-34034
Figure 60-123-26
Figure 60-123-28
1
1
3
2
P-34035
Connect the handle harness connectors (Item 1) [Figure
60-123-25] & [Figure 60-123-26] to the loader harness
connectors.
P13735
Left and Right Control Lever Switch Handle [Figure 60123-28]
1-Terminal - Yellow/Red
2-Terminal - Open
3-Terminal - Orange/Black
60-123-11
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT'D)
Actuators Disassembly and Assembly
Remove the control panel.
Switch Handle Installation (Cont'd)
Remove the actuator. (See Actuator Removal And
Installation (In Loader) on Page 20-41-1.)
Figure 60-123-29
Figure 60-123-30
1
P-21804
N-18940
Connect the handle harness connectors to the sensor
and lock solenoid connectors [Figure 60-123-29].
Check the mounting block (Item 1) [Figure 60-123-30]
and bolts for wear and replace as needed.
60-123-12
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT'D)
Handle Lock Solenoid Removal And Installation
Figure 60-123-32
Actuators Disassembly And Assembly (Cont’d)
Figure 60-123-31
2
2
1
P-21836
1
N-17742
Disconnect the harness connector (Item 1) [Figure 60123-32] from the handle sensor connector.
N-17741
Check the actuator wiring harness connector (Item 1)
[Figure 60-123-31] and replace if broken.
Disconnect the harness connector (Item 2) [Figure 60123-32] from the handle lock solenoid connector.
Installation: Install the wires into the connector as listed
below. The terminal numbers are written on the back of
the connector (Item 2) [Figure 60-123-31].
Figure 60-123-33
Lift and Tilt Actuator
1 - Terminal-Black/Green-Larger diameter wire (16
gauge)
2 - Terminal-Green-Larger diameter wire (16 gauge)
3 - Terminal-Red/Green-Larger diameter wire (16
gauge)
4 - Terminal-Open
5 - Terminal-Red-Smaller diameter wire (18 gauge)
6 - Terminal-Open
7 - Terminal-Open
8 - Terminal-Black-Smaller diameter wire (18 gauge)
NOTE: The calibration procedure must be followed
when replacing a handle sensor, actuator or
ACS controller. (See Contents, Page 60-01)
1
P-21832
Remove the two screws (Item 1) [Figure 60-123-33]
holding the handle lock solenoid to the handle.
Installation: Tighten the screws to 32-38 in.-lbs. (3,6-4,3
Nm) torque.
Remove handle lock solenoid assembly from handle.
60-123-13
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT'D)
Handle Lock Solenoid Connector
Figure 60-123-36
Handle Lock Solenoid Disassembly And Assembly
Figure 60-123-34
1
1
2
P-21787
The wire connector (Item 1) [Figure 60-123-36] can be
removed from the solenoid, use the following procedure.
P-21787
Remove solenoid (Item 1) [Figure 60-123-34] from the
solenoid mount (Item 2) [Figure 60-123-34].
Figure 60-123-37
Installation: Apply a drop of oil to the solenoid threads
and tighten solenoid to 35-40 ft.-lbs. (47-54 Nm) lubed
torque.
Figure 60-123-35
1
1
P-21800
1
P-21801
Remove the wedge (Item 1) [Figure 60-123-37] from the
connector.
P-21789
Check the O-ring (Item 1) [Figure 60-123-35] for
damage. Replace as necessary.
60-123-14
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT'D)
Switchable Hand/Foot Controls Calibration
Procedure
Handle Lock Solenoid Connector (Cont’d)
Figure 60-123-39
Figure 60-123-38
1
2
3
1
1
P-24182
P-21802
With a pointed tool, lift the tab (Item 1) [Figure 60-12338] and pull the wire from the connector.
Switch the rocker switch (Item 1) [Figure 60-123-39] to
the hand control mode.
Installation: Install the wires into the connector as listed
below [Figure 60-123-38].
1 - Terminal - Black
2 - Terminal - Open
3 - Terminal - Black
Calibration Of The ACS System
The new controller uses a calibration sequence to
optimize the control system. The optimizing ensures full
spool stroke (full flow) while preventing over stroke
(loading) of the actuator.
NOTE: This calibration procedure must be followed
when replacing a handle sensor, actuator or
ACS controller. Failure to calibrate after
component replacement may result in poor
performance or reduced life of actuator(s).
(See Calibration Of The ACS System on Page
60-123-15.)
60-123-15
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT'D)
Figure 60-123-42
Switchable Hand/Foot Controls Calibration
Procedure (Cont'd)
Stroke Both Handles Fully In and Hold Them
Figure 60-123-40
Then Turn Key On
or
B-16628
Press RUN/ENTER
Fully stroke both control handles in toward the center of
the cab and hold the handles there [Figure 60-123-42].
Turn the ignition key off (keyless panel power off).
B-16626
Figure 60-123-43
Figure 60-123-41
Then Turn Key On
or
Press RUN/ENTER
1
B-16626
B-16627
With the seat bar down, turn the ignition key on (keyless
panel choose RUN/ENTER) [Figure 60-123-40] and
push the PRESS TO OPERATE button (Item 1) [Figure
60-123-41] to unlock the hand controls.
Turn the ignition key on (keyless panel choose RUN/
ENTER) [Figure 60-123-43].
NOTE: Do Not start engine.
NOTE: Do not start the engine.
60-123-16
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT'D)
Hand Controls Only Calibration Procedure
Figure 60-123-45
Switchable Hand/Foot Controls Calibration
Procedure (Cont'd)
Stroke Both Handles Fully In and Hold Them
Figure 60-123-44
B-16628
1
B-16627
Push the PRESS TO OPERATE button (Item 1) [Figure
60-123-44] to begin the calibration.
With the seat bar down and the ignition key off (keyless
panel power off), fully stroke both control handles in
toward the center of the cab and hold the handles there
[Figure 60-123-45].
Figure 60-123-46
NOTE: The ACS icon will light up and if you listen
closely the cycling of the actuators can be
heard. The ACS icon will stay lit until the
ignition key is cycled or the loader is started
and a function is operated.
Then Turn Key On
NOTE: During the calibration cycle, the system will
beep three times. The calibration process
generates two codes 32-35 (tilt handle not
calibrated) and 32-40 (lift handle not
calibrated). Ignore these two codes, this is
normal during the calibration procedure.
or
Press RUN/ENTER
Release the control handles.
B-16626
NOTE: After pushing the PRESS TO OPERATE
button, the handle position does not affect the
calibration process.
Turn the ignition key on (keyless panel choose RUN/
ENTER) [Figure 60-123-46]. Do not start the engine.
NOTE: The ACS controller cycles the actuators,
records the values and optimizes the system
automatically in approximately 5 seconds.
Calibration is complete.
60-123-17
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT'D)
Foot Sensor Disassembly And Assembly
Figure 60-123-48
Hand Controls Only Calibration Procedure (Cont'd)
Figure 60-123-47
1
1
1
P-24269
Remove the two bolts (Item 1) [Figure 60-123-48] from
the end of the foot sensor.
B-16627
Push the PRESS TO OPERATE button (Item 1) [Figure
60-123-47] to begin the calibration.
NOTE: The ACS icon will light up and if you listen
closely the cycling of the actuators can be
heard. The ACS icon will stay lit until the
ignition key is cycled or the loader is started
and a function is operated.
Installation: Tighten the bolts to 90 in.-lbs. (10,2 Nm)
torque. Apply LOCTITE 242 to the threads.
Figure 60-123-49
5
NOTE: During the calibration cycle, the system will
beep three times. The calibration process
generates two codes 32-35 (tilt handle not
calibrated) and 32-40 (lift handle not
calibrated). Ignore these two codes, this is
normal during the calibration procedure.
4
Release the control handles.
2
NOTE: After pushing the PRESS TO OPERATE
button, the handle position does not affect the
calibration process.
NOTE: The ACS controller cycles the actuators,
records the values and optimizes the system
automatically in approximately 5 seconds.
Calibration is complete.
1
3
P-24270
Remove the boot retainer (Item 1) [Figure 60-123-49],
boot (Item 2) [Figure 60-123-49], spool stop plate (Item
3) [Figure 60-123-49], O-ring (Item 4) [Figure 60-12349].
NOTE: Do not disassemble the sensor assembly
(Item 5) [Figure 60-123-49]. The sensor
assembly is a calibrated assembly and cannot
be serviced. Order through Bobcat Parts.
60-123-18
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT'D)
Figure 60-123-52
Foot Sensor Connector
1
Figure 60-123-50
3
1
2
1
P-24274
With a pointed tool, lift the tab (Item 1) [Figure 60-12352] and pull the wire from the connector.
P-24271
The wire connector (Item 1) [Figure 60-123-50] can be
removed from the sensor wires, use the following
procedure.
Installation: Install the wires into the connector as listed
below [Figure 60-123-52]:
Figure 60-123-51
1 - Terminal - Red
2 - Terminal - Black
3 - Terminal - Green
1
1
P-24272
P-24273
Remove the wedge (Item 1) [Figure 60-123-51] from the
connector.
60-123-19
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT'D)
Figure 60-123-55
Foot Lock Solenoid Removal And Installation
Figure 60-123-53
2
1
P-21790
Check the O-ring (Item 1) [Figure 60-123-55] for
damage. Replace as necessary
1
P-21938
Foot Lock Solenoid Connector
Remove the two bolts (Item 1) [Figure 60-123-53] from
the foot sensor shield.
Installation: Tighten the bolts to 32-38 in.-lbs. (3,6-4,3
Nm) torque.
The wire connector (Item 2) [Figure 60-123-55] can be
removed from the solenoid wires, use the following
procedure.
Figure 60-123-54
1
2
P-21939
Disconnect the foot lock solenoid connector (Item 1)
[Figure 60-123-54] from the harness.
Remove foot lock solenoid (Item 2) [Figure 60-123-54].
Installation: Apply a drop of oil on the solenoid threads
and tighten the solenoid to 35-40 ft.-lbs. (47-54 Nm)
lubed torque.
60-123-20
863 Bobcat Loader
Service Manual
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT'D)
Figure 60-123-57
Foot Lock Solenoid Connector (Cont’d)
Figure 60-123-56
3
1
2
1
P-21802
1
1
With a pointed tool, lift the tab (Item 1) [Figure 60-12357] and pull the wire from the connector.
P-21800
P-21801
Remove the wedge (Item 1) [Figure 60-123-56] from the
connector.
Installation: Install the wires into the connector as listed
below [Figure 60-123-57]:
60-123-21
1 - Terminal - Black
2 - Terminal - Open
3 - Terminal - Black
863 Bobcat Loader
Service Manual
60-123-22
863 Bobcat Loader
Service Manual
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
Controls Identification Chart
Left Side
Control Handle
Switches
B-16447
xxxxxxxxx
Switch
Number
Solenoid Number
Activated
RH
HFH
Attachment
Harness
Terminal
Activated
Attachment Harness
Connector
Right Side
Control Handle
Switches
Fourteen Pin
Connector Viewed
from front
(pin side of
connector)
of loader.
1
1
1
1, 8
K
2
2
2
2
K
*3
1
1
1, 8
K
4
2
2, 3
6, 7
K, A, D
5
1
1, 3
5, 7
K, A, C
6
1
1, 3
5, 7
K, E
7
1
1, 3
5, 7
K, F
8
1
1, 3
5, 7
K, G
9
1
1, 3
5, 7
K, H
10, 11, 12,
13, 14
-
--
--
K
B-16449
B-16448
Early
Version
1
2
Current
Version
1
NOTE: All diagnostics must be done at the fourteen pin connector (Item 1).
On earlier versions, the switch (Item 2) must be in the fourteen pin position. The current version ACD
(Attachment Control Device) without switch, automatically recognizes the use of the seven or fourteen pin
connector when connected.
The ACD (Attachment Control Device) Icon, located in the right instrument panel on the loader cab, must
be illuminated continuously.
If the ACD light flashes, check for diagnostic service codes. See the Electrical System Service Manual for
the proper procedure.
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
* If harness terminals K & L are jumped together, switches 4 thru 9 will function the same as switch 1 & 2.
* Terminal K is activated with Key switch ON.
60-130-1
863 Bobcat Loader
Service Manual
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
(CONT’D)
Controls Identification Chart (Cont’d)
8
6
3
4
2
Solenoid
Number
3
1
1
2
3 (Top)
4 (Bottom)
9
8
7
6
2
5
5
8
6
3
H
6
1
7 (Bottom)
8 (Middle)
9 (Top)
Hydraulic
Coupler
Front
Female
(Rod)
Front
Male
(Base)
Diverter
Bleed - Rear
Male & Female
Rear
Female
(Rod)
Rear
Male
(Base)
Diverter
High
Flow
Bleed - Rear
Male & Female
Wiring
Number
4330
4340
4450
4480
4430
4440
4450
4460
4480
MC-2314A
NOTE: Pushing the Hydraulic Pressure release button ON activates solenoids number 1, 4 and 9. The high flow
button in the left side instrument panel must be pushed ON to activate solenoid number 8.
60-130-2
863 Bobcat Loader
Service Manual
ENGINE SERVICE
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Blower Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-5
Drive Tension Pulley Removal And Installation . . . . . . . . . . . . . . . . . 70-60-1
Gearbox Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-12
Gearbox/Blower Housing Removal And Installation . . . . . . . . . . . . . 70-60-2
Gearbox, Checking Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-17
Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-7
Gearbox Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-6
SAFETY &
MAINTENANCE
DRIVE
ENGINE AND ENGINE MOUNTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Engine Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-7
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
ENGINE COMPONENTS AND TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Engine Compression, Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Injection Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-7
Fuel Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-4
Fuel Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-6
Fuel Injector Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12
Fuel Injector, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-10
Fuel Injector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-11
Fuel Injector Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . 70-70-9
Fuel Shut-Off Solenoid, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-3
Fuel Shut-Off Solenoid Removal and Installation . . . . . . . . . . . . . . . 70-70-4
Glow Plug, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-2
Thermostat, Oil Pressure Control Valves And Heater Connections. 70-70-27
Timing Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-14
Timing Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-15
Timing Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-14
Timing Belt, Replacement In the Loader . . . . . . . . . . . . . . . . . . . . . 70-70-19
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-24
Valve Timing, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-25
ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed Control Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70-20-1
70-20-1
70-20-2
70-20-3
FLYWHEEL AND HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel Housing Removal And Installation . . . . . . . . . . . . . . . . . . .
Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .
70-90-1
70-90-1
70-90-1
70-90-1
ENGINE
SERVICE
ENGINE
SERVICE
HVAC
SPECIFICATIONS
Continued On Next Page
70-01
863 Bobcat Loader
Service Manual
ENGINE SERVICE (CONT’D)
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Oil Cooler Removal And Installation . . . . . . . . . . . . . . . . . 70-50-1
RECONDITIONING THE ENGINE . . . . . . . . . . . . . . . . . . . . 70-100-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-6
Deutz Engine Tools Identification Chart . . . . . . . . . . . . . . 70-100-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-2
Camshaft Bearing, Checking . . . . . . . . . . . . . . . . . . . . . 70-100-23
Camshaft Bearing, Removal And Installation. . . . . . . . . 70-100-23
Connecting Rod, Checking . . . . . . . . . . . . . . . . . . . . . . 70-100-33
Control Rod Guide Bushing Installation . . . . . . . . . . . . . 70-100-26
Control Rod Guide Bushing Removal . . . . . . . . . . . . . . 70-100-24
Crankshaft, Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-31
Crankshaft Gear Mounting Bolt Torque Procedure . . . . 70-100-58
Cylinder, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-22
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . 70-100-41
Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . 70-100-39
Front Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-48
Front Cover Disassembly. . . . . . . . . . . . . . . . . . . . . . . . 70-100-43
Piston, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-35
Piston Installation On the Connecting Rod . . . . . . . . . . 70-100-37
Piston Pin, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-36
Piston Rings Installation. . . . . . . . . . . . . . . . . . . . . . . . . 70-100-36
Rear Cover Seal Removal And Installation . . . . . . . . . . 70-100-30
Rocker Arm and Bracket, Checking. . . . . . . . . . . . . . . . 70-100-42
Turbo Charger Removal and Installation . . . . . . . . . . . . 70-100-57
Valves, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-39
Valve Seats, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-40
Valve Spring, Checking . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-41
RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-91-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-91-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
70-02
863 Bobcat Loader
Service Manual
TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM
Slow cranking speed.
Engine will not start.
Difficult to start.
No power for engine.
Engine is mis-firing.
Too much fuel consumption.
Black exhaust.
Blue/white exhaust.
Low oil pressure.
Engine knocking.
Engine running rough.
Vibration.
High oil pressure warning.
Overheating.
Too much crankcase pressure.
Poor compression.
Start and stop.
CAUSE
1, 2, 3, 4
2, 5, 6, 7, 8, 9, 11, 12,13, 14, 15, 16, 17, 19, 27, 28, 29
5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25,27, 28, 29
8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29,
8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 24, 25, 26, 28
10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
4, 10, 15, 16, 17, 21, 23,27, 29, 30, 47, 46
4, 31, 32, 33, 34, 35, 37, 39, 48
13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 49
7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 49
2, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
4, 33, 36
10, 12, 13, 15, 16, 20, 21, 32, 40, 44, 47
22, 27, 29, 46
10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 49
9, 10, 11
KEY TO CORRECT THE CAUSE
1. Battery capacity low.
2. Bad electrical connection.
3. Faulty starter motor.
4. Incorrect grade of oil.
5. Low cranking speed.
6. Fuel tank empty.
7. Faulty stop control operation.
8. Plugged fuel line.
9. Plugged fuel filter.
10. Restriction in the air cleaner.
11. Air in the fuel system.
12. Faulty fuel injection pump.
13. Faulty fuel injectors.
14. Broken injection pump drive.
15. Incorrect injection pump timing.
16. Incorrect valve timing.
17. Poor compression.
18. Plugged fuel tank vent.
19. Incorrect grade of fuel.
20. Exhaust pipe restriction.
21. Cylinder head gasket leaking.
22. Overheating.
23. Cold running.
24. Incorrect tappet adjustment.
25. Sticking valves.
26. Incorrect high pressure fuel pipes.
27. Worn cylinder bores.
28. Worn valve and seats.
29. Broken, worn, or sticking piston rings.
30. Worn valve stems or guides.
31. Worn or damaged bearings.
32. Not enough oil in the oil pan.
33. Switch/sensor is defective.
34. Oil pump worn.
35. Pressure relief valve is sticking open.
36. Pressure relief valve is sticking closed.
37. Broken relief valve spring.
38. Faulty suction pipe.
39. Plugged oil filter.
40. Piston seizure.
41. Incorrect piston height.
42. Faulty engine mounting.
43. Incorrect alignment of flywheel.
44. Faulty thermostat.
45. Plugged oil cooler.
46. Plugged PCV System.
47. Damaged valve stem oil deflectors.
48. Plugged oil pump pipe strainer.
49. Broken valve spring.
70-10-1
863 Bobcat Loader
Service Manual
70-10-2
863 Bobcat Loader
Service Manual
ENGINE SPEED CONTROL
Removal And Installation
Installation: Tighten the bolts evenly until the speed
control lever moves backward and forward at a
comfortable tension.
Figure 70-20-1
Figure 70-20-3
1
2
1
P-4731
P-5375
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Remove the speed control lever (Item 1) [Figure 70-203] and mounting bracket (Item 2) [Figure 70-20-3].
Figure 70-20-4
Raise the operator cab. (See OPERATOR CAB on Page
10-30-1.)
Remove the two mounting bolts (Item 1) [Figure 70-201].
3
Figure 70-20-2
1
2
1
2
P-5378
Remove the retainer pin (Item 1) [Figure 70-20-4] and
pivot pin (Item 2) [Figure 70-20-4] from the speed control
arm (Item 3) [Figure 70-20-4] to disconnect the speed
control cable clevis.
P-5368
Mark the front of the stop bracket (Item 1) [Figure 70-202] and remove the stop bracket
NOTE: Do not lubricate the speed control parts when
assembling.
Installation: It is important for the front and rear stop on
the bracket to be located correctly.
Remove the bolts (Item 2) [Figure 70-20-2].
70-20-1
863 Bobcat Loadcer
Service Manual
ENGINE SPEED CONTROL (CONT’D)
Figure 70-20-6
Speed Control Cable
2
Figure 70-20-5
3
1
4
1
P-5545
Remove the u-bolt (Item 1) [Figure 70-20-6] from the
cable.
N-20414
NOTE: Do not lubricate the speed control parts when
assembling.
Raise the lift arm and install an approved lift arm support
device. (See LIFT ARM SUPPORT DEVICE on Page 1020-1.)
NOTE: The throttle mount bracket bolts (Item 2)
[Figure 70-20-6] can be removed to assist ubolt removal.
Remove the nut (Item 3) [Figure 70-20-6] to disconnect
the cable from the linkage.
Remove the speed control cable.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the speed control lever assembly. (See Removal
And Installation on page 70-20-1.)
NOTE: The front panel/steering levers are shown
removed for clarity.
Remove the u-bolt (Item 1) [Figure 70-20-5] from the
cable.
Open the rear door.
NOTE: Engine is shown removed from loader for
clarity.
70-20-2
863 Bobcat Loader
Service Manual
ENGINE SPEED CONTROL (CONT’D)
Speed Control Linkage
Figure 70-20-7
2
3
5
4
1
P-5544
Loosen the bolt (Item 1) [Figure 70-20-7] to remove the
linkage rod (Item 2) [Figure 70-20-7].
Disconnect the cable nut (Item 3) [Figure 70-20-7].
Remove the nut (Item 4) [Figure 70-20-7] from the pivot
bolt (Item 4) [Figure 70-20-6].
Remove the bellcrank linkage (Item 5) [Figure 70-20-7]
and spring.
70-20-3
863 Bobcat Loadcer
Service Manual
70-20-4
863 Bobcat Loader
Service Manual
MUFFLER
Figure 70-30-3
Removal And Installation
Open the rear door.
Raise the rear grill.
Figure 70-30-1
1
1
P-7899
Remove the two bolts and nuts (Item 1) [Figure 70-30-3]
from the muffler mounting bracket.
Remove the muffler.
1
P-7898
Remove the four bolts and nuts (Item 1) [Figure 70-30-1]
from the engine muffler mounting bracket.
Remove the bracket.
Figure 70-30-2
1
P-7900
Remove the three bolts and nuts (Item 1) [Figure 70-302] from the muffler exhaust flange.
70-30-1
863 Bobcat Loader
Service Manual
70-30-2
863 Bobcat Loader
Service Manual
AIR CLEANER
Figure 70-40-6
Housing Removal And Installation
Figure 70-40-4
1
1
2
N-19673
Disconnect the sensor wiring harness connector (Item 1)
[Figure 70-40-6] from the air cleaner.
N-19671
Loosen the hose clamp (Item 1) [Figure 70-40-4] and
disconnect the inlet hose from the air cleaner.
Remove the air cleaner housing from the loader.
Loosen the hose clamp (Item 2) [Figure 70-40-4] and
disconnect the hose from the air cleaner to the turbo
charger.
Figure 70-40-5
1
1
N-19672
Remove the two mounting bolts (Item 1) [Figure 70-405].
70-40-1
863 Bobcat Loader
Service Manual
70-40-2
863 Bobcat Loader
Service Manual
RADIATOR
Figure 70-50-3
Oil Cooler Removal And Installation
Raise the rear grill.
Remove the hydraulic oil cooler. (See Removal And
Installation With STC (Seal Tight Connector) on Page 3060-1.)
Figure 70-50-1
1
1
P-7906
Lift the oil cooler from the loader frame [Figure 70-50-3].
Figure 70-50-4
2
1
2
1
P-7904
Remove the four mounting bolts (Item 1) [Figure 70-501] from the oil cooler.
1
1
Disconnect the tubelines (Item 2) [Figure 70-50-1] from
the bulkhead fittings.
Figure 70-50-2
P-7909
1
2
Before installing the oil cooler, check the seals (Item 1)
[Figure 70-50-4] at both sides of the oil cooler mounting
frame. Replace the seals as needed.
1
2
P-7907
Loosen the tubeline fittings (Item 1) [Figure 70-50-2] and
raise the tubelines (Item 2) [Figure 70-50-2] (both sides)
as shown and tighten the fittings so they can be used as
handles when removing or installing the oil cooler.
70-50-1
863 Bobcat Loader
Service Manual
70-50-2
863 Bobcat Loader
Service Manual
COOLING FAN
Figure 70-60-3
Drive Tension Pulley Removal And Installation
Figure 70-60-1
1
1
2
P-5551
Figure 70-60-4
P-5550
3
Remove the fan drive belt (Item 1) [Figure 70-60-1].
Remove the idler pulley bolt (Item 2) [Figure 70-60-1].
4
Figure 70-60-2
3
2
1
5
1
N-303A
P-0581
Remove the bolt (Item 1) [Figure 70-60-3] & [Figure 7060-4].
Remove the thrust washer (Item 2) [Figure 70-60-4], Orings (Item 3) [Figure 70-60-4] and spring (Item 4)
[Figure 70-60-4].
P-4956
Remove the spacers, bolt and washers from the arm
[Figure 70-60-2].
Installation: Put a small amount of grease around the
outside edge on the grease rings (Item 1) [Figure 70-602] between ring and bearing.
Check all parts for damage or wear and replace them as
needed.
NOTE: When making any repairs, replace the bronze
bushing (Item 5) [Figure 70-60-4] with a new
style nylon bushing. Clean all parts and
assemble dry. Do not lubricate. (See Parts
Manual for correct part numbers.)
70-60-1
863 Bobcat Loader
Service Manual
COOLING FAN (CONT'D)
Figure 70-60-6
Gearbox/Blower Housing Removal And Installation
2
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Figure 70-60-5
1
1
P-7966
N-19623
Remove the mounting bolts (Item 1) [Figure 70-60-5]
from the gas cylinder mounting bracket. (See Gas
Cylinder Removal And Installation on Page 50-20-1.)
Installation: Tighten the mounting bolts to 80-90 in.-lbs.
(9-10 Nm) torque.
Remove the hydraulic fluid reservoir. (See Removal And
Installation on Page 20-80-1.)
Disconnect the wiring
1)[Figure 70-60-6].
harness
connectors
(Item
Remove the harness clamp (Item 2) [Figure 70-60-6].
Move the electrical harness down for clearance at the
blower housing.
70-60-2
863 Bobcat Loader
Service Manual
COOLING FAN (CONT'D)
Figure 70-60-9
Gearbox/Blower Housing Removal And Installation
(Cont'd)
1
Figure 70-60-7
2
2
Oil Level
1
P7936-
Remove the sealant from the blower housing and loader
frame (Item 1) [Figure 70-60-9].
N-19736
Remove the belt shield (Item 1) [Figure 70-60-7] from
the fan drive.
Remove fuel fill hose (Item 2) [Figure 70-60-9] and the
fuel vent hose.
Figure 70-60-10
Disconnect the breather hose (Item 2) [Figure 70-60-7]
from the fan drive housing.
Installation: When checking the fan gearbox oil level,
make sure the level does not go above the top of the
shaft in the gearbox [Figure 70-60-7]. Use 90W gear
lube oil if the level is low.
Figure 70-60-8
1
P-7775
Remove the four mounting bolts (Item 1) [Figure 70-6010] and spacer tubes (two outside housing and two
inside housing).
1
P-7774
Remove the fan drive belt (Item 1) [Figure 70-60-8].
NOTE: Remove the two rear mounting bolts first.
Installation: Use sealant on each end of the inside
spacer tubes to prevent the tubes from falling out of the
housing during installation. Tighten the mounting bolts to
25-28 ft.-lbs. (34-38 Nm) torque.
70-60-3
863 Bobcat Loader
Service Manual
COOLING FAN (CONT'D)
Figure 70-60-12
Gearbox/Blower Housing Removal And Installation
(Cont'd)
Figure 70-60-11
1
1
P-7776
The blower housing must be moved away from the loader
frame if the side grills need to be replaced [Figure 70-6012].
P-7773
Slide the blower housing forward and remove the fan/fan
gearbox assembly. Remove the blower housing [Figure
70-60-11].
To replace the side grill, remove the four mounting
screws (Item 1) [Figure 70-60-12] from the blower
housing.
Install the new grill and replace the screws.
Installation: Use R.T.V. sealant to re-seal the blower
housing to the loader frame (Item 1) [Figure 70-60-9].
(See Gearbox Disassembly on page 70-60-7 for
Disassembly of the Fan Gearbox.)
70-60-4
863 Bobcat Loader
Service Manual
COOLING FAN (CONT'D)
Figure 70-60-15
Blower Removal And Installation
Figure 70-60-13
CD-9953
Remove the fan from the tapered shaft [Figure 70-6015].
CD-9952
Figure 70-60-16
Remove the lock nut and spacer [Figure 70-60-13].
Installation: Tighten the nut to 45-55 ft.-lbs. (61-75 Nm)
torque.
1
Figure 70-60-14
1
2
1
CD-9954
To remove the blower housing mounting plate, remove
the six bolts (Item 1) [Figure 70-60-16].
1
P-3006
Use the following procedure to remove the fan from the
shaft:
Install the nut (Item 1) [Figure 70-60-14] on the tapered
shaft to protect the shaft and threads.
Install the puller on the fan as shown [Figure 70-60-14].
As the center bolt (Item 2) [Figure 70-60-14] is
tightened, periodically strike the bolt head to loosen the
fan from the shaft.
70-60-5
863 Bobcat Loader
Service Manual
COOLING FAN (CONT'D)
Gearbox Parts Identification
1
18
1
6
2
3
4
4
7
5
8
22
4
12
13
9
14
10
*16
21
11
15
17
20
1. Seal
2. Snap Ring (Small)
3. Shims (1.0 inch O.D.)
4. Bearing
5. Shaft (Long)
6. Shims (2.0 inch O.D.)
7. Long Key
8. Shaft (Short)
9. Short Key
10. Long Housing
12
11. Nut
12. Gear
13. Washer
14. Screw
15. Square Shim
*16. Short Housing
17. Bolt
18. Snap Ring (Large)
19. Cap
20. Long Housing Assy.
21. Short Housing Assy.
22. Fill Plug
3
4
13
14
18
19
*Individual Part not available
TS-1002A
70-60-6
863 Bobcat Loader
Service Manual
COOLING FAN (CONT'D)
Figure 70-60-18
Gearbox Disassembly
Figure 70-60-17
Part Number
Tag
2
P2983
3
1
Remove the four mounting bolts and the part number tag
[Figure 70-60-18].
P-37891
NOTE: When repairing the
following as needed:
gearbox
order
the
Remove the oil from the gearbox.
WARNING
1. Complete Assembly
2. Long Housing Assembly
3. Long Housing
4. Short Housing Assembly (See Note Below)
5. Internal Parts
AVOID INJURY OR DEATH
Wear safety goggles to prevent eye injury when
drilling or grinding.
NOTE: The short housing is only available as an
assembly. (See Gearbox Parts Identification
on page 70-60-6) (Order parts from Bobcat
Parts Sales.)
W-2108-1186
Figure 70-60-19
NOTE: Be sure to count the number and thickness of
shims during disassembly. Install the shims
in the original location during assembly.
Remove the fan and blower housing mounting plate. (See
Gearbox/Blower Housing Removal And Installation on
page 70-60-2)
Long Housing
Loosen the set screws (Item 1) [Figure 70-60-17] and
remove the pulley (Item 2) [Figure 70-60-17].
P-2999
Remove the long key (Item 3) [Figure 70-60-17].
Drill an 1/8 inch (13 mm) hole in the seal. Use a slide
hammer tool to remove the seal [Figure 70-60-19].
70-60-7
863 Bobcat Loader
Service Manual
COOLING FAN (CONT'D)
Figure 70-60-22
Gearbox Disassembly (Cont'd)
Figure 70-60-20
P-2966
P-2964
Remove the screw and washer from the shaft [Figure 7060-22].
Figure 70-60-23
Remove the small snap ring [Figure 70-60-20].
Figure 70-60-21
P-3004
P-2963
Remove the small shims [Figure 70-60-21].
Support the lower flange and press the shaft from the
bearing [Figure 70-60-23].
NOTE: The gear and the other bearing (pulley end)
will be removed with the shaft.
70-60-8
863 Bobcat Loader
Service Manual
COOLING FAN (CONT'D)
Figure 70-60-26
Gearbox Disassembly (Cont'd)
Figure 70-60-24
P-2996
Drill an 1/8 inch (3 mm) hole in the seal. Use a slide
hammer tool to remove the seal [Figure 70-60-26].
P-3298
Figure 70-60-27
Support the bearing and press the shaft from the bearing
[Figure 70-60-24].
Short Housing
WARNING
AVOID INJURY OR DEATH
Wear safety goggles to prevent eye injury when
drilling or grinding.
W-2108-1186
P-2970
Figure 70-60-25
Remove the large snap ring from the flange end of the
housing [Figure 70-60-27].
P-2997
Remove the end cap [Figure 70-60-25].
Use care not to damage the housing.
70-60-9
863 Bobcat Loader
Service Manual
COOLING FAN (CONT'D)
Figure 70-60-30
Gearbox Disassembly (Cont'd)
Figure 70-60-28
P-2973
Remove the snap ring from the cap end of the housing
[Figure 70-60-30].
P-2969
Remove the large shims from the housing [Figure 70-6028].
Figure 70-60-31
NOTE: Use the same size and thickness of shims
during assembly.
Figure 70-60-29
P-2998
Press the shaft from the housing [Figure 70-60-31].
1
NOTE: Both bearings may come out of the housing
with the shaft. If one bearing remains in the
housing, use a non metal object to tap the
bearing from the housing.
P-2978
Remove the screw and washer (Item 1) [Figure 70-6029] from the shaft.
70-60-10
863 Bobcat Loader
Service Manual
COOLING FAN (CONT'D)
Figure 70-60-34
Gearbox Disassembly (Cont'd)
Figure 70-60-32
1
P-2972
Remove the key (Item 1) [Figure 70-60-34] from the
shaft.
P-3088
Press the bearing from the tapered end of the shaft
[Figure 70-60-32].
Figure 70-60-33
P-3001
Press the bearing, shims and gear from the shaft [Figure
70-60-33].
70-60-11
863 Bobcat Loader
Service Manual
COOLING FAN (CONT'D)
Figure 70-60-36
Gearbox Assembly
NOTE: See Gearbox Parts Identification on page 7060-6 when ordering parts for the Fan Gearbox.
Always replace seals during assembly.
Replace the parts in the gearbox as needed.
NOTE: Do not install the seals and cap in the housing
until after the backlash has been checked.
NOTE: Use care when pressing the bearings into the
aluminum housing. The housing can be
damaged if too much pressure is used.
NOTE: For procedures requiring the use of #242
LOCTITE adhesive, thoroughly clean and dry
affected parts before the application of #242
LOCTITE.
P-2960
Install the long housing on the shaft [Figure 70-60-36].
Long Housing
Be sure the bearing is seated in the bore at the lower end
of the housing.
Figure 70-60-35
Figure 70-60-37
P-2962
P-2961
Press a bearing on the short keyed end of the long shaft
[Figure 70-60-35].
Install a bearing on the long keyed end of the shaft
[Figure 70-60-37].
Support the lower bearing and press the other bearing in
the housing until the bearings seat in the housing [Figure
70-60-37].
70-60-12
863 Bobcat Loader
Service Manual
COOLING FAN (CONT'D)
Figure 70-60-40
Gearbox Assembly (Cont'd)
Figure 70-60-38
P-2965
Install the gear key in the flange end of the shaft [Figure
70-60-40].
P-2963
Figure 70-60-41
Install on the bearing, the same number and size shims
that were removed during disassembly [Figure 70-6038].
Figure 70-60-39
P-2967
Align the key and gear. While supporting the bearing on
the other end, press the gear on the shaft until it seats
against the bearing [Figure 70-60-41].
P-2964
Install the small snap ring in the groove above the shims
[Figure 70-60-39].
70-60-13
863 Bobcat Loader
Service Manual
COOLING FAN (CONT'D)
Figure 70-60-44
Gearbox Assembly (Cont'd)
Figure 70-60-42
P-2969
Install the large shims on the bearing (flanged end)
[Figure 70-60-44].
P-2966
Figure 70-60-45
Install the washer [Figure 70-60-42].
Put liquid adhesive (LOCTITE #242) on the screw
threads. Install and tighten the screw [Figure 70-60-42].
Short Housing
Figure 70-60-43
P-2970
Install the large snap ring in the groove above the shims
[Figure 70-60-45].
P-2968
Install a bearing in the flanged end of the housing
[Figure 70-60-43].
70-60-14
863 Bobcat Loader
Service Manual
COOLING FAN (CONT'D)
Figure 70-60-48
Gearbox Assembly (Cont'd)
Figure 70-60-46
P-2976
1
Install the shaft in the housing, tapered end in the bearing
at the round flange end of the housing [Figure 70-60-48].
P-2971
Figure 70-60-49
Install the short key (Item 1) [Figure 70-60-46].
Align and press the gear on the shaft (teeth toward the
tapered end of the shaft)[Figure 70-60-46].
Figure 70-60-47
P-2977
Install on the shaft, the same number and size shims that
were removed during disassembly [Figure 70-60-49].
P-2975
After the gear is seated, drive the key down inside the
gear key way [Figure 70-60-47].
NOTE: This will prevent damage to the shims when
the bearing is installed later.
70-60-15
863 Bobcat Loader
Service Manual
COOLING FAN (CONT'D)
Figure 70-60-52
Gearbox Assembly (Cont'd)
Figure 70-60-50
1
P-2978
Install the washer (Item 1) [Figure 70-60-52] on the
shaft. Put liquid adhesive (LOCTITE #242) on the screw
threads and install the screw [Figure 70-60-52].
P-2974
Install a bearing on the gear end of the shaft [Figure 7060-50].
Figure 70-60-51
P-2973
Install the snap ring in the groove above the bearing
[Figure 70-60-51].
70-60-16
863 Bobcat Loader
Service Manual
COOLING FAN (CONT'D)
Figure 70-60-54
Gearbox, Checking Backlash
NOTE: For procedures requiring the use of #242
LOCTITE adhesive, thoroughly clean and dry
affected parts before the application of #242
LOCTITE.
The backlash tolerance between the gears should be
0.005-0.008 inch (0,127-0,203 mm).
To check the gear backlash use the following procedure:
Figure 70-60-53
P-2981
Install the same size and number of square shims (if
present during disassembly) between the two housings
[Figure 70-60-54].
Set the long housing on the short housing with a small
amount of liquid adhesive (LOCTITE #242) between the
mounting surfaces.
NOTE: If square shims are used, put a small amount
of the liquid adhesive on both sides of all
shims.
P-2987
Figure 70-60-55
Put the short housing in a vise, square flange facing up
as shown [Figure 70-60-53].
Part Number
Tag
P-2983
Install the four mounting bolts through the flange holes
[Figure 70-60-55].
Install the part number tag [Figure 70-60-55].
Install and tighten the nut to 25-28 ft.-lbs. (34-38 Nm)
torque.
70-60-17
863 Bobcat Loader
Service Manual
COOLING FAN (CONT'D)
Figure 70-60-58
Gearbox, Checking Backlash (Cont'd)
Figure 70-60-56
1
2
1.000”
(25,4mm)
P-37893
1
Using a magnetic based dial indicator mounted on a
bench vise, touch the dial stem on the bolt (Item 1)
[Figure 70-60-58].
P-37894
Install the long key (Item 1) [Figure 70-60-56] and the
pulley (Item 2) [Figure 70-60-56].
Install a bolt in the set screw hole to maintain a 1.000
inch (25,4 mm) distance from the shaft center to the bolt
head (to be used with a dial indicator)[Figure 70-60-56].
Figure 70-60-57
Hold the locking pliers against the long housing and
rotate the pulley back and forth to read the dial gauge
[Figure 70-60-58].
If the backlash is GREATER than 0.008 inch (0,203 mm),
do the following:
1. Remove a square shim(s) (if present) between the
two housing
2. Remove a large shim(s) from the tapered end of the
short shaft and add a small shim (s) of the same
thickness between the bearing and the gear on the
screw end of the shaft.
If the backlash is LESS than 0.005 inch (0,127 mm) do
the following:
1
1. Add a square shim(s) between the two housings.
2. Remove a small shim(s) between the bearing and the
gear on the screw end of the short shaft and add a
large shim(s) of the same thickness between the snap
ring and the bearing on the tapered end of the shaft.
P-37892
Put the fan nut (Item 1) [Figure 70-60-57] on the shaft
and tighten snugly.
Install a locking pliers on the fan nut and support the
handle against the long housing [Figure 70-60-57].
70-60-18
863 Bobcat Loader
Service Manual
COOLING FAN (CONT'D)
Figure 70-60-60
LONG HOUSING
Gearbox Checking Backlash (Cont'd)
Figure 70-60-59
P2985
Figure 70-60-61
P3089
SHORT HOUSING
When the backlash is correct, install the seals, cap and
gear oil as follows:
Remove the bolts from the flanges and separate the two
housings.
Put liquid adhesive (LOCTITE #242) on the outside
diameter of the seal(s) [Figure 70-60-59].
P2986
Install the seal(s) flush with the housing surface [Figure
70-60-60] & [Figure 70-60-61].
Clean any oil from the flange surface.
Install the long housing on the short housing flange.
Install the four bolts and part number tag.
Install and tighten the nuts to 25-28 ft.-lbs. (34-38 Nm)
torque.
NOTE: When filling the fan gearbox with oil, be sure
the level does not go above the top of the
shaft in the gearbox. Use a light colored 90W
gear lube.
70-60-19
863 Bobcat Loader
Service Manual
70-60-20
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS
Figure 70-70-3
Engine Compression, Checking
The tools listed will be needed to do the following
procedure:
MEL 10630 Engine Compression Tester
MEL 1489 Compression Test Adapter
1
Warm the engine.
Clean the area around the fuel injection pump, injectors
and glow plugs.
Figure 70-70-1
N-19012
Figure 70-70-4
1
1
N-19024
Remove the electrical connection (Item 1) [Figure 70-701] from the fuel shut off solenoid.
Figure 70-70-2
N-19022
Install the compression adapter tool (Item 1) [Figure 7070-3] & [Figure 70-70-4] into the glow plug hole and
tighten to 15-18 ft.-lbs. (20-24 Nm) torque.
2
1
N-19021
Remove the high pressure fuel line (Item 1) [Figure 7070-2] from the fuel pump and the fuel injector.
Installation: Tighten the fuel line nuts to 10-12 ft.-lbs.
(13,5-16,5 Nm) torque.
Disconnect the glow plug harness (Item 2) [Figure 7070-2] from the glow plug.
Remove the glow plug from the cylinder head.
Installation: Tighten the glow plugs to 15-18 ft.-lbs. (2024 Nm) torque.
70-70-1
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-7
Engine Compression, Checking (Cont'd)
Figure 70-70-5
P-9452
Use a test meter to measure the resistance of each glow
plug.
N-19023
Connect the compression gauge to the adapter [Figure
70-70-5].
Turn the engine with the starter at 200 to 300 RPM. Run
the test for each cylinder two times at 5 to 10 seconds
each time and take the average reading.
Connect the test meter lead to the terminal of the glow
plug as shown in figure [Figure 70-70-7].
Touch the other lead from the test meter to the base of
the glow plug as shown in figure [Figure 70-70-7].
The reading must be approximately 0.2 ohms.
The correct compression to the engine is 320-392 PSI
(2206-2703 kPa) with no more than 10% difference
between the cylinders.
If the resistance is zero ohms the glow plug has a short
circuit and must be replaced.
Glow Plug, Checking
If the resistance is infinite, the coil of the glow plug is
broken and the glow plug must be replaced.
Figure 70-70-6
1
P-9451
Loaders use four glow plugs, one for each cylinder. The
glow plugs are located on the rear side of engine in the
cylinder head as shown in figure [Figure 70-70-6].
Unplug the wire from the glow plug (Item 1) [Figure 7070-6].
70-70-2
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-10
Fuel Shut-Off Solenoid, Checking
1
Figure 70-70-8
1
N-19026
1
The reading must be approximately 02.8 ohms.
N-19024
Remove the screw (Item 1) [Figure 70-70-8] from the
electrical connection on the fuel shut off solenoid.
If the resistance is zero ohms the solenoid has a short
circuit.
If the resistance is infinite, the coil in the solenoid is
broken.
Disconnect the electrical connector from the solenoid.
Replace the solenoid if needed. (See “Fuel Shut-Off
Solenoid Removal and Installation” on Page 70-70-4)
Figure 70-70-9
1
N-19025
Use a test meter to measure the resistance of the fuel
shut-off solenoid.
Connect the test meter leads to the terminals (Item 1)
[Figure 70-70-9] & [Figure 70-70-10].
70-70-3
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Fuel Injection Pump Removal
Fuel Shut-Off Solenoid Removal and Installation
The injection pump(s) contain parts which have a very
close tolerance and its operation has a direct effect on
the performance of the engine.
Figure 70-70-11
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
1
I-2028-0289
Figure 70-70-13
3
3
N-19027
Remove the two mounting bolts (Item 1) [Figure 70-7011].
2
Installation:Tighten the mounting bolts to 10-12 ft.-lbs.
(13,5-16,3 Nm) torque.
2
1
Remove the fuel shut-off solenoid from the engine.
Figure 70-70-12
P-5282
Remove the fuel tubeline (Item 1) [Figure 70-70-13] to
the fuel injection pumps (Item 2) [Figure 70-70-13].
1
Disconnect the respective high pressure fuel line (Item 3)
[Figure 70-70-13] from the injection pump to be removed
and fuel injector.
2
N-19028
Check the solenoid spring (Item 1) [Figure 70-70-12]
and linkage (Item 2) [Figure 70-70-12]. Replace the
solenoid as needed.
NOTE: When installing the fuel shut-off solenoid in
the engine the linkage (Item 2) [Figure 70-7012] must engage the fuel control rack.
70-70-4
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-16
Fuel Injection Pump Removal (Cont'd)
1
IMPORTANT
2
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
Figure 70-70-14
P-5283
Remove the fuel injection pump (Item 1) [Figure 70-7016].
Remove the shim (Item 2) [Figure 70-70-16].
NOTE: The shim(s) are used to time the injection
pump, keep the same thickness for each
injection pump.
1
Figure 70-70-17
P-5280
Use a flare nut wrench (Item 1) [Figure 70-70-14] to
loosen the high pressure fuel line nut.
Figure 70-70-15
P-5279
1
Use a magnet to remove the injection pump tappet
[Figure 70-70-17].
Inspect the tappet for wear or damage, replace as
needed.
P-5281
Remove the two mounting nuts (Item 1) [Figure 70-7015] from the injection pump.
70-70-5
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-20
Fuel Injection Pump Removal (Cont'd)
Figure 70-70-18
Tappet
a
MC-2175
Measure the distance between the engine block surface
(without shim) and surface of the tappet [Figure 70-7020].
P-5278
Install the tappet into its respective bore [Figure 70-7018].
Installation dimension of the injection pump is 2.32 inch
(59 mm).
EXAMPLE:
Specifications:
Fuel Injection Pump Timing
The fuel injection pump does not need to be timed if the
tappet, shim(s) and the camshaft are not changed.
Installation Depth
Measured Depth a
Difference
Figure 70-70-19
2.32 inch (59 mm)
2.25 inch (57,55 mm)
0.07 inch (1.78 mm)
Determine the number of shim(s) needed to get the
correct installation height.
1
Install the appropriate number of shims(s) on the engine
block surface.
P-5284
Install a depth micrometer (Item 1) [Figure 70-70-19].
70-70-6
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-23
Fuel Injection Pump Installation
Figure 70-70-21
2
1
1
P-5288
Use the centering pin (Item 1) [Figure 70-70-23] to
remove the press-in plug (Item 2) [Figure 70-70-23] from
the injection pump. (See “Deutz Engine Tools
Identification Chart” on Page 70-100-1 for correct tool.)
P-5287
Remove the plug from the engine block. Install controll
rack locating pin (Item 1) [Figure 70-70-21]. (See “Deutz
Engine Tools Identification Chart” on Page 70-100-1 for
correct tool.)
Figure 70-70-24
Figure 70-70-22
2
3
1
1
2
P-5289
P-5286
Move the control rack until the slot (Item 1) [Figure 7070-22] is in the center of the injection pump bore.
Install the centering pin (Item 1) [Figure 70-70-24] into
the injection pump and into the control lever (Item 2)
[Figure 70-70-24]. Align the marks (Item 3) [Figure 7070-24] on the pump body and the control lever. Make
sure the control lever is in the center position.
Tighten the locating pin (Item 2) [Figure 70-70-22].
70-70-7
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-27
Fuel Injection Pump Installation (Cont'd)
Figure 70-70-25
1
P-5280
2
1
Install the high pressure fuel line.
P-5294
Tighten the fuel line nut to 10-12 ft.-lbs. (13,5-16,5 Nm)
torque [Figure 70-70-27].
Install the injection pump into the engine block. Make
sure the control lever goes into the slot on the fuel control
rack.
Figure 70-70-28
Install the two nuts (Item 1) [Figure 70-70-25].
Tighten the mounting nuts to 15 ft.-lbs. (21 Nm) torque
[Figure 70-70-25].
Figure 70-70-26
1
P-5285
Install new washers (Item 1) [Figure 70-70-28] on the
fuel line fastening bolt.
2
Install the fuel line on the injection pumps and tighten to
20-23 ft.-lbs. (27-31 Nm) torque.
1
P-5291
Remove the fuel control rack locating pin (Item 1) [Figure
70-70-26] and install the plug.
Remove the centering pin (Item 2) [Figure 70-70-26] and
install the press-in plug (Item 2) [Figure 70-70-25].
70-70-8
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D)
Figure 70-70-30
Fuel Injector Removal and Installation
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
1
I-2029-0289
Figure 70-70-29
P-5293
Remove the bolt (Item 1) [Figure 70-70-30] and
holddown clamp from the fuel injector.
Installation: Tighten the bolt to 15.5 ft.-lbs. (21 Nm)
torque.
1
Figure 70-70-31
P-5280
Disconnect the respective high pressure fuel line from
fuel injector to be removed and fuel injection pump.
1
Use a flare nut wrench (Item 1) [Figure 70-70-29] to
loosen the high pressure fuel line nut.
2
Remove the high pressure fuel line.
Installation: Tighten the fuel line nut to 10-12 ft.-lbs.
(13,5-16,5 Nm) torque.
P-5290
Remove the fuel injector (Item 1) [Figure 70-70-31] and
washer (Item 2) [Figure 70-70-31] from the cylinder
head.
70-70-9
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-33
Fuel Injector, Checking
IMPORTANT
Do not disassemble or test the fuel injector nozzles
unless you have the correct service and testing
tools.
I-2027-0284
The tools listed will be needed to do the following
procedure:
OEM1064 - Injection Nozzle Tester
OEM1065 - Accessory Set
MC-2177
Check nozzles spray pattern [Figure 70-70-33]:
Figure 70-70-32
The spray pattern must be uniform from all four holes of
the nozzle.
The nozzles are dirty or defective:
•
•
•
If the spray pattern is not uniform.
If fuel drips from the end of the nozzle.
If the spray is a solid stream instead of a mist.
B-8971
Connect the nozzle to the test pump, in a down position
[Figure 70-70-32].
Injection Pressure
3045 PSI (210 bar)
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496
70-70-10
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-36
Fuel Injector Disassembly
Figure 70-70-34
CD-15334
The nozzle needle and body [Figure 70-70-36] are
lapped together and can not be exchanged with other
nozzle parts.
CD-15332
Remove the nozzle cap nut [Figure 70-70-34].
DO NOT touch the nozzle needle with your fingers.
Figure 70-70-35
When the nozzle body is held in the upright position, the
needle should by its own weight slide slowly and
smoothly on its seat [Figure 70-70-36].
NOTE: If the nozzle needle does not slide smoothly,
wash the injector nozzle parts again in clean
diesel fuel. Blow dry with compressed air. Redo the procedure again. Replace the injectors
as needed. Wash all new injectors in clean
diesel fuel before installation.
1
2
6
5
4
3
Figure 70-70-37
CD-15333
Disassemble the parts as shown in [Figure 70-70-35].
1.
2.
3.
4.
5.
6.
Nozzle Cap Nut
Injector Nozzle
Adapter
Thrust Pin
Spring
Shim(s)
CD-15335
Wash all the parts in clean diesel fuel and blow dry using
compressed air.
Check the seat surface of the adapter for wear. Make
sure the centering pins are in place [Figure 70-70-37].
70-70-11
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-40
Fuel Injector Assembly
Figure 70-70-38
CD-15338
Install the thrust pin with the centering collar facing
toward the compression spring [Figure 70-70-40].
CD-15336
Figure 70-70-41
Install the shim(s) [Figure 70-70-38].
The injector opening pressure is adjusted by selecting
the correct amount of shim(s). A thicker shim will
increase the opening pressure at the injector nozzle.
Figure 70-70-39
CD-15339
Install the adapter with the centering pins toward the
thrust pin [Figure 70-70-41].
CD-15337
Install the compression spring [Figure 70-70-39].
70-70-12
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-44
Fuel Injector Assembly (Cont'd)
Figure 70-70-42
CD-15342
Tighten the cap nut to 35 ft.-lbs. (47 Nm) torque [Figure
70-70-44].
CD-15340
Install the injector nozzle, make sure the center bore fits
over the centering pins of the adapter [Figure 70-70-42].
Check the injector nozzle on the nozzle tester before
installation. (See “Deutz Engine Tools Identification
Chart” on Page 70-100-1 for correct tool.)
NOTE: Be careful that the nozzle needle does not fall
out of the nozzle body.
Figure 70-70-43
CD-15341
Install the nozzle cap nut [Figure 70-70-43].
70-70-13
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-46
Timing Belt Inspection
NOTE: The timing belt is maintenance free. Timing
belts that are in operation do not need to be
re-tensioned. The timing belt, belt tensioner
and mount bolt must be replaced every 3000
operating hours or every 5 years. A repair kit
is available.
NOTE: If the timing belt has to be removed before
200 hours of engine operation, the timing belt
can be re-used and re-tensioned according to
the procedure listed.
P-5298
To do the following procedure you need the following tool:
Check the timing belt, sprockets and tensioner for wear,
cracks or damage [Figure 70-70-46].
MEL1552 - Torx Bit
Figure 70-70-45
Check the timing belt in detail for the following conditions,
replace as needed.
1.
2.
3.
4.
5.
6.
7.
2
1
P-5292A
Oil deposits
Hardened back rubber surfaces
Cracked
Badly worn teeth
Missing tooth
Side of belt badly worn
Side of belt cracked
Timing Belt Removal
Remove the bolts (Item 1) [Figure 70-70-45] from the
timing belt inspection cover.
3
P-5292
Remove the bolts (Item 1) [Figure 70-70-45] from the
timing belt inspection cover.
Remove the torx bolt (Item 2) [Figure 70-70-45].
Remove the cover (Item 3) [Figure 70-70-45].
Remove the torx bolt (Item 2) [Figure 70-70-45].
Remove the cover (Item 3) [Figure 70-70-45].
70-70-14
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Timing Belt Installation
Timing Belt Removal (Cont’d)
Figure 70-70-49
Figure 70-70-47
3
1
4
1
1
2
P-9575
P-5295
Remove the bolts (Item 1) [Figure 70-70-47] from the vbelt pulley (Item 2) [Figure 70-70-47].
NOTE: Remove the fuel injectors from the cylinder
head. (See “Fuel Injector Removal and
Installation” on Page 70-70-9) This will let the
crankshaft turn easier for timing belt
installation.
Remove the V-belt pulley.
Remove the bolts (Item 3) [Figure 70-70-47] from the
timing belt cover.
Remove the cover (Item 4) [Figure 70-70-47].
The camshaft plug is located at the rear of the engine
block (Item 1) [Figure 70-70-49] on the fuel injection
pump side. See “Deutz Engine Tools Identification Chart”
on Page 70-100-1 for the correct tool.
Remove the plug.
Figure 70-70-48
Rotate the camshaft until the notch in the camshaft can
be seen through the plug hole.
Figure 70-70-50
1
1
P-5299
Loosen the belt tensioner mounting bolt (Item 1) [Figure
70-70-48].
P-9573
Loosen the belt tensioner.
Remove the timing belt.
Install the timing tool (Item 1) [Figure 70-70-50] and
tighten.
70-70-15
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-53
Timing Belt Installation (Cont'd)
Figure 70-70-51
1
2
P-5301
P-9577
Loosen the nut at the camshaft gear [Figure 70-70-53].
(See “Deutz Engine Tools Identification Chart” on Page
70-100-1 for correct tool.)
P-9578
The crankshaft plug is located at the front of the engine
block (Item 1) [Figure 70-70-51] on the exhaust manifold
side.
Install the new timing belt.
Figure 70-70-54
Remove the plug.
Figure 70-70-52
1
2
P-5630
Measure the distance from the edge of the belt to the
front cover surface [Figure 70-70-54].
B-14401
Rotate the crankshaft until the flat spot on the crankshaft
throw (Item 1) [Figure 70-70-52] can be seen through
the plug hole. Turn the crankshaft back a small amount.
Install the timing tool (Item 2) [Figure 70-70-51] &
[Figure 70-70-52] and tighten.
Rotate the crankshaft until it hits the timing tool and
stops.
70-70-16
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-57
Timing Belt Installation (Cont'd)
Figure 70-70-55
N-18867
Remove the belt tension tool.
P-5632
Initially tighten camshaft bolt to 22 ft.-lbs. (30 Nm)
[Figure 70-70-57].
Using the dimension, align the timing belt to make sure it
is at an equal distance from the front cover [Figure 7070-55].
Figure 70-70-58
1
Figure 70-70-56
2
1
N-18866
With a torque degree wheel (Item 1) [Figure 70-70-58]
tighten the camshaft bolt an additional 210°.
N-18863
Install the belt tension tool (Item 1) [Figure 70-70-56].
(See “Deutz Engine Tools Identification Chart” on Page
70-100-1 for correct tool.)
Remove the camshaft and crankshaft locating pins. .
Turn the idler tensioner pulley in counterclockwise
direction to obtain a scale reading of 3.0-3.5. Tighten the
idler tensioner pulley nut (Item 2) [Figure 70-70-56] to 33
ft.-lbs. (45 Nm) torque.
70-70-17
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-61
Timing Belt Installation (Cont'd)
Figure 70-70-59
1
1
N-18853
Check the position of the belt tension tool (Item 1)
[Figure 70-70-61] on the belt.
N-18864
Figure 70-70-62
Mark the crankshaft pulley (Item 1) [Figure 70-70-59].
Make four complete crankshaft revolutions in a clockwise
direction of engine rotation. Bring the mark on the
crankshaft pulley back to the same position.
Figure 70-70-60
2
N-18865
Measure the belt tension [Figure 70-70-62], the reading
should be 6.5-9.5.
1
NOTE: If the specified scale reading is not obtained,
repeat the installation procedure starting with
[Figure 70-70-49].
N-18852
Install the belt tension tool (Item 1) [Figure 70-70-60].
Remove the belt tension tool.
NOTE: The belt tension tool may touch the governor
linkage cover (Item 2) [Figure 70-70-60], but
will not effect the belt tightening procedure.
70-70-18
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Timing Belt, Replacement In the Loader
Timing Belt Installation (Cont’d)
Figure 70-70-65
Figure 70-70-63
1
2
1
2
P-5295
NOTE: See “Valve Timing, Checking” on Page 70-7025 before installing the timing belt cover.
Install the belt cover (Item 1) [Figure 70-70-63] and
tighten the bolts.
Install the v-belt pulley (Item 2) [Figure 70-70-63] and
tighten the bolts to 30-36 ft.-lbs. (41-49 Nm) torque.
Figure 70-70-64
P-9566
Use the following procedure to replace the timing belt,
tensioner and tensioner bolt. If the belt is broken,
additional procedures are required and noted.
•
For Broken Belt Replacement Only
•
Remove the engine muffler. (See Removal And
Installation on Page 70-30-1.)
Remove the valve cover. Remove and inspect the
rocker arms/brackets and push rods. (See Valves,
Checking on Page 70-100-39.)
•
Disconnect the negative (-) battery cable.
1
Loosen the screw and unplug the fuel solenoid connector
(Item 1) [Figure 70-70-65].
P-5292
Install the timing belt inspection cover (Item 1) [Figure
70-70-64] and tighten the bolts.
NOTE: Do not lose the rubber seal gasket on the
solenoid connector.
Remove the bolts (Item 2) [Figure 70-70-65] holding the
belt shield. Move the shield away from the work area.
70-70-19
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-68
Timing Belt, Replacement In the Loader (Cont'd)
Figure 70-70-66
1
1
2
N-20431
Remove the camshaft access plug (Item 1) [Figure 7070-68].
P-9563
Loosen the alternator adjustment bolt (Item 1) [Figure
70-70-66] and remove the alternator belt.
Figure 70-70-69
Remove the crankshaft pulley bolts (Item 2) [Figure 7070-66]. Remove the pulley.
Figure 70-70-67
1
2
P-9577
2
Remove the crankshaft access plug (Item 1) [Figure 7070-69].
1
NOTE: The plug is located on the front of crankcase,
below the turbocharger and just above the
right side front engine mount.
P-9564
Remove the throttle linkage bolts (Item 1) [Figure 70-7067]. Lower the throttle linkage.
Remove the four belt cover bolts (Item 2) [Figure 70-7067]. Remove the front and rear belt covers.
70-70-20
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-72
Timing Belt, Replacement In the Loader (Cont'd)
Figure 70-70-70
1
P-9605
•
For Broken Belt Replacement Only
•
Remove the number four cylinder fuel injector. (See
“Fuel Injector Removal and Installation” on Page 7070-9)
•
Rotate the crankshaft and use a wire (Item 1) [Figure
70-70-72] in the fuel injector hole to indicate piston is
moving upward, to top dead center (T.D.C.).
P-9570
Rotate the crankshaft in correct rotation as shown in
figure [Figure 70-70-70] until the notch in the camshaft
can be seen through the access hole.
NOTE: The crankshaft must be turned in correct
rotation. Turn clockwise as viewed from the
timing belt end of engine as shown.
Figure 70-70-71
NOTE: The crankshaft must be turned in correct
rotation. Turn clockwise as viewed from the
timing belt end of engine.
Figure 70-70-73
1
1
P-9573
Install the camshaft timing tool (Item 1) [Figure 70-7071] and tighten. (See “Deutz Engine Tools Identification
Chart” on Page 70-100-1 for correct tool.)
P-9578
•
•
Install the crankshaft timing tool (Item 1) [Figure 7070-73] and tighten. (See “Deutz Engine Tools
Identification Chart” on Page 70-100-1 for correct
tool.)
Rotate crankshaft against timing tool.
Install the crankshaft timing tool (Item 1) [Figure 70-7073] and tighten. (See “Deutz Engine Tools Identification
Chart” on Page 70-100-1 for correct tool.)
70-70-21
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-76
Timing Belt, Replacement In the Loader (Cont'd)
Figure 70-70-74
1
P9576
P-9574
Install the belt tension tool as shown in [Figure 70-7076]. (See “Deutz Engine Tools Identification Chart” on
Page 70-100-1 for correct tool.)
P-9565
Remove the tensioner bolt (Item 1) [Figure 70-70-74]
and the tensioner. Remove the timing belt.
Figure 70-70-77
NOTE: The timing belt, belt tensioner and mount bolt
must be replaced as a set. A repair kit is
available.
Install the new timing belt, belt tensioner and mount bolt.
Do not tighten the mount bolt.
NOTE: Align the timing belt on gears to obtain equal
distance between the belt and front cover to
insure belt runs straight on gears.
Figure 70-70-75
P-9579
Use a hex wrench to turn the idler tension pulley in
counterclockwise direction as shown in figure [Figure 7070-77]. Obtain a scale reading of 3.0-3.5. Tighten the
idler tension pulley mount bolt to 33 ft.-lbs. (45 Nm)
torque.
P-9571
Install the camshaft gear tool (Item 1) [Figure 70-70-75].
(See “Deutz Engine Tools Identification Chart” on Page
70-100-1 for correct tool.)
Loosen the camshaft gear [Figure 70-70-75].
70-70-22
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-80
Timing Belt, Replacement In the Loader (Cont'd)
Figure 70-70-78
P-9570A
Make four complete crankshaft revolutions in the
direction of engine rotation. Bring the mark on the
crankshaft pulley back to the same position as before
[Figure 70-70-80].
P-9569
Remove the belt tension tool, hex wrench and torque
wrench.
Install the belt tension tool. Check the belt tension
reading. It should be 6.5-9.5.
Install the camshaft gear tool.
Tighten camshaft bolt to 22 ft.-lbs. (30 Nm) torque as
shown in figure [Figure 70-70-78]. Mark the camshaft
bolt and tighten an additional 210°.
Figure 70-70-79
NOTE: If the specified scale reading is not obtained,
repeat the procedure.
Remove the belt tension tool.
•
For Broken Belt Replacement Only
•
Install the push rods and rocker arms/brackets.
Replace all damaged parts. (See Contents, Page 7001.)
Set the valve clearance. (See “Valve Clearance
Adjustment” on Page 70-70-24)
Install the valve cover and gasket. Tighten the bolts
to 75 in.-lbs. (8,5 Nm) torque.
•
1
•
Install the crankshaft and camshaft access plugs.
Install the belt covers and four mounting bolts.
Install the throttle linkage and bolts.
P-9565A
Remove the camshaft and crankshaft timing tools (Item
1) [Figure 70-70-71] & [Figure 70-70-73].
Mark the crankshaft pulley hub (Item 1) [Figure 70-7079].
Install the crankshaft pulley and bolts. Tighten the bolts to
30-36 ft.-lbs. (41-49 Nm) torque.
Install the alternator belt. Adjust the belt tension.
Install the belt shield and bolts.
Plug in the fuel solenoid connector and tighten the screw.
Reconnect the negative (-) battery cable.
70-70-23
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-83
Valve Clearance Adjustment
Figure 70-70-81
1
P-5633
Loosen the locknut and turn the set screw until the
clearance is correct.
P-5297
Intake Exhaust -
Make the valve clearance adjustment with engine
stopped and cold.
0.012 inch (0,3 mm)
0.020 inch (0,5 mm)
Tighten the locknut to 13-16 ft.-lbs. (18-22 Nm) torque.
Remove the valve cover (Item 1) [Figure 70-70-81].
When installing the valve cover bolts, tighten them to 75
in.-lbs. (8,5 Nm) torque.
Figure 70-70-82
CRANKSHAFT POSITION
ONE
Turn crankshaft
until valves
of cylinder No. 1 Overlap
DO NOT ADJUST
CRANKSHAFT POSITION
TWO
Turn crankshaft futher by
one complete revolution
(360°)
ADJUST
MC-2174
Use the following sequence as shown in figure [Figure
70-70-82] to set the valve clearance.
Turn the crankshaft until the valves of cylinder No. 1 overlap [Figure 70-70-82].
Turn the crankshaft by one complete revolution (360°)
and set the other valves.
70-70-24
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-86
Valve Timing, Checking
Figure 70-70-84
1
P-9563
At the crankshaft pulley bolt, install a torque wrench and
turn the engine in the direction of rotation to 30 ft.-lbs. (40
Nm) torque [Figure 70-70-86].
P-9575
Remove the camshaft access plug (Item 1) [Figure 7070-84].
Remove the torque wrench, DO NOT change the
crankshaft position.
Figure 70-70-85
1
P-9573
Rotate the crankshaft/camshaft until the notch in the
camshaft can be seen through the plug hole.
Install the timing tool (Item 1) [Figure 70-70-85].
70-70-25
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Valve Timing, Checking (Cont’d)
Figure 70-70-87
2
1
P-9577
P-9578
Remove the crankshaft access plug (Item 1) [Figure 7070-87].
NOTE: The access plug is located on the front of the
crankcase, below the turbocharger and just
above the right side front engine mount.
Turn the crankshaft timing tool (Item 2) [Figure 70-7087] into the crankcase until it makes slight contact with
the crankshaft.
Mark the position of the timing tool.
The valve timing is correct if the timing tool can be turned
into the crankcase another 3/4 to 2-1/4 turns until it stops.
If the timing tool can not be turned into the crankcase the
required turns, the camshaft (valve timing) setting will
have to be redone.
70-70-26
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Thermostat, Oil Pressure Control Valves And Heater
Connections
Figure 70-70-88
Remove the plug (Item 1) [Figure 70-70-88] and remove
the thermostat and spring assembly (Item 1) [Figure 7070-89] from the engine block. (See [Figure 70-70-90] for
detail parts.)
Installation: Install the plug and tighten to 82 ft.-lbs. (111
Nm) torque.
Remove the plug and O-ring (Item 2) [Figure 70-70-88]
and remove the spring and oil pressure control valve
(Item 2) [Figure 70-70-89] from the engine block. (See
[Figure 70-70-91] for detail parts.)
1
Installation: Install the plug and tighten to 82 ft.-lbs. (111
Nm) torque.
Remove the adapter fitting (Item 3) [Figure 70-70-88]
plug and O-ring (Item 3) [Figure 70-70-89]. (See [Figure
70-70-92] for detail parts.)
2
Installation: Install the fitting and/or plug and tighten to
82 ft.-lbs. (111 Nm) torque.
3
4
Remove the plug and O-ring (Item 4) [Figure 70-70-88]
and remove the spring and oil pressure control valve
(Item 4) [Figure 70-70-89] from the engine block. (See
[Figure 70-70-93] for detail parts.)
5
N-18909
Figure 70-70-89
Installation: Install the plug and tighten to 82 ft.-lbs. (111
Nm) torque.
Remove the adapter fitting (Item 5) [Figure 70-70-88]
plug and O-ring (Item 5) [Figure 70-70-89].
Remove the valve and spring (Item 6) [Figure 70-70-89]
from the engine block. (See [Figure 70-70-94] for detail
parts.)
1
Installation: Install the fitting and/or plug and tighten to 82
ft.-lbs. (111 Nm) torque.
2
NOTE: Be sure the valve and spring (Item 6) [Figure
70-70-89] is installed as shown in [Figure 7070-89].
3
4
6
5
B-14310
70-70-27
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Figure 70-70-92
Thermostat, Oil Pressure Control Valves And Heater
Connections (Cont'd)
1
Figure 70-70-90
2
1
N-18870
NOTE: The adapter fitting (Item 1) [Figure 70-70-92] is
removed when a cab heater is installed on the
loader. The port it comes from on the engine
block is the oil out let port to the heater.
N-18868
Remove the thermostat spring (Item 1) [Figure 70-70-90]
from the thermostat (Item 2) [Figure 70-70-90], inspect
all parts and replace as needed.
Installation: (See (Item 1) [Figure 70-70-88] for location
on the engine block.)
Installation: (See (Item 3) [Figure 70-70-88] for location
on the engine block.)
Figure 70-70-93
1
Figure 70-70-91
2
3
3
1
2
N-18871
Replace the O-ring (Item 1) [Figure 70-70-93]. Remove
the spring (Item 2) [Figure 70-70-93] from the oil
pressure control valve (Item 3) [Figure 70-70-93].
N-18869
Remove the spring (Item 1) [Figure 70-70-91] from the
oil pressure control valve (Item 2) [Figure 70-70-91].
Replace the O-ring (Item 3) [Figure 70-70-91].
The spring is marked with a red mark, for proper
installation. If the red mark is missing, the spring coil
diameter is .055 inch (1,4 mm).
The spring is marked with a yellow mark, for proper
installation. If the yellow mark is missing, the spring coil
diameter is .047 inch (1,2 mm).
Installation: (See (Item 4) [Figure 70-70-88] for location
on the engine block.)
Installation: (See (Item 2) [Figure 70-70-88] for location
on the engine block.)
70-70-28
863 Bobcat Loader
Service Manual
ENGINE COMPONENTS AND TESTS (CONT'D)
Thermostat, Oil Pressure Control Valves And Heater
Connections (Cont'd)
Figure 70-70-94
2
1
N-18872
Remove the spring (Item 1) [Figure 70-70-94] from the
valve (Item 2) [Figure 70-70-94].
The spring is marked with a blue mark, for proper
installation. If the blue mark is missing, the spring coil
diameter is .039 inch (1,0 mm).
Installation: (See (Item 5) [Figure 70-70-88] for location
on the engine block.)
70-70-29
863 Bobcat Loader
Service Manual
70-70-30
863 Bobcat Loader
Service Manual
ENGINE AND ENGINE MOUNTS
Figure 70-80-2
Removal And Installation
NOTE: The engine and hydrostatic pumps will be
removed as an assembly.
2
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
2
1
Place the loader on jackstands. (See LIFTING AND
BLOCKING THE LOADER on Page 10-10-1.)
Raise the operator cab. (See OPERATOR CAB on Page
10-30-1.)
Remove the rear tires. (Both Sides.)
N-19664
Mark the steering linkages (Item 1) [Figure 70-80-2].
Remove the four steering linkage bolts (Item 2) [Figure
70-80-2] and separate the linkages.
Figure 70-80-1
Installation: Tighten the nuts and bolts to 25-28 ft.-lbs.
(34-38 Nm) torque.
Figure 70-80-3
1
2
1
N-19953
Remove the eight access cover mount bolts (Item 1)
[Figure 70-80-1]. Remove the access cover (Item 2)
[Figure 70-80-1]. (Both Sides.)
Drain the fluid from the hydraulic reservoir. (See Removal
And Installation on Page 20-80-1.)
2
N-19740
Disconnect the hydraulic hose (Item 1) [Figure 70-80-3]
from the hydraulic pump to the control valve.
Disconnect the inlet hose (Item 2) [Figure 70-80-3] that
comes from the reservoir to the pump.
70-80-1
863 Bobcat Loader
Service Manual
ENGINE AND ENGINE MOUNTS (CONT’D)
Figure 70-80-6
Removal And Installation (Cont'd)
Figure 70-80-4
1
1
1
N-19956
Remove the four high pressure hoses (Item 1) [Figure
70-80-6] from the hydrostatic pump.
N-19742
Disconnect the charge pressure hose (Item 1) [Figure
70-80-4] from the charge pressure sendor.
Figure 70-80-7
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
1
I-2003-0888
Figure 70-80-5
N-19951
At the left side access cover, remove the fan drive belt
(Item 1) [Figure 70-80-7] from the flywheel pulley.
1
2
N-19736
Disconnect the hose (Item 1) [Figure 70-80-5] that goes
from the hydrostatic pump to the hydrostatic filter.
Move the charge pressure hose (Item 2) [Figure 70-805], (that was disconnected earlier) between the engine
and the pump.
70-80-2
863 Bobcat Loader
Service Manual
ENGINE AND ENGINE MOUNTS (CONT'D)
Figure 70-80-10
Removal And Installation (Cont'd)
Figure 70-80-8
1
N-19983
1
Disconnect the engine electrical harness (Item 1) [Figure
70-80-10] from the loader harness.
N-19952
Remove the engine mount bolt (Item 1) [Figure 70-80-8]
at the left front engine mount.
Figure 70-80-11
Installation: Tighten the mounting bolt to 61-69 ft.-lbs.
(83-94 Nm) torque.
Figure 70-80-9
1
1
N-19655
Disconnect the engine electrical harness (Item 1) [Figure
70-80-11] from the tailgate harness.
N-19955
Remove the engine mount bolt (Item 1) [Figure 70-80-9]
at the right front engine mount.
Installation: Tighten the mounting bolt to 61-69 ft.-lbs.
(83-94 Nm) torque.
At the engine compartment, remove the battery. (See
Removal And Installation on Page 60-20-1.)
70-80-3
863 Bobcat Loader
Service Manual
ENGINE AND ENGINE MOUNTS (CONT'D)
Figure 70-80-14
Removal And Installation (Cont'd)
Figure 70-80-12
1
N-19982
1
Disconnect and cap the engine oil to cooler hoses (Item
1) [Figure 70-80-14].
N-19959
Disconnect and plug the fuel return line (Item 1) [Figure
70-80-12].
Remove the engine air cleaner. (See Housing Removal
And Installation on Page 70-40-1.)
Remove the engine muffler.
Installation on Page 70-30-1.)
Figure 70-80-13
(See
Removal
And
Figure 70-80-15
1
1
2
1
N-19325
P-5545
Disconnect and plug the fuel supply hose (Item 1)
[Figure 70-80-13].
At the right side of the engine, remove the two throttle
bracket mount bolts (Item 1) [Figure 70-80-15].
Disconnect the throttle rod connector (Item 2) [Figure
70-80-15].
70-80-4
863 Bobcat Loader
Service Manual
ENGINE AND ENGINE MOUNTS (CONT'D)
Figure 70-80-18
Removal And Installation (Cont'd)
1
Figure 70-80-16
2
2
1
2
P-7917
Use the dimensions from [Figure 70-80-19 on Page 6] to
make engine removal and installation brackets.
3
N-19989
Disconnect the positive battery cable (Item 1) [Figure 7080-16] from the starter.
Disconnect the negative battery cable (Item 2) [Figure
70-80-16] from the starter.
Remove the left rear engine mounting bolt (Item 3)
[Figure 70-80-16] and nut.
Install the lift bracket (Item 1) [Figure 70-80-18] on the
engine.
Tighten the bolts (Item 2) [Figure 70-80-18] until the lift
bracket is held firmly against the valve cover.
NOTE: Bolts required are two 12 x 80 mm x 1.75
thread.
Installation: Tighten the bolt and nut to 61-69 ft.-lbs. (8394 Nm) torque.
Figure 70-80-17
1
N-19990
Remove the right rear engine mounting bolt (Item 1)
[Figure 70-80-17] and nut.
Installation: Tighten the bolt and nut to 61-69 ft.-lbs. (8394 Nm) torque.
70-80-5
863 Bobcat Loader
Service Manual
ENGINE AND ENGINE MOUNTS (CONT'D)
Removal And Installation (Cont'd)
Figure 70-80-19
13.0
(330)
2.5
(64)
1-1/2” I.S. Dia.
2-1/2” O.S. Dia.
2.5 (64)
1-1/2” Square Tubing
4.0
2.0 (102)
(51)
0.5
(12,7)
1/4” (4)
Thick Gusset
1.0
(25)
1.375
(35,0)
16.0
(406)
0.66 (16,8)
4.5
(114)
1.0 (25)
0.375
(9,5)
Use Two 3/8”x1-1/4” Bolts
for Drilled and Tapped Holes
1.125
(28,6)
4.0
(102)
4.25
(108)
0.5
(12,7)
1.0
(25)
0.6875
(17,5)
1.75
(44,5)
(2) 2x2x1/4
Gusset
17.750
2.0 (51)
9.0
(229)
8.525
(218)
1.125
(28,6)
0.775
(19,7)
9/16
Dia. Hole (2)
2-1/2x2-1/2x22
1/4” Thick
3/8 Dia. Hole (4)
Gusset
45°
1.75
(44,5)
MC-1799A
MC-1799A
Figure 70-80-20
Connect a chain hoist to the ring (Item 1) [Figure 70-8020] on the lift bracket.
Remove the engine/hydrostatic pump assembly from the
loader [Figure 70-80-20].
1
P-24730
70-80-6
863 Bobcat Loader
Service Manual
ENGINE AND ENGINE MOUNTS (CONT'D)
Figure 70-80-22
HEAVY DUTY
ENGINE
MOUNT
Engine Mount Replacement
Figure 70-80-21
Engine
Mounting
Bracket
Washer
1
2
Loader
Frame
3
Engine
Mount
4
5
Snubbing
Washer
6
Spacer
TS-1520
Install the new engine mount as shown in the cut away
side view [Figure 70-80-22].
7
MC-1771
Use the following procedure to install new engine
mounts:
Tighten the mounting bolts to 61-69 ft.-lbs. (83-94 Nm)
torque.
Remove the existing mount from the engine. Refer to
engine removal and installation for engine mount
locations.
Replace all four engine mounts (two front and two rear).
Use the parts shown to install the new engine mounts
[Figure 70-80-21].
Item 1 - Square Nut - Used on left side engine mounts
Item 2 - Hex Nut - Used on right side engine mounts
Item 3 - Mount Washer
Item 4 - Engine Mount
Item 5 - Tube Spacer
Item 6 - Snubbing Washer
Item 7 - Mounting Bolt
70-80-7
863 Bobcat Loader
Service Manual
70-80-8
863 Bobcat Loader
Service Manual
FLYWHEEL AND HOUSING
Ring Gear Removal And Installation
Flywheel Removal And Installation
NOTE: The lead chamfer on ring gear tooth must face
the starter.
NOTE: To avoid damage to the RPM senor, remove
the RPM sensor before removing the flywheel.
Remove the drive belt. (See DRIVE BELT on Page 3050-1.)
The ring gear (Item 1) [Figure 70-90-2] on the flywheel is
an interference fit. Heat the ring gear enough to expand it
and hit it with a hammer to remove it evenly.
Clean the outer surface of the flywheel to give it a smooth
fit.
Figure 70-90-1
Clean the new ring gear and heat it to a maximum
temperature of 428°F (220°C).
Fit the ring gear over the flywheel. Make sure the gear is
on the seat correctly.
Flywheel Housing Removal And Installation
1
Remove the drive belt. (See DRIVE BELT on Page 3050-1.)
Remove the hydrostatic pump. (See Hydraulic Pump
Removal & Installation on Page 30-40-7.)
P-5558
Remove the bolts (Item 1) [Figure 70-90-1] from the
flywheel.
Installation: Tighten the flywheel bolts as follows:
Initial Torque
1st. Step Angle
2nd Step Angle
Remove the belt tension pulley assembly. (See Tensioner
Pulley Removal And Installation on Page 30-50-2.)
Remove the starter. (See Removal And Installation on
Page 60-40-1.)
Figure 70-90-3
22 ft.-lbs. (30 Nm)
60°
30°
Figure 70-90-2
1
1
1
P-5562
Remove the flywheel housing mounting bolts (Item 1)
[Figure 70-90-3].
P-5564
Remove the flywheel housing from the engine.
Remove the flywheel from the engine crankshaft [Figure
70-90-2].
70-90-1
863 Bobcat Loader
Service Manual
70-90-2
863 Bobcat Loader
Service Manual
RPM SENSOR
Figure 70-91-2
Adjustment
1
Figure 70-91-1
2
1
P-4317
Turn the RPM sensor and the jam nut out from the
flywheel. Set a clearance of 0.050 inch (1,27 mm)
between the jam nut and the housing with a feeler gauge
(Item 1) [Figure 70-91-2].
P-4313
When reinstalling the RPM sensor, turn the RPM sensor
(Item 1) [Figure 70-91-1] in until it makes contact with
the engine flywheel.
Turn the jam nut (Item 2) [Figure 70-91-1] until it
contacts the flywheel housing. The jam nut should not be
tightened, it needs to turn with the RPM sensor when the
sensor is turned back out for adjustment.
Hold the sensor and retighten the jam nut.
NOTE: New RPM sensors have a plastic tip which is
used as a gauge during installation. The
plastic tip is designed to come off after the
engine is started.
70-91-1
863 Bobcat Loader
Service Manual
70-91-2
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE
Deutz Engine Tools Identification Chart
B-16718
70-100-1
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-2
Disassembly
Remove the starter. (See Removal And Installation on
Page 60-40-1.)
Remove the alternator. (See Removal And Installation on
Page 60-30-3.)
Drain the oil from the engine oil pan.
Remove the turbocharger. (See Turbo Charger Removal
and Installation on Page 70-100-57.)
Remove the exhaust manifold.
CD-15481
Remove the intake manifold.
Remove the fuel injection pumps. (See Fuel Injection
Pump Removal on Page 70-70-4.)
Remove the rocker arms and brackets [Figure 70-1002].
Figure 70-100-3
Remove the fuel injectors. (See Fuel Injector Removal
and Installation on Page 70-70-9.)
Remove the oil filter.
Figure 70-100-1
CD-15480
Remove the push rods [Figure 70-100-3].
CD-15486
Remove the fuel filter & fuel lift pump[Figure 70-100-1].
Remove the valve cover.
70-100-2
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-6
Disassembly (Cont'd)
Figure 70-100-4
1
P-5292
Remove the belt pulley (Item 1) [Figure 70-100-6].
CD-15513
Remove the front cover and timing belt. (See Timing Belt
Removal on Page 70-70-14.)
Remove the cylinder head bolts [Figure 70-100-4].
Remove the crankshaft gear.
Remove the cylinder head.
Figure 70-100-7
Figure 70-100-5
1
CD-15471
CD-15515
Remove the oil pressure control valve [Figure 70-100-5].
Remove the plugs or fittings from the engine block.
Remove the oil pump [Figure 70-100-7].
Remove the oil pump relief valve (Item 1) [Figure 70100-7].
70-100-3
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-10
Disassembly (Cont'd)
Figure 70-100-8
CD-15520
Remove the connecting rod bolts [Figure 70-100-10].
CD-15518
Remove all the piston/connecting rod assembly from the
engine block.
Remove the oil pan [Figure 70-100-8].
To check the piston/connecting rod assembly. (See
Piston, Checking on Page 70-100-35.)
Figure 70-100-9
Figure 70-100-11
CD-15519
CD-15521
Remove the oil suction pipe [Figure 70-100-9].
Remove the front cover [Figure 70-100-11].
To disassemble and assemble the front cover. (See
Front Cover Disassembly on Page 70-100-43.)
Remove the flywheel. (See Flywheel Removal And
Installation on Page 70-90-1.)
70-100-4
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-14
Disassembly (Cont'd)
Figure 70-100-12
CD-15541
Remove the camshaft [Figure 70-100-14].
CD-15524
Mark the location of each main bearing cap so it will be
returned to original position.
Remove the rear cover [Figure 70-100-12].
Figure 70-100-15
To install a new rear seal and inspect the cover. (See
Rear Cover Seal Removal And Installation on Page 70100-30.)
Figure 70-100-13
1
CD-15526
Remove the main bearing caps bolts [Figure 70-100-15].
Remove the main bearing caps.
CD-15525
Install the timing tool (Item 1) [Figure 70-100-13] for the
camshaft.
Remove the thrust washer from the camshaft [Figure 70100-13].
Remove the crankshaft.
To check the crankshaft specifications. (See Crankshaft,
Checking on Page 70-100-31.)
Remove the upper half of the main bearings.
Remove the timing tool.
70-100-5
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-18
Disassembly (Cont’d)
Figure 70-100-16
CD-15531
Install the oil pressure control valve and compression
spring [Figure 70-100-18].
CD-15527
Remove the tappets from the engine block [Figure 70100-16].
Install the plug.
Figure 70-100-19
Assembly
Figure 70-100-17
CD-15532
Install new seals on the fittings and/or plugs.
CD-15528
Install the thermostat and compression spring [Figure
70-100-17].
Install all the fittings and/or plugs and tighten to 82 ft.-lbs.
(111 Nm) torque [Figure 70-100-19].
Install the plug and tighten to 82 ft.-lbs. (111 Nm) torque.
70-100-6
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-22
Assembly (Cont'd)
Figure 70-100-20
CD-15539
Install a new seal on the plug and install in the block.
Tighten the plug to 21 ft.-lbs. (28 Nm) torque [Figure 70100-22].
CD-15537
Install the plug and tighten to 37 ft.-lbs. (50 Nm) torque
[Figure 70-100-20].
Figure 70-100-23
Figure 70-100-21
CD-15540
Install the tappets [Figure 70-100-23].
CD-15538
Install the oil pressure switch and tighten to 115 in.-lbs.
(13 Nm) torque [Figure 70-100-21].
70-100-7
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-26
Assembly (Cont'd)
Figure 70-100-24
CD-15542
Install the thrust washer with the lubricating groove
toward the crankcase [Figure 70-100-26].
CD-15435
Figure 70-100-27
Before installing the new piston cooling oil nozzle, check
that the bores in the block are clean and free of oil. Press
in the piston cooling nozzle as far as it will go [Figure 70100-24].
Figure 70-100-25
1
CD-15543
Install the camshaft timing tool (Item 1) [Figure 70-10027].
CD-15541
Install the camshaft [Figure 70-100-25].
Tighten the camshaft thrust washer bolt to 15 ft.-lbs. (21
Nm) torque [Figure 70-100-27].
Remove the timing tool.
70-100-8
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-30
Assembly (Cont'd)
Figure 70-100-28
CD-15546
Install the thrust bearings halves on the main bearing cap
[Figure 70-100-30].
CD-15544
Install the upper main bearing halves [Figure 70-10028].
Measure the width of the thrust washers/main bearing
cap [Figure 70-100-30].
Figure 70-100-29
CD-15545
Install the other main bearing half into the main bearing
caps [Figure 70-100-29].
70-100-9
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-32
Assembly (Cont'd)
Figure 70-100-31
CD-15547
CD-15549
Install the main bearing locating sleeves [Figure 70-10032].
CD-15548
Figure 70-100-33
Measure the bearing journal width at the crankshaft
(inset) [Figure 70-100-31].
Specifications:
Journal Width
Std.
Limit for O/S
1.378-1.379 inch
(35,0-35,04 mm)
1.395 inch (35,44 mm)
Determine the end play for the crankshaft [Figure 70100-31].
Specifications:
Std. End Play
Wear Limit
0.004-0.010 inch
(0,1-0,273 mm)
0.016 inch (0,4 mm)
CD-15550
Use new thrust washer as needed to get the correct end
play.
Install the crankshaft into the engine block [Figure 70100-33].
70-100-10
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-36
Assembly (Cont'd)
Figure 70-100-34
CD-15553
Install the main bearing caps/main bearing assembly
[Figure 70-100-36].
CD-15551
Make sure they are returned to their original location.
Lubricate the thrust washer with grease and install them
on the main bearing cap [Figure 70-100-34].
Figure 70-100-37
Figure 70-100-35
CD-15554
CD-15552
Install the main bearing/thrust washer assembly [Figure
70-100-35].
NOTE: The main bearing cap No. 1, at the flywheel
end, the chamfer must be towards the
flywheel end.
Tighten the main bearing cup bolts as follows [Figure 70100-37]:
Initial Torque
1st Step Angle
2nd Step Angle
70-100-11
37 ft.-lbs. (50 Nm)
60°
45°
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-40
Assembly (Cont'd)
Figure 70-100-38
CD-15557
Measure the distance between the top edge of the
crankpin (TDC) and cylinder head sealing surface at
every cylinder [Figure 70-100-40].
CD-15555
Put sealing compound on the rear cover [Figure 70-10038].
Figure 70-100-41
Figure 70-100-39
A
CD-15558
Compare actual dimension with the dimension listed
[Figure 70-100-41]:
CD-15556
Install the rear cover complete with a new rear seal
[Figure 70-100-39].
Specifications:
Piston Class A
NOTE: Make sure the rear cover oil pan surface
aligns with the engine block surface.
Tighten the bolts to 15 ft.-lbs. (21 Nm) torque [Figure 70100-39].
7.732-7.736 inch
(196,39-196,49 mm)
NOTE: If the crankshaft is undersize, 0.005 inch
(0,125 mm) must be added to the dimension
listed.
70-100-12
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-44
Assembly (Cont'd)
Figure 70-100-42
CD-15561
Install a piston ring compressor on the piston rings.
CD-15559
Install the piston/connecting rod assembly into the engine
block [Figure 70-100-44].
Install the connecting rod bearing halves into the
connecting rod [Figure 70-100-42].
Figure 70-100-43
NOTE: The flywheel symbol on the piston must be
toward the flywheel.
Figure 70-100-45
CD-15560
CD-15562
Before installing piston/connecting rod assembly, make
sure the piston ring gaps are staggered as shown in
[Figure 70-100-43].
Install the connecting rod cap on the connecting rod,
make sure the numbers are aligned [Figure 70-100-45].
70-100-13
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-48
Assembly (Cont'd)
Figure 70-100-46
CD-15565
Put sealing compound on the front cover sealing surface
[Figure 70-100-48].
CD-15563
Tighten the connecting rod bolts as follows [Figure 70100-46]:
Initial Torque
1st Step Angle
2nd Step Angle
NOTE: Make sure the camshaft/centrifugal governor
connecting is clean and free of oil.
Figure 70-100-49
22 ft.-lbs. (30 Nm)
60°
60°
Figure 70-100-47
CD-15566
Install the front cover with the new shaft seals on the
engine block [Figure 70-100-49].
CD-15564
Check that the connecting rods can be easily moved
back and forth on the crankpin [Figure 70-100-47].
NOTE: Make sure the oil pan sealing surface on the
front cover aligns with the sealing surface on
the block [Figure 70-100-49].
70-100-14
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-52
Assembly (Cont'd)
Figure 70-100-50
CD-15468
Install the camshaft gear [Figure 70-100-52].
CD-15567
Make sure all mating surfaces are clean and free of oil.
Tighten the front cover bolts to 15 ft.-lbs. (21 Nm) torque
[Figure 70-100-50].
Install the camshaft bolt [Figure 70-100-52].
Figure 70-100-53
Figure 70-100-51
CD-15469
CD-15568
Install the crankshaft gear on the crankshaft [Figure 70100-51]. Make sure the mating surfaces are clean and
free of oil.
Tighten the camshaft bolt finger tight only [Figure 70100-53]. Camshaft gear must still turn freely.
Install the bolt and tighten to 243-295 ft.-lbs. (330-400
Nm) torque.
70-100-15
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-56
Assembly (Cont'd)
Figure 70-100-54
CD-15472
Tighten the oil pump bolts to 16 ft.-lbs. (22 Nm) torque
[Figure 70-100-56].
CD-15470
Install a new gasket on the oil pump [Figure 70-100-54].
Install the engine timing belt. (See Timing Belt Installation
on Page 70-70-15.)
Figure 70-100-55
Figure 70-100-57
CD-15471
CD-15473
Install the oil pump on the engine block [Figure 70-10055].
Put spacers on sealing surface of the engine block and
set dial indicator gauge to 0 [Figure 70-100-57]. (See
Deutz Engine Tools Identification Chart on Page 70-1001. for correct tool.)
70-100-16
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-60
Assembly (Cont'd)
Figure 70-100-58
CD-15475
Compare the measurements with the specifications to
determine the correct cylinder head gasket.
CD-15474
Position the dial gauge on the piston [Figure 70-100-58].
Figure 70-100-59
Specifications:
Piston Projection
Marking of Cylinder
Head Gasket [Figure 70-100-60]
0.023-0.027 inch (0,59-0,69 mm)
0.027-0.030 inch (0,69-0,76 mm)
0.030-0.033 inch (0,76-0,83 mm)
1
1 Notch
2 Notches
3 Notches
Figure 70-100-61
1
Piston pin axis
B-14695
Measure at the gauge points (Item 1) [Figure 70-10059].
To determine maximum piston projection measure all the
pistons.
CD-15476
Make sure the dowel pins are installed in the engine
block [Figure 70-100-61].
70-100-17
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-64
Assembly (Cont'd)
8
6
4
5
9
Figure 70-100-62
10
3
1
2
7
CD-15479
Tighten the cylinder head bolts to the correct torque in
the correct sequence [Figure 70-100-64].
CD-15477
Install the cylinder head gasket [Figure 70-100-62].
Gasket is marked TOP.
Make sure the sealing surfaces of the cylinder head
gasket is free of oil.
Initial Torque
1st Stage Torque
2nd Stage Torque
3rd Stage Torque
22 ft.-lbs. (30 Nm)
59 ft.-lbs. (80 Nm)
118 ft.-lbs. (160 Nm)
90°
Figure 70-100-65
Install the cylinder head.
Measure the cylinder head bolts.
Std. Length
5.90 ± 0.03 inch (150 ± 0,8 mm)
Figure 70-100-63
CD-15480
Install the push rods [Figure 70-100-65].
CD-15478
Put a light coat of oil on the head bolts [Figure 70-10063].
Install the head bolts.
70-100-18
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-68
Assembly (Cont'd)
Figure 70-100-66
CD-15483
Install the valve cover gasket [Figure 70-100-68]. Install
the valve cover. Tighten the bolts to 75 in.-lbs. (8,5 Nm)
torque.
CD-15481
Install the rocker arms/bracket assembly [Figure 70-10066].
Install new intake manifold gasket.
Figure 70-100-67
Install the intake manifold and tighten the bolts to 15 ft.lbs. (20 Nm) torque.
Install new exhaust manifold gaskets.
Install the exhaust manifold and tighten the bolts to 30 ft.lbs. (40 Nm) torque.
Figure 70-100-69
CD-15482
Tighten the rocker arm bracket bolts to 15 ft.-lbs. (21 Nm)
torque [Figure 70-100-67].
Set the valve clearance. (See
Adjustment on Page 70-70-24.)
Valve
Clearance
CD-15484
Install a new seal on the fuel lift pump [Figure 70-10069].
70-100-19
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-72
Assembly (Cont'd)
Figure 70-100-70
CD-15487
Tighten the lift pump bolts to 15 ft.-lbs. (21 Nm) torque
[Figure 70-100-72].
CD-15485
Install a new oil filter.
Turn the camshaft so the fuel lift pump lobe is at B.D.C.
(bottom dead center) [Figure 70-100-70].
Figure 70-100-71
Install the fuel injectors. (See Fuel Injector Removal and
Installation on Page 70-70-9.)
Install the fuel injector pumps. (See Fuel Injection Pump
Installation on Page 70-70-7.)
Figure 70-100-73
CD-15486
Install the fuel lift pump [Figure 70-100-71].
CD-15488
Put sealing compound on the sealing surface of the oil
suction pipe [Figure 70-100-73].
70-100-20
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-76
Assembly (Cont’d)
Figure 70-100-74
B-14696
Install the oil pan bolts and tighten to 15 ft.-lbs. (21 Nm)
torque as shown in [Figure 70-100-76].
CD-15489
Install the oil suction pipe and tighten the bolts to 16 ft.lbs. (22 Nm) torque [Figure 70-100-74].
Install the oil pan plug and tighten to 40 ft.-lbs. (55 Nm)
torque.
Install the flywheel. (See Flywheel Removal And
Installation on Page 70-90-1.)
Figure 70-100-75
Install the turbocharger. (See Turbo Charger Removal
and Installation on Page 70-100-57.)
Install the starter. (See Removal And Installation on Page
60-40-1.)
Install the alternator. (See Removal And Installation on
Page 60-30-3.)
CD-15490
Put sealing compound on the sealing surface of the oil
pan [Figure 70-100-75].
Install the oil pan.
Initially install the corner bolts first and tighten to 5 in.-lbs.
(0,5 Nm) torque.
70-100-21
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT’D)
Figure 70-100-79
Cylinder, Checking
Figure 70-100-77
b
a
1
1
2
2
3
b
B-14697A
B-14697
Check the cylinders with engine block longitudinal (a) and
transverse (b) axis and in three planes [Figure 70-10079].
CD-15319
Clean the engine block and inspect for damage.
Specification
Install the main bearing caps [Figure 70-100-77].
Cylinder Bore
Tighten the main bearing cap bolts as follows:
Wear Limit
Initial Torque
1st Stage Angle
2nd Stage Angle
3.58 + 0.0008 inch
(91 + 0,02 mm)
3.59 inch (91,1 mm)
37 ft.-lbs. (50 Nm)
60°
45°
Figure 70-100-78
CD-15421
Using a dial indicator gauge check the cylinders [Figure
70-100-78].
70-100-22
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Camshaft Bearing, Removal And Installation
Camshaft Bearing, Checking
Figure 70-100-82
Figure 70-100-80
b
a
1
2
CD-15361
B-14698
Check the camshaft bearing bushings at points (1) and
(2) in the planes of (a) and (b) [Figure 70-100-80].
Remove all the camshaft bearing bushings using a
camshaft bushing removal tool as needed [Figure 70100-82].
0.019±0.012inch
(0,5±0,3 mm)
0
4.61±0.012inch
(117,1±0,3 mm)
8.98±0.012inch
(228,1±0,3 mm)
4.681±0.012inch
(118,9±0,3 mm)
0
A
0.098±0.012inch
(2,5±0,3 mm)
Figure 70-100-83
Figure 70-100-81
B
B-14699
CD-15350
Check the camshaft bushings using a gauge [Figure 70100-81].
Inner Diameter
Wear Limit
Use the dimensions in figure [Figure 70-100-83] to install
the camshaft bushings.
2.126 + 0.002 inch
(54 + 0,054 mm)
2.129 inch (54,08 mm)
70-100-23
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Control Rod Guide Bushing Removal
Camshaft Bearing Removal And Installation (Cont'd)
Figure 70-100-86
Figure 70-100-84
CD-15409
CD-15383
Remove the parallel pin [Figure 70-100-86].
When installing the new camshaft bushings make sure
the oil lube hole aligns with the oil hole in the engine
block [Figure 70-100-84].
Figure 70-100-87
Figure 70-100-85
CD-15411
Remove the control rod and spring [Figure 70-100-87].
CD-15404A
Install the new camshaft bushings using a camshaft
bushing installation tool [Figure 70-100-85].
70-100-24
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-90
Control Rod Guide Bushing Removal (Cont'd)
Figure 70-100-88
CD-15414
Install the puller into the bore until the pin engages
[Figure 70-100-90].
CD-15412
Figure 70-100-91
Remove the cover [Figure 70-100-88].
Figure 70-100-89
CD-15415
Install the spacer tool in position. Pull the pipe from the
lower press fit [Figure 70-100-91].
CD-15413
Drill a 7/32 inch (5,5 mm) hole on one side of the pipe
[Figure 70-100-89].
NOTE: Carefully clean the engine block after drilling.
NOTE: Do Not pull pipe completely out.
Remove the spacer tool.
70-100-25
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Control Rod Guide Bushing Installation
Control Rod Guide Bushing Removal (Cont’d)
Figure 70-100-94
Figure 70-100-92
CD-15418
CD-15416
Install the new bushing into the center of the arbor
assembly [Figure 70-100-94].
Press pin in until it does not project beyond the pipe
[Figure 70-100-92]. Pull the pipe out completely.
Figure 70-100-95
Figure 70-100-93
CD-15419
CD-15417
Using the tool, drive the guide bushing out [Figure 70100-93].
Install the guide on the arbor assembly with the chamfer
pointing toward the crankcase [Figure 70-100-95].
70-100-26
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-98
Control Rod Guide Bushing Installation (Cont'd)
Figure 70-100-96
CD-15423
Remove the arbor assembly [Figure 70-100-98].
CD-15420
Figure 70-100-99
Fasten the arbor assembly and bushing on the engine
block [Figure 70-100-96].
Figure 70-100-97
CD-15424
Remove the guide bushing at the flywheel end of the
engine block [Figure 70-100-99].
CD-15422
Drive the bushing into the engine block as far as it will go
[Figure 70-100-97].
70-100-27
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-102
Control Rod Guide Bushing Installation (Cont'd)
Figure 70-100-100
CD-15427
Fasten the arbor assembly and guide bushing to the
engine block [Figure 70-100-102].
CD-15425
Assemble the arbor without the spacer [Figure 70-100100].
Figure 70-100-103
Figure 70-100-101
CD-15428
Drive in the guide bushing as far as it will go, at the
flywheel end [Figure 70-100-103].
CD-15426
Install the guide bushing on the arbor assembly with the
chamfer pointing toward the crankcase [Figure 70-100101].
70-100-28
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-106
Control Rod Guide Bushing Installation (Cont'd)
Figure 70-100-104
CD-15431
Put sealing compound on the new cover [Figure 70-100106].
CD-15429
Figure 70-100-107
Remove the arbor assembly [Figure 70-100-104].
Figure 70-100-105
CD-15432
Install the new cover flush with the engine block [Figure
70-100-107].
CD-15430
Install the new pipe in the block as far as it will go with the
arbor assembly [Figure 70-100-105].
70-100-29
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Rear Cover Seal Removal And Installation
Control Rod Guide Bushing Installation (Cont’d)
Figure 70-100-110
Figure 70-100-108
CD-15438
CD-15433
Remove the rear cover shaft seal [Figure 70-100-110].
Install the control rod with starter spring into the guide
bushings [Figure 70-100-108].
Figure 70-100-111
Figure 70-100-109
CD-15439
Clean the seal seating surface [Figure 70-100-111].
Inspect the cover for damage, replace as needed.
CD-15434
Compress the starter spring. Install the parallel pin into
the recess for the control rod travel limitation [Figure 70100-109].
Check to make sure it is flush with the surface.
70-100-30
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Crankshaft, Checking
Rear Cover Seal Removal And Installation (Cont’d)
Figure 70-100-114
0.803 ± 0.008 inch
(20,4 ± 0,2 mm)
Figure 70-100-112
CD-15443
B-14700
Put the crankshaft on v-blocks.
When installing the new shaft seal, use the dimension
shown in [Figure 70-100-112].
Check the main bearing journals:
Specifications:
Journal Dia.
Figure 70-100-113
Each Undersize
Undersize Limit
Wear Limit
Journal Oval
2.755
-0.0004 inch
-0.0012
(70 -0.0001 mm)
-0.03
0,010 inch
(0,25 mm)
2.736
-0.0004 inch
-0.0012
(69,51 -0.01 mm)
-0.03
0.0003 inch
(0,008 mm)
Check the thrust bearing width [Figure 70-100-114].
CD-15441
Use the seal driver tool and install to the correct depth
[Figure 70-100-113]. (See Deutz Engine Tools
Identification Chart on Page 70-100-1. for correct tool.)
70-100-31
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-116
Crankshaft, Checking (Cont’d)
Figure 70-100-115
CD-15445
Use a dial indicator and check crankshaft for out of
roundness [Figure 70-100-116].
CD-15444
Specifications:
Journal Width
Each Oversize
Oversize Limit
Specifications:
Out of Roundness
Max
1.378 + 0.0016 inch
(35 + 0.04 mm)
0.002 inch (0,05 mm)
Figure 70-100-117
0.016 inch (0,4 mm)
1.395 inch (35,44 mm)
Check the connecting rod journals [Figure 70-100-115].
Pin Dia.
2.16
Undersize Limit
Wear Limit
Oval
Pin
-0.0004
-0.0012 inch
(55 -0.01 mm)
-0.03
2.146
-0.0004
-0.0012 inch
(54,5 -0.01 mm)
-0.03
0.0004 inch
(0,01 mm)
CD-15446
Check the surface of the crankshaft seal area [Figure
70-100-117].
Recondition the crankshaft as needed.
70-100-32
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT’D)
Figure 70-100-120
Connecting Rod, Checking
Figure 70-100-118
b
1
a
2
CD-15448
Replace small end bushing as needed [Figure 70-100120].
B-14701
Specifications:
Bore for Small End
Bushing
O.D. of Small End
Bushing
When checking the connecting rod large and small end,
measure at the points (1) and (2) and in planes (a) and
(b) [Figure 70-100-118].
Figure 70-100-119
1.299 + 0.0008 inch
(33 + 0,02 mm)
1.299
+0.0004
+0.0027
inch
(33 +0,110 mm)
+0,070
Figure 70-100-121
CD-15447
Check the small end bushing [Figure 70-100-119].
Specifications:
I.D. of Small End Bushing
CD-15449
1.18
30
+ 0.00014
+ 0.00009 inch
+ 0,035
+ 0,025 mm
Press in the small end bushing, make sure the lubrication
holes are in alignment [Figure 70-100-121].
Wear Limit Bushing
Clearance
0.003 inch (0,08 mm)
70-100-33
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-124
Connecting Rod, Checking (Cont'd)
Figure 70-100-122
CD-15452
Tighten the connecting rod cap nuts as follows [Figure
70-100-124].
CD-15450
After pressing in the small end bushing, bore the bushing
to the following dimensions [Figure 70-100-122].
Specifications:
I.D. of Small End
Bushing
Initial Torque
1st Step Angle
2nd Step Angle
22 ft.-lbs. (30 Nm)
60°
60°
1.181
+0.00014
+0.00009 inch
(30 + 0,035 mm)
+ 0,025
Figure 70-100-123
2908
2908
CD-15451
Install the correct cap on the correct rod [Figure 70-100123].
70-100-34
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Piston, Checking
Connecting Rod, Checking (Cont’d)
Figure 70-100-126
Figure 70-100-125
B-8194
CD-15454
Measure the big end bore [Figure 70-100-125]. If the
measurement is the same as the specific valve, the
necessary preload on the bearing halves will be
obtained.
Specifications:
Big End I.D.
Remove the piston rings from the piston [Figure 70-100126].
Remove the piston from the connecting rod.
(See Connecting Rod, Checking on Page 70-100-33. to
check connecting rod specifications.)
Figure 70-100-127
2.303 + 0.0008 inch
(58,5 + 0,02 mm)
Remove connecting rod cap. Install new bearing halves.
Tighten the connecting rod cap nuts and tighten as listed
above.
Measure the bearing halves:
Big End Bearing I.D.
Each Undersize
Limit For Undersize
Radial Clearance
Wear Limit
2.1655-2.167 inch
(55,004-55,04 mm)
0.010 inch (0,25 mm)
2.148-2.1472 inch
(54,504-54,54 mm)
.005 inch (0,12 mm)
B-8231
Clean and inspect piston and piston ring grooves [Figure
70-100-127].
Check the connecting rod, without bearing halves, on a
connecting rod tester.
Specifications:
Parallel Check-Tolerance
Over a Distance of
Squareness CheckTolerance
0.004 inch (0,10 mm)
3.94 inch (100 mm)
0.002 inch (0,05 mm)
70-100-35
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Piston, Checking (Cont’d)
Specifications:
Wear Limit
1st Ring
2nd Ring
3rd Ring
Figure 70-100-128
0.008 inch (0,2 mm)
0.006 inch (0,16 mm)
0.005 inch (0,12 mm)
Piston Pin, Checking
Figure 70-100-130
B-8229
Measure the ring gap with a feeler gauge in the cylinder
[Figure 70-100-128].
Specifications:
Wear Limit
1st Ring Gap
2nd Ring Gap
3rd Ring Gap
B-8230
0.012-0.020 inch (0,3-0,5 mm)
0.031-0.039 inch (0,8-1,0 mm)
0.018-0.028 inch (0,45-0,7 mm)
Check piston pin for wear [Figure 70-100-130].
Specifications:
Piston Pin O.D.
Figure 70-100-129
1.118-0.0002 inch (30,0-0,005 mm)
Piston Rings Installation
Figure 70-100-131
B-8228
Using new rings, measure the ring grooves using a feeler
gauge [Figure 70-100-129].
B-8194
When installing the piston rings position them as listed
below [Figure 70-100-131]:
70-100-36
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Piston Installation On the Connecting Rod
Piston Rings Installation (Cont’d)
Figure 70-100-134
Figure 70-100-132
1
2
3
CD-15456
TS-1927
Figure 70-100-133
Install the snap ring into the piston [Figure 70-100-134].
Figure 70-100-135
1
2
1
3
TS-1928A
1st Ring - Is a double tapered ring, (Item 1) [Figure 70100-132] & [Figure 70-100-133]. It is installed on the
piston with the mark TOP facing the combustion
chamber.
CD-15457
NOTE: The snap ring gap must be towards the piston
crown (Item 1) [Figure 70-100-135].
2nd Ring - Is a rectangular ring, (Item 2) [Figure 70-100132] on earlier model loaders, or an inside tapered ring
(Item 2) [Figure 70-100-133] which is installed on the
piston with the mark TOP facing the combustion chamber
[Figure 70-100-133], on later model loaders.
3rd Ring - Is a bevelled edge slotted oil control ring (Item
3) [Figure 70-100-132] & [Figure 70-100-133].
The gap of each ring must be offset by 90° to the other
ring.
NOTE: Check the piston rings that are installed on
your loaders engine before ordering new ring
sets from Melroe Parts, to insure proper fit.
70-100-37
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-138
Piston Installation On the Connecting Rod (Cont'd)
Figure 70-100-136
2908
2908
1
CD-15451
Figure 70-100-139
CD-15458
1
Install the piston on the connecting rod [Figure 70-100136].
Figure 70-100-137
1
3
2
P13908
The numbers on the connecting rod and cap (Item 1)
[Figure 70-100-138]& (Item 2) [Figure 70-100-139] point
toward the camshaft side of the engine when being install
in the engine block.
Figure 70-100-140
N-19068
The flywheel symbol (Item 1) [Figure 70-100-137] &
[Figure 70-100-139] on the piston must point toward the
flywheel (Item 3) [Figure 70-100-139], when properly
installed on the connecting rod.
CD-15459
Install the other side snap ring [Figure 70-100-140].
70-100-38
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Valves, Checking
Cylinder Head Disassembly
Figure 70-100-142
Figure 70-100-141
B-8205
CD-15461
Measure the valve stem clearance [Figure 70-100-142].
NOTE: Do not grind the cylinder head surface, if its
damaged, replace the cylinder head.
Using a valve spring tool, remove the spring locks, valve
spring cap, valve spring and valve [Figure 70-100-141].
(See Deutz Engine Tools Identification Chart on Page
70-100-1. for correct tool.)
Specifications:
Wear Limits
Intake Valve
Exhaust Valve
0.005 inch (0,12 mm)
0.006 inch (0,15 mm)
Figure 70-100-143
Repeat the procedure for all the valves.
Remove the valve seals.
Clean the cylinder head and inspect for damage.
B-8204
Measure the valve stem diameter [Figure 70-100-143].
Std. Intake Valve
Std. Exhaust Valve
70-100-39
0.314 -0.0006 inch
(7,98 -0,015 mm)
0.313 - 0.0006 inch
(7,96 -0,15 mm)
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Valve Seats, Checking
Valves, Checking (Cont’d)
Figure 70-100-145
Figure 70-100-144
Angle
Diameter
Thickness
CD-15463
B-8202
Measure the valve rim thickness [Figure 70-100-144].
Specifications (BF4M1011F):
Intake Valve
Exhaust Valve
0.055 inch (1,4 mm)
0.05 inch (1,2 mm)
Measure the valve head diameter [Figure 70-100-144].
Measure the valve seat width [Figure 70-100-145].
Specifications:
Width (Intake)
(Exhaust)
0.062 ± 0.016 inch (1,58 ± 0,4 mm)
0.067 ± 0.016 inch (1,7 ± 0,4 mm)
Figure 70-100-146
Specifications (BF4M1011):
Intake Valve
1.594 ± 0.004 inch (40,1 ± 0,1 mm)
Exhaust Valve
1.374 + 0.004 inch 34,9 + 0,01 mm)
Specifications (BF4M1011F):
Intake Valve
1.594 ± 0.004 inch (40,1 ± 0,1 mm)
Exhaust Valve
1.374 ± 0.004 inch 34,9 ± 0,01 mm)
Valve seat angle [Figure 70-100-144].
Specifications (BF4M1011F):
Intake Valve
Exhaust Valve
30°
45°
CD-15464
Measure the valve clearance between the valve head
and cylinder head sealing surface [Figure 70-100-146].
Valve penetration into cylinder head:
Specifications:
Wear Limit
0.0512 ± 0.0051 inch (1,3 ± 0,13 mm)
Recondition the valve seats and valve guides if worn.
70-100-40
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-149
Valve Spring, Checking
Figure 70-100-147
Free Length
Inclination
CD-15323
Square
Install the valve seal on the protective sleeve and push
the seal down [Figure 70-100-149].
B-8208
Remove the protective sleeve.
Measure valve spring free length [Figure 70-100-147].
Figure 70-100-150
Specifications:
Valve Spring Dia.
Free Length
Valve Spring Dia.
Free Length
Inclination
0.132 inch (3,35 mm)
1.74 inch (44,3 mm)
0.134 inch (3,40 mm)
1.547 inch (39,3 mm)
0.126 inch (3,2 mm)
Cylinder Head Assembly
Figure 70-100-148
CD-15324
Use the tool and press the valve stem as far as it will go
[Figure 70-100-150]. (See Deutz Engine Tools
Identification Chart on Page 70-100-1. for correct tool.)
CD-15322
Install the valve into the cylinder head [Figure 70-100148].
Install the protective sleeve or masking tape on the valve
stem grooves [Figure 70-100-148].
70-100-41
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Rocker Arm and Bracket, Checking
Cylinder Head Assembly (Cont'd)
Figure 70-100-153
Figure 70-100-151
CD-15327
CD-15325
Disassemble the rocker arms from the bracket [Figure
70-100-153].
Install the valve spring and cap [Figure 70-100-151].
Figure 70-100-154
Figure 70-100-152
CD-15328
CD-15461
Use the valve spring tool, install the valve spring lock
[Figure 70-100-152].
Repeat the above procedure to install all the valves.
Check for wear at the following locations and replace as
needed [Figure 70-100-154]:
Journals
Adjusting Bolt
Rocker Arm Contact Face
Bore
70-100-42
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Front Cover Disassembly
Rocker Arm and Bracket, Checking (Cont’d)
Figure 70-100-157
Figure 70-100-155
CD-15343
CD-15330
NOTE: Dynamometer testing is recommended if the
governor assembly is re-built.
Check the oil passages that they are open and clean
[Figure 70-100-155].
Figure 70-100-156
Remove the engine shut-down solenoid [Figure 70-100157].
Figure 70-100-158
CD-15331
CD-15344
Install the rocker arms on the bracket.
Install the snap ring [Figure 70-100-156].
Disconnect the governor spring [Figure 70-100-158].
70-100-43
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-161
Front Cover Disassembly (Cont'd)
Figure 70-100-159
1
CD-15347
Remove the centrifugal governor [Figure 70-100-161].
CD-15345
Figure 70-100-162
Mark the governor lever shaft (Item 1) [Figure 70-100159] for proper installation.
Remove the governor lever shaft.
Figure 70-100-160
CD-15348
Remove the camshaft seal [Figure 70-100-162].
Figure 70-100-163
CD-15346
Remove the shims below the governor lever shaft
[Figure 70-100-160].
CD-15349
Remove the crankshaft seal [Figure 70-100-163].
70-100-44
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-166
Front Cover Disassembly (Cont'd)
Figure 70-100-164
CD-15353
CD-15351
Remove the shut-down lever with spacer bushings
[Figure 70-100-166].
Figure 70-100-167
Disconnect the spring [Figure 70-100-164].
Figure 70-100-165
CD-15354
Remove the shaft, spacer bushing and spring [Figure
70-100-167].
CD-15352
Figure 70-100-168
Remove the dowel pin [Figure 70-100-165].
CD-15355
Remove the O-ring [Figure 70-100-168].
70-100-45
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-171
Front Cover Disassembly (Cont'd)
Figure 70-100-169
CD-15358
Remove the pin from the lever [Figure 70-100-171].
CD-15356
Do not damage the cover sealing surface.
Remove the cover [Figure 70-100-169].
Figure 70-100-172
Figure 70-100-170
CD-15359
CD-15357
Remove the dowel pin [Figure 70-100-170].
Remove the speed control lever and spacer bushing
[Figure 70-100-172].
70-100-46
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-175
Front Cover Disassembly (Cont'd)
Figure 70-100-173
CD-15363
Remove the nut and clamp [Figure 70-100-175].
CD-15360
Remove the torque control assembly.
Remove the O-ring [Figure 70-100-173].
Figure 70-100-176
Figure 70-100-174
CD-15364
CD-15373
Remove the breather vent [Figure 70-100-176].
Before removing the torque control assembly, measure
the height from the cover [Figure 70-100-174] and make
a record of this for assembly.
NOTE: On later model Deutz engines the breather is
located in the valve cover. The breather vent
shown in photo [Figure 70-100-176] is used in
both engines.
70-100-47
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-179
Front Cover Assembly
2
Figure 70-100-177
3
1
5
6
4
0-0,39 inch
(0-1 mm)
B-14704
If the torque control was disassembled, do the following
procedure to assemble:
CD-15365
Inspect the front cover for damage [Figure 70-100-177].
Turn (Item 1) [Figure 70-100-179] into (Item 2) [Figure
70-100-179] to leave a protrusion of 0-0.039 inch (0-1
mm).
Replace the front cover as needed.
Tighten the lock nut (Item 3) [Figure 70-100-179] to 12
ft.-lbs. (16 Nm) torque.
Figure 70-100-178
Turn (Item 4) [Figure 70-100-179] as far as it will go into
(Item 5) [Figure 70-100-179]. Turn back one full turn.
Tighten the lock nut (Item 6) [Figure 70-100-179] to 53
in.-lbs. (6 Nm) torque.
Figure 70-100-180
B-14703
Inspect the individual parts of the torque control
assembly [Figure 70-100-178].
Replace the parts as needed.
CD-15371
Install the torque control into the front cover [Figure 70100-180].
70-100-48
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-183
Front Cover Assembly (Cont'd)
Figure 70-100-181
CD-15375
Tighten the clamp nut to 88 in.-lbs. (10 Nm) torque
[Figure 70-100-183].
CD-15373
Figure 70-100-184
Install the torque control assembly to the dimensions
taken [Figure 70-100-181] or use the procedure below:
Figure 70-100-182
CD-15376
Put a light coat of oil on the camshaft seal.
CD-15374
Press the camshaft seal into the front cover [Figure 70100-184]. (See Deutz Engine Tools Identification Chart
on Page 70-100-1. for correct tool.)
Measure the thread reach [Figure 70-100-182].
Specifications:
Thread Reach
0.252 ± 0.019 inch
(6,4 ± 0,5 mm)
NOTE: Dynamometer testing may be necessary
depending on engine performance.
Install the clamp and nut [Figure 70-100-182].
70-100-49
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-187
Front Cover Assembly (Cont'd)
0.79 ± 0.039 inch
(20 ± 1 mm)
Figure 70-100-185
B-14706
Adjust the minimum speed screw to 0.79 ± 0.039 inch (20
± 1,0 mm) [Figure 70-100-187].
CD-15377
Tighten the lock nut to 40 in.-lbs. (4,5 Nm) torque.
Do Not put oil on the crankshaft seal.
Press the crankshaft seal into the front cover [Figure 70100-185].
Figure 70-100-188
Figure 70-100-186
0.236 ± 0.039 inch
(6 ± 1 mm)
CD-15380
Install the spacer bushing and spring on the shut down
shaft [Figure 70-100-188].
B-14705
Adjust the distance of the shut-down stop screw to 0.236
± 0.039 inch (6 ± 1 mm) [Figure 70-100-186].
Tighten the lock nut to 40 in.-lbs. (4,5 Nm) torque.
70-100-50
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-191
Front Cover Assembly (Cont'd)
Figure 70-100-189
CD-15384
Install the spacer bushing [Figure 70-100-191].
B-14707
Figure 70-100-192
Install the shut down shaft [Figure 70-100-189].
Figure 70-100-190
CD-15385
Install the shut down lever and dowel pin [Figure 70-100192].
CD-15382
Put grease on the O-ring and install on the shaft [Figure
70-100-190].
70-100-51
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-195
Front Cover Assembly (Cont'd)
Figure 70-100-193
B-14708
When installing the speed control lever, make sure it is
installed in the correct direction [Figure 70-100-195].
CD-15386
Figure 70-100-196
Put grease on the O-ring and install in the front cover
[Figure 70-100-193].
Figure 70-100-194
CD-15389
Install the dowel pin into the speed control lever [Figure
70-100-196].
CD-15387
Install the spacer bushing on the speed control lever
[Figure 70-100-194].
Install the speed control lever into the front cover [Figure
70-100-194].
70-100-52
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-199
Front Cover Assembly (Cont'd)
Figure 70-100-197
CD-15392
Inspect the governor plate for wear [Figure 70-100-199].
CD-15390
Replace as needed.
Drive the pin into the lever [Figure 70-100-197].
Figure 70-100-200
The groove in the speed control shaft must be in line with
the dowel pin bore.
Figure 70-100-198
CD-15393
Assemble the governor plate with the centrifugal
governor [Figure 70-100-200].
CD-15391
Inspect the centrifugal governor for wear [Figure 70-100198]. Replace as needed.
70-100-53
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-203
Front Cover Assembly (Cont'd)
Figure 70-100-201
1
2
CD-15396
Install shims of at least 0.011 inch (0,3 mm) thickness at
points (Items 1 & 2) [Figure 70-100-203].
CD-15394
Figure 70-100-204
Install centrifugal governor assembly into the front cover
[Figure 70-100-201].
Be careful not to damage the shaft seal.
Figure 70-100-202
1
N-18859
CD-15397
Install the governor lever shaft without the idling lever
[Figure 70-100-204]. Tighten the bolts to 81 in.-lbs. (9,2
Nm) torque.
CD-15395
Inspect roller lever, shaft and idling lever wear [Figure
70-100-202].
NOTE: The longer space (Item 1) [Figure 70-100-204]
on the governor lever shaft goes toward the
cover when being installed.
Replace the parts as needed.
70-100-54
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-207
Front Cover Assembly (Cont'd)
Figure 70-100-205
CD-15400
Assemble the roller lever with the idling lever and shaft
[Figure 70-100-207].
1
CD-15398
Measure the ball bearing (Item 1) [Figure 70-100-205],
by lightly pressing the roller lever.
Figure 70-100-208
Set the dial gauge to zero.
Figure 70-100-206
1
N-18859
CD-15401
Install the complete governor lever shaft assembly into
the front cover.
1
Tighten the bolts to 81 in.-lbs. (9,2 Nm) torque [Figure
70-100-208].
CD-15399
Place dial indicator on ball bearing (Item 1) [Figure 70100-206].
NOTE: The longer space (Item 1) [Figure 70-100-208]
on the governor lever shaft goes down toward
the cover when installed.
Make record of the two readings.
The required tolerance is 0.0019 inch (0,05 mm).
It is possible to install extra shims at (Items 1 & 2)
[Figure 70-100-203] to get the required measurement.
70-100-55
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-211
Front Cover Assembly (Cont'd)
Figure 70-100-209
CD-15405
Install a greased O-ring on the shut down solenoid
[Figure 70-100-211].
CD-15402
Figure 70-100-212
Connect the governor spring [Figure 70-100-209].
Figure 70-100-210
CD-15406
Install the shut down solenoid into the front cover [Figure
70-100-212].
CD-15403
Install the cover with new gasket. Tighten the bolts to 40
in-lbs. (4,5 Nm) torque [Figure 70-100-210].
Tighten the bolts to 79 in.-lbs. (9 Nm) torque.
70-100-56
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Turbo Charger Removal and Installation
Front Cover Assembly (Cont'd)
Figure 70-100-215
Figure 70-100-213
1
P-7780
CD-15407
Remove the exhaust pipe (Item 1) [Figure 70-100-215].
Install new O-ring on the breather vent [Figure 70-100213].
Figure 70-100-216
Figure 70-100-214
3
4
1
2
P-7779
Disconnect the air cleaner hose (Item 1) [Figure 70-100216], inspect the air intake system.
CD-15408
Install the breather vent into the front cover. Tighten the
bolts to 75 in.-lbs. (8,5 Nm) torque [Figure 70-100-214].
Remove the oil tubeline (Item 2) [Figure 70-100-216]
and clean the inside of the line with solvent or air, to
remove contaminated oil.
70-100-57
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Turbo Charger Removal And Installation (Cont’d)
Drain the engine oil from the crankcase again, replace
the engine oil and filter. (See Replacing Oil And Filter on
Page 10-110-1.)
Figure 70-100-217
Re-start engine, check for leaks and performance.
Crankshaft Gear Mounting Bolt Torque Procedure
Figure 70-100-218
1
1
P-5292
P-7343
Remove the oil tubeline (Item 1) [Figure 70-100-217],
clean the inside of the line with solvent or air to remove
contaminated oil.
Remove the exhaust manifold nuts (Item 3) [Figure 70100-216].
Installation: Tighten the nuts to 22 ft.-lbs. (30 Nm)
torque.
The tool listed will be needed to do the following
procedure:
MEL 1522 Torque Multiplier Support Device
MEL 1526 Torque Multiplier
If the v-belt pulley is installed, remove the four bolts and
remove the pulley (Item 1) [Figure 70-100-218].
Figure 70-100-219
Remove the hose clamps (Item 4) [Figure 70-100-216].
1
Remove the turbocharger from the intake manifold hose.
Install the replacement turbo.
NOTE: In the event of severe engine oil
contamination, drain and flush the engine oil
cooler, cab heater and plumbing.
2
Drain the engine oil from the crankcase and replace the
engine oil and filter. (See Replacing The Oil on Page 10130-1.)
P-13135A
Start the engine and run at idle until oil pressure is
assured.
Work the unit until operating temperature of engine is
maintained for approximately 15 minutes.
Idle and cool the down engine approximately 3 to 4
minutes, and stop the engine.
Install the tool (Item 1) [Figure 70-100-219] on the
crankshaft hub using the v-belt pulley bolts.
Install the crankshaft gear mounting bolt (Item 2) [Figure
70-100-219] and tighten to 95 ft.-lbs. (130 Nm) torque.
70-100-58
863 Bobcat Loader
Service Manual
RECONDITIONING THE ENGINE (CONT'D)
Figure 70-100-222
Crankshaft Gear Mounting Bolt Torque Procedure
(Cont'd)
Figure 70-100-220
1
P-13137
Figure 70-100-223
P-13135B
Mark the crankshaft gear mounting bolt (Item 1) [Figure
70-100-220].
Figure 70-100-221
1
P-13135
Tighten the gear bolt 210° (+ or - 10°) [Figure 70-100222] & [Figure 70-100-223].
P-13136
NOTE: If the torque multiplier tool (Item 1) [Figure 70100-221] has a degree wheel, the crankshaft
bolt does not have to be marked.
Install the torque multiplier tool (Item 1) [Figure 70-100221], with the socket, into the tool.
70-100-59
863 Bobcat Loader
Service Manual
70-100-60
863 Bobcat Loader
Service Manual
HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SERVICE . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . 80-10-2
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-3
Principals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
BASIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Checking The Electrical System . . . . . . . . . . . . . . . . . . . . 80-50-3
Cleaning The A/C Evaporator Coil & Heater Coil . . . . . . . 80-50-1
Compressor Drive Belt Inspection: . . . . . . . . . . . . . . . . . 80-50-11
Engine Coolant By-Passing The Heater Valve . . . . . . . . 80-50-11
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . 80-50-12
Poor A/C Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-13
SAFETY &
MAINTENANCE
DRIVE
SYSTEM
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1
Compressor Clutch Disassembly. . . . . . . . . . . . . . . . . . . 80-110-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1
ELECTRICAL
SYSTEM &
ANALYSIS
HVAC
EVAPORATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-190-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-190-1
EVAPORATOR/HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . 80-160-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 80-160-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-160-1
SPECIFICATIONS
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-180-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-180-1
GENERAL AIR CONDITIONING SERVICE GUIDELINES . . .
Component Replacement And Refrigeration Leaks. . . . . .
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Check. . . . . . . . . . . . . . . . . . . . . . . . . . . .
80-60-1
80-60-3
80-60-1
80-60-1
HEATER COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-200-1
Removal And Installation With A/C . . . . . . . . . . . . . . . . . 80-200-1
Removal And Installation Without A/C . . . . . . . . . . . . . . . 80-200-2
Continued On Next Page
80-01
863 Bobcat Loader
Service Manual
HEATING, VENTILATION, AIR CONDITIONING (CONT’D)
HEATER/AC FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassmbly And Assembly. . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Connector Removal And Installation . . . . . . . . . . . .
80-210-1
80-210-2
80-210-1
80-210-4
HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-220-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 80-220-2
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-220-1
PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1
PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1
RECEIVER/DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning The Condenser . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Drive Belt Inspection . . . . . . . . . . . . . . . . . . .
Filter Elements Removal And Installation . . . . . . . . . . . . .
80-40-1
80-40-1
80-40-2
80-40-2
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . .
Charging Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging Procedure With A Manifold Gauge Set . . . . . .
Reclamation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . .
80-100-1
80-100-4
80-100-3
80-100-1
SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . 80-70-1
Gauge Pressure Related Troubleshooting. . . . . . . . . . . . . 80-70-2
Troubleshooting Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-4
TEMPERATURE/PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1
80-02
863 Bobcat Loader
Service Manual
80-10-1
863 Bobcat Loader
Service Manual
AIR CONDITIONING SYSTEM FLOW
Principals
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) from the Chart on Page 80-10-3 takes in low pressure refrigerant gas through the suction valve
(low pressure side) and as the name indicates, pressurizes the heat laden refrigerant and forces it through the discharge
valve (high pressure side) on the condenser (Item 2) from the Chart on Page 80-10-3.
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver/drier (Item 3) from the Chart on Page 80-10-3 where impurities such as
moisture and dirt are filtered out. The receiver/drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) from the Chart on Page 80-10-3.
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) from the Chart on Page 80-10-3.
As the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature,
low-pressure liquid and saturated vapor. The low-pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn or blown into through the evaporator by the evaporator fan
(Item 6) from the Chart on Page 80-10-3. Since the refrigerant is colder than the air, it absorbs the heat from the air and
produces cooled air, which is pushed into the cab by the fan. The moisture in the air condenses on the evaporator coil and
drips into the drain pan, which directs the water out of the cab.
The refrigerant cycle is completed when the heated low-pressure gas is again drawn into the compressor.
80-10-2
863 Bobcat Loader
Service Manual
AIR CONDITIONING SYSTEM FLOW (CONT'D)
Chart
Thermostat
Cold Air
Evaporator
5
Evaporator
4
Expansion Valve
Blower
6
1 Compressor
2 Condenser
Sight
Glass
Pressure
Switch
Fan
Dessicant
3
Receiver Drier
Status Of R134a_______________________________________________
High Pressure Gas
Low Pressure Liquid
High Pressure Liquid
Low Pressure Gas
b-16691
80-10-3
863 Bobcat Loader
Service Manual
80-10-4
863 Bobcat Loader
Service Manual
COMPONENTS
Figure 80-20-3
Identification
2
Figure 80-20-1
1
1
N-22134
N-22252
Compressor: The compressor (Item 1) [Figure 80-20-1]
is the pump that circulates the refrigerant throughout the
system. It raises the pressure of the refrigerant for heat
transfer through the condenser and evaporator.
Receiver/Drier: The receiver/drier (Item 1) [Figure 80-203] is the unit that receives the liquid refrigerant from the
condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
extra liquid refrigerant until it is needed by the evaporator.
Figure 80-20-4
NOTE: The
A/C
system
(Compressor)
is
recommended to be turned on for at least 5
minutes weekly throughout the year to
lubricate the internal components.
1
Figure 80-20-2
N-22206
1
Pressure Relief Valve: The pressure relief valve (Item 2)
[Figure 80-20-3] is located on the receiver drier
assembly. This small brass valve (Item 1) [[Figure 80-204] is a safety feature that is designed to open and release
the A/C charge if the pressure reaches 535 psi.
P-28471
Condenser: The condenser (Item 1) [Figure 80-20-2] is
the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.
80-20-1
863 Bobcat Loader
Service Manual
COMPONENTS (CONT'D)
Figure 80-20-7
Identification (Cont'd)
Figure 80-20-5
3
1
1
2
N-22087
Evaporator Coil: The evaporator coil (Item 1) [Figure 8020-7] cools and dehumidifies the air before it enters the
cab.
N-22121
Heater/Evaporator Unit: The heater/evaporator unit (Item
1) [Figure 80-20-5] is located behind the loader cab. The
unit delivers the cold air for the A/C and warm air for heat
into the cab. The unit contains the blower, heat & A/C
coils , thermostat and expansion valve.
Figure 80-20-6
Thermostat: The thermostat (Item 2) [Figure 80-20-7]
controls the temperature of the evaporator coil.
Heater Coil: The heater coil (Item 3) [Figure 80-20-7]
supplies the warm air into the cab by passing air through
the coil.
Figure 80-20-8
1
1
N-22150
N-22100
Expansion Valve: The expansion valve (Item 1) [Figure
80-20-6] controls the amount of refrigerant entering the
evaporator coil.
Heater/Evaporator Blower: The blower (Item 1) [Figure
80-20-8] is used to push air through the heater and
evaporator coils and into the cab.
80-20-2
863 Bobcat Loader
Service Manual
COMPONENTS (CONT'D)
Figure 80-20-11
Identification (Cont'd)
Figure 80-20-9
1
1
2
4
3
N-22134
N-22261
Control Panel: The panel (Item 1) [Figure 80-20-9] has
three separate components.
Pressure Switch: The pressure switch (Item 1) [Figure
80-20-11] will disengage the compressor clutch at high
pressure readings over 384 PSI. (2647 kPa) on the high
side, or if it senses very low pressure of 28 PSI (193 kPa)
or less on the high side, which indicates loss of
refrigerant.
Fan Switch: This is a four position rotary switch (Item
2) [Figure 80-20-9]. When the fan switch is in the off
position the A/C will not engage, but the heat valve
will operate, as it is controlled by the ignition power.
A/C Switch: The rocker switch (Item 3) [Figure 80-209] will be illuminated when the A/C is engaged.
Potentiometer: The potentiometer (Item 4) [Figure
80-20-9] controls the Heat Valve from fully Off to fully
On. This can be used in conjunction with the A/C for
defrost of the windows and temperature control.
Figure 80-20-10
1
N-22149
Heater Valve: The heater (Item 1) [Figure 80-20-10] is
used to control the amount of engine coolant that flows to
the heater coil.
80-20-3
863 Bobcat Loader
Service Manual
80-20-4
863 Bobcat Loader
Service Manual
SAFETY
Figure 80-30-2
Safety Equipment
Figure 80-30-1
P16399
P16398
In servicing A/C and heater systems you will be exposed
to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.
R-134a inside a canister or in an A/C system is a liquid
under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO 21.6 F DEGREES
"INSTANTLY". If it spills on your skin or in your eyes you
should flood the area with cool water and SEEK
MEDICAL ATTENTION FAST! It is a good idea to wear
gloves [Figure 80-30-2] to prevent frost bite if you should
get refrigerant on your hands.
In addition to exercising caution in your work, DO WEAR
SAFETY GLASSES OR A FACE SHIELD [Figure 8030-1] when you are using R-134a or a leak detector,
adjusting service valves or the manifold gage set
connectors. Safety glasses or a transparent face shield
are practical safety items and one or the other is
absolutely required.
80-30-1
863 Bobcat Loader
Service Manual
80-30-2
863 Bobcat Loader
Service Manual
REGULAR MAINTENANCE
Figure 80-40-3
Cleaning The Condenser
1
Open the rear door.
Raise the rear grill on the loader.
Figure 80-40-1
2
1
N-23036
Rotate the condenser (Item 1) [Figure 80-40-3] up
against the right side lift arm.
2
Slide the hydraulic cooler (Item 2) [Figure 80-40-3]
toward the rear of the loader.
P-28466
Figure 80-40-4
Check the condenser (Item 1) [Figure 80-40-1] for mud
and dirt.
Remove the two retainer clips (Item 2) [Figure 80-40-1].
1
Figure 80-40-2
3
2
N-22272
1
With water, or air, the radiator (Item 1) [Figure 80-40-4]
the oil cooler (Item 2) [Figure 80-40-4] and the
condenser (Item 3) [Figure 80-40-4] can be cleaned.
P-28466
Lift the condenser, and slide it toward the rear of the
loader until the mounting tabs (Item 1) [Figure 80-40-2]
clear the frame of the loader.
80-40-1
863 Bobcat Loader
Service Manual
REGULAR MAINTENANCE (CONT’D)
Filter Elements Removal And Installation
Compressor Drive Belt Inspection
Figure 80-40-6
It is a good rule to regularly inspect (weekly) the
compressor drive belt for tension and wear.
Open the rear door.
Figure 80-40-5
1
1
N-22247
Remove the two mount bolts [Figure 80-40-6] from the
fresh air filter cover at the rear of the loader cab.
Figure 80-40-7
N-23037
Check the tension on the compressor belt (Item 1)
[Figure 80-40-5].
1
N-22064
Remove the filter cover and filter (Item 1) [Figure 80-407] from the loader.
80-40-2
863 Bobcat Loader
Service Manual
REGULAR MAINTENANCE (CONT’D)
Figure 80-40-10
Filter Elements Removal And Installation (Cont’d)
1
Figure 80-40-8
1
N-22061
Remove the recirculating filter (Item 1) [Figure 80-40-10]
from the rear of the cab.
N-22063
Remove the filter (Item 1) [Figure 80-40-8] from the
cover.
Figure 80-40-11
The fresh air filter must be cleaned sometimes as often
as twice a day, depending on the operating environment.
The filter can be cleaned by removing it and shaking it. A
small amount of air pressure can be used to clean the
filter. However the fresh air filter should be changed at
least 2-4 time per year in normal conditions. In extremely
dusty conditions the fresh air filter may need to be
changed weekly.
Figure 80-40-9
N-22274
The recirculating air filter [Figure 80-40-11] is made of
open cell foam and should be cleaned with water. A mild
detergent may also be used. It does not require cleaning
as frequently as the fresh air intake filter.
2
1
N-22153
Remove the two retaining knobs (Item 1) [Figure 80-409] from the recirculating air filter cover, at the back of the
cab.
Remove the retaining cover (Item 2) [Figure 80-40-9]
from the loader cab.
80-40-3
863 Bobcat Loader
Service Manual
80-40-4
863 Bobcat Loader
Service Manual
BASIC TROUBLESHOOTING
Figure 80-50-3
Cleaning The A/C Evaporator Coil & Heater Coil
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
1
Figure 80-50-1
N-22129
Disconnect the blower fan wiring connector (Item 1)
[Figure 80-50-3] from the loader wiring harness.
1
Figure 80-50-4
N-22122
At the rear of the cab, disconnect the thermostat wiring
connector (Item 1)[Figure 80-50-1].
1
Figure 80-50-2
2
N-22119
Remove the two mounting nuts (Item 1) [Figure 80-504].
1
N-22130
Remove the mount bolt (Item 1) [Figure 80-50-2] from
the left side of the cab access cover.
Remove the access cover (Item 2) [Figure 80-50-2] from
the loader.
80-50-1
863 Bobcat Loader
Service Manual
BASIC TROUBLESHOOTING (CONT'D)
Figure 80-50-7
Cleaning The A/C Evaporator Coil & Heater Coil
(Cont'd)
Figure 80-50-5
1
1
N-22124
Remove the two mount bolts (Item 1) [Figure 80-50-7].
from the Evaporator/Heater Unit rear cover.
N-22120
Figure 80-50-8
Remove the two mounting nuts (Item 1) [Figure 80-505].
Figure 80-50-6
1
2
N-22125
1
Remove the three mount bolts (Item 1) [Figure 80-50-8]
and the one center mount bolt (Item 2) [Figure 80-50-8]
from the Evaporator/Heater Unit rear cover.
N-22123
Remove the rear cover from the unit.
Remove the Evaporator/Heater Unit from the rear of the
cab and place it on the fenders of the loader supported
by 2 x 4’s [Figure 80-50-6].
Remove the two mount bolts (Item 1) [Figure 80-50-6]
form the Evaporator/Heater Unit rear cover.
80-50-2
863 Bobcat Loader
Service Manual
BASIC TROUBLESHOOTING (CONT'D)
Checking The Electrical System
Cleaning The A/C Evaporator Coil & Heater Coil
(Cont'd)
Check to see if the compressor clutch is engaging.
With an operator in the loader seat and the cab door
open, turn the loader key switch to RUN (Standard Panel)
OR press the RUN/ENTER Button (Deluxe Panel),
without starting the loader.
Figure 80-50-9
1
Figure 80-50-10
2
2
N-22127
1
With air or water clean the heater coil (Item 1) [Figure
80-50-9] and evaporator unit (Item 2) [Figure 80-50-9].
N-22284
Push the A/C switch (Item 1) [Figure 80-50-10] to the
ON position. Turn the blower fan switch (Item 2) [Figure
80-50-10] to the first ON position.
The compressor clutch should make a click sound, which
indicates the clutch is engaging.
Figure 80-50-11
1
2
N-22287
If the compressor clutch does not engage, check the
loader fuse (Item 1) [Figure 80-50-11] located on the
control panel in the loader cab.
Replace the fuse if burned out.
NOTE: The decal inside the fuse cover, refers to the
fuse as HEATER. This fuse controls the
power for both the Heater and the A/C
systems.
80-50-3
863 Bobcat Loader
Service Manual
BASIC TROUBLESHOOTING (CONT'D)
Figure 80-50-14
Checking The Electrical System (Cont’d)
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Figure 80-50-12
1
N-23041
With a multimeter, check the voltage to the compressor
clutch at the loader harness (Item 1) [Figure 80-50-14].
The voltage reading should be around 12 volts.
1
If there is no power at the clutch, check the wiring
harness for broken wires.
If there is power at the clutch, reconnect the wiring
harness to the compressor clutch.
N-23040
Disconnect the loader harness (Item 1) [Figure 80-5012] from the compressor clutch wire.
Figure 80-50-15
Figure 80-50-13
2
1
1
N-22256
Disconnect the loader harness (Item 1) [Figure 80-5015] from the pressure switch (Item 2) [Figure 80-50-15].
N-23041
With a multimeter, check the resistance to
compressor clutch (Item 1) [Figure 80-50-13].
the
If there is no resistance value, replace the compressor
clutch. (See Removal And Installation on Page 80-1101.)
80-50-4
863 Bobcat Loader
Service Manual
BASIC TROUBLESHOOTING (CONT'D)
Figure 80-50-18
Checking The Electrical System (Cont’d)
Figure 80-50-16
1
1
N-22258
Disconnect the thermostat wiring connector (Item 1)
[Figure 80-50-18] from the loader wiring harness.
N-22257
Figure 80-50-19
Using a multimeter check the loader wiring harness (Item
1) [Figure 80-50-16] for voltage.
The voltage should be around 12 volts.
If there is no voltage at the wiring harness, check the
harness for broken wires.
Figure 80-50-17
1
1
N-22259
Check the loader harness (Item 1) [Figure 80-50-19] for
voltage. The voltage should be 12 volts.
If there is no voltage at the wiring harness, check the
harness for broken wires.
N-22257
If there is voltage at the harness, check the resistance at
the pressure switch (Item 1) [Figure 80-50-17].
If there is no resistance value, check for low refrigerant
level. (See Contents, Page 80-01.)
If a resistance level is seen, the pressure switch is good.
Reconnect the loader harness to the pressure switch.
80-50-5
863 Bobcat Loader
Service Manual
BASIC TROUBLESHOOTING (CONT'D)
Figure 80-50-22
Checking The Electrical System (Cont'd)
Figure 80-50-20
1
1
N-22129
Disconnect the blower fan wiring connector (Item 1)
[Figure 80-50-22] from the loader wiring harness.
N-22259
Figure 80-50-23
If there is voltage at the wiring harness, check the
thermostat (Item 1) [Figure 80-50-20] for resistance.
The resistance value of the thermostat should be 10
Ohms at 68° F (20° C).
If there is no resistance value, replace the thermostat.
(See Removal And Installation on Page 80-170-1.)
1
If there is a resistance value, check the blower fan.
Figure 80-50-21
N-22260
2
Check the loader harness (Item 1) [Figure 80-50-23] for
voltage. The voltage should be 12 volts.
If there is no voltage at the wiring harness, check the
harness for broken wires.
1
N-22130
Remove the mount bolt (Item 1) [Figure 80-50-21] from
the left side cab access cover.
Remove the access cover (Item 2) [Figure 80-50-21]
from the loader.
80-50-6
863 Bobcat Loader
Service Manual
BASIC TROUBLESHOOTING (CONT'D)
Figure 80-50-26
Checking The Electrical System (Cont'd)
Figure 80-50-24
1
N-22262
Remove the control panel and wiring harness from the
cab [Figure 80-50-26].
N-22260
Figure 80-50-27
If there is voltage at the wiring harness, check the
resistance to the blower fan at the blower fan wiring
connector (Item 1) [Figure 80-50-24].
If there is no resistance value replace the blower fan.
(See Removal And Installation on Page 80-210-1.)
1
If there is a resistance value check the climate controls at
the control panel inside the loader cab.
Figure 80-50-25
N-22265
1
Disconnect the loader wiring harness (Item 1) [Figure
80-50-27] from the blower switch.
Check the loader harness for voltage.
should be 12 volts.
1
The voltage
If there is no voltage at the wiring harness, check the
harness for broken wires.
N-22261
Remove the three mount bolts (Item 1) [Figure 80-50-25]
from the cab control panel.
80-50-7
863 Bobcat Loader
Service Manual
BASIC TROUBLESHOOTING (CONT'D)
Figure 80-50-29
Checking The Electrical System (Cont'd)
Figure 80-50-28
1
H
C
B
M
L
N-22264
At the loader cab, disconnect the loader harness (Item 1)
[Figure 80-50-29] from the A/C switch.
N-22288
If there is voltage at the wiring harness, check the blower
switch (Item 1) [Figure 80-50-28] for resistance.
With the switch in the OFF position, there should be zero
resistance between terminals.
With the switch in the 1 position, there should be
resistance between C terminal and the B terminal. And
also between the C terminal and the L terminal frame
[Figure 80-50-28].
Check the harness for voltage. The voltage should be
about 12 volts.
If there is no voltage at the wiring harness, check the
harness for broken wires.
Figure 80-50-30
2
With the switch in the 2 position, there should be
resistance between C terminal and the B terminal. And
also between the C and the M terminal frame [Figure 8050-28].
1
With the switch in the 3 position, there should be
resistance between the C terminal and the B terminal.
And also between the C terminal and the H terminal
frame [Figure 80-50-28].
N-22289
If any of the above resistance tests fail, replace the
blower switch.
If the above resistance tests are good, check the A/C
switch.
If there is voltage at the wiring harness, check the A/C
switch (Item 1) [Figure 80-50-30] for resistance.
With the switch in the OFF position there should be no
resistance between any of the three terminals on the A/C
switch.
With the switch in the ON position there should be
resistance between terminal (Item 1) and terminal (Item
2) [Figure 80-50-30].
If no resistance value is found, replace the A/C switch.
If a resistance value is found, check the potentiometer.
80-50-8
863 Bobcat Loader
Service Manual
BASIC TROUBLESHOOTING (CONT'D)
Figure 80-50-33
Checking The Electrical System (Cont'd)
The potentiometer will effect the A/C system and also
effect the operation of the heater.
If heater valve does not open, or close, or the A/C does
not work, check the potentiometer.
C
A
Figure 80-50-31
B
N-22290
If there is voltage at the wiring harness, check the
potentiometer [Figure 80-50-33] for resistance.
1
The resistance should be 10 k Ohm’s between wire pin A
and wire pin C frame [Figure 80-50-33].
If no resistance is found replace the potentiometer.
N-22262
Figure 80-50-34
At the loader cab, disconnect the loader harness (Item 1)
[Figure 80-50-31] from the potentiometer.
Figure 80-50-32
1
1
N-22201
The white wire B, (Item 1) [Figure 80-50-34] on the
potentiometer, is a resister wire.
N-22263
Check the loader harness (Item 1) [Figure 80-50-32] for
voltage. The voltage should be 12 volts.
If there is no voltage at the wiring harness, check the
harness for broken wires.
80-50-9
863 Bobcat Loader
Service Manual
BASIC TROUBLESHOOTING (CONT'D)
Figure 80-50-37
Checking The Electrical System (Cont'd)
Figure 80-50-35
1
N-22175
1
To check the resistance of the white wire, turn the
potentiometer control (Item 1) [Figure 80-50-37] to the
full Heater position.
N-22175
To check the resistance of the white wire, turn the
potentiometer control (Item 1) [Figure 80-50-35] to the
full A/C position [Figure 80-50-35].
Figure 80-50-38
Figure 80-50-36
C
A
C
A
B
N-22290
B
Check the resistance between the wire terminal A and
wire terminal B frame [Figure 80-50-38] should be
around 39 k Ohm’s.
N-22290
The resistance between the wire terminal A and wire
terminal B frame [Figure 80-50-36] should be around 49
k Ohm’s.
Check the resistance between the wire terminal C and
wire terminal B frame [Figure 80-50-38] should be
around 49 k Ohm’s.
Check the resistance between the wire terminal C and
wire terminal B frame [Figure 80-50-36] should be
around 39 k Ohm’s.
If the resistance is not found replace the potentiometer.
80-50-10
863 Bobcat Loader
Service Manual
BASIC TROUBLESHOOTING (CONT'D)
Engine Coolant By-Passing The Heater Valve
Compressor Drive Belt Inspection:
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
It is a food rule to inspect (weekly) the compressor drive
belt for tension and wear.
Figure 80-50-40
Open the rear door.
Figure 80-50-39
1
2
3
1
N-22284
N-23037
Check the tension on the compressor belt (Item 1)
[Figure 80-50-39].
The belt tension should be set by measuring the belt
deflection, which should be 0.16 in. (4 mm) with a
deflection load of 3.5-4 lbs. (1,6-1,8 kg) force.
Push the A/C switch (Item 1) [Figure 80-50-40] to the
OFF position. Turn the fan switch (Item 2) [Figure 8050-40] to the High Speed position. Turn the temperature
control (Item 3) [Figure 80-50-40] to the High A/C
position, with the loader ignition switch OFF.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Connect the remote start tool to the loader.
REMOTE START on Page 10-60-1.)
(See
Start the loader and run at high idle, for ten minutes.
If the hose is hot, the heater valve is leaking by, and
needs to be replaced.
80-50-11
863 Bobcat Loader
Service Manual
BASIC TROUBLESHOOTING (CONT'D)
Engine Coolant By-Passing The Heater Valve (Cont'd)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Connect the remote start tool to the loader.
REMOTE START on Page 10-60-1.)
Figure 80-50-41
(See
Figure 80-50-43
1
1
N-22131
N-22131
Check the heater hose (Item 1) [Figure 80-50-41] for
temperature.
If the hose is hot, the heater valve is leaking by, and
needs to be replaced.
Heater Valve Not Opening Or Closing
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Place the remote start tool on the left fender of the
loader, so the heater valve can be clearly seen. Watch
the valve shaft (Item 1) [Figure 80-50-43], as the key of
the remote start switch is turned to the ON position
without starting the loader. The heater valve should
rotate. Place a mark on the loader shaft.
Turn the remote start key to the OFF position and remove
the remote start tool from fender.
Lower operator cab.
Figure 80-50-42
Turn the temperature control (Item 3) [Figure 80-50-42]
to the High Heater position, with the loader ignition switch
OFF.
Raise the operator cab.
2
Place the remote start tool on the left fender of the
loader, so the heater valve can be clearly seen. Watch
the valve shaft (Item 1) [Figure 80-50-43], as the key of
the remote start is turned to the ON position without
starting the loader. The heater valve should rotate.
3
1
If it does not rotate, check the potentiometer for proper
function. (See Checking The Electrical System on Page
80-50-3.)
N-22284
Push the A/C switch (Item 1) [Figure 80-50-42] to the
OFF position. Turn the fan switch (Item 2) [Figure 8050-42] to position 1. Turn the temperature control (Item
3) [Figure 80-50-42] to the High A/C position, with the
loader ignition switch OFF.
Replace the heater valve. (See Removal and Installation
on Page 80-220-1.)
80-50-12
863 Bobcat Loader
Service Manual
BASIC TROUBLESHOOTING
Figure 80-50-45
Poor A/C Performance
Start the loader, lock the park brake, and engage the A/C
system with the blower fan on High. Run the loader at full
throttle for approximately 15 minutes, with the loader cab
door closed.
Figure 80-50-44
N-22411
1
Check the temperature at the louvers (Item 1) [Figure
80-50-44] with a thermometer [Figure 80-50-45].
The louver temperature should be between 36-53° F
(2,2-11,6° C) depending on the amount of humidity in the
air.
N-22273
If louver temperature is too high.
(See SYSTEM
TROUBLESHOOTING CHART on Page 80-70-1.)
Check the blower fan for proper operation, or noise, and
replace if necessary. (See Removal And Installation on
Page 80-210-1.)
Check the belt tension on the A/C compressor. (See
Compressor Drive Belt Inspection on Page 80-40-2.)
Check the A/C condenser for dirt or mud and clean if
necessary. (See Cleaning The Condenser on Page 8040-1.)
Check the A/C evaporator coil for dirt or mud and clean if
necessary. (See Cleaning The A/C Evaporator Coil &
Heater Coil on Page 80-50-1.)
Inspect the sight glass located on the receiver/drier for air
bubbles. (See Compressor Drive Belt Inspection on
Page 80-40-2.)
Check the engine coolant to see if it is bypassing the
heater valve. (See Engine Coolant By-Passing The
Heater Valve on Page 80-50-11.)
80-50-13
863 Bobcat Loader
Service Manual
80-50-14
863 Bobcat Loader
Service Manual
GENERAL AIR CONDITIONING SERVICE
GUIDELINES
Compressor Oil Check
The compressor oil should be checked as follows when
oil is being added to an in service loader.
Compressor Oil
Figure 80-60-1
There is a close affinity between oil and refrigerant.
During normal operation, part of the oil circulates with the
refrigerant in the system. Therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run in advance to
insure return of oil to the compressor.
1
If the amount of refrigerant in the system has decreased,
charge the system. (See Charging Procedure on Page
80-100-4.)
Open the cab door and windows.
Run the blower at maximum speed.
N-22243
Run the compressor for at least 20 minutes at 800-1200
RPM.
The compressor (Item 1) [Figure 80-60-1] is factory filled
with 150-170 cc's of PAG oil (Poly Alkelene Glycol).
Remove the compressor from the loader. (See Removal
And Installation on Page 80-110-1.)
Unlike engine oil, it is not necessary to frequently check
or change the compressor oil.
It is necessary to check, replenish or replace the
compressor oil in the following cases:
1. When ever the evaporator, condenser or receiver
drier is replaced.
2. Whenever the refrigerant has leaked from the system.
3. Whenever the refrigerant is suddenly released from
the cooling cycle.
4. Whenever any oil-related problems occur in the
cooling cycle.
When one of the components (the evaporator, condenser
or receiver-drier) is replaced, one ounce of oil should be
added for each component replaced.
If the A/C compressor is changed, no oil should be added
to the system, because the compressor comes factory
filled with oil.
NOTE: Only PAG oil should be used, and never mix
R-12 and R-134a Oils.
80-60-1
863 Bobcat Loader
Service Manual
GENERAL AIR CONDITIONING SERVICE
GUIDELINES (CONT'D)
Figure 80-60-4
Compressor oil Check (Cont’d)
Figure 80-60-2
1
1
N-22246
NOTE: After draining the oil through the drain hole
and the connectors, extract the remaining oil
through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-604] several times by hand.
N-22245
Figure 80-60-3
Measure the drained oil in a measuring cylinder.
Check the oil for contamination, dirt, metal shavings, or
varnish color, discard the oil if contaminated.
NOTE: If metal shavings are found in the compressor
oil, replace the complete compressor
assembly.
Figure 80-60-5
1
P-16534A
Remove the oil drain plug (Item 1) [Figure 80-60-2] and
drain the oil through the connectors and the oil drain hole
[Figure 80-60-3].
Installation: Tighten the oil drain plug to 9.4-10.8 ft.-lbs.
(13-15 Nm) torque.
N-22245
Add new compressor oil through the suction side
connector (Item 1) [Figure 80-60-5].
Installation: Add 150 -170 cc's of PAG oil.
NOTE: The suction port on the compressor is marked
with an S and is the larger port on the
compressor.
80-60-2
863 Bobcat Loader
Service Manual
GENERAL AIR CONDITIONING SERVICE
GUIDELINES (CONT'D)
Component Replacement And Refrigeration Leaks
Figure 80-60-6
1
N-22134
Whenever the A/C system is opened to the atmosphere
or there has been a leak in the system, the receiver/drier
(Item 1) [Figure 80-60-6] must be changed.
Never leave hose fittings, compressor fittings or
components uncapped while working on the A/C system.
80-60-3
863 Bobcat Loader
Service Manual
80-60-4
863 Bobcat Loader
Service Manual
SYSTEM TROUBLESHOOTING CHART
Blower motor does not operate
Possible Cause
1. Blown fuse.
2. Broken wiring or bad
connection.
3. Fan motor malfunction.
Inspection
Solution
Inspect the fuse/wiring.
Check the fan motor ground and connectors.
Replace fuse/repair wiring.
Repair the wiring or connector.
Check the lead wires form the motor with a circuit
tester.
Check resistor using a circuit tester.
Check power into and out of the fan switch.
Replace Motor.
4. Resistor malfunction.
5. Fan motor switch
malfunction.
Blower motor operates normally, but air flow is insufficient
Possible Cause
Replace Resistor.
Replace Fan Switch.
Inspection
1. Evaporator inlet obstruction.
Check evaporator for plugging.
2. Air leak.
Check to make sure air hoses are properly hooked
to Louvers, and air ducts.
Check thermostat using a circuit tester.
3. Defective thermo. switch
(frozen evaporator).
4. Plugged cab filters
Check cab filter condition.
Insufficient cooling although air flow and compressor operation are normal
Possible Cause
Solution
Remove obstruction and clean
evaporator fins with air or
water.
Repair of adjust.
Replace thermostat.
Clean or replace filters.
Inspection
1. System low on refrigerant.
The high side pressure will be low and bubbles
may be present in sight glass on receive drier.
2. Excessive refrigerant.
The high pressure side pressure will be high.
Solution
Repair any leaks and recharge
the refrigerant to the correct
level.
Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
The compressor does not operate at all, or operates improperly
Possible Cause
1. Loose drive belt.
2. Internal compressor
malfunction.
Inspection
The belt is vibrating or oscillating.
The compressor is locked up and the belt slips.
Solution
Adjust tension.
Replace compressor.
Magnetic clutch related
3. Low battery voltage.
4. Faulty coil.
5. Oil on the clutch surface.
Clutch slips.
Clutch slips.
Clutch slips.
6. Open oil.
Clutch does not engage and there is no reading
when a circuit tester is connected between the coil
and terminals.
Clutch will not engage. Inspect the ground and
connections.
Test the conductance of the pressure switch,
thermostat, Relay, etc.
7. Broken wiring or poor
ground.
8. Wiring harness
components.
80-70-1
Recharge the battery.
Replace the magnetic clutch.
Replace or clean the clutch
surface.
Replace clutch.
Repair.
Check operation.
863 Bobcat Loader
Service Manual
SYSTEM TROUBLESHOOTING CHART (CONT'D)
Gauge Pressure Related Troubleshooting
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86-96 degrees F
(30-38 degrees C) and compressor speed of approximately 2000 RPM are:
High pressure side pressure: 210-265 PSI
Low pressure side pressure: 15-33 PSI
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure.
Possible Cause
Low pressure side
Too high.
1. Expansion valve
opens too far.
2. Dective compressor.
Low pressure side
Too low.
1. Low refrigerant
charge.
Inspection
The low pressure side pressure normally becomes too
high when the high pressure side pressure is too high. As
this is explained below, the following inspection is only
used when the low pressure side is too high.
Frost is present on the suction hose.
Solution
Replace expansion valve.
The high and low pressure side gauge pressures
equalize when the magnetic clutch is engaged.
Replace compressor.
The high side pressure will be low and bubbles may be
present in sight glass on receive drier.
Repair any leaks and recharge
the refrigerant to the correct
level.
Clean or replace the expansion
Valve.
Flush system or replace hose.
2. Clogged or closed
expansion valve.
3. Restriction between
drier and expansion
valve.
4. Thermostat
malfunction.
The expansion valve’s inlet side is frosted. Moisture or
other Contaminants can be the cause.
Frost on the line between drier and expansion valve. A
Negative low pressure reading may be shown.
5. Restriction in
reciever drier.
High pressure side
Too high.
1. Poor condenser
performance.
2. Excessive
refrigerant.
Excessive frost on reciever drier.
3. Excessive oil charge.
The high pressure side will be high.
4. Air in system.
Pressure is high on both high and low sides.
5. Restriction in drier,
condenser or high
pressure line.
High pressure side will be high, and low pressure side
will be low.
The evaportator is frozen.
Dirty or clogged condenser fins. Condenser fans not
Operating.
The high pressure side pressure will be high.
80-70-2
Adjust themostat’s
temperature setting or probe
placement or replace
thermostat.
Replace reciever drier.
Clean fins, and/or repair the
fan.
Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
Evacuate system. Remove oil
from condenser and
compressor. Measure oil from
compressor and add correct oil
charge back into compressor.
Flush system with nitrogen.
Replace drier.
Evacuate and recharge with
Refrigerant.
Evacuate and flush system
replacing defective parts.
863 Bobcat Loader
Service Manual
SYSTEM TROUBLESHOOTING CHART (CONT'D)
Gauge Pressure Related Troubleshooting (Cont'd)
Possible Cause
Inspection
High pressure side Too
low.
1. Low refirgerant charge. The high side pressure will be low and bubbles may be
present in sight glass on receive drier.
System pressures Equal
1. Clutch not operating.
2. Compressor not
pumping.
See magnetic clutch related topics above.
Equal high and low pressures.
80-70-3
Solution
Repair any leaks and
recharge the refrigerant to
the correct level.
Replace compressor.
863 Bobcat Loader
Service Manual
SYSTEM TROUBLESHOOTING CHART (CONT'D)
Troubleshooting Tree
B-21491
80-70-4
863 Bobcat Loader
Service Manual
SYSTEM TROUBLESHOOTING CHART (CONT'D)
Troubleshooting Tree (Cont’d)
B-21491A
80-70-5
863 Bobcat Loader
Service Manual
SYSTEM TROUBLESHOOTING CHART (CONT'D)
Troubleshooting Tree (Cont’d)
B-21492
80-70-6
863 Bobcat Loader
Service Manual
SYSTEM TROUBLESHOOTING CHART (CONT'D)
Troubleshooting Tree (Cont’d)
B-21493
80-70-7
863 Bobcat Loader
Service Manual
80-70-8
863 Bobcat Loader
Service Manual
TEMPERATURE/PRESSURE
Chart
NORMAL EVAPORATOR RANGE
NORMAL CONDENSER RANGE
TEMP F.
PSIG
TEMP F.
PSIG
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
45
50
55
60
65
70
75
80
85
90
91
92
15.69
17.04
18.43
19.87
21.35
22.88
24.47
26.10
27.79
29.52
31.32
33.17
35.07
37.03
39.05
40.09
45.48
51.27
57.47
64.10
71.19
78.75
86.80
95.40
104.40
106.30
108.20
93
94
95
100
102
104
106
108
110
112
114
116
118
120
122
124
126
128
130
135
140
145
150
155
160
165
170
110.20
112.10
114.10
124.30
128.50
132.90
137.30
141.90
146.50
151.30
156.10
161.10
166.10
171.30
176.60
182.00
187.50
193.10
198.90
213.70
229.40
245.80
263.00
281.10
300.10
320.10
340.80
Evaporator
Pressures represent gas temperatures inside the coil, not the coil surface. For an estimate of the temperature of the air
coming off the coil add 8-10 degrees F to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 40 degrees F to the ambient temperature
to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient
temperature.
Example: Ambient
Temperature = 90 degrees F
90 degrees F
+40 degrees F
130 degrees F condenser temperature = 200 psig
Conditions and pressures will vary from system to system. Check with MCC for system specifications.
80-80-1
863 Bobcat Loader
Service Manual
80-80-2
863 Bobcat Loader
Service Manual
AIR CONDITIONING SERVICE
Chart
Service Company/Phone Number:
Date:
Machine Model:
Machine Serial Number:
Machine Hours:
Pre Service Conditions
Ambient Temperature:
Louver Temperature:
Cab Temperature At Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:
Machine Dealer:
Customer:
15 Minutes
30 Minutes
Notes
15 Minutes
30 Minutes
Notes
Explain Services Required:
Post Service Conditions
Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:
80-90-1
863 Bobcat Loader
Service Manual
80-90-2
863 Bobcat Loader
Service Manual
SYSTEM CHARGING AND RECLAMATION
WARNING
Reclamation Procedure
Figure 80-100-1
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
1
W-2371-0500
NOTE: This test is run with the loader engine OFF,
and the A/C switch in the OFF position.
Figure 80-100-3
N-23024
NOTE: Before reclaiming a refrigeration system, it is
recommended to identify the type of
refrigerant that is in the A/C system and if it is
pure enough to use. The tool MEL1592,
Refrigerant Identifier (Item 1) [Figure 80-100-1]
will determine, the kind of refrigerant and any
possible harmful or dangerous substances
that may be present in the system. Thus
preventing mixing of dangerous material with
your reclaimed R-134a in your reclaimer, and
further contamination to other A/C systems
that are reclaimed and charged from your
MEL1581 Recovery / Recycling / Recharging
Machine.
Figure 80-100-2
N-23026
Connect the Refrigerant Identifier to the low pressure
hose [Figure 80-100-3].
Connect the Refrigerant Identifier to its power source.
Follow the steps displayed on the refrigerant identifier
screen.
Allow two minutes for the refrigerant identifier to display
the type of refrigerant and air content. An alarm will
sound if potentially flammable hydrocarbons are present
and will also indicate on the visual display.
1
Disconnect the refrigerant identifier from the loader A/C.
If the refrigerant is dangerous or flammable, it must be
evacuated from the A/C system into a separate container
and properly and safely disposed of.
If R134a is found, evacuate the system.
N-22293
Remove the protective cap (Item 1) [Figure 80-100-2]
from the low pressure hose.
80-100-1
863 Bobcat Loader
Service Manual
SYSTEM CHARGING AND RECLAMATION (CONT'D)
Figure 80-100-5
Reclamation Procedure (Cont'd)
NOTE: Only A/C trained technicians should perform
the reclaiming and recharging procedure.
1
2
WARNING
HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
if it contacts the eyes and may cause serious
frostbite if it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air.
Any servicing work that involves release or addition
of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration
equipment.
N-22380
Connect the Red hose (Item 1) [Figure 80-100-5] to the
high pressure port and open the valve.
Connect the Blue hose (Item 2) [[Figure 80-100-5] to the
low pressure port and open the valve.
Figure 80-100-6
W-2373-0500
Figure 80-100-4
N-22292
Turn the reclaimer unit [Figure 80-100-6] to the ON
position and follow the on screen instructions.
N-22291
Use an approved recovery/charging unit [Figure 80-1004] to evacuate the system.
Connect the reclaimer to the loader A/C charge ports.
80-100-2
863 Bobcat Loader
Service Manual
SYSTEM CHARGING AND RECLAMATION (CONT'D)
Figure 80-100-8
Reclamation Procedure (Cont’d)
Figure 80-100-7
1
N-22382
Check to see that the hand valves (Item 1) [Figure 80100-8] are closed on the manifold gauge set.
N-22381
NOTE: The reclaimer unit, has a complete step by
step set of instructions [Figure 80-100-7] to
follow for reclamation and recharging of the
A/C system. A trained technician should
follow these instructions as they may very
slightly depending on the model and brand of
reclaimer used.
If there is any refrigerant in the A/C system, it must be
recovered by an approved A/C reclamation procedure.
(See Reclamation Procedure on Page 80-100-1.)
Connect the gauges to the loader A/C charge ports.
Figure 80-100-9
Charging Procedure With A Manifold Gauge Set
Raise the loader lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
2
1
WARNING
N-22382
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
Connect the Red hose (Item 1) [Figure 80-100-9] to the
high pressure port and open the valve.
Connect the Blue hose (Item 2) [Figure 80-100-9] to the
low pressure port and open the valve.
80-100-3
863 Bobcat Loader
Service Manual
SYSTEM CHARGING AND RECLAMATION (CONT'D)
Charging Procedure
Charging Procedure With A Manifold Gauge Set
(Cont’d)
Figure 80-100-12
Figure 80-100-10
1
1
N-22382
N-23042
Connect the Yellow hose (Item 1) [Figure 80-100-10] to
the vacuum pump.
Figure 80-100-11
Note vacuum pressure indicated on the low pressure
(Blue) gauge (Item 1) [Figure 80-100-12]. Let stand for
5-10 min. and recheck the pressure for changes.
If the pressure drops, this may be an indication of a leak
in the A/C system.
Determine the problem with the A/C system and repair it.
1
N-23043
Start the vacuum pump and open Iso-valve (Item 1)
[Figure 80-100-11] on the vacuum pump.
Run the vacuum pump for at least 5-10 minutes to insure
that a vacuum has been pulled on the system.
Close the Iso-valve (Item 1) [Figure 80-100-11] (which
isolates the vacuum pump from the A/C system) and turn
OFF the vacuum pump.
80-100-4
863 Bobcat Loader
Service Manual
SYSTEM CHARGING AND RECLAMATION (CONT'D)
Figure 80-100-14
Charging Procedure (Cont'd)
3
Figure 80-100-13
1
2
1
N-23044
Place a refrigerant container with R134a (Item 1) [Figure
80-100-14] on a charging scale (Item 2) [Figure 80-10014] and zero out the scale.
N-22385
A thermistor vacuum gauge (Item 1) [Figure 80-100-13]
may be necessary to use to determine the critical
vacuum level during evacuation. It is a solid state
instrument that constantly monitors and visually indicates
the vacuum level.
Connect the yellow hose (Item 3) [Figure 80-100-14]
from the manifold gauge set to the valve on the
refrigerant tank.
Figure 80-100-15
The thermistor vacuum gauge is used with the vacuum
pump [Figure 80-100-13].
2
Start the vacuum pump and open Iso-valve on the
vacuum pump.
Be sure that both hand valves, and both charge port
valves are open.
1
Run the vacuum pump for at least 45 minutes to insure
that all the moisture is boiled out of the system.
Stop the vacuum pump and close the Iso-valve on the
vacuum pump.
Close both hand valves on the manifold gauge set and
remove the yellow hose from the vacuum pump that goes
to the manifold gauge set.
Remove the vacuum pump and thermister vacuum
gauge.
N-23044
Open the valve on the refrigerant container (Item 1)
[Figure 80-100-15] and open the low pressure hand
valve (Blue) (Item 2) [Figure 80-100-15] on the manifold
gauge set. Allow the vacuum to pull in the refrigerant until
the pressure stabilizes.
80-100-5
863 Bobcat Loader
Service Manual
SYSTEM CHARGING AND RECLAMATION (CONT'D)
Charging Procedure (Cont'd)
Connect the remote start tool to the loader. (See
REMOTE START on Page 10-60-1.)
Figure 80-100-16
2
1
N-22284
Press the A/C (Item 1) [Figure 80-100-16] switch to ON
position.
Turn fan switch (Item 2) [Figure 80-100-16] to HIGH
position.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Start loader engine, with the remote start switch, and run
at medium speed.
Watch the scale and run system until the predetermined
amount of refrigerant is added to the A/C system.
The A/C system holds 2 lbs. (0,19 kg) of refrigerant.
Turn OFF the valve on the refrigerant container, and hand
valves on the manifold gauge set.
Turn OFF the engine, and remove the A/C charging
equipment from the loader.
Lower the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
80-100-6
863 Bobcat Loader
Service Manual
COMPRESSOR
Figure 80-110-2
Removal And Installation
WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
1
W-2371-0500
Raise the loader lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Evacuate the A/C system. (See SYSTEM CHARGING
AND RECLAMATION on Page 80-100-1.)
N-22377
Remove the compressor mount bolt (Item 1) [Figure 80110-2].
Remove the compressor from the loader.
Figure 80-110-1
2
1
N-22379A
Remove the compressor adjustment bolt (Item 1) [Figure
80-110-1].
Installation: Tighten the compressor adjustment bolt to
34 ft.-lbs. (46 Nm) torque.
Remove the compressor belt.
Mark the compressor hoses for proper installation.
Remove the compressor hoses (Item 2) [Figure 80-1101] from the compressor.
Installation: Tighten the compressor hoses to 22 ft.-lbs.
(29,8 Nm) torque.
Cap and plug the compressor hoses and the fittings with
with the proper A/C caps and plugs.
80-110-1
863 Bobcat Loader
Service Manual
COMPRESSOR (CONT'D)
Figure 80-110-5
Compressor Clutch Disassembly
1.32”
Figure 80-110-3
1.32”
1.32”
2
1
1
N-22275
N-22244
Remove the center armature bolt (Item 1) [Figure 80110-3].
The armature plate puller, (Item 1) [Figure 80-110-5] can
be constructed by drilling three 10 mm holes in a flat
circular plate, located 1.32 inches apart [Figure 80-1105].
Figure 80-110-6
Installation: Tighten the armature bolt to 8-10 ft.-lbs.
(12-14 Nm) torque.
Figure 80-110-4
1
2
N-22278
Attach the puller to the armature plate using three 8 mm
bolts (Item 2) [Figure 80-110-5].
N-22277
To remove the armature plate (Item 1) [Figure 80-110-4]
from the clutch face, you must make an armature plate
puller.
Turn the bolts into the three 8 mm holes (Item 2) [Figure
80-110-4] on the armature plate as shown in [Figure 80110-6].
80-110-2
863 Bobcat Loader
Service Manual
COMPRESSOR (CONT'D)
Figure 80-110-9
Compressor Clutch Disassembly (Cont'd)
Figure 80-110-7
1
1
N-22283
Remove the snap ring (Item 1) [Figure 80-110-9] from
the pulley assembly.
N-22279
Attach a slide hammer puller (Item 1) [Figure 80-110-7]
to the armature puller disk.
Figure 80-110-10
Remove the armature plate from the compressor clutch.
Figure 80-110-8
1
N-22369
Install the pulley puller tool MEL 1595 on the compressor
pulley [Figure 80-110-10].
N-22280
Remove the shims (Item 1) [Figure 80-110-8] from either
the armature shaft or armature plate.
Installation: Insure that the clutch has the correct
clearance by adding the shims (Item 1) [Figure 80-1108].
The specified clearance for the clutch is 0.01-0.02 in.
(0.3-0.6 mm). Adjusting shims are available in the
following thicknesses:
0.0039 in. (0.1 mm)
0.0118 in. (0.3 mm)
0.0197 in. (0.5 mm)
80-110-3
863 Bobcat Loader
Service Manual
COMPRESSOR (CONT'D)
Figure 80-110-13
Compressor Clutch Disassembly (Cont'd)
Figure 80-110-11
1
N-22373
Slide the wire grommet (Item 1) [Figure 80-110-13] from
the wire holder.
N-22370
Remove the pulley from the compressor [Figure 80-11011].
Figure 80-110-14
Figure 80-110-12
1
N-22374
Remove the coil lead wire (Item 1) [Figure 80-110-14]
from the wire holder on the compressor.
N-22371
The pulley assembly and bearing [Figure 80-110-12]
must be replaced as a complete unit.
80-110-4
863 Bobcat Loader
Service Manual
COMPRESSOR (CONT'D)
Figure 80-110-16
Compressor Clutch Disassembly (Cont'd)
Figure 80-110-15
1
N-22375
1
The compressor [Figure 80-110-16] must be replaced as
a complete unit.
N-22372
Remove the three coil mount bolts (Item 1) [Figure 80110-15] from the compressor.
Installation: Tighten the mount bolts to 2.9-4.3 ft.-lbs. (46 Nm) torque.
Remove the coil from the compressor.
80-110-5
863 Bobcat Loader
Service Manual
80-110-6
863 Bobcat Loader
Service Manual
CONDENSER
WARNING
Removal And Installation
Remove the refrigerant from the A/C system. (See
SYSTEM CHARGING AND RECLAMATION on Page 80100-1.)
Open the rear door of the loader.
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
Open the rear grill on the loader.
Disconnect the two hoses from the condenser.
Figure 80-120-1
Cap and plug the hoses and the condenser fittings with
the proper A/C caps and plugs.
Figure 80-120-3
1
N-22976
Remove the two retaining clips (Item 1) [Figure 80-1201] from the condenser mount bracket.
N-22978
Figure 80-120-2
Lift the rear of the condenser, and pull toward the rear of
the loader [Figure 80-120-3].
Remove the condenser from the loader.
1
P-28470
Mark the two A/C hoses (Item 1) [Figure 80-120-2] for
proper installation.
80-120-1
863 Bobcat Loader
Service Manual
CONDENSER (CONT’D)
Removal And Installation (Cont’d)
Figure 80-120-4
1
N-22977A
Installation: When installing the condenser, be sure the
condenser tabs (Item 1) [Figure 80-120-4] are positioned
in the slots in the loader frame
80-120-2
863 Bobcat Loader
Service Manual
RECEIVER/DRIER
Figure 80-130-2
Removal And Installation
Raise the loader lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
1
2
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
3
Remove the refrigerant from the A/C system. (See
SYSTEM CHARGING AND RECLAMATION on Page 80100-1.)
Figure 80-130-1
N-22134
Remove the two A/C hoses (Item 2) [Figure 80-130-2]
from the receiver/drier.
Cap and plug the hoses and the receiver/drier fittings
with the proper A/C caps and plugs.
Loosen the hose clamps (Item 3) [Figure 80-130-2] that
holds the receiver/drier to the mount.
1
Remove the receiver/drier from the loader.
NOTE: When replacing a receiver/drier in an A/C
system 1 fl. oz. (30 cc) of PAG oil must be
added to the system when recharging.
N-22134
Mark the A/C hoses (Item 1) [Figure 80-130-1] for proper
installation.
Figure 80-130-3
Both fittings on the drier are the same size, so the hoses
can be hooked up incorrectly.
1
Note the flow direction on the drier (Item 1) [Figure 80130-2] for proper installation
WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
N-22135
Remove the two mount bolts (Item 1) [Figure 80-130-3]
from the receiver/drier mount bracket.
Remove the bracket from from the top of the hydraulic
filter bracket.
80-130-1
863 Bobcat Loader
Service Manual
80-130-2
863 Bobcat Loader
Service Manual
PRESSURE RELIEF VALVE
Figure 80-140-2
Removal And Installation
Figure 80-140-1
1
N-22206
The pressure relief valve [Figure 80-140-2] is designed
to open and release the A/C charge if the pressure
reaches 535 PSI (3689 kPa)
N-22205
The pressure relief valve (Item 1) [Figure 80-140-1] is
located on the drier assembly.
This will cause the A/C system to shut down, saving the
compressor.
The Pressure Relief Valve is a secondary protection
device in the A/C system, with the Pressure Switch
shutting down the system at 384 PSI (2648 kPa).
NOTE: If a Pressure Relief Valve is found open, check
the A/C system for problems. Replace the
complete receiver/drier unit.
80-140-1
863 Bobcat Loader
Service Manual
80-140-2
863 Bobcat Loader
Service Manual
PRESSURE SWITCH
Figure 80-150-2
Removal And Installation
Raise the loader lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
1
Figure 80-150-1
N-22134
Remove the pressure switch (Item 1) [Figure 80-150-2]
from the A/C high pressure hose.
1
Remove the pressure switch from the loader.
N-22256
Disconnect the loader wire harness (Item 1) [Figure 80150-1] from the pressure switch wire harness.
NOTE: The pressure switch can be changed without
evacuating the A/C system.
WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
80-150-1
863 Bobcat Loader
Service Manual
PRESSURE SWITCH (CONT’D)
Shreader Valve Removal And Installation
Figure 80-150-3
1
N-22166
The shreader valve (Item 1) [Figure 80-150-3] is located
in the A/C high pressure hose and is located under the
pressure switch.
Raise the loader lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the refrigerant from the A/C system. (See
SYSTEM CHARGING AND RECLAMATION on Page 80100-1.)
Remove the pressure switch.
With a tire valve core removal tool, remove the valve core
from the hose.
Replace with a new core.
80-150-2
863 Bobcat Loader
Service Manual
EVAPORATOR/HEATER UNIT
Figure 80-160-3
Removal And Installation
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
1
Evacuate the A/C system. (See SYSTEM CHARGING
AND RECLAMATION on Page 80-100-1.)
Figure 80-160-1
N-22129
Disconnect the blower fan wiring connector (Item 1)
[Figure 80-160-3] from the loader wiring harness.
Figure 80-160-4
1
N-22122
1
At the rear of the cab, disconnect the thermostat wiring
connector (Item 1) [Figure 80-160-1].
Figure 80-160-2
N-22119
Remove the two mounting nuts (Item 1) [Figure 80-1604].
2
1
N-22130
Remove the mount bolt (Item 1) [Figure 80-160-2] from
the left side cab access cover.
Remove the access cover (Item 2) [Figure 80-160-2]
from the loader.
80-160-1
863 Bobcat Loader
Service Manual
EVAPORATOR/HEATER UNIT (CONT'D)
NOTE: Mark the lines before removal for proper
installation.
Removal And Installation (Cont'd)
Installation: Tighten the A/C hoses to 22 ft.-lbs. (29,8
Nm) torque.
Figure 80-160-5
Cap and plug the hoses and the expansion valve fittings
with the proper A/C caps and plugs.
Figure 80-160-7
1
N-22120
Remove the two mounting nuts (Item 1) [Figure 80-1605].
1
N-22128
WARNING
Remove the heater hoses (Item 1) [Figure 80-160-7]
from the heater coil.
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
Installation: Tighten the Heater hoses to 22 ft.-lbs. (29,8
Nm) torque.
Remove the evaporator/heater unit from the loader
Disassembly And Assembly
Figure 80-160-6
Figure 80-160-8
1
1
1
1
N-22126
Remove the Evaporator/Heater Unit from the rear of the
cab and place it on the fenders of the loader supported
by blocking [Figure 80-160-6].
Remove the two A/C hoses (Item 1) [Figure 80-160-6]
from the expansion valve.
N-22065
Remove the eight mount bolts (Item 1) [Figure 80-160-8]
from the Evaporator/Heater Unit rear cover.
Remove the rear cover from the unit.
80-160-2
863 Bobcat Loader
Service Manual
THERMOSTAT
Figure 80-170-3
Removal And Installation
NOTE: The thermostat can be changed without
evacuating the A/C system, or removing the
evaporator/heater unit from the loader.
Remove the rear cover from the evaporator/heater unit.
(See Removal And Installation on Page 80-160-1.)
Figure 80-170-1
2
N-22072
Remove the thermostat from the unit [Figure 80-170-3].
Figure 80-170-4
1
A
B
N-22069
C
Remove the two thermostat mount bolts (Item 1) [Figure
80-170-1], and remove the wiring harness and grommet
(Item 2) [Figure 80-170-1] from the evaporator/heater
housing.
1
Figure 80-170-2
N-22072A
The wire connector (Item 1) [Figure 80-170-4] can be
changed. The wiring position and color in the connector is:
A Blue
B White
C Black
1
N-22071
Remove the thermostat probe (Item 1) [Figure 80-170-2]
from the A/C evaporator coil.
80-170-1
863 Bobcat Loader
Service Manual
80-170-2
863 Bobcat Loader
Service Manual
EXPANSION VALVE
Figure 80-180-2
Removal And Installation
NOTE: The expansion valve can be changed without
removing the evaporator/heater unit from the
loader.
1
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
2
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Evacuate the A/C system.(See SYSTEM CHARGING
AND RECLAMATION on Page 80-100-1.)
N-22073A
Remove the two evaporator fittings (Item 1) [Figure 80180-2] from the expansion valve.
WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
Installation: Tighten the two evaporator fittings to 22 ft.lbs. (29,8 Nm) torque.
Remove the two mount bolts (Item 2) [Figure 80-180-2].
Remove the expansion valve from the loader.
Figure 80-180-3
Figure 80-180-1
1
1
N-22074A
N-22150
Remove the two A/C hoses (Item 1) [Figure 80-180-1]
from the expansion valve.
Cap and plug the evaporator tubelines (Item 1) [Figure
80-180-3] and the expansion valve fittings with the proper
A/C caps and plugs.
NOTE: Mark the lines before removal for proper
installation.
Installation: Tighten the two A/C hose fittings to 22 ft.lbs. (29,8 Nm) torque.
Cap and plug the hoses and the expansion valve fittings
with the proper A/C caps and plugs.
80-180-1
863 Bobcat Loader
Service Manual
EXPANSION VALVE (CONT'D)
Figure 80-180-5
Removal And Installation (Cont'd)
Figure 80-180-4
1
1
N-22085
The expansion valve [Figure 80-180-5] is replaced as a
complete unit.
N-22074A
Remove the two mount bolts (Item 1) [Figure 80-180-4]
from the expansion valve mount.
Remove the expansion valve mount from the unit.
80-180-2
863 Bobcat Loader
Service Manual
EVAPORATOR
Figure 80-190-3
Removal And Installation
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
2
Evacuate the A/C system. (See SYSTEM CHARGING
AND RECLAMATION on Page 80-100-1.)
1
Remove the evaporator/heater unit from the back of the
cab. (See Removal And Installation on Page 80-160-1.)
Figure 80-190-1
N-22075
Remove the two mount bolts (Item 1) [Figure 80-190-3]
from the mount plate (Item 2) [Figure 80-190-3].
Remove the mount plate from the unit.
Figure 80-190-4
1
N-22073
Remove the expansion valve (Item 1) [Figure 80-190-1]
from the unit. (See Removal And Installation on Page 80180-1.)
1
N-22076
Figure 80-190-2
Remove the two retaining clips (Item 1) [Figure 80-1904] that connect the evaporator coil, to the heater coil.
Remove the evaporator coil from the unit.
1
N-22074
Remove the expansion valve mount bracket (Item 1)
[Figure 80-190-2] from the unit.
80-190-1
863 Bobcat Loader
Service Manual
EVAPORATOR (CONT'D)
Removal And Installation (Cont'd)
Figure 80-190-5
N-22078
Inspect the evaporator coil [Figure 80-190-5] for leaks,
and replace as needed.
Clean with low water or air pressure.
80-190-2
863 Bobcat Loader
Service Manual
HEATER COIL
Figure 80-200-2
Removal And Installation With A/C
1
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the evaporator/heater unit from the back of the
cab. (See Removal And Installation on Page 80-160-1.)
1
Figure 80-200-1
N-22086
Remove the two mount bolts (Item 1) [Figure 80-200-2]
from the heater coil at the expansion valve end of the
unit.
1
Figure 80-200-3
N-22128
Mark the heater hoses (Item 1) [Figure 80-200-1] for
proper installation.
1
Remove the two heater hoses from the heater coil.
Cap the hoses and the heater coil with hydraulic caps
and plugs to prevent oil loss from the system.
Installation: Tighten the two heater hose fittings to 22 ft.lbs. (29,8 Nm) torque.
N-22087
Remove the two retaining clips (Item 1) [Figure 80-2003] that connect the evaporator coil, to the heater coil.
Remove the rear cover from the evaporator/heater unit.
(See Removal And Installation on Page 80-160-1.)
80-200-1
863 Bobcat Loader
Service Manual
HEATER COIL (CONT'D)
Removal And Installation Without A/C
Removal And Installation With A/C (Cont'd)
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
Figure 80-200-4
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
1
Remove the heater unit from the back of the cab. (See
Removal And Installation on Page 80-160-1.)
1
Figure 80-200-6
2
2
N-22089
1
Remove the three mount bolts (Item 1) [Figure 80-200-4]
and remove the mount plate from the end of the unit.
Remove the two mount bolts (Item 2) [Figure 80-200-4]
that support the heater coil tubelines to the unit.
N-22128
Remove the heater coil from the unit.
Figure 80-200-5
Mark the heater hoses (Item 1) [Figure 80-200-6] for
proper installation.
Remove the two heater hoses from the heater coil.
Cap the hoses and the heater coil with hydraulic caps
and plugs to prevent oil loss from the system.
Installation: Tighten the two heater hose fittings to 22 ft.lbs. (29,8 Nm) torque.
Remove the rear cover from the evaporator/heater unit.
(See Removal And Installation on Page 80-160-1.)
N-22090
The heater coil [Figure 80-200-5] can be cleaned with
low air or water pressure.
If the heater coil needs replacement it must be replaced
as complete unit.
80-200-2
863 Bobcat Loader
Service Manual
HEATER COIL (CONT’D)
Removal And Installation Without A/C (Cont’d)
Figure 80-200-7
1
1
2
2
N-22093
Remove the three mount bolts (Item 1) [Figure 80-200-7]
and remove the mount plate from the end of the unit.
Remove the two mount bolts (Item 2) [Figure 80-200-7]
that support the heater coil tubelines to the unit.
Figure 80-200-8
1
N-22094
Remove the two mount bolts (Item 1) [Figure 80-200-8]
from the heater coil.
Remove the heater coil from the unit.
80-200-3
863 Bobcat Loader
Service Manual
80-200-4
863 Bobcat Loader
Service Manual
HEATER/AC FAN
Figure 80-210-3
Removal And Installation
Raise the lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)
1
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the evaporator/heater unit from the back of the
cab. (See Removal And Installation on Page 80-160-1.)
NOTE: The heater/AC fan assembly can be removed
from the evaporator/heater unit without
disconnecting the heater or A/C plumbing.
The unit is removed here for photo clarity.
N-22098
If the metal is not cut out of the housing, mark the area
(Item 1) [Figure 80-210-3] and remove it with metal
shears.
Figure 80-210-1
Figure 80-210-4
1
1
N-22096
Remove the seal (Item 1) [Figure 80-210-1] from the
side of the evaporator/heater unit.
N-22099
Figure 80-210-2
Remove the blower fan wiring harness and grommet
(Item 1) [Figure 80-210-4] from the unit.
1
N-22097
NOTE: On some early evaporator/heater units the
metal was not cut out, so the blower wiring
harness (Item 1) [Figure 80-210-2] could be
removed without removing the wiring
connector.
80-210-1
863 Bobcat Loader
Service Manual
HEATER/AC FAN (CONT'D)
Figure 80-210-7
Removal And Installation (Cont’d)
Figure 80-210-5
1
1
2
N-22107
Check the blower housing (Item 1) [Figure 80-210-7] and
fan mount (Item 2) [Figure 80-210-7] for wear and
replace as needed.
N-22100
Remove the three mount bolts (Item 1) [Figure 80-210-5]
from the blower fan housing.
Figure 80-210-8
1
Remove the blower fan housing from the evaporator/
heater unit.
Disassmbly And Assembly
Figure 80-210-6
2
2
N-22108
1
1
2
Remove the outside rings (Item 1) [Figure 80-210-8] and
fan wheel covers (Item 2) [Figure 80-210-8] from the fan
motor and blower wheels.
N-22102
Remove the eight mount bolts (Item 1) [Figure 80-210-6]
from the blower wheel cover.
Remove the blower wheel cover from the fan housings.
Remove the four mount bolts (Item 2) [Figure 80-210-6]
from the fan motor mount.
Remove the fan motor mount.
Remove the fan motor assmbly from the housing.
80-210-2
863 Bobcat Loader
Service Manual
HEATER/AC FAN (CONT'D)
Figure 80-210-10
Disassembly And Assembly (Cont'd)
Figure 80-210-9
1
N-22110
Figure 80-210-11
N-22109
Inspect the end rings and fan wheel covers for wear and
replace as needed [Figure 80-210-9].
1
N-22112
Remove the outside blower wheel clamp (Item 1) [Figure
80-210-10] & [Figure 80-210-11] from the blower wheel.
80-210-3
863 Bobcat Loader
Service Manual
HEATER/FAN (CONT’D)
Wire Connector Removal And Installation
Disassembly And Assembly (Cont’d)
Figure 80-210-14
Figure 80-210-12
1
1
N-22103
N-22111
Figure 80-210-15
Remove the inside blower wheel clamp (Item 1) [Figure
80-210-12] from the blower wheel.
Figure 80-210-13
1
1
2
N-22104
Remove the plastic wedge (Item 1) [Figure 80-210-14] &
[Figure 80-210-15] from the center of the blower fan
motor wiring connector.
N-22116
Remove the blower wheel (Item 1) [Figure 80-210-13]
and inside ring (Item 2) [Figure 80-210-13] from the
blower fan motor shaft.
Repeat the procedure for the other blower wheel.
80-210-4
863 Bobcat Loader
Service Manual
HEATER/FAN (CONT’D)
Wire Connector Removal And Installation (Cont’d)
Figure 80-210-16
1
1
1
1
N-22105
With a pointed screwdriver lightly press in on the tabs
(Item 1) [Figure 80-210-16] and remove the individual
wires from th connector.
Figure 80-210-17
N-22106
The wiring code for the blower fan connector [Figure 80210-17] is:
Number on Connector
1
2
3
4
5
6
Wire Color
Orange
Red
Yellow
Black
Open
Open
80-210-5
863 Bobcat Loader
Service Manual
80-210-6
863 Bobcat Loader
Service Manual
HEATER VALVE
Figure 80-220-3
Removal and Installation
Figure 80-220-1
2
1
1
N-22133
Figure 80-220-4
N-22131
Remove the mount bolt (Item 1) [Figure 80-220-1] from
the electrical relay mount.
1
Move the electrical relay to the side for clearance.
Figure 80-220-2
1
N-22139
NOTE: Early model loaders were equipped with a
heater valve that had a wiring harness, and
connector (Item 1) [Figure 80-220-3]. Later
model loaders are equipped with heater
valves that allowed the loader wiring harness
(Item 1) [Figure 80-220-4] to be connected
directly to the rear of the valve.
2
N-22132
Remove the two hydraulic hoses (Item 1) [Figure 80220-2] from the heater valve.
Cap the hoses and the heater valve with hydraulic caps
and plugs to prevent oil loss from the system.
Remove the two mount bolts (Item 2) [Figure 80-220-3]
from the heater valve mount bracket.
Remove the heater valve and mount bracket from the
loader.
Disconnect the loader wiring harness (Item 2) [Figure
80-220-2] from the heater valve.
80-220-1
863 Bobcat Loader
Service Manual
HEATER VALVE (CONT'D)
Figure 80-220-7
Disassembly And Assembly
Figure 80-220-5
1
1
N-22157
Remove the three mounting bolts (Item 1) [Figure 80220-7] from the heater valve mount plate.
N-22155
Remove the three mount bolts (Item 1) [Figure 80-220-5]
from the heater valve actuator.
Figure 80-220-8
Figure 80-220-6
1
2
1
N-22158
Remove the mount plate (Item 1) [Figure 80-220-8] from
the heater valve bracket.
N-22156
Remove the actuator (Item 1) [Figure 80-220-6] and the
three mounting spacers (Item 2) [Figure 80-220-6] from
the heater valve mount plate.
80-220-2
863 Bobcat Loader
Service Manual
HEATER VALVE (CONT'D)
Figure 80-220-10
Disassembly And Assembly (Cont'd)
Figure 80-220-9
1
N-22160
1
Remove the heater valve mount bracket (Item 1) [Figure
80-220-10] from the heater valve.
N-22159
Remove the two mounting bolts (Item 1) [Figure 80-2209] from the heater valve.
Replace the parts as needed.
80-220-3
863 Bobcat Loader
Service Manual
80-220-4
863 Bobcat Loader
Service Manual
SPECIFICATIONS
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-70-1
Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . SPEC-70-1
U.S. To Metric Conversion . . . . . . . . . . . . . . . . . . . . . . SPEC-70-2
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Bearings . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Main Bearings. . . . . . . . . . . . . . . . . . .
Cylinder Head and Block . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve and Valve Guide and Seat Insert . . . . . . . . . . . .
SPEC-20-1
SPEC-20-4
SPEC-20-3
SPEC-20-4
SPEC-20-4
SPEC-20-1
SPEC-20-1
SPEC-20-4
SPEC-20-3
SPEC-20-2
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . .
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O-ring Face Seal Connection. . . . . . . . . . . . . . . . . . . .
O-ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . .
Tubelines And Hoses. . . . . . . . . . . . . . . . . . . . . . . . . .
SPEC-50-1
SPEC-50-2
SPEC-50-1
SPEC-50-3
SPEC-50-5
SPEC-50-1
SPEC-50-1
HYDRAULIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . SPEC-60-1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1
LOADER SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . .
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loader Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPEC-10-1
SPEC-10-4
SPEC-10-2
SPEC-10-4
SPEC-10-3
SPEC-10-2
SPEC-10-3
SPEC-10-1
SPEC-10-2
SPEC-10-4
SAFETY &
MAINTENANCE
DRIVE
SYSTEM
ELECTRICAL
SYSTEM &
AALYSIS
ENGINE
SERVICE
SPECIFICATIONS
LOADER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . SPEC-40-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . SPEC-40-2
Torque For General SAE Bolts. . . . . . . . . . . . . . . . . . . SPEC-40-1
SPEC-01
863 Bobcat Loader Loader
Service Manual
SPEC-02
863 Bobcat Loader
Service Manual
LOADER SPECIFICATIONS
Loader Dimensions
•
•
Dimensions are given for loader equipped with standard tires and dirt bucket and may vary with other bucket types.
All dimensions are shown in inches. Respective metric dimensions are given in millimeters inclosed by parentheses.
Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
12 - 16.5 TIRES - 67.2 (1707)
12 - 16.5 TIRES - 54.4 (1382)
74” BUCKET WIDTH - 74.0 (1880)
12 - 16.5 TIRES - 72.0 (1829)
12 - 16.5 TIRES - 59.2 (1503)
68” BUCKET - 68.0 (1727)
31 - 15.5 X 15 TIRES - 73.0 (1853)
31 X 15.5 - 15 TIRES - 57.5 (1459)
8.00 - 16 SOLID TIRES - 66.81 (1697)
Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the
loader parts.
SPEC-10-1
863 Bobcat Loader Loader
Service Manual
LOADER SPECIFICATIONS (CONT’D)
Performance
863
863H
Rated Operating Capacity (SAE)
1900 lbs. (862 kg)
Tipping Load (SAE Rating)
3800 lbs. (1724 kg)
Operating Weight
7045 lbs. (3196 kg)
SAE Breakout Force-Lift
7090 lbs. (3216 kg)
3700 lbs. (16458 N)
-Tilt
3800 lbs. (16902 N)
Axle Torque
6100 ft.-lbs (8272 Nm)
Travel Speed (Low Range)
0-6.6 MPH (10,6 km/hr.)
(High Range)
0-12.5 MPH (20,1 km/hr.)
Controls
Vehicle Steering
Loader Hydraulics Lift and Tilt
Direction and speed controlled by two hand levers.
Controlled by separate foot pedals or optional hand controls.
Front Auxiliary (Option)
Proportional Controls Controlled by electrical switch on RH steering lever.
Rear Auxiliary (Option)
Controlled by electrical switch on LH steering lever.
Engine
Starting Aid
Service Brake
Hand lever throttle: Key-type starter switch and shutdown.
Glow Plugs – Automatically activated by Standard Or Deluxe Instrumentation.
Two independent hydrostatic systems controlled by two hand operated steering
levers
Secondary Brake
One of the hydrostatic transmissions
Parking Brake
Mechanical Disc, foot operated pedal.
Engine
Make/Model
Deutz/BF4M1011F Turbo-Charged
Fuel/Cooling
Diesel/Oil
Horsepower (SAE Net)
73.0 HP (54 kW)
Maximum Governed RPM
2350 RPM
Torque @ 1800 RPM (SAE Net)
178 ft.–lbs. (239 Nm)
Number of Cylinders
Four
Displacement
177.7 cu. in. (2,92 L)
Bore/Stroke
3.58/4.41 (91/112)
Lubrication
Pressure System W/Filter
Crankcase Ventilation
Air Cleaner
Closed
Dry replaceable cartridge w/safety element
Ignition
Diesel-Compression
Low Idle
1125-1175 RPM
High Idle
2530-2690 RPM
SPEC-10-2
863 Bobcat Loader
Service Manual
LOADER SPECIFICATIONS (CONT’D)
Hydraulic System
863
Pump
863H
Engine Driven, Gear Type
Pump Capacity @ 2615 Engine RPM
S/N 514440001-514441938
18.7 GPM (70,8 L/min.)
29.0 GPM (109,8 L/min.)
S/N 514441939 & Above
20.7 GPM (78,4 L/min.)
30.7 GPM (116,2 L/min.)
System Relief at Quick Couplers
Filters (Charge & Implement)
Hydraulic Cylinders
Bore Diameter
3000PSI (206 Bar)
Full flow replaceable, 3 micron synthetic media element doubleacting;
Tilt cylinder has cushioning feature on dump & rollback
- Lift Cylinder (2)
2.50 (63,5)
- Tilt Cylinder (1)
Rod Diameter
Stroke
3.50 (88,9)
-Lift Cylinder (2)
1.75 (44,5)
- Tilt Cylinder (1)
1.57 (39,9)
- Lift Cylinder (2)
32.50 (825,0)
- Tilt Cylinder (1)
18.17 (461,5)
Control Valve
3-spool, open center type w/float detent on lift and electrically controlled
auxiliary spool.
Fluid Lines
SAE standard tubelines, hoses & fittings
Fluid Type
Bobcat Fluid (P/N 6563328) if fluid is not available, use10W-30/10W-40 Class
SE motor oil for temp above 0°F (-18°C) 5W-30 Motor Oil for temperatures
below 0°F (-18°C)
Hydraulic Function Time
Raise Lift Arms
5.1 Seconds
Lower Lift Arms
3.3 Seconds
Bucket Dump
2.8 Seconds
Bucket Rollback
2.4 Seconds
Electrical
Alternator
Belt Driven; 50 amp or 90 amps; open
Battery
12 volt; 1000 cold cranking amps @ 0°F (-18°C); 180 minute reserve capacity
Starter
12 volt; Direct Drive; 4.0 HP (3.0 kW)
Instrumentation
Gauges: Hourmeter, Fuel, Engine Coolant Temperature; Warning lights: Fuel
Level, Glow Plugs,System Voltage, Seat Belt, Engine Coolant Temperature,
Engine Oil Pressure, Hydrostatic Charge Pressure, Hydraulic Oil Temperature,
Engine Air Filter & Hydraulic Filter; Other: Audible Alarm, BICS function, Lights,
Opt./Accessory Switches.
Optional Deluxe Instrumentation:
*Same gauges and warning lights as standard instrumentation.
*Additional bar-type gauges for :Engine Oil Pressure, System Voltage,
Hydrostatic Charge Pressure and Hydraulic Oil Temperature.
*Additional Features Incl.: Keyless Start, Clock, Job Clock, Help Screens,
Diagnostic Capability, Automatic Shutdown Function.
SPEC-10-3
863 Bobcat Loader Loader
Service Manual
LOADER SPECIFICATIONS (CONT’D)
Drive System
863
Main Drive
Transmission
Final Drive
863H
Hydrostatic 4 wheel drive
Infinitely variable tandem hydrostatic piston pumps, driving 2 fully reversing
hydrostatic motors
#100 Hs endless roller chain & sprockets in sealed chaincase with oil
lubrication
Total Engine to Wheel Reduction
39:1
Axle Size
2.76 (70,1)
Wheel Bolts
(8) 9/16”
Capacities
Fuel
25 gals. (95 L)
Engine/Cooling Oil W/Filter
16 qts. (15,1 L)
Hydraulic/Hydro. Reservoir
4.7 gals. (17,8 L)
Hydraulic/Hydro. System
10.7 gals. (40,5 L)
Chaincase Reservoir
11 gals. (41,6 L)
Tires
Standard
12 - 16.5, 10 ply rating
Flotation
31 - 15.5 x 15,8 Ply Rating
Recommended Pressure
Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT
mix brands of tires used on the same loader.
SPEC-10-4
863 Bobcat Loader
Service Manual
ENGINE SPECIFICATIONS
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
General
Displacement
Bore
Stroke
Crankshaft Rotation (Facing Flywheel)
Ignition
Combustion System
Compression Ratio
Compression
Firing Order
177.7 cu. in (2912 cu. cm.)
3.58 (91)
4.41 (112)
Counterclockwise
4 Stroke Diesel-Compression
Direct Injection
17-1
320-392 PSI (2206-2703 kPa) (22-27 bar)
1-3-4-2
Fuel System
Fuel Injection Pump Pressure (5 Revolutions)
Injection Pump Testing Tightness
Injection Nozzle Opening Pressure
Min. 4350 PSI (29993 kPa) (300 bar)
2175 PSI-145 PSI permissible drop/min. (14997 kPa-1000
kPa) (150 bar - 10 bar)
3625 PSI + 116 (24994 kPa + 800 kPa) (21-0 bar + 8 bar)
SPEC-20-1
863 Bobcat Loader
Service Manual
ENGINE SPECIFICATIONS (CONT’D)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Valve and Valve Guide and Seat Insert
Valve Clearance (Intake) Oil Temp Below 176°F (80°C)
Valve Clearance (Exhaust) Oil Temp Below 176°F (80°C)
Valve Guide I.D.
Valve Seat Insert O.D. (Intake)
Valve Seat Insert O.D. (Exhaust)
Valve Seat Insert Bore (Intake)
Valve Seat Insert Bore (Exhaust)
Valve Stem Diameter (Intake)
Valve Stem Diameter (Exhaust)
Valve Stem Clearence (Intake)
Wear Limit
Valve Stem Clearence (Exhaust)
Wear Limit
Valve Head O.D. (Intake)
Valve Head O.D. (Exhaust)
Valve Seat Width
(Intake)
(Exhaust)
Seat Angle
(Intake)
(Exhaust)
Marg Thickness (Intake)
Wear Limit
Marg Thickness (Exhaust)
Wear Limit
Valve Recess
Wear Limit
Valve Spring Free Length 0.132 (3,35) diameter
0.134 (3,40) diameter
Valve Spring Inclination
SPEC-20-2
0.012 (0,3)
0.020 (0,5)
0.315±0.0010 (8,0±0,025)
1.680±0.0002 (42,67±0,005)
1.460±0.0002 (37,075±0,006)
1.677±0.001 (42,6±0,03)
1.457±0.001 (37,0±0,03)
0.314-0.0006 (7,98-0,015)
0.313-0.0006 (7,96-0,015)
0.0008-0.0023 (0,02-0,06)
0.005 (0,12)
0.0016-0.003 (0,04-0,08)
0.006 (0,15)
1.594±0.004 (40,5±0,1)
1.374±0.004 (34,9±0,1)
0.062±0.016 (1,58±0,4)
0.067±0.016 (1,7±0,4)
30°
45°
N/A
0.0551 (1,4)
N/A
0.047 (1,2)
0.0512±0.0051 (1,3±0,13)
0.0512 (1,3)
1.531 (38,9)
1.547 (39,3)
0.126 (3,2)
863 Bobcat Loader
Service Manual
ENGINE SPECIFICATIONS (CONT’D)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Piston and Rings
Piston Diameter
I.D. for Piston Pin
Piston Pin Diameter
Piston Ring Groove 1st
2nd
3rd
Piston Ring Clearence 1st
Wear Limit
2nd
Wear Limit
3rd
Wear Limit
Piston Ring Gap
1st
2nd
3rd
Wear Limit
1st
2nd
3rd
Bore for Piston Pin Bushing
Piston Pin Bushing O.D.
Piston Pin Bushing I.D. (pressed in)
Piston Pin Clearance
Wear Limit
3.578 (90,9)
1.0236+0.0004-0.0016 (26,0+0,01-0,04)
1.118-0.0002 (30,0-0,005)
0.0787+0.004 (2,0+0,10-0,08)
0.0787+0.004-0.003 (2,0+0,10-0,08)
0.118+0.002-0.0008 (3,0+0,04-0,02)
0.004-0.005 (0,09-0,12)
0.0078 (0,2)
0.003-0.004 (0,07-0,10)
0.006 (0,16)
0.015-0.003 (0,04-0,07)
0.0005 (0,12)
0.0118-0.019 (0,3-0,5)
0.0315-0.039 (0,8-1,0)
0.018-0.028 (0,45-0,7)
0.0315 (0,8)
0.071 (1,8)
0.035 (0,9)
N/A
N/A
N/A
0.0009-0.0016 (0,025-0,04)
0.0031 (0,08)
Connecting Rod
Small End Bushing I.D. (Pressed In)
Wear Limit
Bore for Small End Bushing
O.D. for Small End Bushing
Parallel Check
1.181+0.0014 +0.00010 (30,0+0,035+0,025)
0.003 (0,08)
1.299+0.0008 (33,0+0,02)
1.299+0.0043 - +0.0028 (33,0+0,11 - +0,07)
Permissible 0.0039 over a distance of 3.937
(0,10 Over 100,0)
0.002 (0,05)
1.063-0.0023 (27,0-0,06)
0.0078-0.022 (0,2-0,56)
0.0315 (0,8)
6.811±0.0012 (173,0±0,03)
2.303+0.0008 (58,5+0,02)
2.166-2.167 (55,004-55,04)
2.146-2.147 (54,504-54,54)
0.0009-0.003 (0,024-0,078)
0.005 (0,12)
1.008-0.012 (25,6-0,3)
Alignment
Connecting Rod Width
Connecting Rod End Play
Wear Limit
Center Distance from Small to Large Bore
Bore for Large End Bearing
Large End Bearing Shells I.D.
Limit for Undersize
Large End Bearing Radial Clearance
Wear Limit
Large End Bearing Width
SPEC-20-3
863 Bobcat Loader
Service Manual
ENGINE SPECIFICATIONS (CONT’D)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Cylinder Head and Block
Cylinder Head Studs - Length
Cylinder Bore
Wear Limit
5.906±0.031 (150,0±0,8)
3.583+0.0008 (91,0+0,02)
3.587 (91,1)
Crankshaft and Main Bearings
Crankshaft Pin Width
Crankshaft Pin Diameter
Oval Wear Limit
Crankshaft Journal Width
Crankshaft Journal Diameter
Oval Wear Limit
Eccentricity Max. Permitted
Thrust Bearing Journal Width
Main Bearing Shell I.D.
Radial Clearance
Wear Limit
Bearing Bore in Crankcase
Thrust Bearing Stop Rings O.D.
Oversize
Limit for Oversize
Crankshaft End Play
Wear Limit
1.220 (31,0)
2.165-0.0004-0.0012 (55,0-0,01-0,03)
0.0004 (0,01)
1.378+0.0016 (35,0+0,04)
2.756-0.0004-0.0012 (70,0-0,01-0,03)
0.0003 (0,008)
0.002 (0,05)
1.378+0.002 (35,0+0,04)
2.757-2.758 (70,02-70,055)
0.0011-0.0033 (0,03-0,084)
0.0047 (0,12)
2.953+0.0007 (75,0+0,019)
1.374-0.005 (34,9-0,133)
0.0157 (0,4)
1.406-0.0052 (35,7-0,133)
0.0039-0.0106 (0,1-0,27)
0.016 (0,4)
Camshaft and Bearings
Camshaft End Play
Wear Limit
Camshaft Bearing I.D.
Wear Limit
Radial Clearance
Cam Lift (Intake)
Cam Lift (Exhaust)
0.0118-0.0236 (0,3-0,6)
0.0315 (0,8)
2.126+0.0021 (54,0+0,054)
2.129 (54,08)
0.0019-0.0048 (0,05-0,124)
0.260 (6,6)
0.268 (6,8)
Oil Pump
Oil Pump Pressure Setting
Min. Eng. Oil Pressure, Oil Temp. 230°F (110°C) at
900 RPM
1800 RPM
2800 RPM
Thermostat Rating
SPEC-20-4
101.5 PSI (700 kPa) (7 bar)
20.3 PSI (140 kPa) (1.4 bar)
31.9 PSI (220 kPa) (2.2 bar)
43.5 PSI (300 kPa) (3.0 bar)
203°F (95°C)
863 Bobcat Loader
Service Manual
LOADER TORQUE
Specifications
Description
Ft.-Lbs.
Nm
Air Intake Manifold Bolts (M8 Torx)
Adapter Housing Bolts (M12)
Camshaft Bolt (M14 x 1,5 x 110) Plus 210 degrees
Camshaft Thrust Washer Bolt (M8)
Connecting Rod Cap Nuts Plus 60 degrees,60 degrees=120 degrees
Crankcase Screw Plugs (M18)
(M24)
(M30)
Crankshaft Gear Mount Bolt
Cylinder Head Bolts
Step 1
Step 2
Step 3 Plus 90 degrees
Exhaust Manifold Bolts (M10)
Exhaust Turbocharger Nuts (M8)
Flywheel Bolts Plus 60 degrees, 30 degrees=90 degrees
Front Cover Bolts
Front Mount Foot Bolts (M14x55)
Fuel Lift Pump Bolts (M8 Torx)
Glow Plug
Injector Cap Nut
Injector Pump Mounting Nuts
Main Bearing Bolts Plus 60 degrees,45 degrees=105 degrees
Oil Pan Bolts (M8)
Oil Pan Drain Plug
Oil Pump Bolts (M8 Torx)
Oil Press. Control Valve Screw Plug
Oil Return Line Cap Nut
Oil Suction Pipe
Oil Temp. Switch
Rocker Arm Bracket Bolts (M8 Torx)
Rear Cover Bolts
Rear Mounting Foot Bolts (M12)
Starter Carrier Bolts (M12)
Starter Fastening Bolts
Thermostat Housing Screw Plug (M38)
Timing Belt Tensioner Pulley Nut
V-Belt Pulley Bolts (M10)
15
21-24
22
15
22
37
82
12-15
243-295
22
59
118
30
22
22
15
38
15
15-18
35
15
37
15
40
16
82
13-14
16
21
15
15
23
15-18
25-28
82
33
30-36
20
28-33
30
20
30
50
111
16-20
330-400
30
80
160
40
30
30
20
52
20
20-24
47
21
50
20
54
22
111
18-19
22
28
20
20
31
20-24
34-38
111
45
41-49
SPEC-30-1
863 Bobcat Loader
Service Manual
LOADER TORQUE (CONT’D)
Specifications (Cont’d)
Description
Ft.-Lbs.
Nm
Air Intake 3-Hole Flange Bolts (M8 Torx)
Breather Vent Bolts
Crankcase Screw Plugs (M20)
(M10)
(M6)
(M16)
Cylinder Head Cover
Fuel Filter Bracket Bolt (M8)
Full Load Stop Screw Nut
Governor Lever Shaft Bolts
Injector Fastening Bolt (M8 Torx)
Injector Line
Minimum Speed Screw
Oil Filter Bracket Bolts (M6)
Oil Intake Housing Bolts (M8 Torx)
Oil Pressure Switch
Piston Cooling Nozzles
Rocker Arm Set Screw Nut
Shut Down Stop Screw
Shut Down Solenoid Bolts
Thermostat Housing Bolts (M6 Torx)
Thermostat Housing Bolts (M8 Torx)
Turbocharger Backing Plate Screws
Turbocharger Compressor Housing Bolts
Turbocharger Compressor Wheel Nut
Valve Plunger Housing Bolts (M8 Torx)
54-65
75
85-104
28-36
13-16
62-78
75
54
40
81
49-59
36-45
40
24-30
54-65
115
11
49-59
40
79
20-24
24-32
88
62
44
24-32
6,1-7,3
8,5
9,6-11,7
3,1-4,0
1,4-1,8
7,0-8,8
8,5
6,1
4,5
9,2
5,5-6,6
4,1-5,1
4,5
2,7-3,4
6,1-7,3
13
1,2
5,5-6,6
4,5
9
2,2-2,7
2,7-3,6
10
7
5
2,7-3,6
SPEC-30-2
863 Bobcat Loader
Service Manual
LOADER TORQUE (CONT’D)
Specifications (Cont’d)
Item
Ft.-Lbs.
Nm
Air Cleaner Mounting Bolts
Alternator Pulley Nut
Axle Hub Mounting Bolt
Axle Sprocket Bolt
25-28
50
175-190
475-525
24-38
68
240-260
645-710
BICS™ Control Valve Mounting Bolts
Bob-Tach Lever Pivot Bolt
15-16
25-28
20-22
34-38
Control Pedal Linkage Bolts
Control Vlave Mounting Bolts & Nuts
21-25
15-16
28-34
20-22
Engine Mounting Bolts
Exhust Pipe to Exhaust Manifold
65-70
20-35
88-95
27-47
Filter Housing Mounting Bolts
Front Panel Bolts
25
16-20
34
22-27
45-50
25-27
16-20
210-230
65-70
175-200
61-68
34-37
22-27
285-310
88-95
237-271
15-16
20-22
Main Frame to Chaincase Bolts
Main Relief Valve
Motor Carrier Bolts
300-330
35-40
220-245
410-450
47-54
300-330
Operator Cab Fastening Nuts
Operator Cab Pivot Bolts & Nuts
40-50
25-35
54-68
34-47
Pedal Lock Linkage to Main Frame Bolts
Pedal Lock Linkage Tab Bolt
Pivot Pins Lick Bolt & Nut
7-8
25
18-20
9,5-10,8
34
24-27
Seat Belt Fastening Bolts
Seat Mounting Bolts
Seat Bar Pivot Bolts
40-45
9-11
25-28
54-61
12,2-15
34-38
105-115
142-156
Hydraulic Pump Bolts
Hydraulic Pump Mounting Bolts
Hydraulic Reservoir Strap Bolts
Hydrostatic Motor Mounting Bolts
Hydrostatic Pump Mounting Bolts
Hydrostatic Pump Pulley Bolt
Lift Arm By-Pass Control Valve Mounting Bolts
Wheel Nuts
SPEC-30-3
863 Bobcat Loader
Service Manual
SPEC-30-4
863 Bobcat Loader
Service Manual
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Melroe that have zinc phosphate coating are specified by the letter H following the part number.
THREAD
SIZE
INCH.
LBS.
(Nm)
FOOT
LBS.
(Nm)
.250
.3125
.375
.4375
.500
.5625
.625
.750
.875
1.000
1.125
1.250
1.375
1.500
1.625
1.750
1.875
2.000
SAE GRADE 5
SAE GRADE 8
80-90
(9,0-10,2)
180-200
(20,3-22,6)
25-28
(34-38)
40-45
(54-61)
65-70
(88-95)
90-100
(122-136)
125-140
(170-190)
220-245
(300-330)
330-360
(450-490)
475-525
(645-710)
650-720
(880-975)
900-1000
(1200-1360)
1200-1350
(1630-1830)
1500-1650
(2040-2240)
2000-2800
(2720-2980)
2500-2750
(3390-3730)
3150-3500
(4270-4750)
3800-4200
(5150-5700)
110-120
(12,4-13,6)
215-240
(24,2-27-1)
35-40
(47-54)
60-65
(81-88)
90-100
(122-136)
125-140
(170-190)
175-190
(240-260)
300-330
(410-450)
475-525
(645-710)
725-800
(985-1085)
1050-1175
(1425-1600)
1475-1625
(2000-2200)
2000-2200
(2720-2980)
2600-2850
(3530-3870)
3450-3800
(4680-5150)
4300-4800
(5830-6500)
5500-6100
(5830-6500)
6500-7200
(8800-9800)
SPEC-40-1
863 Bobcat Loader
Service Manual
TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)
Torque For General Metric Bolts
THREAD SIZE
(DIA. X PITCH)
MATERIAL
HEAD MARK 4
HEAD MARK 7
HEAD MARK 10
6-9 ft.-lbs.
(8-12 Nm)
13-18 ft.-lbs.
(18-24 Nm)
22-30 ft.-lbs.
(30-41 Nm)
36-50 ft.-lbs.
(49-68 Nm)
3-4 ft.-lbs.
(4-5 Nm)
6-7 ft.-lbs.
(8-9 Nm)
11-16 ft.-lbs.
(15-22 Nm)
22-30 ft.-lbs.
(30-41 Nm)
40-54 ft.-lbs.
(54-73 Nm)
58-80 ft.-lbs.
(79-108 Nm)
6-9 ft.-lbs.
(8-12 Nm)
18-25 ft.-lbs.
(24-34 Nm)
36-50 ft.-lbs.
(49-68 Nm)
69-87 ft.-lbs.
(94-118 Nm)
116-137 ft.-lbs.
(157-186 Nm)
M 5 x 0.8
M 6 x 1.0
M 8 x 1.25
M 10 x 1.25
M 12 x 1.25
M 14 x 1.25
SPEC-40-2
863 Bobcat Loader
Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS
Straight Thread O-ring Fitting
O-ring Face Seal Connection
Figure SPEC-50-2
WARNING
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Nut
Washer
Nut
Washer
O-ring
O-ring
I-2003-0888
Figure SPEC-50-1
A-1852
Lubricate the O-ring before installing the fitting. Loosen
the jam nut and install the fitting. Tighten the jam nut until
the washer is tight against the surface [Figure SPEC-502].
Tubelines And Hoses
Replace any tubelines that are bent or flattened. They will
restrict flow, which will slow hydraulic action and cause
heat.
Replace hoses which show signs of wear, damage or
weather cracked rubber.
B-7575
When the fitting is tightened, you can feel when the fitting
is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-50-1].
Always use two wrenches when loosening and tightening
hose or tubeline fittings.
SPEC-50-1
863 Bobcat Loader
Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS
(CONT'D)
Use the following procedure to tighten the flare fitting:
Tighten the nut until it makes contact with the seat. Make
a mark across the flats of both the male and female parts
of the connection (Item 1) [Figure SPEC-50-3].
Flare Fitting
Figure SPEC-50-3
Use the chart below to find the correct tightness needed
(Item 2) [Figure SPEC-50-3]. If the fitting leaks after
tightening, disconnect it and inspect the seat area for
damage.
1
2
TS-1619
Flare Fitting Tightening Torque
Wrench Size
Tubeline
Outside
Diameter
Thread Size
TORQUE
Ft.-Lbs.
(Nm)
NEW
Rotate No.
of Hex Flats
RE-ASSEMBLY
Rotate No.
of Hex Flats
5/8”
11/16”
7/8”
1”
1-1/4”
1-3/8”
5/16”
3/8”
1/2”
5/8”
3/4”
1”
1-2”-20
9/16”-18
3/4”-16
7/8”-14
1-1/16”-12
1-5/16”-12
17 (23)
22 (30)
40 (54)
60 (81)
84 (114)
118 (160)
2-1/2
2
2
1-1/2
1
3/4
1
1
1
1
3/4
3/4
SPEC-50-2
863 Bobcat Loader
Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS
(CONT'D)
Figure SPEC-50-5
Hex Flat Tightening Method
O-ring Flare Fitting
Figure SPEC-50-4
1
O-ring Flare
Primary
Seal
2
TS-1619
Use the following procedure to tighten the O-ring flare
fitting.
Secondary
Seal
P13009
The flare is the primary seal, the O-ring is the secondary
seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-50-4].
If necessary, the O-ring-flare fitting can be used without
an O-ring.
Tighten the nut until it contacts with the seat. Make a
mark across the flats of both the male and female parts
of the connection (Item 1) [Figure SPEC-50-5].
Use the chart below to find the correct tightness needed
(Item 2) [Figure SPEC-50-5]. If the fitting leaks after
tightening, disconnect it and inspect the seat area for
damage.
O-Ring Flare Fitting Tightening Torque
*
**
***
Wrench Size
Tubeline
Outside
Diameter
Thread Size
TORQUE
Ft.-Lbs.
(Nm)
NEW
Rotate No.
of Hex Flats
RE-ASSEMBLY
Rotate No.
of Hex Flats
5/8”
11/16”
7/8”
1”
1-1/4”
1-3/8”
5/16”
3/8”
1/2”
5/8”
3/4”
1”
1-2”-20
9/16”-18
3/4”-16
7/8”-14
1-1/16”-12
1-5/16”-12
17 (23)
22 (30)
40 (54)
60 (81)
84 (114)
118 (160)
2-1/2
2
2
1-1/2
1
3/4
1
1
1
1
3/4
3/4
*
If a torque wrench is used to tighten a new fitting to a used hose/tubeline.
*
If a torque wrench is used to tighten a used fitting to a new hose/tubeline.
*
If a torque wrench is used to tighten a new fitting to a new hose/tubeline.
**
If using the hex flat tightening method to tighten a new fitting to a new hose/tubeline.
**
If using the hex flat tightening method to tighten a new fitting to a used hose/tubeline.
*** If using the hex flat tightening method to tighten a used fitting to a new hose/tubeline.
SPEC-50-3
863 Bobcat Loader
Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS
(CONT'D)
Figure SPEC-50-7
O-ring Flare Fitting (Cont'd)
2
NOTE: O-ring flare fittings are not recommended in
all applications. Use the standard flare fittings
in these applications.
Do not use a O-ring flare fitting when a copper bonnet
orifice is used. When tightened the connection at the
bonnet may distort the flare face and prevent it from
sealing.
Figure SPEC-50-6
1
P13573
Copper Bonnet Orifice
Always remove the O-ring (Item 1) [Figure SPEC-507] from the flare face as shown.
An O-ring (Item 2) [Figure SPEC-50-7] is added to the
flat boss of the fitting to seal the connection in this
application.
1
P13572
Use a standard flare fitting (Item 1) [Figure SPEC-50-6]
as shown.
When a O-ring flare fitting is used as a straight thread
port adapter the O-ring flare face is not used to seal. The
O-ring may come off the fitting and enter the system.
SPEC-50-4
863 Bobcat Loader
Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS
(CONT'D)
Port Seal and O-ring Boss
Tightening Torque
Port Seal Fitting
Figure SPEC-50-8
Fitting Nut
Wrench Size
Thread Size
Torque Ft.-Lbs.
(Nm)
11/16”
15/16”
1-1/8”
1-1/4”
1-1/2”
9/16”-18
3/4”-16
7/8”-14
1-1/16”-12
1-5/16”-12
22 (30)
40 (54)
60 (81)
84 (114)
118 (160)
NOTE: If a torque wrench cannot be used, use the
hex flat tightening method as an approximate
guideline.
Nut Seals
to Fitting
NOTE: Port seal fittings are not recommended in all
applications. Use O-ring boss fittings in these
applications.
Nut Seals
to Port
Figure SPEC-50-9
2
Secondary O-ring Seal
P13008
1
The nut is the primary seal, the O-ring is the secondary
seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-50-8].
P13571
The hex portion of the nut does not contact the surface of
the component when the nut is tight.
Use the following procedure to tighten the port seal
fitting:
Do not use port seal fittings when a thread in orifice (Item
1) [Figure SPEC-50-9] is used in the port. The orifice
may interfere with the fitting and prevent it from sealing.
Port seal and nut, washer and O-ring (O-ring Boss)
fittings use the same tightening torque valve chart.
Use an O-ring boss fitting (Item 2) [Figure SPEC-50-9]
as shown.
If a torque wrench cannot be used, use the following
method.
Tighten the nut until it just makes metal to metal contact,
you can feel the resistance.
Tighten the nut with a wrench no more than one hex flat
maximum.
Do not over tighten the port seal fitting.
SPEC-50-5
863 Bobcat Loader
Service Manual
SPEC-50-6
863 Bobcat Loader
Service Manual
HYDRAULIC FLUID SPECIFICATIONS
Specifications
Use Bobcat hydraulic transmission fluid (P/N 6563328). If
this fluid is not available, use 10W-30 or 10W-40 SAE
Motor Oil (5W-30 for 0°F [-18°C] and Below).
When temperatures below zero degree F (-18°C) are
common, the loader must be kept in a warm building.
Extra warm-up time must be used each time the loader is
started during cold temperature conditions. Cold fluid will
not flow easily and it makes action on the hydraulic
function slower. Loss of fluid flow to the hydrostatic
transmission pump (indicated by TRANS light ON) can
cause transmission damage in less than 60 seconds.
DO NOT use automatic transmission fluids in the loader
or permanent damage to the transmission will result.
WARNING
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496
During cold weather (32°F [0°C] and below), do not
operate machine until the engine has run for at least
five minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.
When temperatures are below -20°F (-30°C), the
hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above 0°F (-18°C) if possible.
W-2027-1285
SPEC-60-1
863 Bobcat Loader
Service Manual
SPEC-60-2
863 Bobcat Loader
Service Manual
CONVERSIONS
Decimal And Millimeter Equivalents
SPEC-70-1
863 Bobcat Loader
Service Manual
CONVERSIONS (CONT’D)
U.S. To Metric Conversion
SPEC-70-2
863 Bobcat Loader
Service Manual
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
Insert This Sheet With The Below Listed Manual For Future Reference.
863/863H-1
17 April 2000
Bobcat Loader
863/863H
6900942 (9-99)
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
Electrical Charts
863 - WIRING SCHEMATIC
S/N 514440001 AND ABOVE
S/N 514540001 AND ABOVE
S/N 514640001 AND ABOVE
(PRINTED SEPTEMBER 1999)
6719967
Electrical Charts
863 - WIRING SCHEMATIC
SINGLE AND TWO-SPEED VALVE
S/N 514440001 AND ABOVE
S/N 514540001 AND ABOVE
S/N 51460001 AND ABOVE
(PRINTED APRIL 2000)
V-003
863 - WIRING SCHEMATIC
ADVANCE HAND CONTROL OPTION
S/N 514440001 AND ABOVE
S/N 514540001 AND ABOVE
S/N 514640001 AND ABOVE
(PRINTED SEPTEMBER 19999)
6719968
863 - WIRING SCHEMATIC
ADVANCED HAND CONTROL OPTION
SINGLE AND TWO-SPEED VALVE
S/N 514440001 AND ABOVE
S/N 514540001 AND ABOVE
S/N 514640001 AND ABOVE
(PRINTED APRIL 2000)
V-0004
REVISION DECRIPTION
Printed in U.S.A.
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
Insert This Sheet With The Below Listed Manual For Future Reference.
863/863H-2
16 June 2000
Bobcat Loader
863/863H
6900942 (9-99)
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
Cover
Cover
Logo change
Cartoon
Cartoon
Text change
Alpha Index
Alpha Index
Text change
i thru ii
i thru ii
Text change
10-30-1 thru 10-30-2
10-40-1 thru 10-40-2
10-30-1 thru 10-30-2
10-40-1 thru 10-40-2
Text change
Text change
20-01 thru 20-02
20-10-5 thru 20-10-6
20-01 thru 20-02
20-10-5 thru 20-10-6
Text change
Text change
HYD/HYDRO SCHEMATIC
863 (S/N 514440001 & Above)
With High Flow Option
(S/N 514640001 & Above)
Mc2636TI
HYD/HYDRO SCHEMATIC
863 (S/N 514440001 & Above)
(S/N 514540074 & Above)
(Printed June 2000)
V-0019ti
HYD/HYDRO SCHEMATIC
WITH HIGH FLOW OPTION
863 (S/N 514440001-41938)
(S/N 514640001-40147)
(Printed June 2000)
V-028ti
CONTINUED ON NEXT PAGE
REVISION DECRIPTION
Routing changed for implementation
of Two Speed Valve
Add Ending Serial Number
Printed in U.S.A.
TAKE OUT
PUT IN
HYD/HYDRO SCHEMATIC
WITH HIGH FLOW OPTION
863 (S/N 514441939 & Above)
(S/N 51460148 & Above)
(Printed June 2000)
V-0023ti
HYD/HYDRO SCHEMATIC
WITH TWO SPEED VALVE OPTION
863 (S/N 514441939 & Above)
(S/N 514540074 & Above)
(Printed June 2000)
V-0022ti
REVISION DECRIPTION
Routing changed for implementation
of Two Speed Valve
Two Speed Valve Added
HYD/HYDRO SCHEMATIC
Two Speed Valve Added
WITH HIGH FLOW AND TWO SPEED
VALVE OPTION
863 (S/N 514441939 & Above)
(S/N 514640148 & Above)
(Printed June 2000)
V-0024ti
20-20-1 thru 20-20-12
20-20-1 thru 20-20-8
20-21-1 thru 20-21-8
20-22-1 thru 20-22-6
20-130-1 thru 20-130-4
20-140-1 thru 20-140-8
Removed Tilt Cylinders
Added Tilt Cylinders
Added Power Bob-Tach Cylinders
Added Rear Auxiliary Diverter Valve (Single
Shuttle)
Added Power Bob-Tach Block
30-01 thru 30-02
30-01 thru 30-02
30-41-1 thru 30-41-20
Text Change
Added Hydrostatic Motor (Two-Speed)
40-01 thru 40-02
40-10-3 thru 40-10-4
40-30-1 thru 40-30-2
40-01 thru 40-02
40-10-3 thru 40-10-4
40-11-1 thru 40-11-8
40-30-1 thru 40-30-2
Text change
Test change
Added Brake (Two-Speed)
Text change
60-01 thru 60-02
60-10-1 thru 60-10-2
60-01 thru 60-02
60-10-1 thru 60-10-2
Text change
Text change
DO NOT REMOVE CHARTS
Section 80
Section 80
Section SPEC
Added HVAC
Change page number system
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
Insert This Sheet With The Below Listed Manual For Future Reference.
863/863H-3
15 August 2000
Bobcat Loader
863/863H
6900942 (9-99)
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
Alpha Index
Alpha Index
Text changes
i thru ii
v thru vi
i thru ii
v thru vi
Text changes
Updated
Section 10
Section 10
20-01 thru 20-02
20-31-1 thru 20-31-2
20-41-1 thru 20-41-2
20-50-1 thru 20-50-2
20-80-1 thru 20-80-2
20-100-1 thru 20-100-1
20-120-3 thru 20-120-4
20-140-1 thru 20-140-2
20-01 thru 20-04
20-31-1 thru 20-31-4
20-41-1 thru 20-41-26
20-50-1 thru 20-50-2
20-80-1 thru 20-80-2
20-100- thru 20-100-6
20-120-3 thru 20-120-4
20-140-1 thru 20-140-2
30-01 thru 30-02
30-31-1 thru 30-31-8
30-70-5 thru 30-70-6
30-01 thru 30-02
30-31-1 thru 30-31-8
30-32-1 thru 30-32-6
30-70-5 thru 30-70-6
CONTINUED ON NEXT PAGE
REVISION DECRIPTION
Added Breather Cap, Added Fan
Gearbox, Added Final Drive
Transmission (Chaincase), Added
Replacing Filter Elements
Text changes
Added Main Relief Valve (AHC)
Added Hydraulic Control Vlave (AHC)
Added Inspecting
Added Draining The Fluid Reservoir
Added Bucket Positioning Valve
Text changes
Text changes
Text changes
Text changes
Added Steering AHC (W/Push Button Float)
Text changes
Printed in U.S.A.
TAKE OUT
PUT IN
REVISION DECRIPTION
40-01 thru 40-02
40-20-7 thru 40-20-8
40-30-1 thru 40-30-4
40-01 thru 40-02
40-20-7 thru 40-20-8
40-30-1 thru 40-30-2
Text changes
Text changes
Removed Chaincase (Checking & Adding Oil)
50-01 thru 50-02
50-30-1 thru 50-30-6
50-01 thru 50-02
50-30-1 thru 50-30-2
50-31-1 thru 50-31-6
Text changes
Text changes
Added Operator Seat (Suspension)
60-01 thru 60-02
60-90-1 thru 60-90-4
60-120-1 thru 60-120-10
60-130-1 thru 60-130-2
60-01 thru 60-02
60-90-1 thru 60-90-4
60-120-1 thru 60-120-4
60-130-1 thru 60-130-10
60-131-1 thru 60-131-12
60-140-1 thru 60-140-2
70-01 thru 70-02
70-40-7 thru 70-40-4
70-60-3 thru 70-60-20
70-01 thru 70-02
70-40-1 thru 70-40-2
70-60-3 thru 70-60-20
Text change
Updated
Added PWM
Page Number change
Added AHC System (W/Push Button Float)
Page and text changes
Text changes
Removed Gearbox Checking And Adding Oil
Remove Gearbox Checking And Adding Oil
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
Insert This Sheet With The Below Listed Manual For Future Reference.
863/863H-4
14 August 2001
Bobcat Loader
863/863H
6900942 (9-99)
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
Alpha Index
Alpha Index
10-01 thru 10-02
10-30-1 thru 10-30-2
10-70-1 thru 10-70-2
10-80-1 thru 10-80-02
10-100-1 thru 10-100-2
10-110-1 thru 10-110-2
10-120-1 thru 10-120-2
10-130-1 thru 10-130-2
10-140-1 thru 10-140-2
10-151-1 thru 10-151-2
10-160-1 thru 10-160-2
10-01 thru 10-02
10-30-1 thru 10-30-2
10-70-1 thru 10-70-2
10-80-1 thru 10-80-2
10-100-1 thru 10-100-2
10-110-1 thru 10-110-2
10-120-1 thru 10-120-4
10-130-1 thru 10-130-2
10-140-1 thru 10-140-2
10-151-1 thru 10-151-2
10-160-1 thru 10-160-2
Section 30
Section 30
50-01 thru 50-02
50-01 thru 50-02
50-41-1 thru 50-41-4
50-80-1 thru 50-80-2
50-90-1 thru 50-90-4
50-91-1 thru 50-91-2
50-100-1 thru 50-100-2
50-80-1 thru 50-80-2
REVISION DECRIPTION
Text changes
Text changes
Text changes
Text changes
Text changes
Text changes
Text changes
Text changes and Added Breather Cap
Text changes
Text changes
Text changes
Text changes
Text changes
Text changes
Added Power Bob-Tach
Text changes
Added Control Panels
Added Control Pedals (ACS)
Added Control Panel
CONTINUED ON NEXT PAGE
Printed in U.S.A.
TAKE OUT
PUT IN
50-110-1 thru 50-110-10
50-112-1 thru 50-112-12
50-113-1 thru 50-113-8
50-114-1 thru 50-114-8
REVISION DECRIPTION
Added Control Handle
Added Control Handle (Advanced Hand Control)
(AHC) (W/Push Button Float)
Added Control Handle (Advanced Control System)
(ACS) Advanced Hand Control
Added Control Handle (Advanced Control System)
(ACS) Selectable Hand/Foot Control
Section 60
(Including SCHEMATICS)
Section 60
(Including SCHEMATICS)
Text changes, added Alternator (90 AMP),Starter
(Checking), Advanced Control System
70-01 thru 70-02
70-20-1 thru 70-20-2
70-70-7 thru 70-70-8
70-70-15 thru 70-70-16
70-90-1 thru 70-90-2
70-100-11 thru 70-100-12
70-100-35 thru 70-100-36
70-100-57 thru 70-100-58
70-01 thru 70-02
70-20-1 thru 70-20-2
70-70-7 thru 70-70-8
70-70-15 thru 70-70-16
70-90-1 thru 70-90-2
70-91-1 thru 70-91-2
70-100-11 thru 70-100-12
70-100-35 thru 70-100-36
70-100-57 thru 70-100-58
Text changes
Text changes
Text changes
Text changes
Text changes
Added RPM Sensor
Text changes
Text changes
Text changes
Section 80
Section 80
Text changes
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
Insert This Sheet With The Below Listed Manual For Future Reference.
863-5
10 September 2001
Bobcat Loader
863 (Includes High Flow)
6900942 (9-99)
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
Alpha Index
Alpha Index
Text changes
10-50-1 thru 10-50-2
10-90-1 thru 10-90-2
10-151-1 thru 10-151-2
10-50-1 thru 10-50-2
10-90-1 thru 10-90-2
10-51-1 thru 10-151-2
Photo change
Photo change
Photo change
Section 20
Section 20
SPEC Section
SPEC Section
Revised Text & photos
Revised Text
Printed in U.S.A.
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
Insert This Sheet With The Below Listed Manual For Future Reference.
863-6
4 April 2002
Bobcat Loader
863 (Includes High Flow)
6900942 (9-99)
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
All Hyd/Hydro Schematics
(Printed June 2000)
All Hyd/Hydro Schematics
(Printed April 2002)
REVISION DECRIPTION
Added Serial Number Information And
New Components
Printed in U.S.A.
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
Insert This Sheet With The Below Listed Manual For Future Reference.
863-7
25 November 2002
Bobcat Loader
863
6900942 (11-02)
Please discard your old 863/863H Service Manual (P/N 6900942) Dated 9-99 and replace it with
the revised 863 Service Manual (P/N 6900942) Dated 11-02.
This Service Manual is in a new format with added updates.
Printed in U.S.A.
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
Insert This Sheet With The Below Listed Manual For Future Reference.
863-8
1 December 2003
Bobcat Loader
863
6900942 (11-02)
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
MSW08-0500
MSW08-0903
Revised text
i thru x
i thru x
Revised text
10-10-1 thru 10-10-2
10-70-1 thru 10-70-2
10-10-1 thru 10-10-2
10-70-1 thru 10-70-2
Revised text
Revised text
Hydraulic/Hydrostatic Schematic
With High Flow Option
863 (S/N 514450946-514451083)
(S/N 514641255-514641266)
(Printed November 2002)
Hydraulic/Hydrostatic Schematic Revised chart
With High Flow Option
863 (S/N 514450946-514451083)
(S/N 514641255-514641266)
(Printed December 2003)
Hydraulic/Hydrostatic Schematic
With Two Speed Valve and High
Flow Option
863 (S/N 514450946-514451083)
(S/N 514641255-514641266)
(Printed November 2002)
Hydraulic/Hydrostatic Schematic Revised chart
With Two Speed Valve and High
Flow Option
863 (S/N 514450946-514451083)
(S/N 514641255-514641266)
(Printed December 2003)
Hydraulic/Hydrostatic Schematic
863 (S/N 5144551084 & Above)
(S/N 514541114 & Above)
(Printed November 2002)
Hydraulic/Hydrostatic Schematic
863 (S/N 514451084 & Above)
(S/N 514541114 & Above)
(Printed December 2003)
Revised chart
Printed in U.S.A.
TAKE OUT
PUT IN
REVISION DECRIPTION
Hydraulic/Hydrostatic Schematic
With Two Speed Valve Option
863 (S/N 514451084 & Above)
(S/N 514541114 & Above)
(Printed November 2002)
Hydraulic/Hydrostatic Schematic
With Two Speed Valve Option
863 (S/N 514451084 & Above)
(S/N 514541114 & Above)
(Printed December 2003)
Revised chart
Hydraulic/Hydrostatic Schematic
With High Flow Option
863 (S/N 514451084 & Above)
(S/N 514641267 & Above)
(Printed November 2002)
Hydraulic/Hydrostatic Schematic
With High Flow Option
863 (S/N 514451084 & Above)
(S/N 514641267 & Above)
(Printed December 2003)
Revised chart
Hydraulic/Hydrostatic Schematic
With Two Speed Valve and High
Flow Option
863 (S/N 514451084 & Above)
(S/N 514641267 & Above)
(Printed November 2002)
Hydraulic/Hydrostatic Schematic
With Two Speed Valve and High
Flow Option
863 (S/N 514451084 & Above)
(S/N 514641267 & Above)
(Printed December 2003)
Revised chart
20-64-1 thru 20-64-22
20-64-1 thru 20-64-22
Revised text
Wiring Schematic
(Without ACS Option)
863 (S/N 514450764 & Above)
(S/N 514541104 & Above)
(S/N 514641255 & Above)
(Printed November 2002)
Wiring Schematic
(Without ACS Option)
863 (S/N 514450764 & Above)
(S/N 514541104 & Above)
(S/N 514641255 & Above)
(Printed December 2003)
Revised chart
Wiring Schematic
(With ACS Option)
863 (S/N 514450764 & Above)
(S/N 514541104 & Above)
(S/N 514641255 & Above)
(Printed November 2002)
Wiring Schematic
(With ACS Option)
863 (S/N 514450764 & Above)
(S/N 514541104 & Above)
(S/N 514641255 & Above)
(Printed December 2003)
Revised chart
60-10-1 thru 60-10-8
60-10-1 thru 60-10-8
Revised text
70-70-1 thru 70-70-30
70-70-1 thru 70-70-30
Revised text
ROUTE TO
ATTENTION
SERVICE MANUAL
REVISION
NOTICE
Revision No:
Date:
Product:
Model:
Manual No:
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
Insert This Sheet With The Below Listed Manual For Future Reference.
863-9
23 March 2006
Bobcat Loader
863
6900942 (11-02)
863 Service Manual (P/N 6900942) Dated (2-06) contains updated service information which replaces the previous
863 Service Manual (P/N 6900942) Dated (11-02).
Printed in U.S.A.