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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
P-90216 B-15590 B-15591

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG
B-15592 B-15593 B-15599

Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
B-15600 B-15601 B-6589

Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW08-0409
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ALPHABETICAL INDEX
ADVANCED CONTROL SYSTEM ENGINE LUBRICATION SYSTEM .........................10-01

(ACS) ADVANCED HAND CONTROL................. 60-01 ENGINE SPECIFACATIONS ............................. SPEC-01
ADVANCED CONTROL SYSTEM ENGINE SPEED CONTROL ...................................70-01
(ACS) SELECTABLE HAND / FOOT CONTROL. 60-01 EVAPORATOR ........................................................80-01
ADVANCED CONTROL SYSTEM (AHC) ............... 60-01 EVAPORATOR / HEATER UNIT..............................80-01
ADVANCED CONTROL SYSTEM EXPANSION VALVE ................................................80-01
(AHC) (W/ PUSH BUTTON FLOAT) .................... 60-01
AIR CLEANER ........................................................ 70-01 FAN GEARBOX .......................................................10-01
AIR CLEANER SERVICE ....................................... 10-01 FINAL DRIVE TRANSMISSION (CHAINCASE)......10-01
AIR CONDITIONG SERVICE ................................. 80-01 FLYWHEEL AND HOUSING ..................................70-01
AIR CONDITIONING SYSTEM FLOW ................... 80-01 FRONT AUXILIARY HYD. COUPLER BLOCK .......20-01
ALTERNATOR (55 AMP) ........................................ 60-01 FUEL SYSTEM........................................................10-01
ALTERNATOR (90 AMP) ........................................ 60-01 FUEL TANK .............................................................50-01
BASIC TROUBLESHOOTING ................................ 80-01 GENERAL AIR CONDITIONING SERVICE

BATTERY ............................................................... 60-01 GUIDELINES ........................................................80-01
BICS™ SYSTEM .................................................... 60-01
BOBCAT CONTROLLER ....................................... 60-01 HEATER COIL .........................................................80-01
BOBCAT INTERLOCK HEATER / AC FAN .................................................80-01
CONTROL SYSTEM (BICS™) ............................ 60-01 HEATER VALVE ......................................................80-01
BOB-TACH................................................... 10-01, 50-01 HYDRAULIC CONNECTION SPECS ............... SPEC-01
BRAKE .................................................................... 40-01 HYDRAULIC CONTROL VALVE
BRAKE (TWO-SPEED)........................................... 40-01 (ADVANCED CONTROL SYSTEM) (ACS) ..........20-01
BUCKET POSITITON VALVE 20-01 HYDRAULIC CONTROL VALVE
(FOOT CONTROL)...............................................20-01
CHAINCASE ........................................................... 40-01 HYDRAULIC FLUID RESERVOIR ..........................20-01
CHARGE PRESSURE ........................................... 30-01 HYDRAULIC / HYDROSTATIC FILTER ..................20-01
COOLING FAN ...................................................... 70-01 HYDRAULIC FLUID SPECIFICATIONS............ SPEC-01
COMPONENTS ..................................................... 80-01 HYDRAULIC / HYDROSTATIC SYSTEM ............10-01
COMPRESSOR ..................................................... 80-01 HYDRAULIC PUMP ................................................20-01
CONDENSER ......................................................... 80-01 HYDRAULIC SYSTEM INFORMATION ..................20-01
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) HYDROSTATIC MOTOR .........................................30-01
(ACS) ADVANCED HAND CONTROL................. 20-01 HYDROSTATIC MOTOR (TWO-SPEED) ................30-01
CONTROL HANDLE (ADVANCED HAND CONTROL) HYDROSTATIC PUMP ............................................30-01
(AHC) .................................................................. 20-01 HYDROSTATIC SYSTEM INFORMATION..............30-01
CONTROL HANDLE (ADVANCED HAND CONTROL)
(AHC) (W/ PUSH BUTTON FLOAT) .................... 20-01 INSTRUMENT PANEL ............................................60-01
CONTROL HANDLE (ADVANCED CONTROL SYSTEM)
(ACS) SELECTABLE HAND / FOOT CONTROL. 20-01 LIFT ARMS ..............................................................50-01
CONTROL PANEL ..................................................50-01 LIFT ARM BYPASS VALVE .....................................20-01
CONTROL PEDALS ............................................... 50-01 LIFT ARM SUPPORT DEVICE................................10-01
CONTROL PEDALS (ACS) .................................... 50-01 LIFTING AND BLOCKING THE LOADER...............10-01
CONVERSIONS ............................................... SPEC-01 LIGHTS....................................................................60-01
CYLINDER (LIFT) ................................................... 20-01 LOADER SPECIFICATIONS ............................. SPEC-01
CYLINDER (POWER BOB-TACH).......................... 20-01 LOADER TORQUE............................................ SPEC-01
CYLINDER (TILT) ................................................... 20-01 LUBRICATING THE LOADER.................................10-01
DELUXE INSTRUMENTATION SERVICE CODES 60-01 MAIN RELIEF VALVE (FOOT CONTROL) ..............20-01
DRIVE BELT ........................................................... 30-01 MUFFLER................................................................70-01
DRIVE COMPONENTS .......................................... 40-01
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
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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
01
TEMPERATURE / PRESSURE.................................80-
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
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CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY AND
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V MAINTENANCE
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

HYDRAULIC
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X SYSTEM
BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . XI HYDROSTATIC

SYSTEM
SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 DRIVE

SYSTEM
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
s
MAINFRAME
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01 A
MAINFRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
ELECTRICAL
SYSTEM &
ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01 ANALYSIS
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 ENGINE

SERVICE
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 80-01
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 HVAC
SPECIFICATIONS
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FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including side screens) is in function correctly.
good condition and is not
modified.
2. Check that ROPS mounting 10. Enclosure door latches must

hardware is tightened and is open and close freely.
Bobcat approved.
3. The seat belt must be 11. Bob-Tach wedges and

correctly installed, functional linkages must function
and in good condition. correctly and be in good
condition.
4. The seat bar must be 12. Safety treads must be in good

correctly adjusted, clean and condition.
lubricated.
5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps.
6. Machine signs (decals) must 14. Check hydraulic fluid level,

be legible and in the correct engine oil level and fuel
location. supply.
7. Steering levers, hand controls 15. Inspect for fuel, oil or

and foot pedals must return to hydraulic fluid leaks.
neutral (as applicable).
8. Check for correct function of 16. Lubricate the loader.

the work lights.
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17. Check the condition of the 23. Operate the machine and
battery and cables. check all functions.
18. Inspect the air cleaner for 24. Check for correct function of
damage or leaks. Check the the Bobcat Interlock Control
condition of the element. System (BICS™) before the
machine is returned to the
customer.
19. Check the electrical charging 25. Check for proper function of
system. front horn and back-up alarm
(if equipped).
20. Check tires for wear and 26. Check function or condition of
pressure. Check tracks for all equipped options and
wear and tension. Use only accessories (examples: fire
approved tires or tracks. extinguisher, rotating beacon,
lift kits, etc.).
21. Inspect for loose or broken 27. Recommend to the owner
parts or connections. that all necessary corrections
be made before the machine
is returned to service.
22. Check for any field

modification not completed.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the state of California
to cause cancer, birth defects and other
reproductive harm.
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SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions • An Operator’s Handbook fastened to the operator
can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903
operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
IMPORTANT
• The AEM Safety Manual delivered with the machine
This notice identifies procedures which must be gives general safety information.
followed to avoid damage to the machine.
I-2019-0284 • The Service Manual and Parts Manual are available
from your dealer for use by mechanics to do shop-
type service and repair work.
• The Skid-Steer Loader Operator Training Course is
DANGER available through your local dealer or at

www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
The signal word DANGER on the machine and in the of correct operation of the Skid-Steer Loader. The
manuals indicates a hazardous situation which, if not course is available in English and Spanish versions.
avoided, will result in death or serious injury.
D-1002-1107 • 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.
WARNING • The Skid-Steer Loader Safety Video is available from

your Bobcat dealer or at www.training.bobcat.com
The signal word WARNING on the machine and in the or www.bobcat.com.
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
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SAFETY INSTRUCTIONS (CONT’D)
The dealer and owner / operator review the

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

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

Dial 811 (USA Only)
1-888-258-0808 (USA & Canada)
When you call, you will be directed to a location in your
state / province, or city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.).
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FIRE PREVENTION Hydraulic System
Check hydraulic tubes, hoses and fittings for damage

and leakage. Never use open flame or bare skin to check
for leaks. Hydraulic tubes and hoses must be properly
routed and have adequate support and secure clamps.
Tighten or replace any parts that show leakage.
Maintenance Always clean fluid spills. Do not use gasoline or diesel

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

regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard. Stop the engine and let it cool before adding fuel. No
smoking! Do not refuel a machine near open flames or
The operator’s area, engine compartment and engine sparks. Fill the fuel tank outdoors.
cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Starting
All fuels, most lubricants and some coolants mixtures are Do not use ether or starting fluids on any engine that has
flammable. Flammable fluids that are leaking or spilled glow plugs or air intake heater. These starting aids can
onto hot surfaces or onto electrical components can cause explosion and injure you or bystanders.
cause a fire.
Use the procedure in the Operation & Maintenance
Operation Manual for connecting the battery and for jump starting.
Do not use the machine where exhaust, arcs, sparks or

hot components can contact flammable material, Spark Arrestor Exhaust System
explosive dust or gases. The spark arrestor exhaust system is designed to control
the emission of hot particles from the engine and exhaust
Electrical system, but the muffler and the exhaust gases are still
hot.
Check the spark arrestor exhaust system regularly to

make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
cleaning the spark arrestor muffler (if equipped).
Check all electrical wiring and connections for damage.
Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or
frayed.
Battery gas can explode and cause serious injury. Use

the procedure in the Operation & Maintenance Manual
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.
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FIRE PREVENTION (CONT’D)
Welding And Grinding
Always clean the machine and attachment, disconnect

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

parts. Wear dust mask when grinding painted parts.
Toxic dust or gas can be produced.
Dust generated from repairing nonmetallic parts such as

hoods, fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away
from open flames or sparks.
Fire Extinguishers
Know where fire extinguishers and first aid kits are

located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.
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SERIAL NUMBER LOCATIONS Engine Serial Number
Always use the serial number of the loader when Figure 2

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Loader Serial Number
Figure 1
P-10443
Figure 3
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 1].
Explanation of loader Serial Number:
XXXX XXXXX N-19359
Model 1.-Model / Engine Model 2.-Production

Combination Sequence (Series) The engine serial number is located on the valve cover at
the right side of the engine [Figure 2]. There is also an
extra S/N tag attached to the engine [Figure 3].
1. The four digit Model / Engine combination Module
number identifies the model number and engine
combination.
2. The five digit Production Sequence Number identifies

the order which the loader is produced.
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DELIVERY REPORT
Figure 4
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
4].
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BOBCAT LOADER IDENTIFICATION
OPERATOR
SEAT With
◆FRONT LIGHTS
SEAT BELT
GRAB
HANDLES
◆REAR
AUXILIARY
QUICK
TILT CYLINDER COUPLERS
◆ FRONT AUXILLIARY
†BUCKET QUICK COUPLERS
BUCKET STEPS SAFETY TREAD B-15565
LIFT ARM
SUPPORT DEVICE •OPERATOR CAB
(ROPS/FOPS)
REAR GRILL
SEAT BAR
LIFT ARM
◆REAR LIGHT LIFT CYLINDER
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).
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SAFETY AND MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
SAFETY &
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1 MAINTENANCE
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1
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 DRIVE
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1 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 ELECTRICAL
SYSTEM &
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 ANALYSIS
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Fuel Lift Pump Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3 ENGINE
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 SERVICE
Removing Air From The Fuel System . . . . . . . . . . . . . . . 10-100-3
HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . 10-120-1

Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-4 SPECIFICATIO
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Replacing The Hydraulic / Hydrostatic Fluid . . . . . . . . . . 10-120-2
Replacing Hydraulic Fluid And Case Drain Filters . . . . . . 10-120-2
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
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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
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LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Procedure
WARNING
AVOID INJURY OR DEATH
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
N-19374
Untrained operators and failure to follow instructions
can cause injury or death. Put a floor jack under the rear of the loader [Figure 10-
W-2003-0807
10-2].
Figure 10-10-1 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 P-7704

assembly, etc., completely to become familiar with the
procedure before beginning [Figure 10-10-1].
Put the floor jack under the front of the loader [Figure 10-
Always park the loader on a level surface. 10-3].
Lift the front of the loader and put jackstands under the
axle tubes [Figure 10-10-3].
WARNING NOTE: Make sure the jackstands do not touch the
tires.
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
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LIFT ARM SUPPORT DEVICE Figure 10-20-2
Engaging The Lift Arm Support Device
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 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
Repair the support device if damaged or if parts are interference with the support device engagement.
missing. Using a damaged support device or with
missing parts can cause lift arms or boom to fall With the operator in the seat, seat belt fastened and seat
causing serious injury or death. bar lowered, start the engine.
W-2271-1007
Figure 10-20-1
DANGER
1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
N-19368 can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
Maintenance and service work can be done with the loft support. Replace if damaged.
arms lowered. If the lift arms are raised, use the following
D-1009-0409
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.
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LIFT ARM SUPPORT DEVICE (CONT’D) Figure 10-20-5
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
N-19370 the support device off the lift cylinder rod [Figure 10-20-
5]. Lower the lift arms. Stop the engine.
Raise the lift arms, until the lift arm support device drops Raise the seat bar and move pedals until both pedals
onto the lift cylinder rod (Inset) [Figure 10-20-3]. lock.
Lower the lift arms slowly until the support device is held
Disconnect the spring from the bracket.
between the lift arm and the lift cylinder. Stop the engine.
Raise the seat bar and move pedals until both pedals
lock. Raise the support device into storage position and insert
pin through lift arm support device and bracket. (See
Install the pin (Item 1) [Figure 10-20-3] into the rear of Engaging The Lift Arm Support Device on Page 10-20-1.)
the lift arm support device below the cylinder rod. (Item 1) [Figure 10-20-1 on Page 1].]
Disengaging The Lift Arm Support Device Connect spring to pin. (See Engaging The Lift Arm
Support Device on Page 10-20-1, [Figure 10-20-1 on
Figure 10-20-4 Page 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.
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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 Company. Changes to
the cab can cause loss of operator protection from
rollover and falling objects, and result in injury or
death.
W-2069-0200 N-19374
Install jackstands under the rear of the loader frame

[Figure 10-30-1].
WARNING Figure 10-30-2
UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT

MOVEMENT CAUSED BY CAB CONTACT WITH
CONTROLS CAN CAUSE SERIOUS
INJURY OR DEATH
• STOP ENGINE before raising or lowering cab.
W-2758-0908
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.
N-19364 N-19365
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 Loosen the nut (both sides) at the front corners of the
is available. operator cab [Figure 10-30-2].
Level 1 - Protection from falling bricks, small concrete Remove the nuts and plates (both sides) [Figure 10-30-
blocks and hand tools encountered in operations such as 2]
highway maintenance, landscaping, and other
construction site services.
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.)
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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.
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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.-lb. (54 - 68 N•m) 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 10-30-

7].
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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.
N-20171 Exit through the front door.
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].
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TRANSPORTING THE LOADER Adjusting The Bumper
Procedure Figure 10-40-2
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0807 N-19048 N-19523
Figure 10-40-1
1
N-19521
P-39472
6707867
A loader with an empty bucket or no attachment must be
loaded backward onto the transport vehicle [Figure 10-
40-1]. Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving
Be sure the transport and towing vehicles are of during sudden stops or when going up or down slopes
adequate size and capacity (See Performance on Page [Figure 10-40-2].
SPEC-10-2.) for weight of loader.
• Lower the bucket or attachment to the floor.
The rear of the trailer must be blocked or supported (Item • Stop the engine.
1) [Figure 10-40-1] when loading or unloading the loader • Engage the parking brake.
to prevent the front end of the trailer from raising up. • 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.
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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
• 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
1 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).
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TOWING THE LOADER (CONT’D) Figure 10-50-3
Procedure For Two-Speeds (S/N 51464170,

514540172, 514449389 And Below)
DANGER
1
P-16466
P-90328
Raise the operator cab. (See Raising The Operator Cab
AVOID DEATH on Page 10-30-1.)
tubeline, hose, fitting, component or a part failure Disengage the parking brake solenoid valve by pushing
can cause lift arms to drop. IN on the red Traction Lock Bypass Knob (Item 1)
• Keep out of this area when lift arms are raised [Figure 10-50-3] and turning it 1/4 TURN
unless supported by an approved lift arm counterclockwise. The knob will come out to release
support. Replace if damaged. the solenoid valve.
D-1009-0409
Figure 10-50-4
WARNING
1
W-2059-0598
P-16465
Connect a Port-a-Power to the coupler (Item 1) [Figure

10-50-4].
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TOWING THE LOADER (CONT’D)
Procedure For Two-Speeds (S/N 51464170,

514540172, 514449389 And Below) (Cont’d)
WARNING
Figure 10-50-5 Never work on a machine with the lift arms up unless
W-2059-0598
Figure 10-50-6
7
5
3
6
P-16467
2
1
Operate the Port-a-Power 350-400 PSI (2413-2758 kPa)
to release the brake [Figure 10-50-5]. 7 4
Lower the operator cab and tow the loader.
Before operating the loader again, disconnect the Port-a- P-34159

Power.
Engage the parking brake solenoid valve, by pushing Raise the operator cab. (See Raising The Operator Cab
IN the red Traction Lock Bypass Knob (Item 1) [Figure on Page 10-30-1.)
10-50-3] and turning it 1/4 TURN clockwise.
The parts from the list below are required to complete the
Procedure (S/N 51451171, 514540173, 514449390 and towing tool needed in this procedure [Figure 10-50-6]:
Above)
1 - 2 ft. common drain hose (Item 1)
1 - 6678026 - Check relief valve (500 PSI) (Item 2)
DANGER 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)
Connect the drain hose (Item 1) [Figure 10-50-6] to the

check valve (Item 2) [Figure 10-50-6].
Connect the Tee fitting (Item 3) [Figure 10-50-6], check

P-90328 valve (Item 2) [Figure 10-50-6], and the coupler (Item 5)
[Figure 10-50-6] to the swivel fitting (Item 4) [Figure 10-
AVOID DEATH 50-6].
can cause lift arms to drop.
support. Replace if damaged.
D-1009-0409
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TOWING THE LOADER (CONT’D) Figure 10-50-9
Procedure (S/N 51451171, 514540173, 514449390 and

Above) (Cont’d)
Figure 10-50-7
P-34090
Operate the Port-a-Power to 350-400 PSI (2413-2758

kPa) to release the brakes [Figure 10-50-9].
P-34088
Lower the cab and tow the loader.
Disconnect the two hoses (Item 1) [Figure 10-50-7] from Release the port-a-power pressure to apply the brakes.
the parking brake solenoid valve that go to the right and
left brake housings on the hydrostatic motors. Remove the towing tool from the brake hoses.
Figure 10-50-8 Install the two hydraulic hoses to the parking brake
solenoid valve.
1
2
1
3
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.
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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:
MEL1563: Remote Start Tool Kit 1
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 2
on or start the engine. Example: adjusting the steering
linkage.
N-19984
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Remove the cap (Item 1) [Figure 10-60-2] from the
Raise the lift arms (if required by the procedure) and loader harness (Item 1) [Figure 10-60-3].
install an approved lift arm support device. (See
Engaging The Lift Arm Support Device on Page 10-20-1.) 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.
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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:
MEL 1563: Remote Start Tool Kit

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 1
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 10-60-4
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
1 linkage.
2 Lift and block the loader. (See LIFTING AND BLOCKING

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

install an approved lift arm support device. (See
N-19985 Engaging The Lift Arm Support Device on Page 10-20-1.)
Connect the remote start tool to the engine harness Raise the operator cab (See Raising The Operator Cab
connector (Item 1) [Figure 10-60-4]. on Page 10-30-1.)
The connector (Item 2) [Figure 10-60-4] from the remote Open the rear door of the loader.
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.
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REMOTE START (CONT’D) Figure 10-60-7
Procedure For Loader With, Attachments Control

Harness (Cont’d)
WARNING
2
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 N-20079
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. Disconnect the attachment control harness (Item 1)
W-2357-0899 [Figure 10-60-6] & [Figure 10-60-7] from the loader
harness (Item 2) [Figure 10-60-7].
Figure 10-60-6 Figure 10-60-8
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 10-60-7].
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.
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REMOTE START (CONT’D) Figure 10-60-10
Procedure
Figure 10-60-9
2
3 1
N-19541
The traction lock switch (Item 1) [Figure 10-60-10] is

P-13842 used to turn traction lock on or off, Push the switch to the
override position. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the wheels are
The remote start tool (Item 1) [Figure 10-60-9] has three able to turn.
rocker switches.
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 10-60-10]

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.
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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.
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
WARNING 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 HOURS

■ ■ ■ ▼
ITEM SERVICE REQUIRED 8-10 50 100 250 500 1000 3000
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.
Engine Cooling System Clean debris from oil cooler, radiator & grill.
Lift Arms, Cylinders, Bob-Tach Lubricate with multi-purpose lithium based grease (14 places).
Pivot Pins and Wedges
Tires Check for damaged tires and correct air pressure.
Seat Bar, Control Interlocks, Seat Check the condition of seat belt. Clean or replace seat belt retractors 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 Remove the trapped water.
Heater and A/C Filters Clean or replace filters as needed during heating / cooling season.
Hydraulic Fluid, Hoses and Check fluid level and add as needed. Check for damage and leaks. Repair or
Tubelines replace as needed.
Final Drive Trans. (Chaincase), Check oil level. Check for correct operation. Repair or adjust as needed.
Foot Pedals or Hand Controls,
and Steering Levers
Wheel Nuts ❏Check for loose wheel nuts and tighten to 105 - 115 ft.-lb. (142 - 156 N•m)
torque
Parking Brake Check operation.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Engine / Hydro. Drive Belt *Check for wear or damage. Check idler arm stop.
Alternator Belt Check tension and adjust as needed.
Air Conditioner Belt Check belt for wear. Adjust or replace as needed.
Bobcat Interlock Control System Check the function of the lift arm bypass control.
(BICS™)
Fuel Filter Replace filter element.
Steering Shaft Grease three fittings.
Fan Drive Gearbox Check gear lube level.
Hydraulic Reservoir Breather Cap Replace the reservoir breather cap.
Hyd. / Hydro. Filter ●Replace the filter element.
Engine Oil and Filter ^Replace oil and filter. Use CD or better grade oil and Bobcat filter. ^ ❍
Final Drive Trans. (Chaincase) Replace the fluid.
Hydraulic Reservoir Replace the fluid.
Case Drain Filters Replace the filters.
Engine Valves #Adjust the engine valves.
Engine Timing Belt ▼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.
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AIR CLEANER SERVICE OUTER FILTER
Replacing Filter Element Figure 10-80-3
Figure 10-80-1
1 2
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)
Disengage the clamps (Item 1) [Figure 10-80-3] and
[Figure 10-80-1] and you hear three beeps from the
remove the dust cover (Item 2) [Figure 10-80-3].
alarm.
Figure 10-80-4
Replace the inner filter every third time the outer filter is
replaced or as indicated. (See Replacing Filter Element
on Page 10-80-1.)
Figure 10-80-2
1 1
P-24844
B-15551
Remove the outer filter element (Item 1) [Figure 10-80-

Press and hold the LIGHT Button (Item 1) [Figure 10-80- 4].
2] for two seconds.
NOTE: Make sure all sealing surfaces are free of dirt
If the filter element needs replacement, the CODE [01- and debris.
17] (Air Filter Plugged) will show in the HOURMETER /
CODE DISPLAY (Item 2) [Figure 10-80-2]. Install a new outer element.
Install the dust cover and fasten the clamps.
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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 / 1
CODE DISPLAY shows [01-17] (Air Filter Plugged),
replace the inner filter element.
P-24843
Figure 10-80-5
Install the dust cover and fasten the clamps (Item 1)

[Figure 10-80-6].
P-24845
Remove the inner filter element (Item 1) [Figure 10-80-

5].
NOTE: Make sure all sealing surfaces are free of dirt

and debris.
Install the new inner element.
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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: 1
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907 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
N-19411
Check the cooling system every day to prevent

overheating, loss of performance or engine damage.
N-19416
Lift the grill [Figure 10-90-1].
Use air pressure or water pressure to clean the top of the Use air pressure or water pressure to clean the top of the
oil cooler (Item 1) [Figure 10-90-1]. engine oil cooler (Item 1) [Figure 10-90-3].
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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].
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FUEL SYSTEM Figure 10-100-2
Fuel Specifications WRONG

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. F° (C°) No. 2 No.1

+15° (9°) 100% 0%
Down to -20° (-29°) 50% 50%
Below -20° (-29°) 0% 100%
B-15602
Contact your fuel supplier for local recommendations.

Use a clean, approved safety container to add fuel of the
Filling The Fuel Tank 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].
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-2063-0807
Open the rear door.
Figure 10-100-1
N-19408
Remove the fuel fill cap (Item 1) [Figure 10-100-1].
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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.
W-2103-0508
Figure 10-100-3
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.)
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FUEL SYSTEM (CONT’D) Removing Air From The Fuel System
Fuel Lift Pump Strainer
Figure 10-100-4
WARNING
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
1
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
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

P-24722
10-100-4] until fuel flows from the vent with no air
bubbles.
Close the vent (Item 2) [Figure 10-100-4].
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.
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ENGINE LUBRICATION SYSTEM Replacing Oil And Filter
Checking Engine Oil
Figure 10-110-1
WARNING
2
explosion or fire.
W-2103-0508
1 Figure 10-110-2
N-19327
Check the engine oil every day.
Before restarting the engine for the work shift, open the 1
rear door. Remove the dipstick (Item 1) [Figure 10-110-
1]
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)
service interval for replacing the engine oil filter.
C°
Run the engine until it its at operating temperature. Stop
the engine.
Open the rear door. Remove the drain plug [Figure 10-
110-2]. 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.
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ENGINE LUBRICATION SYSTEM (CONT’D)
Replacing Oil And Filter (Cont’d)
Figure 10-110-3
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 qt. (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.
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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
CD-12250 N-19360
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.
P-4613 NOTE: Before installing the fill breather cap, make

sure the rubber gasket is installed on the cap
(inset) [Figure 10-120-2].
Install the fill cap [Figure 10-120-2].
N-19361
Check the fluid level in the sight gauge (Item 1) [Figure

10-120-1].
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HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Check the fluid level in the reservoir and add as needed.
Replacing The Hydraulic / Hydrostatic Fluid
WARNING
WARNING AVOID INJURY OR DEATH
AVOID INJURY OR DEATH sparks or lighted tobacco away from fuel and oil.
Diesel fuel or hydraulic fluid under pressure can Failure to use care around combustibles can cause
penetrate skin or eyes, causing serious injury or explosion or fire.
W-2103-0508
not use your bare hand. Wear safety goggles. If fluid Replacing Hydraulic Fluid And Case Drain Filters
from a physician familiar with this injury. (See SERVICE SCHEDULE on Page 10-70-1.) for the
W-2072-0807 correct service interval.
(See SERVICE SCHEDULE on Page 10-70-1.) for the Replace the fluid if it becomes contaminated or after
correct service interval. major repair.
Raise the operator cab. (See Raising The Operator Cab Always replace the hydraulic / hydrostatic filter and clean
on Page 10-30-1.) the hydraulic fill screen and the case drain filters
whenever the hydraulic fluid is replaced.
Figure 10-120-3
Remove the fill cap and raise the operator cab. (See
Raising The Operator Cab on Page 10-30-1.)
Hydraulic Fill Screen
Figure 10-120-4
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 N-19362
new filter element.
Install and hand tighten the filter element. Remove two hose clamps and remove the hose (Item 1)
[Figure 10-120-4]
Lower the operator cab.
Start the engine and operate the loader hydraulic

controls.
Stop and check for leaks at the filter.
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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
N-19496
explosion or fire.
W-2103-0508
Drain the reservoir [Figure 10-120-6]. Remove Left

Figure 10-120-5 Motor Cover.
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 10-120-

5] and use clean solvent to remove contamination from
the screen.
Use air pressure to dry the screen.
Install screen, hose and hose clamps.
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HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Breather Cap
Replacing Hydraulic Fluid And Case Drain Filters The fill cap is also a breather for the hydraulic /
(Cont’d) 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
N-19360
N-19495
Remove the cap (Item 1) [Figure 10-120-9] and use

Figure 10-120-8 clean solvent to remove debris. Dry the cap thoroughly.
LEFT CASE DRAIN Install the fill / breather cap.
FILTER
N-19497
Disconnect the hoses from the hydrostatic motor case

drain filter (Item 1) [Figure 10-120-7] and [Figure 10-
120-8].
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.
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FINAL DRIVE TRANSMISSION (CHAINCASE) Replacing The Oil
Checking And Adding Oil Figure 10-130-2
Figure 10-130-1
P-1616
P-10153
To drain the oil from the chaincase, remove the cover
(Item 1) [Figure 10-130-2] which is installed over the
The chaincase contains the final drive sprockets and the drain plug at the rear of the chaincase.
chains and uses the same type of fluid as is used in the
hydraulic / hydrostatic system. (See HYDRAULIC FLUID Figure 10-130-3
SPECIFICATIONS on Page SPEC-60-1.)
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.
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FAN GEAR BOX
Checking And Adding Oil
Figure 10-140-1
Gear Lube 1
Level
P-7616

correct service interval.

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.
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BOB-TACH Figure 10-150-3
Inspection And Maintenance
Bob-Tach
Wedge
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0497
Wedge Must Contact
Lower Edge Of Hole
Figure 10-150-1 In The Attachment 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 LUBRICATING THE

LOADER on Page 10-160-1.)
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].
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POWER BOB-TACH (OPTION) Figure 10-151-3
Inspection And Maintenance
Figure 10-151-1
B-15177
Wedge Must Contact

Lower Edge Of Hole
In The Attachment N-17043
B-15554B If the wedge does not contact the lower edge of the hole
B-15554A [Figure 10-151-3], the attachment will be loose and can
B-15993C
come off the Bob-Tach.
Push and hold the BOB-TACH “WEDGES UP” switch Figure 10-151-4
[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 10-151-2
TS-1062
Inspect the mounting frame on the attachment and the

1
Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-151-4]. Replace any parts including
N-17043 decals and lever that are damaged, bent, or missing.
Keep all fasteners tight. Inspect the hoses and fittings for
leaks.
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [Figure 10-151-2] Look for cracked welds. Contact your Bobcat dealer for
and must contact the lower edge of the hole in the repair or replacement parts.
attachment [Figure 10-151-2] and (Item 1) [Figure 10-
151-3]. Lubricate the wedges. (See LUBRICATING THE
LOADER on Page 10-160-1.)
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LUBRICATING THE LOADER Figure 10-160-3
Procedure
Figure 10-160-1
3
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 10-
160-1.)
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]. P-7641
Figure 10-160-2
4. Base End Tilt Cylinder (Both Sides) [Figure 10-160-
4].
P-10815
2. Base End Lift Cylinder (Both Sides) [Figure 10-160-

2].
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LUBRICATING THE LOADER (CONT’D) Figure 10-160-7
Procedure (Cont’d)
Figure 10-160-5
1
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
N-19500
6. Bob-Tach Pivot Pin (Both Sides) [Figure 10-160-6].
7. Bob-Tach Wedge (Both Sides) [Figure 10-160-6].
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TIRE MAINTENANCE Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
Wheel Nuts capability. Check for the correct pressure before
operating the loader.
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-2078-1007
P-10142
(See SERVICE SCHEDULE on Page 10-70-1.) for the IMPORTANT

service interval to check the wheel nuts. The correct
torque is 105 - 115 ft.-lb. (142 - 156 N•m) torque [Figure Inflate tires to the MAXIMUM pressure shown on the
10-170-1]. sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
Tire Rotation I-2057-0794
Check the tires regularly for wear, damage and pressure. Tires are to be repaired only by an authorized person
(See Tires on Page SPEC-10-4.) for the correct tire using the proper procedures and safety equipment. Tires
pressure.) and rims must always be checked for correct size before
mounting. Check rim and tire bead for damage.
Figure 10-170-2
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
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.
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HYDRAULIC SYSTEM
BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-4
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1 SAFETY &
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-2 MAINTENANCE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-2
CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1 HYDRAULIC

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-7 SYSTEM
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4 DRIVE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2 SYSTEM
CYLINDER (POWER BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-5
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-2 ELECTRICAL
SYSTEM &
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 ANALYSIS
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-7
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5 ENGINE
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-4 SERVICE
Rod End Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-3
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK. . . . . . . . . . . . . 20-130-1 SPECIFICATIO

Disassembly And Assembly (518916011 & Above). . . . . . . . . . . . . 20-130-1
Removal And Installation (514449564 & Above) . . . . . . . . . . . . . . . 20-130-1
Continued On Next Page
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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 Bypass 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
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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 Bypass 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
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HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 & BELOW) . . . . . . . . . . . . . . 20-60-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-7
Checking The Output Of The Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-6
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
HYDRAULIC PUMP (CAST IRON) (S/N 514449260 & ABOVE) . . . . . . . . . . . . . . 20-62-1

Check The Output Of The Hydraulic Pump With Power Bob-Tach . . . . . . . . . . 20-62-3
Check The Output Of The Hydraulic Pump Without Power Bob-Tach . . . . . . . . 20-62-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-7
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-6
HYDRAULIC PUMP (CAST IRON HIGH FLOW) (S/N 514449484-514450945) . . 20-63-1

Check The Output Of The Hydraulic Pump With Power Bob-Tach . . . . . . . . . . 20-63-2
Check The Output Of The Hydraulic Pump Without Power Bob-Tach . . . . . . . . 20-63-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-6
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Tighten Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Additional Inspection For Loaders With ACS. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
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MAIN RELIEF VALVE (FOOT CONTROL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-5
Checking The Main Relief Valve At Front Auxiliary Hydraulics . . . . . . . . . 20-30-1
Checking The Main Relief Valve Without Front Auxiliaries . . . . . . . . . . . . 20-30-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

REAR AUXILIARY DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2
SELECT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Checking The High Flow Pump Relief Valve (S/N 514450945 & Below). 20-100-1
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE
SPECIFICATIONS FOR BOLTS, SPEC SECTION) UNLESS OTHERWISE SPECIFIED.
863 Bobcat Loader

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863 Bobcat Loader
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HYDRAULIC/HYDROSTATIC SCHEMATIC
863 (S/N 514440001-41938)
(S/N 514540001-40073)
(PRINTED NOVEMBER 2002)
V-0027legend
LEGEND
1 RESERVOIR: 14 SOLENOID ACTIVATED DIRECTIONAL 29 CHARGE PUMP 41 CHECK VALVE - BICS CONTROL VALVE
Capacity . . . . . . 18.8 Qts. (17.8 L) CONTROL VALVE - BICS CONTROL 11.0 GPM (41,6 L/min.) at 2615 Engine RPM
2 FILTER - CASE DRAIN (90 Micron) 42 LIFT ARM BY-PASS RESTRICTOR
15 PULL BUTTON ACTIVATED 30 HYDRAULIC PUMP . . . . . . . Gear Type
DIRECTIONAL CONTROL VALVE - LIFT 18.0 GPM (68,1 L/min.) at 2615 Engine RPM
3 FILTER - HYDRAULIC (CANISTER) ARM BY-PASS 43 CHECK VALVE - AUXILIARY
31 DRIVE MOTOR SHUTTLE VALVE
16 FILTER - BICS CONTROL VALVE
*
4 SPRING LOADED FILTER BY-PASS 44 MUFFLER (If Equipped)
VALVE: 45-55 PSI (311-379 kPa) (SCREEN) 32 SHUTTLE RELIEF VALVE:
200 PSI (1378 kPa) 45 VARIABLE CAPACITY DISPLACEMENT
5 PILOT ACTIVATED DIRECTIONAL 17 BOOM DOWN RESTRICTOR
BIDIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - HYDRAULIC 33 SOLENOID ACTIVATED DIRECTIONAL
POWERED BOB-TACH 18 LIFT AND TILT LOAD CHECK VALVE CONTROL VALVE - BLEED OFF REAR 46 RESTRICTOR - 0.020 inch (0,5 mm)
AUXILIARY ("SV2")
6 DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa) 19 RELIEF VALVE - MAIN: 47 SOLENOID ACTIVATED DIRECTIONAL
2950-3050 PSI (20340-21030 kPa) 34 LOAD SHUTTLE VALVE - BLEED OFF CONTROL VALVE (TWO COIL)
7 FLOW DIVIDER ADJUSTMENT VALVE at Front Quick Couplers
48 RELIEF VALVE - 1200 PSI (8268 kPa)
35 PILOT ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: CONTROL VALVE - FOR REAR
8 CHECK VALVE - BUCKET POSITION
3500 PSI (24132 kPa) AUXILIARY - NORMALLY CLOSED 49 RESTRICTOR - 0.090 inch (2,3 mm)
VALVE
("P2" and "F2")
21 ANTICAVITATION VALVE
9 FIXED CAPACITY DISPLACEMENT 50 RELIEF VALVE - 2000 PSI (13780 kPa)
BIDIRECTIONAL HYDROSTATIC 36 PILOT ACTIVATED DIRECTIONAL
MOTOR 22 RELIEF/ANTICAVITATION VALVE - CONTROL VALVE - FOR REAR
PORT (TILT BASE END) AUXILIARY - NORMALLY OPEN 51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa) ("D1" and "P1") 3500 PSI (24132 kPa)
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL 52 SOLENOID ACTIVATED DIRECTIONAL
23 ONE WAY RESTRICTOR VALVE 37 PILOT ACTIVATED DIRECTIONAL
SPOOL CONTROL VALVE - BUCKET POSITION
CONTROL VALVE - FOR REAR VALVE (ON/OFF)
11 PILOTED ACTIVATED DIRECTIONAL 24 SOLENOID ACTIVATED DIRECTIONAL AUXILIARY - NORMALLY OPEN
("D2" and "P2") 53 SCREEN
CONTROL VALVE - UNLOADING CONTROL VALVE - AUXILIARY
SPOOL
25 RELIEF VALVE - PORT: . . . . . (Optional) 38 FILTER - DIVERTER VALVE (SCREEN)
12 PILOTED ACTIVATED DIRECTIONAL 3500 PSI (24132 kPa) INTEGRATED IN SOLENOID
CONTROL VALVE - TILT CONTROL
26 RELIEF/REPLENISHING VALVE - HIGH 39 SOLENOID ACTIVATED DIRECTIONAL
13 PILOTED ACTIVATED DIRECTIONAL PRESSURE: 4712 PSI (32489 kPa) CONTROL VALVE - TO ACTIVATE NOTE: Unless otherwise specified
CONTROL VALVE - LIFT CONTROL REAR AUXILIARY ("SV1") springs have NO significant
27 CHARGE PRESSURE SWITCH pressure value.
28 RELIEF VALVE - CHARGE: CONTROL VALVE - FOR REAR
120 degrees F. (53 degrees C.)Fluid AUXILIARY - NORMALLY CLOSED
at 1775 Pump RPM ("P1" and "F1")
390 - 430 PSI (2689 - 2965 kPa)
Printed in U.S.A. V-0027legend (11-5-02)
73 of 968
DIVERTER VALVE (OPTIONAL)
863 (S/N 514440001-41938) 38
(S/N 514540001-40073)
39
(PRINTED NOVEMBER 2002) PILOT
V-0027
DRIVE MOTOR
40 36
MALE MALE F1 D1 MALE
31 2
32
34 (FRONT AUXILIARY
(REAR QUICK
COUPLERS) LEFT SIDE LIFT ARM)
33 35 37
F2 D2
FEMALE
FEMALE FEMALE
9
DRAIN P1 P2
HYDRAULIC FILTER
3
BUCKET POSITION VALVE (OPTIONAL)
HYDROSTATIC PUMPS OIL
4 D
COOLER
45 8
28
26
26 7
6
A
CHARGE INLET OUTLET
52 C
HYDRAULIC CONTROL VAVLE 10
29
43
11
26 27
26
BOB-TACH
24 24
CYLINDER 25
45 (OPTIONAL) B
A B
HYDRAULIC
POWERED 53 AUXILIARY
BOB-TACH SPOOL
DR (OPTIONAL)
INLET OUTLET
23 TILT CYLINDER
22
BICS CONTROL VALVE
30 46 47
48
49
50 A B 12
51 TILT
CYLINDER
SPOOL
DRIVE MOTOR
21
18
9
20 LIFT CYLINDERS
P1 17
P2
5 13
A B
LIFT
CYLINDER
SPOOL
31 32
*
18 42 (If Equipped)
19 14 WORKING CIRCUITS
* 44 16 41 16 PILOT CIRCUITS
2 DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY- PASS VALVE
15
Printed in U.S.A. V-0027 (11-5-02)
74 of 968
WITH HIGH FLOW OPTION
863 (S/N 514440001-41938)
(S/N 514640001-40147)
V-0028legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 32 SHUTTLE RELIEF VALVE: 50 RELIEF VALVE - 2000 PSI (13780 kPa)
Capacity . . . . . . 18.8 Qts. (17.8 L) (SCREEN) 200 PSI (1378 kPa)
17 BOOM DOWN RESTRICTOR 51 RELIEF VALVE - PORT:
2 FILTER - CASE DRAIN (90 Micron) 33 REAR AUXILIARY BLEED SHUTTLE VALVE
3500 PSI (24132 kPa)
3 FILTER - HYDRAULIC (CANISTER) 18 LIFT AND TILT LOAD CHECK VALVE 34 LOAD CHECK VALVE - SELECT VALVE 52 SOLENOID ACTIVATED DIRECTIONAL
(HIGH FLOW)
19 RELIEF VALVE - MAIN: CONTROL VALVE - BUCKET POSITION
4 SPRING LOADED FILTER BY-PASS
35 SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF)
VALVE: 45-55 PSI (311-379 kPa) 2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers CONTROL VALVE - HIGH FLOW
5 PILOT ACTIVATED DIRECTIONAL 53 HYDRAULIC HIGH FLOW PUMP
20 RELIEF VALVE - PORT: 36 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC 10.0 GPM (37,8 L/min.) at 2615 Engine RPM
POWERED BOB-TACH 3500 PSI (24132 kPa) CONTROL VALVE - DIVERTER
21 ANTICAVITATION VALVE 54 SELECT VALVE RESTRICTOR
6 DIFFERENTIAL PRESSURE SWITCH: 37 RELIEF VALVE - MAIN (HIGH FLOW)
36-44 PSI (248-303 kPa) 3000 PSI (20685 kPa)
22 RELIEF/ANTICAVITATION VALVE - 55 SCREEN
PORT (TILT BASE END) 38 SOLENOID ACTIVATED DIRECTIONAL
7 FLOW DIVIDER ADJUSTMENT VALVE
3500 PSI (24132 kPa) CONTROL VALVE (TWO COIL)
8 CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE 39 PILOT TO OPEN CHECK VALVE
VALVE
24 SOLENOID ACTIVATED DIRECTIONAL 40
9 FIXED CAPACITY DISPLACEMENT SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - BLEED OFF
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional)
3500 PSI (24132 kPa) 41 CHECK VALVE - BICS CONTROL VALVE
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH 42 LIFT ARM BY-PASS RESTRICTOR
SPOOL PRESSURE: 4712 PSI (32489 kPa)
43 CHECK VALVE - AUXILIARY
11 PILOTED ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH
*
CONTROL VALVE - UNLOADING 44 MUFFLER (If Equipped)
28 RELIEF VALVE - CHARGE:
SPOOL
120 degrees F. (53 degrees C.)Fluid 45 VARIABLE CAPACITY DISPLACEMENT
12 PILOTED ACTIVATED DIRECTIONAL at 1775 Pump RPM
CONTROL VALVE - TILT CONTROL 390 - 430 PSI (2689 - 2965 kPa)
46 RESTRICTOR - 0.020 inch (0,5 mm)
13 PILOTED ACTIVATED DIRECTIONAL 29 CHARGE PUMP
CONTROL VALVE - LIFT CONTROL 11.0 GPM (41,6 L/min.) at 2615 Engine RPM 47 SOLENOID ACTIVATED DIRECTIONAL
14 SOLENOID ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . Gear Type CONTROL VALVE (TWO COIL)
CONTROL VALVE - BICS CONTROL 18.0 GPM (68,1 L/min.) at 2615 48 RELIEF VALVE - 1200 PSI (8268 kPa)
Engine RPM
15 PULL BUTTON ACTIVATED 53
HIGH FLOW CAPACITY: (Includes ) 49 RESTRICTOR - 0.090 inch (2,3 mm)
DIRECTIONAL CONTROL VALVE - LIFT 28.0 GPM (106 L/min.) at 2615
ARM BY-PASS Engine RPM
31 DRIVE MOTOR SHUTTLE VALVE NOTE: Unless otherwise specified
springs have NO significant
pressure value.
75 of 968
863 (S/N 514441939 - 514449259)
(S/N 514540074 - 514541068)
V-0019legend
LEGEND
1 RESERVOIR: 15 PULL BUTTON ACTIVATED 29 CHARGE PUMP 41 CHECK VALVE - BICS CONTROL VALVE
Capacity . . . . . . . 18.8 Qts. (17.8 L) DIRECTIONAL CONTROL VALVE - LIFT (S/N 514441939-46864)
ARM BY-PASS (S/N 514540074-41034)
2 FILTER - CASE DRAIN (90 Micron) 42 LIFT ARM BY-PASS RESTRICTOR
11.0 GPM (41,6 L/min.) at 2615 Engine RPM
16 FILTER - BICS CONTROL VALVE (S/N 514446865 AND ABOVE)
3 FILTER - HYDRAULIC (CANISTER) (SCREEN) (S/N 514541035 AND ABOVE) 43 CHECK VALVE - AUXILIARY
17 BOOM DOWN RESTRICTOR 30
*
4 SPRING LOADED FILTER BY-PASS HYDRAULIC PUMP . . . . . . . Gear Type 44 MUFFLER (If Equipped)
VALVE: 45-55 PSI (311-379 kPa) (S/N 514441939-46864)
18 LIFT AND TILT LOAD CHECK VALVE (S/N 514540074-41034)
45 VARIABLE CAPACITY DISPLACEMENT
5 PILOT ACTIVATED DIRECTIONAL 18.0 GPM (68,1 L/min.) at 2615 EngineRPM
(S/N 514446865 AND ABOVE) BIDIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - HYDRAULIC
19 RELIEF VALVE - MAIN: (S/N 514541035 AND ABOVE)
POWERED BOB-TACH 46
2950-3050 PSI (20340-21030 kPa) 20.0 GPM (75,7 L/min.) at 2615 Engine RPM RESTRICTOR - 0.020 inch (0,5 mm)
6 DIFFERENTIAL PRESSURE SWITCH: at Front Quick Couplers
36-44 PSI (248-303 kPa) 31 DRIVE MOTOR SHUTTLE VALVE 47 SOLENOID ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: CONTROL VALVE (TWO COIL)
FLOW DIVIDER ADJUSTMENT VALVE 3500 PSI (24132 kPa) 32 SHUTTLE RELIEF VALVE:
7
200 PSI (1378 kPa) 48 RELIEF VALVE - 1200 PSI (8268 kPa)
33 SOLENOID ACTIVATED DIRECTIONAL
8 CHECK VALVE - BUCKET POSITION CONTROL VALVE - BLEED OFF REAR 49 RESTRICTOR - 0.090 inch (2,3 mm)
VALVE 22 RELIEF/ANTICAVITATION VALVE - AUXILIARY ("SV2")
PORT (TILT BASE END)
34 LOAD SHUTTLE VALVE - BLEED OFF 50 RELIEF VALVE - 2000 PSI (13780 kPa)
9 FIXED CAPACITY DISPLACEMENT 3500 PSI (24132 kPa)
BIDIRECTIONAL HYDROSTATIC 35 PILOT ACTIVATED DIRECTIONAL
MOTOR 23 ONE WAY RESTRICTOR VALVE CONTROL VALVE - FOR REAR 51 RELIEF VALVE - PORT:
AUXILIARY - NORMALLY CLOSED 3500 PSI (24132 kPa)
10 PILOTED ACTIVATED DIRECTIONAL 24 SOLENOID ACTIVATED DIRECTIONAL ("P2" and "F2")
CONTROL VALVE - FLOW CONTROL 52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY 36 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION
SPOOL
CONTROL VALVE - FOR REAR VALVE (ON/OFF)
25 RELIEF VALVE - PORT: . . . . . . . . (Optional) AUXILIARY - NORMALLY OPEN
11 PILOTED ACTIVATED DIRECTIONAL 53 SCREEN
3500 PSI (24132 kPa) ("D1" and "P1")
CONTROL VALVE - UNLOADING
SPOOL 37 PILOT ACTIVATED DIRECTIONAL
26 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - FOR REAR 54 ACCUMULATOR - FOUND ONLY ON
PRESSURE: (S/N 514441939-46864) AUXILIARY - NORMALLY OPEN MACHINES WITH
(S/N 514540074-41034) ("D2" and "P2") S/N 514444558 AND ABOVE
CONTROL VALVE - TILT CONTROL
4712 PSI (32489 kPa) S/N 514540126 AND ABOVE
38 FILTER - DIVERTER VALVE (SCREEN)
(S/N 514446865 AND ABOVE)
13 PILOTED ACTIVATED DIRECTIONAL INTEGRATED IN SOLENOID
CONTROL VALVE - LIFT CONTROL 39 SOLENOID ACTIVATED DIRECTIONAL
5000 PSI (34475 kPa)
27 CHARGE PRESSURE SWITCH CONTROL VALVE - TO ACTIVATE NOTE: Unless otherwise specified
14 SOLENOID ACTIVATED DIRECTIONAL REAR AUXILIARY ("SV1") springs have NO significant
CONTROL VALVE - BICS CONTROL pressure value.
28 RELIEF VALVE - CHARGE: 40 PILOT ACTIVATED DIRECTIONAL
120 degrees F. (53 degrees C.) Fluid CONTROL VALVE - FOR REAR
at 1775 Pump RPM AUXILIARY - NORMALLY CLOSED
390 - 430 PSI (2689 - 2965 kPa) ("P1" and "F1")
77 of 968
WITH TWO SPEED VALVE OPTION
863 (S/N 514441939 - 514449259)
(S/N 514540074 - 514541068)
V-0022legend
LEGEND
1 RESERVOIR: 19 RELIEF VALVE - MAIN: 34 LOAD SHUTTLE VALVE - BLEED OFF 50 RELIEF VALVE - 2000 PSI (13780 kPa)
Capacity . . . . . . . . 18.8 Qts. (17.8 L) 2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers 35 PILOT ACTIVATED DIRECTIONAL 51 RELIEF VALVE - PORT:
2 FILTER - CASE DRAIN (90 Micron) 3500 PSI (24132 kPa)
AUXILIARY - NORMALLY CLOSED 52 SOLENOID ACTIVATED DIRECTIONAL
3 FILTER - HYDRAULIC (CANISTER) 3500 PSI (24132 kPa)
("P2" and "F2") CONTROL VALVE - BUCKET POSITION
21 ANTICAVITATION VALVE VALVE (ON/OFF)
4 SPRING LOADED FILTER BY-PASS 36 PILOT ACTIVATED DIRECTIONAL
VALVE: 45-55 PSI (311-379 kPa) 22 RELIEF/ANTICAVITATION VALVE - CONTROL VALVE - FOR REAR 53 FIXED CAPACITY DISPLACEMENT
AUXILIARY - NORMALLY OPEN BIDIRECTIONAL HYDROSTATIC
5 PILOT ACTIVATED DIRECTIONAL PORT (TILT BASE END)
("D1" and "P1") MOTOR
CONTROL VALVE - HYDRAULIC 3500 PSI (24132 kPa)
POWERED BOB-TACH 54 HYDRAULIC BRAKE - SPRING APPLIED -
23 ONE WAY RESTRICTOR VALVE 37 PILOT ACTIVATED DIRECTIONAL PRESSURE TO RELEASE
6 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE - FOR REAR
36-44 PSI (248-303 kPa) 24 SOLENOID ACTIVATED DIRECTIONAL AUXILIARY - NORMALLY OPEN 55 PULL BUTTON ACTIVATED
CONTROL VALVE - AUXILIARY ("D2" and "P2") DIRECTIONAL CONTROL VALVE -
7 FLOW DIVIDER ADJUSTMENT VALVE BRAKE
25 RELIEF VALVE - PORT: . . . . . . . (Optional) 38 FILTER - DIVERTER VALVE (SCREEN)
8 CHECK VALVE - BUCKET POSITION 3500 PSI (24132 kPa) 56 SOLENOID ACTIVATED DIRECTIONAL
INTEGRATED IN SOLENOID
VALVE CONTROL VALVE - MAKE-UP
26 RELIEF/REPLENISHING VALVE - HIGH
39 SOLENOID ACTIVATED DIRECTIONAL 57 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT PRESSURE: 5000 PSI (34475 kPa)
CONTROL VALVE - TO ACTIVATE CONTROL VALVE - TWO SPEED
BIDIRECTIONAL HYDROSTATIC REAR AUXILIARY ("SV1")
MOTOR 27 CHARGE PRESSURE SWITCH 58 BRAKE DIAGNOSTIC PLUG
10 PILOTED ACTIVATED DIRECTIONAL 28 RELIEF VALVE - CHARGE:
CONTROL VALVE - FOR REAR 59 SCREEN
CONTROL VALVE - FLOW CONTROL 120 degrees F. (53 degrees C.)Fluid
AUXILIARY - NORMALLY CLOSED
SPOOL at 1775 Pump RPM
("P1" and "F1")
390 - 430 PSI (2689 - 2965 kPa)
11 PILOTED ACTIVATED DIRECTIONAL 41 60 ACCUMULATOR - FOUND ONLY ON
29 CHECK VALVE - BICS CONTROL VALVE
CONTROL VALVE - UNLOADING CHARGE PUMP MACHINES WITH
SPOOL 14.0 GPM (53,0 L/min.) at 2615 Engine RPM 42 S/N 514444558 AND ABOVE
LIFT ARM BY-PASS RESTRICTOR
S/N 514540126 AND ABOVE
12 PILOTED ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . . Gear Type
CONTROL VALVE - TILT CONTROL 20.0 GPM (75,7 L/min.) at 2615 Engine RPM 43 CHECK VALVE - AUXILIARY
13 PILOTED ACTIVATED DIRECTIONAL 31 DRIVE MOTOR SHUTTLE VALVE 44 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL CONTROL VALVE - TWO SPEED
14 SOLENOID ACTIVATED DIRECTIONAL 32 SHUTTLE RELIEF VALVE: DRIVE MOTOR
CONTROL VALVE - BICS CONTROL 200 PSI (1378 kPa)
15 PULL BUTTON ACTIVATED 33 45 VARIABLE CAPACITY DISPLACEMENT
SOLENOID ACTIVATED DIRECTIONAL
DIRECTIONAL CONTROL VALVE - LIFT CONTROL VALVE - BLEED OFF REAR BIDIRECTIONAL HYDROSTATIC PUMP
ARM BY-PASS AUXILIARY ("SV2") 46 RESTRICTION - 0.020 inch (0,5 mm)
(SCREEN) 47 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL) NOTE: Unless otherwise specified
17 BOOM DOWN RESTRICTOR
48 springs have NO significant
RELIEF VALVE - 1200 PSI (8268 kPa)
18 LIFT AND TILT LOAD CHECK VALVE pressure value.
49 RESTRICTOR - 0.090 inch (2,3 mm)
79 of 968
863 (S/N 514441939 - 514449483)
(S/N 514640148 - 514641170)
V-0023legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 30 HYDRAULIC PUMP . . . . . . . . Gear Type 42 LIFT ARM BY-PASS RESTRICTOR
Capacity . . . . . . . . . 18.8 Qts. (17.8 L) (SCREEN) (S/N 514441939-46822)
(S/N 514640148-41074) 43 CHECK VALVE - AUXILIARY
2 FILTER - CASE DRAIN (90 Micron) 17 BOOM DOWN RESTRICTOR
18.0 GPM (68,1 L/min.) at 2615
18 LIFT AND TILT LOAD CHECK VALVE Engine RPM 44 MUFFLER (If Equipped)
3 FILTER - HYDRAULIC (CANISTER)
SPRING LOADED FILTER BY- PASS 19 RELIEF VALVE - MAIN: HIGH FLOW CAPACITY: (Includes )

53 45 VARIABLE CAPACITY DISPLACEMENT
4
*
VALVE: . . . 45-55 PSI (311-379 kPa) 2950-3050 PSI (20340-21030 kPa) 28.0 GPM (106,0 L/min.) at 2615
at Front Quick Couplers Engine RPM 46 RESTRICTOR - 0.020 inch (0,5 mm)
CONTROL VALVE - HYDRAULIC 20 RELIEF VALVE - PORT:
(S/N 514446823 AND ABOVE) 47
POWERED BOB-TACH 3500 PSI (24132 kPa) SOLENOID ACTIVATED DIRECTIONAL
21 ANTICAVITATION VALVE CONTROL VALVE (TWO COIL)
6 DIFFERENTIAL PRESSURE SWITCH: 20.0 GPM (75,7 L/min.) at 2615
Engine RPM 48 RELIEF VALVE - 1200 PSI (8268 kPa)
36-44 PSI (248-303 kPa)
22 RELIEF/ANTICAVITATION VALVE -
7 FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END) 53
HIGH FLOW CAPACITY: (Includes ) 49 RESTRICTOR - 0.090 inch (2,3 mm)
3500 PSI (24132 kPa) 30.0 GPM (113,6 L/min.) at 2615
8 50 RELIEF VALVE - 2000 PSI (13780 kPa)
CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE Engine RPM
VALVE 51 RELIEF VALVE - PORT:
24 SOLENOID ACTIVATED DIRECTIONAL 31 DRIVE MOTOR SHUTTLE VALVE 3500 PSI (24132 kPa)
9 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - AUXILIARY 52 SOLENOID ACTIVATED DIRECTIONAL
32 SHUTTLE RELIEF VALVE:
MOTOR 25 RELIEF VALVE - PORT: . . . . . . (Optional) CONTROL VALVE - BUCKET POSITION
200 PSI (1378 kPa)
3500 PSI (24132 kPa) VALVE (ON/OFF)
10 PILOTED ACTIVATED DIRECTIONAL 33 REAR AUXILIARY BLEED SHUTTLE VALVE
CONTROL VALVE - FLOW CONTROL 53 HYDRAULIC HIGH FLOW PUMP
SPOOL 10.0 GPM (37,8 L/min.) at 2615 Engine RPM
PRESSURE: (S/N 514441939-46822) 34 LOAD CHECK VALVE - SELECT VALVE
(S/N 514640148-41074) (HIGH FLOW) 54 FILTER - CASE DRAIN (ATTACHMENT)
CONTROL VALVE - UNLOADING 4712 PSI (32489 kPa) 35 SOLENOID ACTIVATED DIRECTIONAL
SPOOL (S/N 514446823 AND ABOVE) CONTROL VALVE - HIGH FLOW 55 RESTRICTION - SELECT VALVE
12 PILOTED ACTIVATED DIRECTIONAL 5000 PSI (34475 kPa) 36 SOLENOID ACTIVATED DIRECTIONAL 56 SCREEN
CONTROL VALVE - TILT CONTROL 27 CONTROL VALVE - DIVERTER
CHARGE PRESSURE SWITCH
13 PILOTED ACTIVATED DIRECTIONAL 37 RELIEF VALVE - MAIN (HIGH FLOW) 57 ACCUMULATOR - FOUND ONLY ON
CONTROL VALVE - LIFT CONTROL 28 RELIEF VALVE - CHARGE: 3000 PSI (20685 kPa) MACHINES WITH
120 degrees F. (53 degrees C.)Fluid
14 SOLENOID ACTIVATED DIRECTIONAL at 1775 Pump RPM 38 SOLENOID ACTIVATED DIRECTIONAL S/N 514444558 AND ABOVE
CONTROL VALVE - BICS CONTROL 390 - 430 PSI (2689 - 2965 kPa) CONTROL VALVE (TWO COIL) S/N 514640276 AND ABOVE
15 PULL BUTTON ACTIVATED 29 CHARGE PUMP: (S/N 514441939-46822) 39 PILOT TO OPEN CHECK VALVE

DIRECTIONAL CONTROL VALVE - LIFT (S/N 514640148-41074)
ARM BY- PASS 11.0 GPM (41,6 L/min.) at 2615 Engine RPM 40 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF
(S/N 514641075 AND ABOVE) NOTE: Unless otherwise specified
14.0 GPM (53,0 L/min.) at 2615 Engine RPM 41 CHECK VALVE - BICS CONTROL VALVE springs have NO significant
pressure value.
81 of 968
FEMALE
MALE
WITH HIGH FLOW OPTION SELECT VALVE C2 C1
863 (S/N 514441939 - 514449483) (RIGHT SIDE LIFT ARM
(S/N 514640148 - 514641170) QUICK COUPLERS)
40
MALE
MALE
FEMALE
FEMALE
V-0023
33
39 39
DRIVE MOTOR
(REAR QUICK COUPLERS)
55 55
31 32 * 44
38 34
FEMALE
PRESS PB
(FRONT AUXILIARY
36
LEFT SIDE LIFT ARM)
MALE
37 35
9
T
DRAIN
HYDRAULIC FILTER (MALE)
3 54
4 D
COOLER
45 8
28
26 26
7
6
57
A
CHARGE INLET OUTLET
52 C
29
43
11
26 27
26
BOB-TACH 24 24
CYLINDER 25
45 B
(OPTIONAL)
A B
HYDRAULIC
POWERED 56 AUXILIARY
BOB-TACH SPOOL
DR (OPTIONAL)
INLET
23
22 TILT CYLINDER
OUTLET BICS CONTROL VALVE
30 46 47
53 48
49
50 A B 12
51 TILT
CYLINDER
SPOOL
DRIVE MOTOR 21
18
9
20 LIFT CYLINDERS
P1 17
P2
5 13
A B
LIFT
CYLINDER
SPOOL
32
31
42
*
18 (If Equipped)
2 * 44 16 41 16 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0023 (11-5-02)
82 of 968
WITH HIGH FLOW AND TWO SPEED VALVE OPTION
863 (S/N 514441939 - 514449483)
(S/N 514640148 - 514641170)
V-0024legend
LEGEND
1 RESERVOIR: 19 RELIEF VALVE - MAIN: 31 DRIVE MOTOR SHUTTLE VALVE 50 RELIEF VALVE - 2000 PSI (13780 kPa)
Capacity . . . . . . . . . . 18.8 Qts. (17.8 L) 2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers 32 SHUTTLE RELIEF VALVE: 200 PSI (1378 kPa) 51 RELIEF VALVE - PORT:
2 FILTER - CASE DRAIN (90 Micron) 3500 PSI (24132 kPa)
20 RELIEF VALVE - PORT:
3500 PSI (24132 kPa) 33 REAR AUXILIARY BLEED SHUTTLE VALVE 52 SOLENOID ACTIVATED DIRECTIONAL
3 FILTER - HYDRAULIC (CANISTER)
CONTROL VALVE - BUCKET POSITION
4 SPRING LOADED FILTER BY-PASS 34 LOAD CHECK VALVE - SELECT VALVE VALVE (ON/OFF)
VALVE: 45-55 PSI (311-379 kPa) 22 RELIEF/ANTICAVITATION VALVE - (HIGH FLOW) 53 FIXED CAPACITY DISPLACEMENT
PORT (TILT BASE END) BIDIRECTIONAL HYDROSTATIC
5 PILOT ACTIVATED DIRECTIONAL 35 SOLENOID ACTIVATED DIRECTIONAL
3500 PSI (24132 kPa) MOTOR
CONTROL VALVE - HYDRAULIC CONTROL VALVE - HIGH FLOW
54 HYDRAULIC BRAKE - SPRING APPLIED -
POWERED BOB-TACH 23 ONE WAY RESTRICTOR VALVE
36 SOLENOID ACTIVATED DIRECTIONAL PRESSURE TO RELEASE
6 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE - DIVERTER
24 SOLENOID ACTIVATED DIRECTIONAL 55 PUSH BUTTON SOLENOID ACTIVATED
36-44 PSI (248-303 kPa)
CONTROL VALVE - AUXILIARY DIRECTIONAL CONTROL VALVE -
37 RELIEF VALVE - MAIN (HIGH FLOW) BRAKE
7 FLOW DIVIDER ADJUSTMENT VALVE 25 RELIEF VALVE - PORT: . . . . . (Optional) 3000 PSI (20685 kPa)
3500 PSI (24132 kPa) 56 SOLENOID ACTIVATED DIRECTIONAL
8 CHECK VALVE - BUCKET POSITION 38 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - MAKE-UP
VALVE 26 RELIEF/REPLENISHING VALVE - HIGH
CONTROL VALVE (TWO COIL) 57 SOLENOID ACTIVATED DIRECTIONAL
PRESSURE: 5000 PSI (34475 kPa)
9 FIXED CAPACITY DISPLACEMENT PILOT TO OPEN CHECK VALVE CONTROL VALVE - TWO SPEED
39
BIDIRECTIONAL HYDROSTATIC 27 CHARGE PRESSURE SWITCH
MOTOR 58 BRAKE DIAGNOSTIC PLUG
28 RELIEF VALVE - CHARGE: 40 SOLENOID ACTIVATED DIRECTIONAL
10 PILOTED ACTIVATED DIRECTIONAL 120 degrees F. (53 degrees C.)Fluid CONTROL VALVE - BLEED OFF 59 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL at 1775 Pump RPM
SPOOL 41 CHECK VALVE - BICS CONTROL VALVE CONTROL VALVE - TWO SPEED
390 - 430 PSI (2689 - 2965 kPa) DRIVE MOTOR
11 PILOTED ACTIVATED DIRECTIONAL 29 CHARGE PUMP 42 LIFT ARM BY-PASS RESTRICTOR
CONTROL VALVE - UNLOADING 60 HYDRAULIC HIGH FLOW PUMP
SPOOL 43 CHECK VALVE - AUXILIARY 10.0 GPM (37,8 L/min.) at 2615 Engine RPM
30 HYDRAULIC PUMP . . . . . . . . Gear Type
12 PILOTED ACTIVATED DIRECTIONAL (S/N 514441939-46822) 44 FILTER - CASE DRAIN (Attachment) 61 RESTRICTION - SELECT VALVE
CONTROL VALVE - TILT CONTROL (S/N 514640148-41074)
13 PILOTED ACTIVATED DIRECTIONAL 18.0 GPM (68,1 L/min.) at 2615 45 VARIABLE CAPACITY DISPLACEMENT 62 SCREEN
CONTROL VALVE - LIFT CONTROL Engine RPM BIDIRECTIONAL HYDROSTATIC PUMP
46 RESTRICTOR - 0.020 inch (0,5 mm) 63 ACCUMULATOR - FOUND ONLY ON
14 SOLENOID ACTIVATED DIRECTIONAL HIGH FLOW CAPACITY: (Includes )
60
CONTROL VALVE - BICS CONTROL MACHINES WITH
28.0 GPM (106,0 L/min.) at 2615 47 SOLENOID ACTIVATED DIRECTIONAL S/N 514444558 AND ABOVE
15 PULL BUTTON ACTIVATED Engine RPM
CONTROL VALVE (TWO COIL) S/N 514640276 AND ABOVE
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS (S/N 514446823 AND ABOVE) 48 RELIEF VALVE - 1200 PSI (8268 kPa)
16 FILTER - BICS CONTROL VALVE 49 RESTRICTOR - 0.090 inch (2,3 mm)
20.0 GPM (75,7 L/min.) at 2615
(SCREEN) NOTE: Unless otherwise specified
Engine RPM
17 BOOM DOWN RESTRICTOR springs have NO significant
pressure value.
60
HIGH FLOW CAPACITY: (Includes )
18 LIFT AND TILT LOAD CHECK VALVE
30.0 GPM (113,6 L/min.) at 2615
Engine RPM
83 of 968
863 (S/N 514449260 - 514449563)
(S/N 514541069 - 514541072)
V-0161legend
LEGEND
Capacity . . . . . . . 18.8 Qts. (17.8 L) DIRECTIONAL CONTROL VALVE - LIFT 14.0 GPM (53,0 L/min.) at 2450 Engine RPM
ARM BY-PASS
2 FILTER - CASE DRAIN (90 Micron) 30 HYDRAULIC PUMP . . . . . . . Gear Type 42 LIFT ARM BY-PASS RESTRICTOR
16 FILTER - BICS CONTROL VALVE 20.7 GPM (78,4 L/min.) at 2450 Engine RPM
3 FILTER - HYDRAULIC (CANISTER) (SCREEN) 31 DRIVE MOTOR SHUTTLE VALVE 43 CHECK VALVE - AUXILIARY
17 BOOM DOWN RESTRICTOR 32 SHUTTLE RELIEF VALVE:
*
4 SPRING LOADED FILTER BY-PASS 44 MUFFLER (If Equipped)
200 PSI (1378 kPa)
VALVE: 45-55 PSI (311-379 kPa)
18 LIFT AND TILT LOAD CHECK VALVE 33 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR 45 VARIABLE CAPACITY DISPLACEMENT
AUXILIARY ("SV2") BIDIRECTIONAL HYDROSTATIC PUMP
19 RELIEF VALVE - MAIN:
POWERED BOB-TACH 34 LOAD SHUTTLE VALVE - BLEED OFF 46
2950-3050 PSI (20340-21030 kPa) TWO STAGE RELIEF VALVE 1000 PSI/
6 at Front Quick Couplers 2000 PSI (6894 kPA/ 13788 kPA)
DIFFERENTIAL PRESSURE SWITCH: 35 PILOT ACTIVATED DIRECTIONAL
36-44 PSI (248-303 kPa) CONTROL VALVE - FOR REAR 47 SOLENOID ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: CONTROL VALVE (TWO COIL)
FLOW DIVIDER ADJUSTMENT VALVE 3500 PSI (24132 kPa)
7 ("P2" and "F2")
21 ANTICAVITATION VALVE 36 PILOT ACTIVATED DIRECTIONAL
8 CHECK VALVE - BUCKET POSITION CONTROL VALVE - FOR REAR 49 PRESSURE COMPENSATED FLOW
VALVE 22 RELIEF/ANTICAVITATION VALVE - AUXILIARY - NORMALLY OPEN
CONTROL
("D1" and "P1")
9 FIXED CAPACITY DISPLACEMENT 3500 PSI (24132 kPa) 37 PILOT ACTIVATED DIRECTIONAL 50 CHECK VALVE WITH .015 (0,38mm)
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - FOR REAR ORIFICE
MOTOR 23 ONE WAY RESTRICTOR VALVE AUXILIARY - NORMALLY OPEN
("D2" and "P2") 51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
10 PILOTED ACTIVATED DIRECTIONAL 38 FILTER - DIVERTER VALVE (SCREEN)
CONTROL VALVE - FLOW CONTROL INTEGRATED IN SOLENOID 52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY CONTROL VALVE - BUCKET POSITION
SPOOL 39 SOLENOID ACTIVATED DIRECTIONAL
VALVE (ON/OFF)
25 RELIEF VALVE - PORT: . . . . . . . . (Optional) CONTROL VALVE - TO ACTIVATE
11 PILOTED ACTIVATED DIRECTIONAL REAR AUXILIARY ("SV1") 53 ACCUMULATOR
3500 PSI (24132 kPa)
CONTROL VALVE - UNLOADING
SPOOL 40 PILOT ACTIVATED DIRECTIONAL
26 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - FOR REAR
PRESSURE: 5000 PSI (34475 kPa) AUXILIARY - NORMALLY CLOSED
CONTROL VALVE - TILT CONTROL ("P1" and "F1")
27 CHARGE PRESSURE SWITCH
CONTROL VALVE - LIFT CONTROL
120 degrees F. (53 degrees C.) Fluid
at 1775 Pump RPM NOTE: Unless otherwise specified
14 SOLENOID ACTIVATED DIRECTIONAL springs have NO significant
390 - 430 PSI (2689 - 2965 kPa)
85 of 968
863 (S/N 514449260 - 514449563) 38
(S/N 514541069 - 514541072) 39
V-0161
DRIVE MOTOR
40 36
31 32
34 (FRONT AUXILIARY
(REAR QUICK
COUPLERS) LEFT SIDE LIFT ARM)
33 35 37
F2 D2
FEMALE
FEMALE FEMALE
9
DRAIN P1 P2
HYDRAULIC FILTER
3
4 D
COOLER
45 8
28
26
26 7
6
53
A
CHARGE INLET OUTLET
52 C
29
43
11
27
26
26
45
Dealer Copy -- Not
24 for Resale 24
BOB-TACH 25 B
CYLINDER A B
HYDRAULIC (OPTIONAL)
POWERED
BOB-TACH
(OPTIONAL) AUXILIARY
DR SPOOL
INLET OUTLET
23
22 TILT CYLINDER
BICS CONTROL VALVE
30
A B 12
46 47 TILT
48 51
49 CYLINDER
SPOOL
DRIVE MOTOR
50 21
9 18
20 LIFT CYLINDERS
17
13
P1 P2
5
A B
PP LIFT
CYLINDER
SPOOL
31 32
18 42
19 14
* (If Equipped)
WORKING CIRCUITS
*
44 16 41 16 PILOT CIRCUITS
2 DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0161 (11-5-02)
86 of 968
863 (S/N 514449260 - 514449563)
(S/N 514541069 - 514541072)
V-0162legend
LEGEND
1 RESERVOIR: 19 RELIEF VALVE - MAIN: 34 LOAD SHUTTLE VALVE - BLEED OFF 47 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . . . 18.8 Qts. (17.8 L) 2950-3050 PSI (20340-21030 kPa) CONTROL VALVE (TWO COIL)
at Front Quick Couplers 35 PILOT ACTIVATED DIRECTIONAL
2 FILTER - CASE DRAIN (90 Micron) 48 RELIEF VALVE - 1200 PSI (8268 kPa)
AUXILIARY - NORMALLY CLOSED 49 PRESSURE COMPENSATED FLOW
("P2" and "F2") CONTROL
4 SPRING LOADED FILTER BY-PASS 36 PILOT ACTIVATED DIRECTIONAL 50 CHECK VALVE WITH .015 (0,38mm)
VALVE: 45-55 PSI (311-379 kPa) 22 RELIEF/ANTICAVITATION VALVE - CONTROL VALVE - FOR REAR ORIFICE
5 PILOT ACTIVATED DIRECTIONAL PORT (TILT BASE END) AUXILIARY - NORMALLY OPEN
3500 PSI (24132 kPa)
POWERED BOB-TACH 23 ONE WAY RESTRICTOR VALVE 37 PILOT ACTIVATED DIRECTIONAL 52 SOLENOID ACTIVATED DIRECTIONAL
6 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE - FOR REAR CONTROL VALVE - BUCKET POSITION
36-44 PSI (248-303 kPa) 24 SOLENOID ACTIVATED DIRECTIONAL AUXILIARY - NORMALLY OPEN VALVE (ON/OFF)
CONTROL VALVE - AUXILIARY ("D2" and "P2")
7 FLOW DIVIDER ADJUSTMENT VALVE 53 FIXED CAPACITY DISPLACEMENT
25 RELIEF VALVE - PORT: . . . . . . . (Optional) BIDIRECTIONAL HYDROSTATIC
8 CHECK VALVE - BUCKET POSITION 3500 PSI (24132 kPa) MOTOR
VALVE 26 RELIEF/REPLENISHING VALVE - HIGH 54 HYDRAULIC BRAKE - SPRING APPLIED -
CONTROL VALVE - TO ACTIVATE
BIDIRECTIONAL HYDROSTATIC REAR AUXILIARY ("SV1") 55 PULL BUTTON ACTIVATED
MOTOR 27 CHARGE PRESSURE SWITCH DIRECTIONAL CONTROL VALVE -
40 PILOT ACTIVATED DIRECTIONAL BRAKE
CONTROL VALVE - FOR REAR
CONTROL VALVE - FLOW CONTROL 120 degrees F. (53 degrees C.)Fluid 56 SOLENOID ACTIVATED DIRECTIONAL
SPOOL at 1775 Pump RPM CONTROL VALVE - MAKE-UP
("P1" and "F1")
390 - 430 PSI (2689 - 2965 kPa)
11 PILOTED ACTIVATED DIRECTIONAL 41 57 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING CHARGE PUMP CONTROL VALVE - TWO SPEED
SPOOL 14.0 GPM (53,0 L/min.) at 2450 Engine RPM 42 LIFT ARM BY-PASS RESTRICTOR 58 BRAKE DIAGNOSTIC PLUG
12 PILOTED ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . Gear Type
CONTROL VALVE - TILT CONTROL 20.7 GPM (78,4 L/min.) at 2450 43 CHECK VALVE - AUXILIARY
59 ACCUMULATOR
13 PILOTED ACTIVATED DIRECTIONAL Engine RPM
31 DRIVE MOTOR SHUTTLE VALVE
14 SOLENOID ACTIVATED DIRECTIONAL DRIVE MOTOR
CONTROL VALVE - BICS CONTROL 32 SHUTTLE RELIEF VALVE:
15 PULL BUTTON ACTIVATED 200 PSI (1378 kPa) 45 VARIABLE CAPACITY DISPLACEMENT
DIRECTIONAL CONTROL VALVE - LIFT BIDIRECTIONAL HYDROSTATIC PUMP
ARM BY-PASS CONTROL VALVE - BLEED OFF REAR 46 TWO STAGE RELIEF VALVE 1000 PSI/
16 FILTER - BICS CONTROL VALVE AUXILIARY ("SV2") 2000 PSI (6894 kPa/ 13788 kPa)
(SCREEN)
NOTE: Unless otherwise specified
87 of 968
863 (S/N 514449260 - 514449563) 38
(S/N 514541069 - 514541072) 39
PILOT
V-0162
TWO SPEED DRIVE MOTOR
40 36
31 32 MALE MALE F1 D1 MALE
34 (FRONT AUXILIARY
(REAR QUICK
LEFT SIDE LIFT ARM)
COUPLERS)
33 35 37
F2 D2
54 44 FEMALE
FEMALE FEMALE
53
DRAIN P1 P2
9 HYDRAULIC FILTER
3
4 D
COOLER
45 8
26 26
28
7
6
60
A
52 C
CHARGE OUTLET HYDRAULIC CONTROL VAVLE 10
INLET 29
43
11
27
BOB-TACH Dealer Copy -- Not

24 for Resale 24
45 CYLINDER 25 B
HYDRAULIC (OPTIONAL) A B
POWERED
BOB-TACH
26 30 26 (OPTIONAL)
INLET OUTLET DR AUXILIARY
SPOOL
58
23
TWO SPEED VALVE B1 22 TILT CYLINDER
BICS CONTROL VALVE
55
46 47
54 48 A B 12
49 51 TILT
56 9
CYLINDER
50 SPOOL
53 21
C
18
P D 44 20 LIFT CYLINDERS
17
P1 P2
5 13
PP
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
16 41 16 PILOT CIRCUITS
T DRAIN CIRCUITS
COMPONENTS
2 LIFT ARM BY- PASS VALVE
15
Printed in U.S.A. V-0162 (11-5-02)
88 of 968
863 (S/N 514449484 - 514449563)
(S/N 514641171 - 514641175)
V-0159legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 30 HYDRAULIC PUMP . . . . . . . Gear Type 45 VARIABLE CAPACITY DISPLACEMENT
Capacity . . . . . . . . . 18.8 Qts. (17.8 L) (SCREEN) 20.7 GPM (78,4 L/min.) at 2450 BIDIRECTIONAL HYDROSTATIC PUMP
*
2 FILTER - CASE DRAIN (90 Micron) 17 BOOM DOWN RESTRICTOR Engine RPM 46 TWO STAGE RELIEF VALVE 1000 PSI/
53
HIGH FLOW CAPACITY: (Includes ) 2000 PSI (6894 kPa/ 13788 kPa)
3 FILTER - HYDRAULIC (CANISTER) 18 LIFT AND TILT LOAD CHECK VALVE 30.7 GPM (116,2 L/min.) at 2450
Engine RPM 47 SOLENOID ACTIVATED DIRECTIONAL
4 SPRING LOADED FILTER BY- PASS 19 RELIEF VALVE - MAIN: CONTROL VALVE (TWO COIL)
VALVE: . . . 45-55 PSI (311-379 kPa) 2950-3050 PSI (20340-21030 kPa) 31 DRIVE MOTOR SHUTTLE VALVE 48 RELIEF VALVE - 1200 PSI (8268 kPa)
at Front Quick Couplers
20 RELIEF VALVE - PORT: 32 SHUTTLE RELIEF VALVE: 49 PRESSURE COMPENSATED FLOW
POWERED BOB-TACH 3500 PSI (24132 kPa) 200 PSI (1378 kPa) CONTROL
21 ANTICAVITATION VALVE 33 REAR AUXILIARY BLEED SHUTTLE VALVE
6 DIFFERENTIAL PRESSURE SWITCH: 50 CHECK VALVE WITH .015 (0,38mm)
36-44 PSI (248-303 kPa) 34 ORIFICE)
22 RELIEF/ANTICAVITATION VALVE - LOAD CHECK VALVE - SELECT VALVE
PORT (TILT BASE END) (HIGH FLOW) 51 RELIEF VALVE - PORT:
7 FLOW DIVIDER ADJUSTMENT VALVE
3500 PSI (24132 kPa) 35 SOLENOID ACTIVATED DIRECTIONAL 3500 PSI (24132 kPa)
8 CHECK VALVE - BUCKET POSITION CONTROL VALVE - HIGH FLOW 52 SOLENOID ACTIVATED DIRECTIONAL
23 ONE WAY RESTRICTOR VALVE
VALVE 36 CONTROL VALVE - BUCKET POSITION
24 SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF)
9 FIXED CAPACITY DISPLACEMENT CONTROL VALVE - DIVERTER
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - AUXILIARY
37 RELIEF VALVE - MAIN (HIGH FLOW) 53 HYDRAULIC HIGH FLOW PUMP:
MOTOR 25 RELIEF VALVE - PORT: . . . . . . (Optional) 10.0 GPM (37,8 L/min.) at 2450 Engine RPM
3000 PSI (20685 kPa)
3500 PSI (24132 kPa)
10 PILOTED ACTIVATED DIRECTIONAL 38 SOLENOID ACTIVATED DIRECTIONAL 54 FILTER - CASE DRAIN (ATTACHMENT)
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE (TWO COIL)
SPOOL PRESSURE: 5000 PSI (34475 kPa)
39 PILOT TO OPEN CHECK VALVE 55 RESTRICTION - SELECT VALVE
27 CHARGE PRESSURE SWITCH
CONTROL VALVE - UNLOADING 56 ACCUMULATOR
SPOOL 28 RELIEF VALVE - CHARGE:
CONTROL VALVE - BLEED OFF
12 PILOTED ACTIVATED DIRECTIONAL 120 degrees F. (53 degrees C.)Fluid
CONTROL VALVE - TILT CONTROL at 1775 Pump RPM 41 CHECK VALVE - BICS CONTROL VALVE
390 - 430 PSI (2689 - 2965 kPa)
13 PILOTED ACTIVATED DIRECTIONAL 42 LIFT ARM BY-PASS RESTRICTOR
29 CHARGE PUMP:
43 CHECK VALVE - AUXILIARY
CONTROL VALVE - BICS CONTROL 44 MUFFLER (If Equipped)
15 PULL BUTTON ACTIVATED
ARM BY- PASS
pressure value.
89 of 968
FEMALE
MALE
863 (S/N 514449484 - 514449563) (RIGHT SIDE LIFT ARM
(S/N 514641171 - 514641175) QUICK COUPLERS)
40
MALE
MALE
FEMALE
FEMALE
V-0159
33
39 39
DRIVE MOTOR
55 55
31 32 * 44
38 34
FEMALE
PRESS PB
(FRONT AUXILIARY
36 LEFT SIDE LIFT ARM)
MALE
37 35
9
T
DRAIN
HYDRAULIC FILTER (MALE)
3 54
4 D
COOLER
45 8
28
26 26
7
6
56
A
CHARGE INLET OUTLET
52 C
29
43
11
26 27
26
BOB-TACH 24 24
45 CYLINDER 25 B
POWERED
BOB-TACH
(OPTIONAL)
DR AUXILIARY
SPOOL
INLET
23
22 TILT CYLINDER
30
53
46 47
48 A B 12
49 51 TILT
CYLINDER
SPOOL
50
DRIVE MOTOR 21
18
9
20 LIFT CYLINDERS
17
P1 P2
5 13
A B
LIFT
CYLINDER
SPOOL
32
31
42
*
18 (If Equipped)
2 * 44 16 41 16 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0159 (11-5-02)
90 of 968
863 (S/N 514449484 - 514449563)
(S/N 514641171 - 514641175)
V-0160legend
LEGEND
1 RESERVOIR: 19 RELIEF VALVE - MAIN: 34 LOAD CHECK VALVE - SELECT VALVE 50 CHECK VALVE WITH .015 (0,38mm)
Capacity . . . . . . . . . . 18.8 Qts. (17.8 L) 2950-3050 PSI (20340-21030 kPa) (HIGH FLOW) ORIFICE
2 FILTER - CASE DRAIN (90 Micron) 35 SOLENOID ACTIVATED DIRECTIONAL 51 RELIEF VALVE - PORT:
20 RELIEF VALVE - PORT: CONTROL VALVE - HIGH FLOW 3500 PSI (24132 kPa)
3 FILTER - HYDRAULIC (CANISTER) 3500 PSI (24132 kPa) 52 SOLENOID ACTIVATED DIRECTIONAL
21 ANTICAVITATION VALVE 36 SOLENOID ACTIVATED DIRECTIONAL
4 SPRING LOADED FILTER BY-PASS CONTROL VALVE - DIVERTER VALVE (ON/OFF)
VALVE: 45-55 PSI (311-379 kPa) 22 RELIEF/ANTICAVITATION VALVE -
PORT (TILT BASE END) 37 RELIEF VALVE - MAIN (HIGH FLOW)
5 PILOT ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC
3500 PSI (24132 kPa) 3000 PSI (20685 kPa)
CONTROL VALVE - HYDRAULIC MOTOR
POWERED BOB-TACH 23 ONE WAY RESTRICTOR VALVE 38 SOLENOID ACTIVATED DIRECTIONAL 54 HYDRAULIC BRAKE - SPRING APPLIED -
6 CONTROL VALVE (TWO COIL) PRESSURE TO RELEASE
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa) 39 PILOT TO OPEN CHECK VALVE 55 PUSH BUTTON SOLENOID ACTIVATED
DIRECTIONAL CONTROL VALVE -
7 FLOW DIVIDER ADJUSTMENT VALVE 25 RELIEF VALVE - PORT: . . . . . (Optional) BRAKE
8 CHECK VALVE - BUCKET POSITION CONTROL VALVE - BLEED OFF 56 SOLENOID ACTIVATED DIRECTIONAL
VALVE 26 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - MAKE-UP
PRESSURE: 5000 PSI (34475 kPa) 41 CHECK VALVE - BICS CONTROL VALVE
9 FIXED CAPACITY DISPLACEMENT 57 SOLENOID ACTIVATED DIRECTIONAL
BIDIRECTIONAL HYDROSTATIC 27 42 LIFT ARM BY-PASS RESTRICTOR CONTROL VALVE - TWO SPEED
28 RELIEF VALVE - CHARGE: 43 CHECK VALVE - AUXILIARY
CONTROL VALVE - FLOW CONTROL at 1775 Pump RPM 44 FILTER - CASE DRAIN (Attachment) 59 PILOT ACTIVATED DIRECTIONAL
SPOOL 390 - 430 PSI (2689 - 2965 kPa) CONTROL VALVE - TWO SPEED
45 VARIABLE CAPACITY DISPLACEMENT DRIVE MOTOR
11 PILOTED ACTIVATED DIRECTIONAL 29 CHARGE PUMP BIDIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - UNLOADING 14.0 GPM (53,0 L/min.) at 2450 Engine RPM 60 HYDRAULIC HIGH FLOW PUMP
SPOOL 46 TWO STAGE RELIEF VALVE 1000 PSI/
30 HYDRAULIC PUMP . . . . . . . Gear Type 10 GPM (37.85 L/min.) at 2450 RPM
2000 PSI (6894 kPa/13788 kPa)
12 PILOTED ACTIVATED DIRECTIONAL 20.7 GPM (78,4 L/min.) at 2450
CONTROL VALVE - TILT CONTROL Engine RPM 47 SOLENOID ACTIVATED DIRECTIONAL
61 RESTRICTION - SELECT VALVE
60
HIGH FLOW CAPACITY: (Includes ) CONTROL VALVE (TWO COIL)
CONTROL VALVE - LIFT CONTROL 30.7 GPM (116,2 L/min.) at 2450 48 RELIEF VALVE - 1200 PSI (8268 kPa) 62 ACCUMULATOR
Engine RPM
14 SOLENOID ACTIVATED DIRECTIONAL 49 PRESSURE COMPENSATED FLOW
CONTROL VALVE - BICS CONTROL 31 DRIVE MOTOR SHUTTLE VALVE
CONTROL
32 SHUTTLE RELIEF VALVE: 200 PSI (1378 kPa)
ARM BY-PASS
33 REAR AUXILIARY BLEED SHUTTLE VALVE
pressure value.
91 of 968
863 (S/N 514449484 - 514449563) SELECT VALVE C2 C1
(S/N 514641171 - 514641175) (RIGHT SIDE LIFT ARM
QUICK COUPLERS)
(PRINTED NOVEMBER 2002) 40
V-0160
MALE
MALE
FEMALE
FEMALE
TWO SPEED DRIVE MOTOR 33
39 39
31 32
61 61
38 34
FEMALE
PRESS PB
(FRONT AUXILIARY
36
LEFT SIDE LIFT ARM)
MALE
59
54 37 35
53
T
DRAIN
9 HYDRAULIC FILTER (MALE)
3 44
4 D
COOLER
45 8
26 26
28
7
6
62
A
52 C
INLET 29
43
11
27
Dealer Copy -- Not
24 for Resale 24
45 25 B
A B
BOB-TACH
CYLINDER
26 30 26 HYDRAULIC (OPTIONAL)
POWERED AUXILIARY
INLET OUTLET BOB-TACH SPOOL
58 (OPTIONAL)
DR
23
TWO SPEED VALVE 22 TILT CYLINDER
B1 BICS CONTROL VALVE
60
55
54 A B 12
51 TILT
56 9
46 CYLINDER
48 47 SPOOL
49
53 21
C
50 18
17
13
57 P1 A B
P2
5 LIFT
CYLINDER
SPOOL
A
18 42
31 32
T DRAIN CIRCUITS
COMPONENTS
2 LIFT ARM BY- PASS VALVE
15
Printed in U.S.A.
V-0160 (11-5-02)
92 of 968
863 (S/N 514449564 - 514451083)
(S/N 514541073 - 514541113)
V-0165legend
LEGEND
ARM BY-PASS 30
2 FILTER - CASE DRAIN (90 Micron) HYDRAULIC PUMP . . . . . . . Gear Type 42 LIFT ARM BY-PASS RESTRICTOR
17 BOOM DOWN RESTRICTOR 44 FRONT AUXILIARY MANUAL
4 SPRING LOADED FILTER BY-PASS 200 PSI (1378 kPa)
VALVE: 45-55 PSI (311-379 kPa) PRESSURE BLEED-OFF VALVE
18 LIFT AND TILT LOAD CHECK VALVE 45
CONTROL VALVE - BLEED OFF REAR VARIABLE CAPACITY DISPLACEMENT
5 PILOT ACTIVATED DIRECTIONAL AUXILIARY ("SV2") BIDIRECTIONAL HYDROSTATIC PUMP
6 at Front Quick Couplers 35 PILOT ACTIVATED DIRECTIONAL 2000 PSI (6894 kPA/ 13788 kPA)
20 RELIEF VALVE - PORT: AUXILIARY - NORMALLY CLOSED CONTROL VALVE (TWO COIL)
FLOW DIVIDER ADJUSTMENT VALVE 3500 PSI (24132 kPa) ("P2" and "F2")
7
8 CONTROL VALVE - FOR REAR
CHECK VALVE - BUCKET POSITION 49 PRESSURE COMPENSATED FLOW
AUXILIARY - NORMALLY OPEN
VALVE 22 RELIEF/ANTICAVITATION VALVE - CONTROL
("D1" and "P1")
37 PILOT ACTIVATED DIRECTIONAL 50 CHECK VALVE WITH .015 (0,38mm)
MOTOR AUXILIARY - NORMALLY OPEN
23 ONE WAY RESTRICTOR VALVE ("D2" and "P2") 51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
10 PILOTED ACTIVATED DIRECTIONAL 24 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TO ACTIVATE VALVE (ON/OFF)
25 RELIEF VALVE - PORT: . . . . . . . . (Optional)
11 PILOTED ACTIVATED DIRECTIONAL REAR AUXILIARY ("SV1")
3500 PSI (24132 kPa)
CONTROL VALVE - UNLOADING 40 PILOT ACTIVATED DIRECTIONAL
SPOOL
12 PILOTED ACTIVATED DIRECTIONAL ("P1" and "F1")
CONTROL VALVE - TILT CONTROL 27 CHARGE PRESSURE SWITCH
390 - 430 PSI (2689 - 2965 kPa)
93 of 968
863 (S/N 514449564 - 514451083)
(S/N 514541073 - 514541113)
V-0166legend
LEGEND
3500 PSI (24132 kPa)
("P1" and "F1")
390 - 430 PSI (2689 - 2965 kPa)
59 FRONT AUXILIARY MANUAL PRESSURE
13 PILOTED ACTIVATED DIRECTIONAL 31 DRIVE MOTOR SHUTTLE VALVE 44 PILOT ACTIVATED DIRECTIONAL BLEED-OFF VALVE
ARM BY-PASS AUXILIARY ("SV2") 46 TWO STAGE RELIEF VALVE 1000 PSI/
16 FILTER - BICS CONTROL VALVE 2000 PSI (6894 kPa/ 13788 kPa)
(SCREEN)
95 of 968
863 (S/N 514449564 - 514450945)
(S/N 514641176 - 514641254)
V-0163legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 30 HYDRAULIC PUMP . . . . . . . Gear Type 47 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . . . . 18.8 Qts. (17.8 L) (SCREEN) 20.7 GPM (78,4 L/min.) at 2450 CONTROL VALVE (TWO COIL)
2 FILTER - CASE DRAIN (90 Micron) 17 BOOM DOWN RESTRICTOR Engine RPM
53
HIGH FLOW CAPACITY: (Includes ) 48 RELIEF VALVE - 1200 PSI (8268 kPa)
3 FILTER - HYDRAULIC (CANISTER) 18 LIFT AND TILT LOAD CHECK VALVE 30.7 GPM (116,2 L/min.) at 2450
49 PRESSURE COMPENSATED FLOW
Engine RPM
SPRING LOADED FILTER BY- PASS 19 RELIEF VALVE - MAIN: CONTROL
4 31 DRIVE MOTOR SHUTTLE VALVE
VALVE: . . . 45-55 PSI (311-379 kPa) 2950-3050 PSI (20340-21030 kPa) 50 CHECK VALVE WITH .015 (0,38mm)
at Front Quick Couplers 32 SHUTTLE RELIEF VALVE: ORIFICE)
CONTROL VALVE - HYDRAULIC 20 RELIEF VALVE - PORT: 200 PSI (1378 kPa)
51 RELIEF VALVE - PORT:
POWERED BOB-TACH 3500 PSI (24132 kPa) 33 REAR AUXILIARY BLEED SHUTTLE VALVE 3500 PSI (24132 kPa)
6 DIFFERENTIAL PRESSURE SWITCH: 21 ANTICAVITATION VALVE
34 LOAD CHECK VALVE - SELECT VALVE 52 SOLENOID ACTIVATED DIRECTIONAL
36-44 PSI (248-303 kPa) CONTROL VALVE - BUCKET POSITION
22 RELIEF/ANTICAVITATION VALVE - (HIGH FLOW)
VALVE (ON/OFF)
7 FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END) 35 SOLENOID ACTIVATED DIRECTIONAL
3500 PSI (24132 kPa) 53 HYDRAULIC HIGH FLOW PUMP:
CONTROL VALVE - HIGH FLOW
8 CHECK VALVE - BUCKET POSITION 10.0 GPM (37,8 L/min.) at 2450 Engine RPM
23 ONE WAY RESTRICTOR VALVE 36 SOLENOID ACTIVATED DIRECTIONAL
VALVE
CONTROL VALVE - DIVERTER 54 FILTER - CASE DRAIN (ATTACHMENT)
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - AUXILIARY 37 RELIEF VALVE - MAIN (HIGH FLOW)
3000 PSI (20685 kPa) 55 RESTRICTION - SELECT VALVE
MOTOR 25 RELIEF VALVE - PORT: . . . . . . (Optional)
CONTROL VALVE - FLOW CONTROL CONTROL VALVE (TWO COIL)
SPOOL PRESSURE: 5000 PSI (34475 kPa) 39 PILOT TO OPEN CHECK VALVE
CONTROL VALVE - UNLOADING 27 CHARGE PRESSURE SWITCH 40 SOLENOID ACTIVATED DIRECTIONAL
SPOOL CONTROL VALVE - BLEED OFF
28 RELIEF VALVE - CHARGE:
12 PILOTED ACTIVATED DIRECTIONAL 120 degrees F. (53 degrees C.)Fluid 41 CHECK VALVE - BICS CONTROL VALVE
CONTROL VALVE - TILT CONTROL at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa) 42 LIFT ARM BY-PASS RESTRICTOR
CONTROL VALVE - LIFT CONTROL 29 CHARGE PUMP: 43 CHECK VALVE - AUXILIARY
CONTROL VALVE - BICS CONTROL
BLEED-OFF VALVE
15 PULL BUTTON ACTIVATED 45 VARIABLE CAPACITY DISPLACEMENT
ARM BY- PASS
46
*
TWO STAGE RELIEF VALVE 1000 PSI/
2000 PSI (6894 kPa/ 13788 kPa) NOTE: Unless otherwise specified
pressure value.
97 of 968
FEMALE
MALE
863 (S/N 514449564 - 514450945)
RIGHT SIDE LIFT ARM
(S/N 514641176 - 514641254) QUICK COUPLERS
40
(PRINTED NOVEMBER 2002) (OPTIONAL)
MALE
MALE
FEMALE
FEMALE
V-0163
33
39 39
DRIVE MOTOR
REAR QUICK COUPLERS
(OPTIONAL)
FRONT AUXILIARY
55 55 (LEFT SIDE LIFT ARM)
44
31 38 34
32 FEMALE
PRESS PB
36 DRAIN
(MALE)
37 35
MALE
9
T 44
HYDRAULIC FILTER
3 54
4 D
COOLER
45 8
28
26 26
7
6
A
CHARGE INLET OUTLET
52 C
29
43
11
26 27
26
BOB-TACH 24 24
45 CYLINDER 25 B
POWERED
BOB-TACH
(OPTIONAL)
DR AUXILIARY
SPOOL
INLET
23
22 TILT CYLINDER
30
53
46 47
48 A B 12
49 51 TILT
CYLINDER
SPOOL
50
DRIVE MOTOR 21
18
9
20 LIFT CYLINDERS
17
P1 P2
5 13
A B
LIFT
CYLINDER
SPOOL
32
31
42
*
18 (If Equipped)
2 DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0163 (11-4-02)
98 of 968
863 (S/N 514449564 - 514450945)
(S/N 514641176 - 514641254)
V-0164legend
LEGEND
1 RESERVOIR: 19 RELIEF VALVE - MAIN: 34 LOAD CHECK VALVE - SELECT VALVE 50 CHECK VALVE WITH .015 (0,38mm)
Capacity . . . . . . . . . . 18.8 Qts. (17.8 L) 2950-3050 PSI (20340-21030 kPa) (HIGH FLOW) ORIFICE
2 FILTER - CASE DRAIN (90 Micron) 35 SOLENOID ACTIVATED DIRECTIONAL 51 RELIEF VALVE - PORT:
20 RELIEF VALVE - PORT: CONTROL VALVE - HIGH FLOW 3500 PSI (24132 kPa)
3 FILTER - HYDRAULIC (CANISTER) 3500 PSI (24132 kPa) 52 SOLENOID ACTIVATED DIRECTIONAL
21 ANTICAVITATION VALVE 36 SOLENOID ACTIVATED DIRECTIONAL
4 SPRING LOADED FILTER BY-PASS CONTROL VALVE - DIVERTER VALVE (ON/OFF)
VALVE: 45-55 PSI (311-379 kPa) 22 RELIEF/ANTICAVITATION VALVE -
PORT (TILT BASE END) 37 RELIEF VALVE - MAIN (HIGH FLOW)
5 PILOT ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC
3500 PSI (24132 kPa) 3000 PSI (20685 kPa)
CONTROL VALVE - HYDRAULIC MOTOR
POWERED BOB-TACH 23 ONE WAY RESTRICTOR VALVE 38 SOLENOID ACTIVATED DIRECTIONAL 54 HYDRAULIC BRAKE - SPRING APPLIED -
6 CONTROL VALVE (TWO COIL) PRESSURE TO RELEASE
36-44 PSI (248-303 kPa) 39 PILOT TO OPEN CHECK VALVE 55 PUSH BUTTON SOLENOID ACTIVATED
DIRECTIONAL CONTROL VALVE -
7 FLOW DIVIDER ADJUSTMENT VALVE 25 RELIEF VALVE - PORT: . . . . . (Optional) BRAKE
8 CHECK VALVE - BUCKET POSITION CONTROL VALVE - BLEED OFF 56 SOLENOID ACTIVATED DIRECTIONAL
VALVE 26 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - MAKE-UP
PRESSURE: 5000 PSI (34475 kPa) 41 CHECK VALVE - BICS CONTROL VALVE
BIDIRECTIONAL HYDROSTATIC 27 42 LIFT ARM BY-PASS RESTRICTOR CONTROL VALVE - TWO SPEED
28 RELIEF VALVE - CHARGE: 43 CHECK VALVE - AUXILIARY
CONTROL VALVE - FLOW CONTROL at 1775 Pump RPM 44 FILTER - CASE DRAIN (Attachment) 59 PILOT ACTIVATED DIRECTIONAL
SPOOL 390 - 430 PSI (2689 - 2965 kPa) CONTROL VALVE - TWO SPEED
45 VARIABLE CAPACITY DISPLACEMENT DRIVE MOTOR
11 PILOTED ACTIVATED DIRECTIONAL 29 CHARGE PUMP BIDIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - UNLOADING 14.0 GPM (53,0 L/min.) at 2450 Engine RPM 60 HYDRAULIC HIGH FLOW PUMP:
SPOOL 46 TWO STAGE RELIEF VALVE 1000 PSI/
30 HYDRAULIC PUMP . . . . . . . Gear Type 10.0 GPM (38,7 L/min.) at 2450 Engine RPM
2000 PSI (6894 kPa/13788 kPa)
12 PILOTED ACTIVATED DIRECTIONAL 20.7 GPM (78,4 L/min.) at 2450
CONTROL VALVE - TILT CONTROL 47 SOLENOID ACTIVATED DIRECTIONAL 61 RESTRICTION - SELECT VALVE
Engine RPM
60
HIGH FLOW CAPACITY: (Includes ) CONTROL VALVE (TWO COIL)
CONTROL VALVE - LIFT CONTROL 30.7 GPM (116,2 L/min.) at 2450 48 RELIEF VALVE - 1200 PSI (8268 kPa) 62 FRONT AUXILIARY MANUAL
Engine RPM PRESSURE BLEED-OFF VALVE
14 SOLENOID ACTIVATED DIRECTIONAL 49 PRESSURE COMPENSATED FLOW
CONTROL VALVE - BICS CONTROL 31 DRIVE MOTOR SHUTTLE VALVE
CONTROL
32 SHUTTLE RELIEF VALVE: 200 PSI (1378 kPa)
ARM BY-PASS
33 REAR AUXILIARY BLEED SHUTTLE VALVE
pressure value.
99 of 968
863 (S/N 514450946 - 514451083)
(S/N 514641255 - 514641266)
(PRINTED DECEMBER 2003)
V-0236legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 31 DRIVE MOTOR SHUTTLE VALVE 44 FRONT AUXILIARY MANUAL
Capacity . . . . . . . . . 18.8 Qts. (17.8 (SCREEN) PRESSURE BLEED-OFF VALVE
L) 32 SHUTTLE RELIEF VALVE:
2 FILTER - CASE DRAIN (90 Micron) 17 ONE WAY RESTRICTOR 200 PSI (1378 kPa) 45 VARIABLE CAPACITY DISPLACEMENT
3 FILTER - HYDRAULIC (CANISTER) 18 LOAD CHECK VALVE 33 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR 46 TWO STAGE RELIEF 1000 PSI/2000 PSI
4 SPRING LOADED FILTER BYPASS 19 RELIEF VALVE - MAIN: AUXILIARY ("SV2") (6894kPa/13788 kPa)
at Front Quick Couplers 34 LOAD SHUTTLE VALVE - BLEED OFF 47 SOLENOID ACTIVATED DIRECTIONAL
5 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)
CONTROL VALVE - HYDRAULIC 20 RELIEF VALVE - PORT: 35 PILOT ACTIVATED DIRECTIONAL
POWERED BOB-TACH 48 RELIEF VALVE - 1200 PSI (8268 kPa)
3500 PSI (24132 kPa) CONTROL VALVE - FOR REAR
6 DIFFERENTIAL PRESSURE SWITCH: AUXILIARY - NORMALLY CLOSED 49
21 ANTICAVITATION VALVE PRESSURE COMPENSATED FLOW
36-44 PSI (248-303 kPa) ("P2" and "F2")
CONTROL
22 RELIEF/ANTICAVITATION VALVE - 36 PILOT ACTIVATED DIRECTIONAL
7 FLOW DIVIDER ADJUSTMENT VALVE 50 CHECK VALVE WITH 0.015 (0,38 mm)
PORT (TILT BASE END) CONTROL VALVE - FOR REAR
RESTRICTION
3500 PSI (24132 kPa) AUXILIARY - NORMALLY OPEN
8 CHECK VALVE - BUCKET POSITION ("D1" and "P1")
37 PILOT ACTIVATED DIRECTIONAL 3500 PSI (24132 kPa)
9 FIXED CAPACITY DISPLACEMENT 24 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - FOR REAR
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - AUXILIARY AUXILIARY - NORMALLY OPEN 52 SOLENOID ACTIVATED DIRECTIONAL
MOTOR 25 ("D2" and "P2") CONTROL VALVE - BUCKET POSITION
RELIEF VALVE - PORT: . . . . . (Optional)
VALVE (ON/OFF)
3500 PSI (24132 kPa)
10 PILOTED ACTIVATED DIRECTIONAL 38 FILTER - DIVERTER VALVE (SCREEN) 53 AUXILIARY HYDRAULIC PUMP
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH INTEGRATED IN SOLENOID 10 GPM (37.85 L/min.)at 2450 RPM
SPOOL PRESSURE: 5000 PSI (34474 kPa) 39 SOLENOID ACTIVATED DIRECTIONAL 54 FILTER - CASE DRAIN (ATTACHMENT)
11 PILOTED ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH CONTROL VALVE - TO ACTIVATE
CONTROL VALVE - UNLOADING REAR AUXILIARY ("SV1") 55 RELIEF VALVE - 3300 PSI (22754 kPa)
12 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FOR REAR 56 DUMP VALVE (ON/OFF)
at 1775 Pump RPM
CONTROL VALVE - TILT CONTROL AUXILIARY - NORMALLY CLOSED
390 - 430 PSI (2689 - 2965 kPa)
("P1" and "F1")
13 PILOTED ACTIVATED DIRECTIONAL 29 57 CHECK VALVE
CHARGE PUMP
CONTROL VALVE - LIFT CONTROL 41 CHECK VALVE - BICS CONTROL VALVE
14.0 GPM (53.0 L/min.) at 2450 RPM
14 SOLENOID ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . Gear Type 42 LIFT ARM BY-PASS RESTRICTOR
CONTROL VALVE - BICS CONTROL 20.7 GPM (78,4 L/min.) at 2450
Engine RPM 43 CHECK VALVE - AUXILIARY
15 PULL BUTTON ACTIVATED NOTE: Unless otherwise specified
53
DIRECTIONAL CONTROL VALVE - LIFT springs have NO significant
30.7 GPM (116,2 L/min.) at 2450 pressure value.
ARM BY PASS
Engine RPM
101 of 968
HYDRAULIC/HYDROSTATIC SCHEMATIC 38
39
863 (S/N 514450946 - 514451083 ) PILOT
(S/N 514641255 - 514641266)
V-0236 DRIVE MOTOR
INTEGRATED QUICK COUPLER BLOCK
40 36
31 32
34 44
(REAR QUICK
COUPLERS) MALE (FRONT AUXILIARY
44 LEFT SIDE LIFT ARM)
33 35 37
F2 D2
FEMALE
9 FEMALE FEMALE
DRAIN P1 P2
HYDRAULIC FILTER
3
54 BUCKET POSITION VALVE (OPTIONAL)
4 D
COOLER
45 8
28
26 26
7
6
A
CHARGE INLET OUTLET
52 C
29
43
11
BOB-TACH 27
26
CYLINDER
26 45 (OPTIONAL) 24 24
25 B
A B
HYDRAULIC
POWERED
BOB-TACH AUXILIARY
(OPTIONAL) SPOOL
INLET OUTLET
23 TILT CYLINDERS
22
BICS CONTROL VALVE
30
53
57 47
48 46
55
56 A B 12
49 51 TILT
CYLINDER
SPOOL
DRIVE MOTOR DR 50 21
9 18
P1 P2
5 20 LIFT CYLINDERS
17
PP 13
A B
LIFT
CYLINDER
SPOOL
32
31
42
*
18 (If Equipped)
2 DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY PASS VALVE
15
Printed in U.S.A. V-0236 (11-26-03)
102 of 968
WITH TWO SPEED VALVE AND HIGH FLOW OPTION
863 (S/N 514450946 - 514451083)
(S/N 514641255 - 514641266)
V-0237legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 32 SHUTTLE RELIEF VALVE: 47 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . 18.8 Qts. (17,8 L) (SCREEN) 200 PSI (1378 kPa) CONTROL VALVE (TWO COIL)
17 ONE WAY RESTRICTOR 33 SOLENOID ACTIVATED DIRECTIONAL 48 RELIEF VALVE - 1200 PSI (8268 kPa)
2 FILTER - CASE DRAIN (90 Micron)
CONTROL VALVE - BLEED OFF REAR
18 LOAD CHECK VALVE AUXILIARY ("SV2") 49 PRESSURE COMPENSATED FLOW
3 FILTER - HYDRAULIC (CANISTER) CONTROL
19 RELIEF VALVE - MAIN: 34 LOAD SHUTTLE VALVE - BLEED OFF 50 CHECK VALVE WITH 0.015 (0,38 mm)
4 SPRING LOADED FILTER BYPASS 2950-3050 PSI (20340-21030 kPa) 35 PILOT ACTIVATED DIRECTIONAL RESTRICTION
VALVE: 45-55 PSI (311-379 kPa) at Front Quick Couplers CONTROL VALVE - FOR REAR 51 RELIEF VALVE - PORT:
5 PILOT ACTIVATED DIRECTIONAL 20 RELIEF VALVE - PORT: AUXILIARY - NORMALLY CLOSED 3500 PSI (24132 kPa)
CONTROL VALVE - HYDRAULIC 3500 PSI (24132 kPa) ("P2" and "F2") 52 SOLENOID ACTIVATED DIRECTIONAL
POWERED BOB-TACH
21 ANTICAVITATION VALVE 36 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION
6 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE - FOR REAR VALVE (ON/OFF)
36-44 PSI (248-303 kPa) 22 RELIEF/ANTICAVITATION VALVE -
AUXILIARY - NORMALLY OPEN 53 FIXED CAPACITY DISPLACEMENT
("D1" and "P1") BIDIRECTIONAL HYDROSTATIC
7 FLOW DIVIDER ADJUSTMENT VALVE 3500 PSI (24132 kPa)
37 MOTOR
23 ONE WAY RESTRICTOR VALVE PILOT ACTIVATED DIRECTIONAL
8 CHECK VALVE - BUCKET POSITION CONTROL VALVE - FOR REAR 54 HYDRAULIC BRAKE - SPRING APPLIED -
VALVE AUXILIARY - NORMALLY OPEN PRESSURE TO RELEASE
CONTROL VALVE - AUXILIARY ("D2" and "P2") 55 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT CONTROL VALVE - BRAKE
BIDIRECTIONAL HYDROSTATIC 25 RELIEF VALVE - PORT: . . . . . (Optional) 38 FILTER - DIVERTER VALVE (SCREEN)
MOTOR 3500 PSI (24132 kPa) INTEGRATED IN SOLENOID 56 SOLENOID ACTIVATED DIRECTIONAL
39 CONTROL VALVE - MAKE-UP
26 RELIEF/REPLENISHING VALVE - HIGH SOLENOID ACTIVATED DIRECTIONAL
10 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TO ACTIVATE 57 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL PRESSURE: 5000 PSI (34475 kPa)
REAR AUXILIARY ("SV1") CONTROL VALVE - TWO SPEED
SPOOL 27 CHARGE PRESSURE SWITCH 40 PILOT ACTIVATED DIRECTIONAL 58 FRONT AUXILIARY MANUAL
11 PILOTED ACTIVATED DIRECTIONAL 28 CONTROL VALVE - FOR REAR PRESSURE BLEED-OFF VALVE
RELIEF VALVE - CHARGE:
CONTROL VALVE - UNLOADING AUXILIARY - NORMALLY CLOSED
120 degrees F. (53 degrees C.)Fluid 59 FILTER - CASE DRAIN (ATTACHMENT)
SPOOL ("P1" and "F1")
at 1775 Pump RPM
12 PILOTED ACTIVATED DIRECTIONAL 390 - 430 PSI (2689 - 2965 kPa) 41 CHECK VALVE - BICS CONTROL VALVE 60 RELIEF VALVE - 3300 PSI (22754 kPa)
CONTROL VALVE - TILT CONTROL 29 CHARGE PUMP 61 DUMP VALVE (ON/OFF)
42 LIFT ARM BY-PASS RESTICTOR
13 PILOTED ACTIVATED DIRECTIONAL 14.0 GPM (53,0 L/min.) at 2450 RPM
30 HYDRAULIC PUMP . . . . . . . Gear Type 43 CHECK VALVE - AUXILIARY 62 CHECK VALVE
20.7 GPM (78,4 L/min.) at 2450 44 PILOT ACTIVATED DIRECTIONAL 63 FILTER (BRAKE)
14 SOLENOID ACTIVATED DIRECTIONAL Engine RPM
CONTROL VALVE - BICS CONTROL CONTROL VALVE - TWO SPEED 64 AUXILIARY HYDRAULIC PUMP
64
HIGH FLOW CAPACITY: (Includes ) DRIVE MOTOR 10 GPM (37.85 L/min.) at 2450 RPM
15 PULL BUTTON ACTIVATED 30.7 GPM (116,2 L/min.) at 2450 45 VARIABLE CAPACITY DISPLACEMENT
DIRECTIONAL CONTROL VALVE - LIFT Engine RPM NOTE: Unless otherwise specified
ARM BY PASS 31 DRIVE MOTOR SHUTTLE VALVE springs have NO significant
46 TWO STAGE RELIEF 1000 PSI/2000 PSI pressure value.
(6894 kPa/13788 kPa)
103 of 968
38
863 (S/N 514450946 - 514451083) PILOT
39
(S/N 514641255 - 514641266)
(PRINTED DECEMBER 2002) TWO SPEED DRIVE MOTOR
V-0237
INTEGRATED QUICK COUPLER BLOCK
40 36
31 32 MALE MALE F1 D1 MALE
34 (FRONT AUXILIARY
58
(REAR QUICK LEFT SIDE LIFT ARM)
MALE
COUPLERS)
58
33 35 37
F2 D2
54 44 FEMALE
FEMALE FEMALE
53
DRAIN P1 P2
9 HYDRAULIC FILTER
3
59 BUCKET POSITION VALVE (OPTIONAL)
4 D
COOLER
45 8
26 26
28
7
6
52 C
INLET 29
26 43
11
27
BOB-TACH Dealer Copy -- Not

24 for Resale 24
45 CYLINDER 25 B
(OPTIONAL) A B
26 30 26
HYDRAULIC
INLET OUTLET POWERED AUXILIARY
BOB-TACH SPOOL
(OPTIONAL)
23 TILT CYLINDERS
TWO SPEED VALVE 22
64 61 BICS CONTROL VALVE
55 B 62
63 60
47
63 TWO SPEED DRIVE MOTOR 48 46
A B 12
51 TILT
56 9
49 CYLINDER
SPOOL
54 53 21
C DR 50 18
P1 P2 17
5 13
PP
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
T DRAIN CIRCUITS
COMPONENTS
2 LIFT ARM BY PASS VALVE
15
Printed in U.S.A. V-0237 (11-26-03)
104 of 968
863 (S/N 514451084 AND ABOVE)
V-0238legend
LEGEND
ARM BY-PASS 30
2 FILTER - CASE DRAIN (90 Micron) HYDRAULIC PUMP . . . . . . . Gear Type 42 LIFT ARM BY-PASS RESTRICTOR
17 BOOM DOWN RESTRICTOR 44 FRONT AUXILIARY MANUAL
4 SPRING LOADED FILTER BY-PASS 200 PSI (1378 kPa)
VALVE: 45-55 PSI (311-379 kPa) PRESSURE BLEED-OFF VALVE
18 LIFT AND TILT LOAD CHECK VALVE 45
CONTROL VALVE - BLEED OFF REAR VARIABLE CAPACITY DISPLACEMENT
5 PILOT ACTIVATED DIRECTIONAL AUXILIARY ("SV2") BIDIRECTIONAL HYDROSTATIC PUMP
6 at Front Quick Couplers 35 PILOT ACTIVATED DIRECTIONAL 2000 PSI (6894 kPA/ 13788 kPA)
20 RELIEF VALVE - PORT: AUXILIARY - NORMALLY CLOSED CONTROL VALVE (TWO COIL)
FLOW DIVIDER ADJUSTMENT VALVE 3500 PSI (24132 kPa) ("P2" and "F2")
7
8 CONTROL VALVE - FOR REAR
CHECK VALVE - BUCKET POSITION 49 PRESSURE COMPENSATED FLOW
AUXILIARY - NORMALLY OPEN
VALVE 22 RELIEF/ANTICAVITATION VALVE - CONTROL
("D1" and "P1")
37 PILOT ACTIVATED DIRECTIONAL 50 CHECK VALVE WITH .015 (0,38mm)
MOTOR AUXILIARY - NORMALLY OPEN
23 ONE WAY RESTRICTOR VALVE ("D2" and "P2") 51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
10 PILOTED ACTIVATED DIRECTIONAL 24 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TO ACTIVATE VALVE (ON/OFF)
25 RELIEF VALVE - PORT: . . . . . . . . (Optional)
11 PILOTED ACTIVATED DIRECTIONAL REAR AUXILIARY ("SV1")
3500 PSI (24132 kPa)
CONTROL VALVE - UNLOADING 40 PILOT ACTIVATED DIRECTIONAL
SPOOL
12 PILOTED ACTIVATED DIRECTIONAL ("P1" and "F1")
CONTROL VALVE - TILT CONTROL 27 CHARGE PRESSURE SWITCH
390 - 430 PSI (2689 - 2965 kPa)
105 of 968
863 (S/N 514451084 AND ABOVE) 38
(S/N 514541114 AND ABOVE) 39
V-0238
DRIVE MOTOR FRONT AUXILIARY
LEFT SIDE LIFT ARM
40 36 44
MALE MALE F1 D1
MALE
31 32
34 DRAIN
REAR QUICK
(MALE)
COUPLERS
(OPTIONAL)
37 FEMALE
33 35
F2 D2 44
FEMALE FEMALE
9
DRAIN P1 P2
HYDRAULIC FILTER
3 2 BUCKET POSITION VALVE (OPTIONAL)
4 D
COOLER
45 8
28
26
26 7
6
A
CHARGE INLET OUTLET
52 C
29
43
11
27
26
26
45
Dealer Copy -- Not
24 for Resale 24
BOB-TACH 25 B
CYLINDER A B
HYDRAULIC (OPTIONAL)
POWERED
BOB-TACH
(OPTIONAL) AUXILIARY
DR SPOOL
INLET OUTLET
23
22 TILT CYLINDER
BICS CONTROL VALVE
30
A B 12
46 47 TILT
48 51
CYLINDER
SPOOL
49
DRIVE MOTOR
50 21
9 18
20 LIFT CYLINDERS
17
P2
13
P1
5 PP
A B
LIFT
CYLINDER
SPOOL
31 32
18 42
19 14
* (If Equipped)
WORKING CIRCUITS
16 PILOT CIRCUITS
2 DRAIN CIRCUITS
COMPONENTS
16
41
15
Printed in U.S.A. V-0238 (11-6-02)
106 of 968
863 (S/N 514451084 AND ABOVE)
V-0239legend
LEGEND
3500 PSI (24132 kPa)
("P1" and "F1")
390 - 430 PSI (2689 - 2965 kPa)
13 PILOTED ACTIVATED DIRECTIONAL 31 DRIVE MOTOR SHUTTLE VALVE 44 PILOT ACTIVATED DIRECTIONAL BLEED-OFF VALVE
ARM BY-PASS AUXILIARY ("SV2") 46 TWO STAGE RELIEF VALVE 1000 PSI/
16 FILTER - BICS CONTROL VALVE 2000 PSI (6894 kPa/ 13788 kPa)
(SCREEN)
107 of 968
863 (S/N 514451084 AND ABOVE)
V-0240legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 31 DRIVE MOTOR SHUTTLE VALVE 44 FRONT AUXILIARY MANUAL
Capacity . . . . . . . . . 18.8 Qts. (17.8 (SCREEN) PRESSURE BLEED-OFF VALVE
L) 32 SHUTTLE RELIEF VALVE:
2 FILTER - CASE DRAIN (90 Micron) 17 ONE WAY RESTRICTOR 200 PSI (1378 kPa) 45 VARIABLE CAPACITY DISPLACEMENT
3 FILTER - HYDRAULIC (CANISTER) 18 LOAD CHECK VALVE 33 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR 46 TWO STAGE RELIEF 1000 PSI/2000 PSI
4 SPRING LOADED FILTER BYPASS 19 RELIEF VALVE - MAIN: AUXILIARY ("SV2") (6894kPa/13788 kPa)
at Front Quick Couplers 34 LOAD SHUTTLE VALVE - BLEED OFF 47 SOLENOID ACTIVATED DIRECTIONAL
5 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)
CONTROL VALVE - HYDRAULIC 20 RELIEF VALVE - PORT: 35 PILOT ACTIVATED DIRECTIONAL
POWERED BOB-TACH 48 RELIEF VALVE - 1200 PSI (8268 kPa)
3500 PSI (24132 kPa) CONTROL VALVE - FOR REAR
6 DIFFERENTIAL PRESSURE SWITCH: AUXILIARY - NORMALLY CLOSED 49
21 ANTICAVITATION VALVE PRESSURE COMPENSATED FLOW
36-44 PSI (248-303 kPa) ("P2" and "F2")
CONTROL
22 RELIEF/ANTICAVITATION VALVE - 36 PILOT ACTIVATED DIRECTIONAL
7 FLOW DIVIDER ADJUSTMENT VALVE 50 CHECK VALVE WITH 0.015 (0,38 mm)
PORT (TILT BASE END) CONTROL VALVE - FOR REAR
RESTRICTION
3500 PSI (24132 kPa) AUXILIARY - NORMALLY OPEN
8 CHECK VALVE - BUCKET POSITION ("D1" and "P1")
37 PILOT ACTIVATED DIRECTIONAL 3500 PSI (24132 kPa)
9 FIXED CAPACITY DISPLACEMENT 24 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - FOR REAR
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - AUXILIARY AUXILIARY - NORMALLY OPEN 52 SOLENOID ACTIVATED DIRECTIONAL
MOTOR 25 ("D2" and "P2") CONTROL VALVE - BUCKET POSITION
RELIEF VALVE - PORT: . . . . . (Optional)
VALVE (ON/OFF)
3500 PSI (24132 kPa)
10 PILOTED ACTIVATED DIRECTIONAL 38 FILTER - DIVERTER VALVE (SCREEN) 53 AUXILIARY HYDRAULIC PUMP
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH INTEGRATED IN SOLENOID 10 GPM (37.85 L/min.) at 2450 RPM
SPOOL PRESSURE: 5000 PSI (34474 kPa) 39 SOLENOID ACTIVATED DIRECTIONAL 54 FILTER - CASE DRAIN (ATTACHMENT)
11 PILOTED ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH CONTROL VALVE - TO ACTIVATE
CONTROL VALVE - UNLOADING REAR AUXILIARY ("SV1") 55 RELIEF VALVE - 3300 PSI (22754 kPa)
12 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FOR REAR 56 DUMP VALVE (ON/OFF)
at 1775 Pump RPM
CONTROL VALVE - TILT CONTROL AUXILIARY - NORMALLY CLOSED
390 - 430 PSI (2689 - 2965 kPa)
("P1" and "F1")
13 PILOTED ACTIVATED DIRECTIONAL 29 57 CHECK VALVE
CHARGE PUMP
CONTROL VALVE - LIFT CONTROL 41 CHECK VALVE - BICS CONTROL VALVE
14.0 GPM (53.0 L/min.) at 2450 RPM
14 SOLENOID ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . Gear Type 42 LIFT ARM BY-PASS RESTRICTOR
CONTROL VALVE - BICS CONTROL 20.7 GPM (78,4 L/min.) at 2450
Engine RPM 43 CHECK VALVE - AUXILIARY
15 PULL BUTTON ACTIVATED NOTE: Unless otherwise specified
53
DIRECTIONAL CONTROL VALVE - LIFT springs have NO significant
30.7 GPM (116,2 L/min.) at 2450 pressure value.
ARM BY PASS
Engine RPM
109 of 968
863 (S/N 514451084 AND ABOVE)
V-0241legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 32 SHUTTLE RELIEF VALVE: 47 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . 18.8 Qts. (17,8 L) (SCREEN) 200 PSI (1378 kPa) CONTROL VALVE (TWO COIL)
17 ONE WAY RESTRICTOR 33 SOLENOID ACTIVATED DIRECTIONAL 48 RELIEF VALVE - 1200 PSI (8268 kPa)
2 FILTER - CASE DRAIN (90 Micron)
CONTROL VALVE - BLEED OFF REAR
18 LOAD CHECK VALVE AUXILIARY ("SV2") 49 PRESSURE COMPENSATED FLOW
3 FILTER - HYDRAULIC (CANISTER) CONTROL
19 RELIEF VALVE - MAIN: 34 LOAD SHUTTLE VALVE - BLEED OFF 50 CHECK VALVE WITH 0.015 (0,38 mm)
4 SPRING LOADED FILTER BYPASS 2950-3050 PSI (20340-21030 kPa) 35 PILOT ACTIVATED DIRECTIONAL RESTRICTION
VALVE: 45-55 PSI (311-379 kPa) at Front Quick Couplers CONTROL VALVE - FOR REAR 51 RELIEF VALVE - PORT:
5 PILOT ACTIVATED DIRECTIONAL 20 RELIEF VALVE - PORT: AUXILIARY - NORMALLY CLOSED 3500 PSI (24132 kPa)
CONTROL VALVE - HYDRAULIC 3500 PSI (24132 kPa) ("P2" and "F2") 52 SOLENOID ACTIVATED DIRECTIONAL
POWERED BOB-TACH
21 ANTICAVITATION VALVE 36 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION
6 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE - FOR REAR VALVE (ON/OFF)
36-44 PSI (248-303 kPa) 22 RELIEF/ANTICAVITATION VALVE -
AUXILIARY - NORMALLY OPEN 53 FIXED CAPACITY DISPLACEMENT
("D1" and "P1") BIDIRECTIONAL HYDROSTATIC
7 FLOW DIVIDER ADJUSTMENT VALVE 3500 PSI (24132 kPa)
37 MOTOR
23 ONE WAY RESTRICTOR VALVE PILOT ACTIVATED DIRECTIONAL
8 CHECK VALVE - BUCKET POSITION CONTROL VALVE - FOR REAR 54 HYDRAULIC BRAKE - SPRING APPLIED -
VALVE AUXILIARY - NORMALLY OPEN PRESSURE TO RELEASE
CONTROL VALVE - AUXILIARY ("D2" and "P2") 55 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT CONTROL VALVE - BRAKE
BIDIRECTIONAL HYDROSTATIC 25 RELIEF VALVE - PORT: . . . . . (Optional) 38 FILTER - DIVERTER VALVE (SCREEN)
MOTOR 3500 PSI (24132 kPa) INTEGRATED IN SOLENOID 56 SOLENOID ACTIVATED DIRECTIONAL
39 CONTROL VALVE - MAKE-UP
26 RELIEF/REPLENISHING VALVE - HIGH SOLENOID ACTIVATED DIRECTIONAL
10 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TO ACTIVATE 57 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL PRESSURE: 5000 PSI (34475 kPa)
REAR AUXILIARY ("SV1") CONTROL VALVE - TWO SPEED
SPOOL 27 CHARGE PRESSURE SWITCH 40 PILOT ACTIVATED DIRECTIONAL 58 FRONT AUXILIARY MANUAL
11 PILOTED ACTIVATED DIRECTIONAL 28 CONTROL VALVE - FOR REAR PRESSURE BLEED-OFF VALVE
RELIEF VALVE - CHARGE:
CONTROL VALVE - UNLOADING AUXILIARY - NORMALLY CLOSED
120 degrees F. (53 degrees C.)Fluid 59 FILTER - CASE DRAIN (ATTACHMENT)
SPOOL ("P1" and "F1")
at 1775 Pump RPM
12 PILOTED ACTIVATED DIRECTIONAL 390 - 430 PSI (2689 - 2965 kPa) 41 CHECK VALVE - BICS CONTROL VALVE 60 RELIEF VALVE - 3300 PSI (22754 kPa)
CONTROL VALVE - TILT CONTROL 29 CHARGE PUMP 61 DUMP VALVE (ON/OFF)
42 LIFT ARM BY-PASS RESTICTOR
13 PILOTED ACTIVATED DIRECTIONAL 14.0 GPM (53,0 L/min.) at 2450 RPM
30 HYDRAULIC PUMP . . . . . . . Gear Type 43 CHECK VALVE - AUXILIARY 62 CHECK VALVE
20.7 GPM (78,4 L/min.) at 2450 44 PILOT ACTIVATED DIRECTIONAL 63 FILTER (BRAKE)
14 SOLENOID ACTIVATED DIRECTIONAL Engine RPM
CONTROL VALVE - BICS CONTROL CONTROL VALVE - TWO SPEED 64 AUXILIARY HYDRAULIC PUMP
64
HIGH FLOW CAPACITY: (Includes ) DRIVE MOTOR 10 GPM (37.85 L/min.) at 2450 RPM
15 PULL BUTTON ACTIVATED 30.7 GPM (116,2 L/min.) at 2450 45 VARIABLE CAPACITY DISPLACEMENT
DIRECTIONAL CONTROL VALVE - LIFT Engine RPM NOTE: Unless otherwise specified
ARM BY PASS 31 DRIVE MOTOR SHUTTLE VALVE springs have NO significant
46 TWO STAGE RELIEF 1000 PSI/2000 PSI pressure value.
(6894 kPa/13788 kPa)
111 of 968
HYDRAULIC SYSTEM INFORMATION
MC 2340 (6-2-98)
863 Bobcat Loader

113 of 968
HYDRAULIC SYSTEM INFORMATION (CONT’D)
MC 2340-2 (6-2-98)
863 Bobcat Loader

114 of 968
HYDRAULIC SYSTEM INFORMATION (CONT’D)
MC 2340-3 (6-2-98)
863 Bobcat Loader

115 of 968
863 Bobcat Loader
116 of 968
HYDRAULIC SYSTEM INFORMATION (CONT’D) Troubleshooting Chart
The following troubleshooting chart is provided for

assistance in locating and correcting problems which are
IMPORTANT most common. Many of the recommended procedures
must be done by authorized Bobcat Service Personnel
only.
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. WARNING
I-2003-0888
Check for correct function after adjustments, repairs
Tighten Procedures or service. Failure to make correct repairs or
adjustments can cause injury or death.
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. 1, 2, 3, 5, 8
The transmission warning light comes ON when hydraulics are operating. 1, 3,
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine RPM. 1, 3, 4, 5, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position. 4, 9, 10, 11
Bypass valve stuck. 12
Bypass valve stem bent or broke. 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.
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CYLINDER (LIFT) Figure 20-20-2
Checking
WARNING
enters skin or eyes, get immediate medical attention CD-15068
W-2072-0807
Install a plug (Item 1) [Figure 20-20-2] in the hose and
tighten.
Figure 20-20-1
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.
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CYLINDER (LIFT) (CONT’D) Figure 20-20-5
Removal And Installation
Figure 20-20-3
CD-15070
Remove the retaining bolt and nut (Item 1) [Figure 20-

P-7960 20-5] from the pivot pin base end of the cylinder.
Installation: Tighten the retainer bolt and nut to 18 - 20

Raise the lift arms so the rod end retaining pin will clear ft.-lb. (24 - 27 N•m) torque.
the loader frame for removal.
Figure 20-20-6
Have a second person put jackstands under the Bob-
Tach to support the lift arms [Figure 20-20-3]. Stop the
engine.

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 20-

20-4] from the pivot pin on the rod end of the cylinder.
Installation: Tighten the retainer bolt and ut to 18 - 20 ft.-

lb. (24 - 27 N•m) torque.
Remove the pivot pin from the rod end of the cylinder.
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CYLINDER (LIFT) (CONT’D)
Removal And Installation (Cont’d)
WARNING
explosion or fire.
W-2103-0508
Figure 20-20-7
CD-15073
Disconnect the two hoses (Item 1) [Figure 20-20-7] from

the lift cylinder.
Remove the lift cylinder.
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CYLINDER (LIFT) (CONT’D)
Parts Identification
1. Tube 10. Spacer

2. O-Ring 11. O-ring
3. Plug 12. Washer
4. Case 13. Head
5. O-Ring 14. Seal
6. Nut 15. Seal
7. Piston 16. Rod
8. Ring
9. O-ring
10
9
B-14213A B-14213B
8
3 6 16
2
5
15
1
14
3
2 13
4
12
11
B-13593B
TS-1060
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Disassembly 4
Figure 20-20-8 3
1 2
P-7428
Lift Cylinder: Remove the head and the rod assembly

P-7429 from the cylinder [Figure 20-20-10]. Put the rod end in a
vise.
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
3
2
1
P-7435
Use the following tools to disassemble the cylinder:

P-7434
MEL1074 - O-ring Seal Hook
Spanner Wrench
Tilt Cylinder: Remove the head and rod assembly from
The lift and tilt cylinders internal components are similar,
the cylinder [Figure 20-20-11]. Put the rod end in a vise.
the differences are listed below:
Tilt: Cylinder: Remove the nut (Item 1) [Figure 20-20-11],
Tilt rod diameter is larger.
Piston relief area is slightly different. piston (Item 2) [Figure 20-20-11] and head (Item 3)
No spacer in the tilt cylinder. [Figure 20-20-11].
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 20-20-

8] & [Figure 20-20-9].
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Disassembly (Cont’d)
Figure 20-20-12
3 3
2
2 1
P-07422
Remove the thick O-ring (Item 1) [Figure 20-20-14] and

P-7430 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].
Standard Piston: Remove the seal (Item 1) [Figure 20-
20-12], and O-ring (Item 2) [Figure 20-20-12] from the Figure 20-20-15
piston (Item 3) [Figure 20-20-12].
Figure 20-20-13
2
2 1
1 3
P-7426
P-7439 Remove the wiper seal (Item 1) [Figure 20-20-15], and

rod seal (Item 2) [Figure 20-20-15].
Cushion Piston: Remove the seal (Item 1) [Figure 20-20- Remove the O-ring (Item 3) [Figure 20-20-15] from the
13] and O-ring (Item 2) [Figure 20-20-13] from the piston rod seal.
(Item 3) [Figure 20-20-13].
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Assembly
3
Figure 20-20-16
2
P-7430
Standard Piston: Install the seal (Item 1) [Figure 20-20-

P-7424 17] and O-ring (Item 2) [Figure 20-20-17] on the piston
(Item 3) [Figure 20-20-17].
Use the following tools to assemble the cylinder: Figure 20-20-18
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. P-7438
Install a new seal on the tool and slowly stretch it until it

fits the piston (Item 1) [Figure 20-20-16]. Cushion Piston: Install the seal and O-ring on the piston
(Item 1) [Figure 20-20-18].
Allow the seal the stretch for 30 seconds before installing
it on the piston. Using a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for about
three minutes.
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Assembly (Cont’d)
Figure 20-20-19
1
2
3
P-7422
Install the thin O-ring (Item 1) [Figure 20-20-21].

P-7427
Install the back-up washer (Item 2) [Figure 20-20-21]
and thick O-ring (Item 3) [Figure 20-20-21] into the
Install the rod seal on the rod seal tool [Figure 20-20-19]. groove in the head.
NOTE: During Installation the O-ring side of the seal NOTE: Clean and dry the threads before installing the
must be toward the inside of the cylinder. nut. Install the new nut from the kit.
Rotate the handles to collapse the rod seal [Figure 20- Figure 20-20-22
20-19].
Figure 20-20-20
1
2
3
P-7434
P-7425 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.
Install the rod seal in the head [Figure 20-20-20].
Tilt Cylinder: Grease the piston where the nut contacts
Install the wiper seal with the wiper toward the outside of the piston. Do not get grease on the threads.
the head.
Tilt Cylinder: Install the nut (Item 3) [Figure 20-20-22].
Tilt Cylinder: Tighten the nut to 100 ft.-lb. (136 N•m)

torque.
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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
2
3
P-7435
4
Tighten the head using a spanner wrench [Figure 20-20-

25] & [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.-lb. (542 N•m) torque.
Put the base end of the hydraulic cylinder in a vise.
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CYLINDER (TILT) Removal And Installation
Checking Figure 20-21-2
WARNING
W-2072-0807 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
P-1187
Remove the attachment. Roll the Bob-Tach fully back.

Disconnect the hose (Item 1) [Figure 20-21-1] which P-7693

goes to the base end of the tilt cylinder.
Remove the retainer bolt and nut (Item 1) [Figure 20-21-
Put a plug in the hose and tighten.
3] from the rod end pivot pin.
Install a test hose between cylinder and drain pan.
Installation: Tighten the retainer nut to 18 - 20 ft.-lb. (24 -
27 N•m) torque.
engine and push the bottom (heel) of the tilt pedal. If
there is leakage from the open port, remove the tilt
cylinder for repair.
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CYLINDER (TILT) (CONT’D) Figure 20-21-5
WARNING
explosion or fire. 1
W-2103-0508
P-7678
Figure 20-21-4

5] from the base end pivot pin.
Installation: Tighten the retainer nut and bolt to 18 - 20

ft.-lb. (24 - 27 N•m) torque.
Figure 20-21-6
P-7695
Remove the rod end pivot pin (Item 1) [Figure 20-21-4].
Engage the parking brake. Lower the seat bar. Start the 1
engine and push the bottom (heel) of the tilt pedal until
rod end of cylinder is fully retracted.
P-7679
Disconnect the hoses (Items 1 & 2) [Figure 20-21-1 on
Page 1]. (See Checking on Page 20-21-1.)
Remove the base end pivot pin (Item 1) [Figure 20-21-
Plug fittings on tilt cylinder 6].
Remove the tilt cylinder from the loader.
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CYLINDER (TILT) Figure 20-21-8
Rod End Seal
Figure 20-21-7
P-3910
1
Using two pieces of shim stock, install the rod end of the
P-3911 tilt cylinder into the Bob-Tach (Item 1) [Figure 20-21-8].
Be careful not to damage the new seals during

Remove the old seal (both sides) from the rod end of the installation.
tilt cylinder.
Hold the rod end in position and remove the shim stock.
Install the new seals (Item 1) [Figure 20-21-7] with the lip
facing out.
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CYLINDER (TILT) (CONT’D)
1. Case
2. Plug
3. O-Ring
4. Tube
5. Nut
6. Clamp
7. Bolt
8. Nut
9. Piston MC-1688B
10. Seal
11. O-Ring 3
12. O-Ring 2
MC-1688A
13. Washer
14. O-Ring 4
15. Head
6 5 1
16. Seal
17. Seal
18. Rod
19. Seal
20. Bushing
15
9
10 16
11 17
12
13
19 20 19 18
14
MC-1688C
MC-1688D
TS-1233
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Disassembly
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.
P-7435
Hold the hydraulic cylinder over a drain pan and move
cylinder. Use a spanner wrench to loosen the head [Figure 20-21-
9] & [Figure 20-21-10].
Figure 20-21-9
P-7429
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Disassembly (Cont’d) 3
Figure 20-21-11
2
4
3 1
1 2
P-7430
Standard piston: Remove the seal (Item 1) [Figure 20-

P-7428 21-13], and O-ring (Item 2) [Figure 20-21-13] from the
Lift Cylinder: Remove the head and the rod assembly Figure 20-21-14
from the cylinder [Figure 20-21-11]. Put the rod end in a
vise. 3
Lift Cylinder: Remover the nut (Item 1) [Figure 20-21-
11], 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
3
2
1
P-7439
Cushion Piston: Remove the seal (Item 1) [Figure 20-21-

14], and O-ring (Item 2) [Figure 20-21-14] from the
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].
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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
2 Inspect the cylinder parts for nicks, scratches or other

1
3 ALways install new O-rings and seals during assembly.

installation.
P-7426 Figure 20-21-17
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 P-7424
1
3 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.
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Assembly (Cont’d)
Figure 20-21-18
P-7427
Install the rod seal on the rod seal tool [Figure 20-21-20].
P-7430
NOTE: During installation the O-ring side of the seal
must be toward the inside of the cylinder.
Standard Piston: Install the seal (Item 1) [Figure 20-21-
18] and O-ring (Item 2) [Figure 20-21-18] on the piston Rotate the handles to collapse the rod seal [Figure 20-
(Item 3) [Figure 20-21-18]. 21-20].
Figure 20-21-19 Figure 20-21-21
P-7438 P-7425
Cushion Piston: Install the seal and O-ring on the piston Install the rod seal in the head [Figure 20-21-21].
(Item 1) [Figure 20-21-19].
Install the wiper seal with the wiper toward the outside of
Use a ring compressor to compress the seal to the the head.
correct size. Leave the piston in the compressor for about
three minutes.
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CYLINDER (TILT) (CONT’D) Tilt Cylinder: Tighten the nut to 100 ft.-lb. (136 N•m)
torque.
Assembly (Cont’d)
Figure 20-21-24
Figure 20-21-22
1
2
3
P-10450 P-10456
P-7422
Tilt Cylinder: Mark the end of the shaft and nut [Figure
Install the thin O-ring (Item 1) [Figure 20-21-22]. 20-21-24]. Tighten the nut an additional 135 degrees or
2-1/4 flats [Figure 20-21-24].
Install the back-up washer (Item 2) [Figure 20-21-22]
and thick O-ring (Item 3) [Figure 20-21-22]into the NOTE: Clean and dry the threads before installing the
groove on the head. nut. Install the new nut from the kit.
NOTE: Clean and dry the threads before installing the Figure 20-21-25
nut. Install the new nut from the kit.
1
Figure 20-21-23 2
3
4
1
2
3
P-7428
Lift Cylinder: Install the head (Item 1) [Figure 20-21-25],

P-7434
and spacer (Item 2) [Figure 20-21-25].
Tilt Cylinder: Install the head (Item 1) [Figure 20-21-23], Lift Cylinder: Install the piston (Item 3) [Figure 20-21-25],
and the piston (Item 2) [Figure 20-21-23]. The small and the nut (Item 4) [Figure 20-21-25].
diameter of the piston goes into the cylinder tube first.
Lift Cylinder: Tighten the nut (Item 4) [Figure 20-21-25]
Tilt Cylinder: Grease the piston where the nut contacts to 400 ft.-lb. (542 N•m) torque.
the piston. Do not get grease on the threads.
Tilt Cylinder: Install the nut (Item 3) [Figure 20-21-23].
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CYLINDER (TILT) (CONT’D)
Assembly (Cont’d)
Figure 20-21-26
P-7429
Figure 20-21-27
P-7435

26] & [Figure 20-21-27].
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CYLINDER (POWER BOB-TACH) Figure 20-22-2
Checking
WARNING
explosion or fire.
W-2103-0508 1
N-23032
WARNING Disconnect the hose (Item 1) [Figure 20-22-2]from the

power Bob-Tach cylinder base end port.
AVOID INJURY OR DEATH Figure 20-22-3

not use your bare hand. Wear safety goggles. If fluid 1
enters skin or eyes, get immediate medical attention 2
W-2072-0807
Figure 20-22-1
N-23033
Install a plug in the hose (Item 1) [Figure 20-22-3] and

tighten.
engine.
Push and hold the BOB-TACH “WEDGES UP” Switch

(Front Accessory Panel).
N-23031
If there is any leakage from the base end cylinder port

Tilt the Bob-Tach forward, so it is parallel to the floor (Item 2) [Figure 20-22-3], remove the lift cylinder for
[Figure 20-22-1]. repair.
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CYLINDER (POWER BOB-TACH) (CONT’D) Figure 20-22-5
Figure 20-22-4
1 1
N-23034
1 2
Remove the bolts (Item 1) [Figure 20-22-5].

N-23031
Installation: Tighten the bolts to 25 - 28 ft.-lb. (34 - 38
N•m) torque.
Disconnect the hoses (Item 1 & 2) [Figure 20-22-4] from
the cylinder fittings. Remove the washers and cylinder from the lever pivots.
Install plugs and cap in fittings.
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CYLINDER (POWER BOB-TACH) (CONT’D)
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
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Disassembly
2
3 1
Figure 20-22-6
P-16294
Remove the head and rod assembly from the cylinder

P-16293 [Figure 20-22-7].
Put the rod end in a vise.

Remove the nut (Item 1) [Figure 20-22-7], piston (Item 2)
MEL 1074 - O-ring Seal Hook [Figure 20-22-7] and head (Item 3) [Figure 20-22-7]
Spanner Wrench from the rod.
Hold the hydraulic cylinder over a drain pan and move Figure 20-22-8
cylinder. 3
2
1
Use a spanner wrench to loosen the head [Figure 20-22-

6].
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].
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CYLINDER (POWER BOB-TACH) (CONT’D) Assembly
Disassembly (Cont’d) Figure 20-22-10
Figure 20-22-9
5
3
4
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 MEL1396 - Seal Installation Tool
rod seal (Item 2) [Figure 20-22-9], the back-up washer MEL1033 - Rod Seal Installation Tool
(Item 3) [Figure 20-22-9] the thin O-ring (Item 4) [Figure Piston Ring Compressor
20-22-9] and the thick O-ring (Item 5) [Figure 20-22-9] Spanner Wrench
from the head.
Inspect the cylinder parts for nicks, scratches or other

Always install new O-rings and seals during assembly.

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.
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Assembly (Cont’d)
Figure 20-22-11
3
1
2
4
N-20613
Rotate the handles to collapse the rod seal [Figure 20-

P-16295 22-13].
Figure 20-22-14
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].
NOTE: The piston center hole (Item 4) [Figure 20-22-

11] has a bevel on one end. The bevel goes
toward the rod.
Figure 20-22-12
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.
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Assembly (Cont’d)
1 3
2 4
Figure 20-22-15
2
3
P-16294
Install the head (Item 1) [Figure 20-22-16], and spacer

P-7422 (Item 2) [Figure 20-22-16].
Install the piston (Item 3) [Figure 20-22-16].

Install the thin O-ring (Item 1) [Figure 20-22-15].
Lift Cylinder: Grease the piston where the nut contacts
Install the back-up washer (Item 2) [Figure 20-22-15] the piston, do not get grease on the threads. Install the
and thick O-ring (Item 3) [Figure 20-22-15] into the new nut (Item 4) [Figure 20-22-16].
groove on the head.
Tighten the nut to 90 ft.-lb. (122 N•m) torque.
NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the seal kit. Figure 20-22-17
P-16293

17].
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MAIN RELIEF VALVE (FOOT CONTROL)
Checking The Main Relief Valve At Front Auxiliary

Hydraulics IMPORTANT
NOTE: This procedure is the same for 863 and 863 H
The hydraulic tester must be in the fully open
in the standard flow mode.
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.

WARNING
procedure: Put jackstands under the front axles and rear corners
MEL 10003 - Hydraulic Tester Failure to use jackstands can allow the machine to
MEL 10006 - Hydraulic Test Kit 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 Figure 20-30-2
couplers.

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
P-5061
ON.
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].
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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 Lift and block the loader. (See LIFTING AND BLOCKING
Control
(Optional) THE LOADER on Page 10-10-1.)
Left
Steering
Lever Figure 20-30-4
Control 1
(Optional)
1
P-2154 P-2152
Push the button (Item 1) [Figure 20-30-3] for fluid

1
pressure to the quick couplers.
Watch the flow meter on the hydraulic tester to make

sure the flow is correct. Increase the engine speed to full
RPM.
CD-15074
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 Disconnect the hydraulic hoses (Item 1) [Figure 20-30-4]
control, on the tester, until the main relief valve opens. from the tilt cylinder.
The correct pressure for the main relief is 3000 PSI
(20685 kPa).
Stop the engine. Replace or adjust the main relief valve.

(See Removal And Installation on Page 20-30-4.)
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MAIN RELIEF VALVE (FOOT CONTROL) (CONT’D) Replace or adjust the main relief valve. (See Removal
And Installation on Page 20-30-4.)
Checking The Main Relief Valve Without Front
Auxiliaries (Cont’d)
Figure 20-30-5
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-2050-0807
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.
IMPORTANT
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).
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.
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MAIN RELIEF VALVE (FOOT CONTROL) (CONT’D) Figure 20-30-7

on Page 10-30-1.)
1
IMPORTANT
When repairing hydrostatic and hydraulic systems, 2
N-19735
damage the system.
I-2003-0888
Loosen and remove the main relief valve (Item 1) [Figure
Figure 20-30-6 20-30-7].
Installation: Tighten the main relief valve to 35 - 40 ft.-lb.

(47 - 54 N•m) torque.
Figure 20-30-8
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.)
Remove the O-rings and back-up washers from the main
Clean the area around the control valve. relief valve [Figure 20-30-8].
Clean the main relief valve in clean solvent. Use air

pressure to dry the valve.
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.)
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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
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.
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Removal And Installation (S/N 514447863 & Below)
Remove the control panel. (See Removal And Installation
on Page 50-100-1.)
IMPORTANT Clean the area around the control valve.
Figure 20-40-1
tubelines and ports to keep dirt out. Dirt can quickly 2
damage the system.
I-2003-0888
DANGER
1
N-19669
Disconnect the linkage (Item 1 & 2) [Figure 20-40-1]

from the lift and tilt spools at the control valve.
P-90328
Figure 20-40-2
AVOID DEATH
• Keep out of this area when lift arms are raised 1
D-1009-0409
WARNING 1
Never work on a machine with the lift arms up unless N-19746

support device can allow the lift arms or attachment Remove the three hydraulic hoses (Item 1) [Figure 20-
to fall and cause injury or death. 40-2] from the lift arm bypass valve.
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.)
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-5
(CONT’D)

(Cont’d)
1
Figure 20-40-3
1
1
N-19756
Disconnect the hydraulic hose (Item 1) [Figure 20-40-5]

1
from the hydraulic pump to the control valve.
N-19754 NOTE: Loosen all hydraulic tubelines that are

connected to the control valve.
Disconnect the wire harness connectors (Item 1) [Figure Connect a chain to the control valve and support the
20-40-3] from the auxiliary solenoids and the lift and tilt valve with an arm hoist.
lock solenoids.
Figure 20-40-6
Remove the Never Modify tie strap, and disconnect the
wire harness connector (Item 2) [Figure 20-40-3] from
the BICS valve solenoid connector.
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
N-19755 back side of the control valve.
Remove the case drain hose (Item 1) [Figure 20-40-4]

from the control valve.
Remove the charge pressure sender (Item 2) [Figure 20-

40-4] from the control valve.
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(CONT’D)

(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.
N-19757 Remove the two auxiliary tubelines (Item 2) [Figure 20-

Disconnect the hydraulic tubeline (Item 1) [Figure 20-40- Figure 20-40-10
7] from the bottom of the control valve.
Figure 20-40-8
1
2
1 N-19761
N-19758 Remove the two tilt tubelines (Item 1) [Figure 20-40-10]

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.
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Removal And Installation (S/N 514447864 & Above)
(CONT’D)
(Cont’d)
Figure 20-40-11
DANGER
1
P-90328
1 AVOID DEATH
N-19762 can cause lift arms to drop.
Remove the three lift tubelines (Item 1) [Figure 20-40- support. Replace if damaged.
11] from the control valve. D-1009-0409
WARNING
W-2059-0598
device.

on Page 10-30-1.)
Drain the hydraulic reservoir. (See Draining The Fluid

Reservoir on Page 20-80-1.)

on Page 50-100-1.)
Clean around the control valve.
Open rear door.
Remove the loader alternator. (See Removal And

Installation on Page 60-30-3.)
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(CONT’D)
Removal And Installation (S/N 514447864 & Above)

(Cont’d)
Figure 20-40-12
N-23632
At the right fender, remove the two mounting bolts and

nuts (Item 1) [Figure 20-40-14] from the lift arm bypass
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
1
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.
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.
P-28560
Disconnect the three hoses (Item 1) [Figure 20-40-13]

from the lift arm bypass valve.
Cap and plug hoses and fittings.
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(CONT’D)

(Cont’d)
Figure 20-40-16
1
1
1
P-28580
Disconnect the foot control linkage (Item 1) [Figure 20-

40-18].
P-28545 Figure 20-40-19

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
P-28563 The hose can be removed from the control valve by
rotating the hose assembly.
Disconnect the harness connector (Item 1) [Figure 20- Cap the hose and plug the fitting.
40-17] from the BICS™ valve solenoid connector.
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(CONT’D)

(Cont’d)
Figure 20-40-20
2 1
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 20-40- 1 2
20] from the control valve to the case drain filter.
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
and nuts (Item 3) [Figure 20-40-23] from the loader
Install a chain hoist (Item 1) [Figure 20-40-21] to the fender.
control valve.
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.
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(CONT’D)

(Cont’d)
1
Figure 20-40-24
P-28552
Disconnect the hydraulic fitting (Item 1) [Figure 20-40-

26] from the charge pressure sender.
P-26831 Move the charge pressure sender and hose assembly to

the side to allow clearance for the control valve removal.
At the right side pump access hole, remove the two Figure 20-40-27
control valve mounting bolts (Item 1) [Figure 20-40-24]
from the mounting plate.
Figure 20-40-25
1
P-28553
Mark all tubelines for correct installation.

P-28551
Remove the two bucket position tubelines (Item 1)
[Figure 20-40-27]. (If so equipped.)
Disconnect the lift tubeline (Item 1) [Figure 20-40-25]
from the control valve. Remove the lift tubeline (Item 2) [Figure 20-40-27] that
goes from control valve to bucket position valve. (If so
Cap and plug the tubeline and fitting. equipped.)
Remove the control valve mount bracket from the loader.
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(CONT’D)

(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
P-28554 Rotate the valve upward until the valve spools are above
the tubelines [Figure 20-40-30].
Disconnect the three auxiliary tubelines that are Remove the control valve from the loader.
connected to the fitting (Item 1) [Figure 20-40-28].
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 20-

40-28] this will allow tubeline movement that will aid in
removal and installation.
Figure 20-40-29
P-28556
Disconnect the auxiliary tubeline (Item 1) [Figure 20-40-

29] from the control valve.
Cap and plug the tubeline and fitting.
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(CONT’D)
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 N-20035
1
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]

N-20033 and the small O-ring (Item 2) [Figure 20-40-33] on top of
the control valve.
To remove the BICS™ valve from the control valve, Figure 20-40-34
loosen and remove the six mounting bolts (Item 1)
[Figure 20-40-31].
Figure 20-40-32
3 6
1 2
5 4
N-18679
Install the six mounting bolts [Figure 20-40-34].

N-20034
The See BICS™ Valve, Removal And Installation
(Cont’d) on Page 20-40-11 lists the correct torque
Remove the BICS™ valve assembly from the top of the specifications and tightening sequence when reinstalling
control valve (Item 1) [Figure 20-40-32]. the BICS™ valve assembly to the control valve.
Thoroughly clean and dry bolts and threads in valve. Use
liquid adhesive Loctite® #242 or equivalent.
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(CONT’D)
BICS™ Valve, Removal And Installation (Cont’d)

Step Torque Sequence
1 110 - 130 in.-lb.
(12,4 - 14,7 N•m)
2 190 - 210 in.-lb.
(21,5 - 23,7 N•m) 1, 2, 3, 4, 5 & 6
3* 190 - 210 in.-lb.
(21,5 - 23,7 N•m)
1
*Torque must be 190 - 210 in.-lb. (21,5 - 23,7 N•m) for
ever bolt or repeat step 3.
BICS™ Valve, Lift arm Bypass Orifice Disassembly N-20041
And Assembly
Figure 20-40-37
Figure 20-40-35
N-18685
N-20040
Using a flat blade screw driver, remove the lift arm

Remove the fitting (Item 1) [Figure 20-40-35] from the
bypass orifice (Item 1) [Figure 20-40-36] & [Figure 20-
valve.
40-37].
Orifice size is 0.078 in.
Reverse the removal procedure to install the lift arm

bypass orifice.
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(CONT’D)
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]

1 on the end of the valve.
N-20037
Remove the check valve (Item 1) [Figure 20-40-38].
Installation: Tighten the valve to 20 ft.-lb. (27 N•m)

torque.
Figure 20-40-39
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.
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(CONT’D)
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 P-37712 Figure 20-40-44
Remove the tubeline (Item 1) and the check valve (Item

2) [Figure 20-40-41].
2
Installation: Tighten the valve to 20 ft.-lb. (27 N•m) 1
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 o-

ring (Item 2) [Figure 20-40-42] on the check valve.
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Installation: Tighten the lock valves to 25 ft.-lb. (34 N•m)
(CONT’D) torque.
BICS™ Valve, Lock Valve Disassembly And Figure 20-40-48

Assembly
Figure 20-40-45 1
1
1
2
2
2 N-18690
N-20033

Figure 20-40-46 back-up rings (Item 2) [Figure 20-40-48] from both the tilt
and lift lock valves.
Install new O-rings (Item 1) [Figure 20-40-48] and back-

up rings (Item 2) [Figure 20-40-48] on the tilt and lift lock
valves.
Reverse the removal procedure to install the lock valve.
N-20039
Figure 20-40-47
N-20040
Remove the lock valves (Item 1) [Figure 20-40-45],

[Figure 20-40-46] & [Figure 20-40-47] from the BICS™
valve.
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(CONT’D)
BICS™ Valve, Solenoid Disassembly And Assembly 1

Figure 20-40-49
N-20038
Remove the solenoid stem (Item 1) [Figure 20-40-51].
N-20037 Installation: tighten the solenoid stem to 20 ft.-lb. (27

N•m) torque.
Remove the mounting nut (Item 1) [Figure 20-40-49] Figure 20-40-52
from the solenoid cartridge.
Installation: Tighten the mounting nut to 53 in.-lb. (6

N•m) torque.
3
Remove the solenoid (Item 2) [Figure 20-40-49]. 2
NOTE: The solenoid resistance is (8 - 10 ohm).
Figure 20-40-50
1 1
1 N-18694

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
NOTE: The screen (Item 3) [Figure 20-40-52] may be
cleaned with solvent. If it is torn or worn
Remove the O-rings (Item 1) [Figure 20-40-50] form replace the solenoid stem.
both ends of the solenoid.
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.
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Identification Chart
(CONT’D)
Item 863 Loader
BICS™ Valve, Solenoid Testing A1 Lift Cylinder Base End / Restrictor
A2 Tilt Cylinder Base End
Figure 20-40-53 A3 Auxiliary Hydraulics
B1 Lift Cylinder Rod End
B2 Tilt Cylinder Rod End
B3 Auxiliary Hydraulics
C1 Load Check Valve / Lift Function
C2 Load Check Valve / Tilt Function
C3 Orifice Load Check Valve / Auxiliary Function
C4 Outlet Fluid Flow
D1 Lift Spool Detent
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool / Centering Springs
E1 Port Relief Valve - 3500 PSI
E2 Anti-Cavitation / Port Relief Valve - 2500 PSI
F1 Anti-Cavitation Valve
F2 Port Relief Valve - 3500 PSI
G1 Lift Spool End
P-9175
G2 Tilt Spool End
G3 Auxiliary Electric Solenoid
Use a test meter to measure the coil resistance [Figure H1 Auxiliary Electric Solenoid
20-40-53]. Coil wires do not have polarity. Correct H2 Plug / Port Relief (Optional) - 3500 PSI
resistance for the auxiliary pressure relief (small) coil is 7- H3 Auxiliary Electric Solenoid
10 ohm and the other coils 5-8 ohms. H4 Lift Lock Solenoid
H5 Tilt Lock Solenoid
Replace the test meter with 12 volt power. You can see MR Main Relief Valve - 3000 PSI
and hear the spool shift.
H2 H1
H3
C4
G3 B3 A3
D3
H5 C3
G2 B2 A2 E2 D2
F2 C2
G1 H4 B1 A1 E1
F1 C1
MR D1 TS-1971
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(CONT’D)
Load Check Valve
Remove the BICS valve assembly from the control valve.

(See Removal And Installation (S/N 514447864 & Above) 2
on Page 20-40-4.)
Figure 20-40-54
1
1
1 N-18698
1
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.-lb. (47 - 54 N•m) torque.
N-20035 Figure 20-40-56
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
N-20077
damage the system.
I-2003-0888
Remove the load check plugs (Item 1) [Figure 20-40-56].
Mark each valve section, spool and related parts so that Remove the spring (Item 2) [Figure 20-40-56] and
they will be returned to its original valve section during poppet (Item 3) [Figure 20-40-56].
assembly.
NOTE: Both load checks poppets, plugs and springs
Use bolts to fasten the control valve to a work bench for are the same for the lift and tilt.
easier disassembly and assembly procedures.
Loosen the load check plug (Item 2) [Figure 20-40-55]
from the auxiliary section of the control valve.
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Main Relief Valve
(CONT’D)
Figure 20-40-58
Load Check Valve (Cont’d)
Figure 20-40-57
N-20039
1
N-20078 Loosen and remove the main relief valve (Item 1) [Figure
20-40-58].
The auxiliary section uses a load check poppet with an Figure 20-40-59
orifice (Item 1) [Figure 20-40-57].
2
NOTE: For correct port locations and valve 3 4 5
component See Identification Chart on Page
20-40-16.
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.-lb. (47 - 54 N•m) torque.
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Port Relief Valve, Lift Spool
(CONT’D)
Figure 20-40-62
Port Relief Valve, Tilt Spool
Figure 20-40-60
1
1
N-20040
N-20043 Remove the port relief valve (Item 1) [Figure 20-40-62]

from the control valve lift section.
Remove the port relief valve (Item 1) [Figure 20-40-60] Figure 20-40-63
from the control valve tilt section.
4
Figure 20-40-61 3
4
3 2
1
2
1
1. O-Ring
2. Back-up Washer
3. O-Ring
1. O-Ring 4. Relief Valve
2. Back-up Washer
3. O-Ring
4. Relief Valve N-18844
N-18844 Remove the O-rings and back-up washer from the port
Remove the O-rings and back-up washer from the port Installation: Always use new O-rings and back-up
relief valve [Figure 20-40-61]. washers. Tighten to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
Installation: Always use new O-rings and back-up

washers. Tighten to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Anti-Cavitation Valve, Lift Spool
(CONT’D)
Figure 20-40-66
Anti-Cavitation Valve / Port Relief Valve, Tilt Spool
Figure 20-40-64 2
N-20043
N-20042 Remove the lift lock solenoid (Item 1) [Figure 20-40-66].
Remove the anti-cavitation valve (Item 2) [Figure 20-40-

Remove the anti-cavitation / port relief valve (Item 1) 66] from the control valve lift section.
[Figure 20-40-64] from the control valve tilt 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 and back-up washer from the anti-

Remove the O-rings (Item 1) [Figure 20-40-65] from the cavitation valve [Figure 20-40-67].
anti-cavitation / port relief valve.

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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Lift And Tilt Block
(CONT’D)
Figure 20-40-70
Rubber Boot
Figure 20-40-68
1 1
2
N-20043
N-20043 Figure 20-40-71
Remove the two screws (Item 1) [Figure 20-40-68] on

the rubber boot retainer. 1
Installation: Tighten the screws to 90 - 100 in.-lb. (10,2-

11,3 N•m) torque.
Figure 20-40-69 1
2 2
2
N-20021
1 2
Remove the lock solenoid (Item 1) [Figure 20-40-70] &

1 [Figure 20-40-71] from the lift and tilt block.
Remove the rubber boot (Item 2) [Figure 20-40-70] &

[Figure 20-40-71]. (See Identification Chart on Page 20-
40-16.)
N-20020
Remove the rubber boot (Item 1) [Figure 20-40-69] and

retainer (Item 2) [Figure 20-40-69].
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Lift Spool And Detent
(CONT’D)
Lift And Tilt Lock Block (Cont’d) procedure:\
Figure 20-40-72 MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool
Figure 20-40-73
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 20-40-
73] 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 O-

ring (Item 2) [Figure 20-40-74] from the lift spool.
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(CONT’D)
Lift Spool And Detent (Cont’d)
Figure 20-40-75
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].
Figure 20-40-76
IMPORTANT
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
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.
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(CONT’D)
Figure 20-40-79
3 2 1
1
N-18930
2 Remove the spool seal (Item 1) [Figure 20-40-81] from

the linkage end of the valve.
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
1 Clamp the linkage end of the spool in a vise [Figure 20-

40-82].
N-18975
Remove the spool assembly and seal (Item 1) [Figure

20-40-80] from the control valve.
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(CONT’D)
Lift Spool And Detent (Cont’d) 1
Figure 20-40-83
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].
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(CONT’D)
Figure 20-40-87
1
2
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
N-18919 break the tap.
Clean all the debris from inside the spool bore.

Inspect the adapter (Item 1) [Figure 20-40-87], collar
(Item 2) [Figure 20-40-87], spring (Item 3) [Figure 20- NOTE: DO NOT USE Loctite® ON THE STUD
40-87] and washer (Item 4) [Figure 20-40-87]. THREADS
Figure 20-40-88 Figure 20-40-90
N-18918
N-18961
Remove the stud from the end of the spool [Figure 20- Install the O-ring (Item 1) [Figure 20-40-90] over the
40-88]. 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 in. drill.
Drill a hole all the way through the plug using a 7/64 in.
tap drill.
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(CONT’D)
Figure 20-40-91
N-18967
Clamp the collar (Item 1) [Figure 20-40-93] in a vise.
N-18963 Figure 20-40-94
Install the plastic plug and O-ring in the spool [Figure 20-
40-91].
2
Figure 20-40-92
O-ring
1
3
2
N-18958
Plastic
Plug Apply grease on all the detent component surfaces
0.60 in. before assembly [Figure 20-40-94].
(15,2 mm)
B-14712 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
Install the stud and tighten until the other end of the stud (Item 1) [Figure 20-40-95 on Page 28].
is out about 0.600 in. (15,2 mm) from the spool [Figure
20-40-92].
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(CONT’D)
Figure 20-40-95
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.-lb. (10,2 - 11,3 N•m).
Install the spring tool (Item 1) [Figure 20-40-96] over the NOTE: The adapter must fit in the center of the washer
washer, spring, collar and detent adapter. (Item 1) [Figure 20-40-98].
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(CONT’D)
Figure 20-40-99
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 N-18972
Install the lift spool assembly in the spool bore [Figure

N-19007 20-40-102].
Install the detent bonnet (Item 1) [Figure 20-40-102].

Hold the detent balls in place with the detent pliers
[Figure 20-40-100]. Install the mounting screws (Item 2) [Figure 20-40-102].
Installation: Tighten the screws to 90 - 100 in.-lb. (10,2-

11,3 N•m) torque.
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(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
Install the bushing (Item 1) [Figure 20-40-106] and O-
ring (Item 2) [Figure 20-40-106] on the linkage end of the
N-20040 lift spool.
Install the end cap (Item 1) [Figure 20-40-104].
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Tilt Spool Removal And Installation
(CONT’D)
Figure 20-40-108
Figure 20-40-107
1
N-20022
1
N-20022 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.)
Install the lift and tilt block (Item 1) [Figure 20-40-107].
(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 O-

ring (Item 2) [Figure 20-40-109] from the tilt spool.
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(CONT’D)
Tilt Spool Removal And Installation (Cont’d)

1
Figure 20-40-110
N-18942
Put the linkage end of the spool in the vise [Figure 20-
40-112].
N-20042
Install the spool tool (Item 1) [Figure 20-40-112] over the
centering spring.
end cap. Figure 20-40-113
Installation: Tighten the bolt to 90 - 100 in.-lb. (10,2 -
11,3 N•m) 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
11,3 N•m) torque.
Remove the spool, centering spring, back-up washer and
spool seal [Figure 20-40-111]. Remove spring tool from the spring assembly.
Assembly: Always use a new spool seal.
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Auxiliary Spool Removal And Installation
(CONT’D)
Figure 20-40-116
Tilt Spool Removal And Installation (Cont’d)
Figure 20-40-114
2 1
3
N-20042
N-18944 Remove the screws (Item 1) [Figure 20-40-116] from the

end cap.
Inspect the adapter (Item 1) [Figure 20-40-114], collar Installation: Tighten the bolt to 90 - 100 in.-lb. (10,2 -
(Item 2) [Figure 20-40-114], spring (Item 3) [Figure 20- 11,3 N•m) torque.
40-114] and washer (Item 4) [Figure 20-40-114].
Figure 20-40-117
Figure 20-40-115
1 2
N-18990
N-19098 N-18943
Remove the end cap, O-ring, springs and spring guide

Remove the spool seal(s) (Item 1) [Figure 20-40-115] [Figure 20-40-117].
and the back-up washer (Item 2) [Figure 20-40-115].
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(CONT’D)
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-40-118
1
N-20073

auxiliary bleed block (Item 2) [Figure 20-40-120].
N-18989
11,3 N•m) torque.
Remove the spool (Item 1) [Figure 20-40-118].
Figure 20-40-121
Assembly: Put grease on all the centering spring
component parts.
Figure 20-40-119 1
N-20074
Remove the auxiliary bleed block (Item 1) [Figure 20-40-

N-20043 121] and O-ring.
Assembly: Always use a new O-ring.

Remove the lock solenoid (Item 1) [Figure 20-40-119]
from the tilt lock block.
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Auxiliary Plug Removal And Installation
(CONT’D)
Figure 20-40-123
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-40-122
1
3
1
P-37717
2
N-20075 Remove the plug (Item 1) [Figure 20-40-123] auxiliary
section of the control valve.
Remove the spring guide (Item 1) [Figure 20-40-122] Figure 20-40-124
and springs (Item 2) [Figure 20-40-122].
Assembly: Put grease on all the centering spring

component parts.
P-37718
Replace the O-rings (Item 1) [Figure 20-40-124].
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(CONT’D)
Auxiliary Electric Solenoid Disassembly
Figure 20-40-125 3
1 2
N-20027
Remove the coil (Item 1) [Figure 20-40-127] and end

1 plate (Item 2) [Figure 20-40-127].
N-20025
Remove the solenoid stem (Item 3) [Figure 20-40-127].
Remove the nut (Item 1) [Figure 20-40-125] from both Installation: Tighten valve to 8 - 12 ft.-lb. (11 - 16 N•m)
solenoids. torque.
Installation: Tighten the nut to 8 - 12 ft.-lb. (11 - 16 N•m) Figure 20-40-128
torque.
Figure 20-40-126
1 N-18795
N-20026 Remove the O-rings (Item 1) [Figure 20-40-128] from

the solenoid stem.
Remove the end plate (Item 1) [Figure 20-40-126] and

housing (Item 2) [Figure 20-40-126].
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HYDRAULIC VALVE CONTROL (FOOT CONTROL) Figure 20-40-130
(CONT’D)
Port Relief-Auxiliary Section Disassembly Plug
Figure 20-40-129
2
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. 2
1
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 20-
40-130] & [Figure 20-40-131] from the plug.
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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.
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HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-2
CONTROL SYSTEM) (ACS)
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 Remove the screws (Item 1) [Figure 20-41-2] from the

actuator retainer.
Installation: Tighten the bolts to 90 - 100 in.-lb. (10,2 -
11,3 N•m) torque.
W-2059-0598
Figure 20-41-3
Figure 20-41-1
1 P-26819
N-23246 Pull the actuator (Item 1) [Figure 20-41-3] away from the
control valve.
Stop the engine. Raise the seat bar. Use a punch and hammer to remove the actuator pin
(Item 2) [Figure 20-41-3] from the actuator and spool.
Remove the access cover (Item 1) [Figure 20-41-1] from
the right side of the loader frame. Remove the actuator from the hydraulic control valve.
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CONTROL SYSTEM (ACS) (CONT’D)
Actuator Removal And Installation (In Loader)

(Cont’d)
Figure 20-41-4
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
P-28622A
Check and replace the O-ring (Item 1) [Figure 20-41-5]

on the spacer.
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Removal & Installation (S/N 514447863 & Below)
DANGER
1
N-19865
P-90328
Loosen the tubeline clamps (Item 1) [Figure 20-41-7] at
AVOID DEATH
the engine compartment.
Clean the area around the control valve.
Figure 20-41-8
D-1009-0409
WARNING
the lift arms are secured by an approved lift arm 1
W-2059-0598
N-23630
device. (See Engaging The Lift Arm Support Device on Disconnect the three hoses (Item 1) [Figure 20-41-8]
Page 10-20-1.) from the lift arm bypass control valve.

on Page 10-30-1.)


on Page 50-100-1.)
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(Cont’d)
Figure 20-41-9 1
1
2
N-23635
Disconnect the harness connector (Item 1) [Figure 20-

41-11] from the auxiliary solenoid.
N-23632 Disconnect the harness connector (Item 2) [Figure 20-

41-11] from the BICS™ valve solenoid connector.
At the right fender, remove the two mounting bolts (Item Figure 20-41-12
1) [Figure 20-41-9].
Remove the lift arm bypass valve and mount from the
loader.
Figure 20-41-10
2
1
1
N-23636
Disconnect both harness connectors (Item 1) [Figure 20-

41-12] from the actuators.
N-23631
Disconnect the wiring harness connectors (Item 1)

[Figure 20-41-10] from the auxiliary solenoids
connectors.

20-41-10] from the BICS™ valve solenoid connector.
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Removal And Installation (S/N 514447863 & Below) 1

(Cont’d)
2
Figure 20-41-13
2
N-23638
1
Remove the hydraulic tubeline (Item 1) [Figure 20-41-
15] from the control valve to the oil cooler.
N-23637 Remove the two auxiliary tubelines (Item 2) [Figure 20-

Disconnect the case drain hose (Item 1) [Figure 20-41- Remove the charge pressure hose and sending unit
13]. (Item 3) [Figure 20-41-15].
Figure 20-41-14 Figure 20-41-16
1 1
2
N-23634
N-23639
Remove the two tubelines clamps (Item 1) [Figure 20- Remove the rod end tilt cylinder tubeline (Item 1) [Figure
41-14]. 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].
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(Cont’d)
Figure 20-41-17
N-23642
1
Install a chain hoist to the control valve for support
[Figure 20-41-19].
2
4 Figure 20-41-20
N-23640
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)

1
[Figure 20-41-17] and (Item 4) [Figure 20-41-17] if
equipped.
Figure 20-41-18
N-23633
1 At the right fender, remove the two control valve mount

bracket mounting bolts (Item 1) [Figure 20-41-20].
Figure 20-41-21
N-23641
Disconnect the inlet hose (Item 1) [Figure 20-41-18] that

comes from the pump.
1
N-23643
Remove the control valve from the loader [Figure 20-41-

21].
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HYDRAULIC CONTROL VALVE (ADVANCED Remove the loader alternator. (See Removal And
CONTROL SYSTEM (ACS) (CONT’D) Installation on Page 60-30-3.)
Removal And Installation (S/N 514447864 & Above) Figure 20-41-22
DANGER
P-90328
1
AVOID DEATH 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
D-1009-0409
removed from the tee fitting located and the rear of
the loader first.
Cap and plug the hose and fitting.


support device can allow the lift arms or attachment 1
W-2059-0598
Page 10-20-1.)
1
Stop the engine. Raise the seat bar. 1
Raise the operator cab. (See Raising The Operator Cab P-26823
on Page 10-30-1.)
Drain the hydraulic reservoir. (See Draining The Fluid Disconnect the three hoses (Item 1) [Figure 20-41-23]
Reservoir on Page 20-80-1.) from the lift arm bypass control valve.
Remove the control panel. (See Removal And Installation Cap and plug the hoses and fittings.
on Page 50-100-1.)
Clean the area around the control valve.
Open the rear door.
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(Cont’d)
1 1
Figure 20-41-24
P-28545

20-41-26] from the auxiliary valve solenoids.
N-23632 Figure 20-41-27
At the right fender, remove the two mounting bolts and

nuts (Item 1) [Figure 20-41-24] from the lift arm bypass
mount.
Remove the lift arm bypass valve and mount from the
loader.
Figure 20-41-25
1
1
N-23635

41-27] from the BICS valve solenoid connector.
P-26824

20-41-25] from the charge pressure sender.
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(Cont’d) 1
Figure 20-41-28
P-28545
Remove the hydraulic hose (Item 1) [Figure 20-41-30]

from the control valve to the auxiliary pressure release
accumulator.
P-26826
Remove the case drain hose (Item 2) [Figure 20-41-30]
from the control valve to the case drain filter.
Disconnect both harness connectors (Item 1) [Figure 20-
41-28] from the actuators. Figure 20-41-31
Figure 20-41-29
2
1
1
P-28549
P-26828
Install a chain hoist (Item 1) [Figure 20-41-31] to the
control valve.
Loosen the fixed end main valve hose assembly (Item 1)
[Figure 20-41-29] from the control valve. Disconnect the hydraulic hose (Item 2) [Figure 20-41-31]
that goes from the control valve to the auxiliary gear
The hose can be removed from the control valve by pump.
rotating the hose assembly.
Remove the right side motor cover.
Remove the right rear wheel / tire assembly from the

loader.
Remove the right side pump access cover.
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(Cont’d)
Figure 20-41-32
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]
P-26832 Cap and plug the tubeline and fitting.

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.

and nuts (Item 3) [Figure 20-41-33] from the loader
fender.
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(Cont’d)
Figure 20-41-36 2
1
1
P-26837
Disconnect the three auxiliary tubelines that are

connected to the fitting (Item 1) [Figure 20-41-38].
P-28547 Remove the fitting from the loader.
Disconnect the tilt tubeline (Item 2) [Figure 20-41-38]

Disconnect the hydraulic fitting (Item 1) [Figure 20-41- from the fitting on the control valve.
36] from the charge pressure sender.
Figure 20-41-39
Move the charge pressure sender and hose assembly to
the side, to allow clearance for the control valve removal.
Mark all tubelines for correct installation.
Figure 20-41-37
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.)
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HYDRAULIC CONTROL VALVE (ADVANCED Actuator Removal And Installation (Out Of Loader)
Figure 20-41-42
(Cont’d)
Figure 20-41-40 2
P-28319
1
Remove the two screws (Item 1) [Figure 20-41-42] on

P-26839 the actuator retainer.
Installation: Tighten the bolt and nut to 90 - 100 in.-lb.

Disconnect the auxiliary tubeline (Item 1) [Figure 20-41- (10,2 - 11,3 N•m) torque.
40] from the control valve.
Pull the actuator (Item 2) [Figure 20-41-42] away the
Cap and plug the tubeline and fitting. control valve.
Figure 20-41-41 Figure 20-41-43
P-26840
P-28320
Lower the chain hoist and valve to allow clearance so the Use a drift pin and hammer to remove the actuator pin
actuators can clear the tubelines. (Item 1) [Figure 20-41-43] from the actuator and the lift
or tilt spool.
Rotate the valve upward until the actuators are above the
tubelines [Figure 20-41-41].
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HYDRAULIC CONTROL VALVE (ADVANCED BICS™ Valve Removal And Installation
Figure 20-41-45
Actuator Removal And Installation (Out Of Loader)
(Cont’d)
Figure 20-41-44
1 1
1
P-28322
4
2 3 Loosen the six mounting bolts (Item 1) [Figure 20-41-45]
P-28321 from the BICS valve.
Remove the mounting bolts.

Remove the actuator (Item 1) [Figure 20-41-44].
Figure 20-41-46
Remove the O-ring (Item 2) [Figure 20-41-44].
Remove the spacer block (Item 3) [Figure 20-41-44].
P-28323
Remove the BICS valve assembly (Item 1) [Figure 20-

41-46] from the top of the control valve.
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HYDRAULIC CONTROL VALVE (ADVANCED The chart below lists the correct torque specifications
CONTROL SYSTEM (ACS) (CONT’D) and tightening sequence when reinstalling the BICS™
valve assembly to the hydraulic control valve. Thoroughly
BICS™ Valve Removal And Installation (Cont’d) clean and dry bolts and threads in valve. Use liquid
adhesive Loctite® #242.
Figure 20-41-47
Step Torque Sequence
1 110 - 130 in.-lb.
(12,4 - 14,7 N•m)
2 190 - 210 in.-lb.
(21,5 - 23,7 N•m) 1, 2, 3, 4, 5 & 6
3* 190 - 210 in.-lb.
1
1 (21,5 - 23,7 N•m)
*Torque must be 190 - 210 in.-lb. (21,5 - 23,7 N•m) for

every bolt or repeat step 3.
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
1 2
5
4
P-28322
Install the six mounting bolts (Item 1) [Figure 20-41-48].
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BICS™ Valve Lift Arm Bypass Orifice Removal And

Installation
Figure 20-41-49
N-18685
Using a flat blade screwdriver, remove the lift arm bypass

orifice (Item 1) [Figure 20-41-50] & [Figure 20-41-51].
P-28332 Orifice size is 0.078 in.
Clean and inspect the orifice. Replace as needed.

Remove the fitting (Item 1) [Figure 20-41-49] from the
BICS valve. Reverse the removal procedure to install the lift arm
bypass orifice.
Figure 20-41-50
P-28333
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BICS™ Valve Check Valve Removal And Installation
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.-lb. (27

N•m) torque.
Figure 20-41-53
N-18684

back-up ring (Item 2) [Figure 20-41-53].

up ring (Item 2) [Figure 20-41-53] on the check valve.
Check valve (Item 3) [Figure 20-41-53] has a rating of 5-

10 PSI.
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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 20-

41-56] & [Figure 20-41-57] from the valve.
P-28335
Installation: Tighten the lock valve(s) to 25 ft.-lb. (34
N•m) torque.
There are two lock valves on the BICS valve, lift lock
valve (Item 1) [Figure 20-41-55] and tilt lock valve (Item Figure 20-41-58
2) [Figure 20-41-55].
Figure 20-41-56 1
1 2
2
2 N-18690
P-28336 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.

up rings (Item 2) [Figure 20-41-58] on the tilt and lift lock
valves.
Reverse the removal procedure to install the lock valve.
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BICS™ Valve Removal Solenoid And Installation
Figure 20-41-59 1
P-28340
2
Remove the solenoid (Item 1) [Figure 20-41-61].
P-28338 Installation: Tighten the stem to 20 ft.-lb. (27 N•m)

torque.
Remove the nut (Item 1) [Figure 20-41-59] from the Figure 20-41-62
solenoid cartridge.
Installation: Tighten the mounting nut to 53 in.-lb. (6

N•m) torque.
2 3
Remove the coil (Item 2) [Figure 20-41-59].
Figure 20-41-60
1 1
N-18694

back-up rings (Item 2) [Figure 20-41-62] from the stem.
Clean all parts in solvent and dry with compressed air.
N-18693 Inspect all parts for wear and replace as needed.
NOTE: the screen (Item 3) [Figure 20-41-62] can be

Remove the O-rings (Item 1) [Figure 20-41-60] from cleaned with solvent. If it is torn or worn it
both ends of the coil. 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 20-41-
62] on the stem.
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HYDRAULIC CONTROL VALVE (ADVANCED Identification Chart
Item 863 Loader
BICS™ Valve Solenoid Testing A1 Lift Cylinder Base End / Restrictor
A2 Tilt Cylinder Base End
Figure 20-41-63 A3 Auxiliary Hydraulics
B1 Lift Cylinder Rod End
B2 Tilt Cylinder Rod End
B3 Auxiliary Hydraulics
C1 Load Check Valve / Lift Function
C2 Load Check Valve / Tilt Function
C3 Orifice Load Check Valve / Auxiliary Function
C4 Outlet Fluid Flow
D1 Lift Spool Detent
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool / Centering Springs
E1 Port Relief Valve - (863) - 3500 PSI
E2 Anti-Cavitation / Port Relief Valve - 3500 PSI
F1 Anti-Cavitation Valve
F2 Port Relief Valve - 3500 PSI
G1 Lift Spool End
P-9175
G2 Tilt Spool End
G3 Auxiliary Spool / Centering Springs
Use an Ohm meter to measure coil resistance [Figure H1 Auxiliary Electric Solenoid
20-41-63]. H2 Plug / Port Relief (Optional) - 3500 PSI
H3 Auxiliary Electric Solenoid
Coil wires do not have polarity. MR Main Relief Valve - (863)-2950-3050 PSI
Correct resistance for the auxiliary, lift and tilt lock coils
are 7-10 ohms. H2 H1
H3
The other coils (BICS, diverter, select valve) are 5-8
ohms.) C4
G3 B3 A3
D3
C3
G2 B2 A2 E2 D2
F2 C2
G1 B1 A1 E1 D1
F1 C1
MR TS-2136
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HYDRAULIC CONTROL VALVE (ADVANCED Load Check Valve
Lift Base End Restrictor
Remove the BICS™ valve assembly from the control IMPORTANT

valve. (See BICS™ Valve Removal And Installation on
page 20-41-13.) When repairing hydrostatic and hydraulic systems,
Figure 20-41-64 parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888
1 Figure 20-41-65
1 1
N-21159
Remove the restrictor (Item 1) [Figure 20-41-64] from

2
the lift section base end port.
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.
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Load Check Valve (Cont’d)
Figure 20-41-66 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
P-28324 the poppet (Item 2) [Figure 20-41-68].
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.-lb. (47 - 54 N•m) 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].
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2
3 5
Main Relief Valve 4
Figure 20-41-69
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
P-28326
Installation: Always use new O-rings, sleeve and glide
ring. Tighten to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
Loosen the main relief valve (Item 1) [Figure 20-41-69].
Figure 20-41-70
P-28327
Remove the main relief valve (Item 1) [Figure 20-41-70].
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Port Relief Valve(s)
Figure 20-41-72
N-18981
Remove the port relief valve (Item 1) [Figure 20-41-74].
N-19000 Figure 20-41-75
Figure 20-41-73 4
3
2
1
1
1. O-Ring
2. Backup Washer
3. O-Ring
4. Relief Valve
N-18844
N-19034 Remove the O-rings and back-up washer from the port
Loosen the port relief valve (Item 1) [Figure 20-41-72] &

[Figure 20-41-73].

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Anti-Cavitation Valve / Port Relief Valve
Figure 20-41-76
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 20-41-

76].

Figure 20-41-77
N-18980
Remove the anti-cavitation / port relief valve (Item 1)

[Figure 20-41-77] from the control valve for the tilt
section.
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2
1 3 4
Anti-Cavitation Valve
Figure 20-41-79
E-1509
1. Anti-Cavitation Valve
2. O-Ring
3. Backup Washer
4. O-Ring
P-28331
Remove the O-rings and back-up washer from the anti-

cavitation valve [Figure 20-41-81].
P-28329
Figure 20-41-80
1
N-19036
Remove the anti-cavitation valve (Item 1) [Figure 20-41-

79] & [Figure 20-41-80] from the control valve.
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Lift Spool Removal And Installation
Figure 20-41-82
N-19003

1 cap.
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
N-18983
2
1 Remove the spool assembly (Item 1) [Figure 20-41-85]

2
and seal from the control valve.
N-19114
Remove the spacer (Item 1) [Figure 20-41-83] and O-

ring (Item 2) [Figure 20-41-83] from the lift spool.
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Tilt Spool Removal And Installation
Figure 20-41-86
1
1
N-19003
2 1
end cap.
P-28320
11,3 N•m) torque.
Remove the bolts (Item1) [Figure 20-41-86] to pull the
actuator (Item 2) [Figure 20-41-86] from the spacer. Figure 20-41-89
Figure 20-41-87
2 N-18985
2 1 P-28321
Remove the spool assembly (Item 1) [Figure 20-41-89]
and seal from the control valve.
Remove the spacer (Item 1) [Figure 20-41-87] and the
O-rings (Item 2) [Figure 20-41-87] from the tilt spool. Assembly: Always use a new spool seal.
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1
Lift And Tilt Spool Disassembly And Assembly 2
3
Figure 20-41-90
4
N-18944
NOTE: The centering spring (Item 3) [Figure 20-41-92]

is orange on all 800 Series loaders.
N-18942
Inspect the adapter (Item 1) [Figure 20-41-92], collar
(Item 2) [Figure 20-41-92], spring (Item 3) [Figure 20-
Put the linkage end of the spool in the vise [Figure 20- 41-92] and washer (Item 4) [Figure 20-41-92].
41-90].
Figure 20-41-93
Install the spool tool (Item 1) [Figure 20-41-90] over the
centering spring.
Figure 20-41-91 1
2
N-18930 N-18943
Remove the spool seal(s) (Item 1) [Figure 20-41-93] and

N-19014 the back-up washer (Item 2) [Figure 20-41-93].

centering spring to the spool.

11,3 N•m) torque.
Remove the spring tool from the spring assembly.
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Auxiliary Spool Removal And Installation
Figure 20-41-94 1
N-18988
N-19003 Assembly: Put grease on all the centering spring

component parts.
end cap (both sides).
Installation: Tighten the screws to 90 - 100 in.-lb. (10,2 -

11,3 N•m) torque.
Figure 20-41-95
N-18987
Remove the end cap, O-ring, springs and washer (both

sides) [Figure 20-41-95].
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Auxiliary Electric Solenoid Disassembly And

Assembly
1
Figure 20-41-97
N-18795

stem.
1
P-28341 Figure 20-41-100
Remove the nut (Item 1) [Figure 20-41-97] from both

solenoids.
Installation: Tighten the nut to 8 - 12 ft.-lb. (11 - 16 N•m)

torque.
Figure 20-41-98
2
1
2 P-28344
1 Disconnect the tubeline (Item 1) [Figure 20-41-100] and

remove the screws (Item 2) [Figure 20-41-100] from the
end cap.

11,3 N•m) 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.-lb. (27 N•m)

torque.
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Auxiliary Electric Solenoid Disassembly And Plug

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) 2

[Figure 20-41-101]. Remove the O-ring, springs and 1
washer [Figure 20-41-101].
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 20-
40-103] & [Figure 20-41-104] from the plug.
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 20-41-

102] is 3500 PSI (24129 kPa).
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HYDRAULIC CONTROL VALVE (ADVANCED
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.
Use new O-rings and back-up rings.
Apply oil to all new O-rings and back-up rings before

installation.
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LIFT ARM BYPASS CONTROL VALVE Removal And Installation
Inspecting
Raise the lift arms 6 feet (2 m) off the ground. Stop the
engine. Turn the Lift Arm Bypass Control Knob clockwise
DANGER
1/4 turn. Then pull up and hold the Lift Arm Bypass
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.
P-90328
Raise the lift arms about 6 feet (2 meters) off the ground.
AVOID DEATH
Turn the key OFF and wait for the engine to come to a • Disconnecting or loosening any hydraulic
complete stop. tubeline, hose, fitting, component or a part failure
Turn the key ON. Press the green PRESS TO OPERATE • Keep out of this area when lift arms are raised
Button, move the let hand control toward the operator. unless supported by an approved lift arm
The lift arms should not lower. support. Replace if damaged.
D-1009-0409
Move the right hand control away from the operator. The
bucket (or attachment) should not tilt forward.
WARNING
W-2059-0598
WARNING
explosion or fire.
W-2103-0508
Raise the lift arms and install the lift arm support device.
(See Engaging The Lift Arm Support Device on Page 10-
20-1.)

on Page 10-30-1.)
Remove the control panel / steering levers. (See

Removal And Installation on Page 50-100-1.)
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LIFT ARM BYPASS CONTROL VALVE (CONT’D) Disassembly And Assembly
Removal And Installation (Cont’d) Figure 20-50-3
Figure 20-50-1
2
1 2
1
1
P7939
P-28558
Remove the bypass valve (Item 1) [Figure 20-50-3] from
the valve block. Inspect the bypass valve for damage and
Disconnect the hydraulic hoses (Item 1) [Figure 20-50-1] replace if necessary.
and cap the plug lines.
Installation: Tighten the valve to 33 - 37 ft.-lb. (45 - 50
Remove the two mounting bolts (Item 2) [Figure 20-50- N•m) torque.
1].
Inspect the hydraulic fittings (Item 2) [Figure 20-50-3] on
Installation: Tighten the mounting bolts to 180 - 200 in.- the valve block for damage and replace if necessary.
Remove the bypass valve.
Figure 20-50-2
N-19734
Remove the two bolts (Item 1) [Figure 20-50-2] to

replace the bypass valve mounting bracket if necessary.
Reverse the removal procedure to install the lift arm

bypass valve in the loader.
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HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 & Disconnect the OUTLET hose (Item 1) [Figure 20-60-1]
BELOW) from the pump.
Checking The Output Of The Pump Figure 20-60-2
WARNING
2
of the frame before running the engine for service. 1
W-2017-0286
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:
MEL 10003 - Hydraulic Tester
MEL 10006 - Hydraulic Test Kit
NOTE: Make sure all the air is removed from the

P-7753
hydraulic system before beginning the test.
Air in the system can give an inaccurate test.
*Relief pressure must be per specification Connect the INLET hose from the tester to the OUTLET
before the test is done. hose (Item 1) [Figure 20-60-1] of the pump. Connect the
OUTLET hose (Item 2) [Figure 20-60-2] from the tester
Lift and block the loader. (See LIFTING AND BLOCKING to the tubeline (Control Valve Inlet) which was previously
THE LOADER on Page 10-10-1.) disconnected from the pump outlet hose (Item 1) [Figure
20-60-2].
Raise the lift arms and install the lift arm support device.
(See Engaging The Lift Arm Support Device on Page 10- Start the engine and ran at low idle RPM. Make sure the
20-1.) tester is connected correctly. If no flow is indicated on the
Raise the operator cab. (See Raising The Operator Cab tester, the hoses are connected wrong. With the hoses
on Page 10-30-1.) connected correctly, increase the engine speed to full
RPM.
Connect the remote start switch. (See REMOTE START
on Page 10-60-1.) Warm the fluid to 140° F (60° C) by turning the restrictor
control on the tester about 1000 PSI (6895 kPa). DO
Figure 20-60-1 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.
HIGH PRESSURE FLOW (GPM)

%= x100
FREE FLOW (GPM)
A low percentage may indicate a pump problem.
N-19740
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HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 & Figure 20-60-3
BELOW) (CONT’D)
DANGER 1
N-19741
P-90328
Loosen the hose clamps and disconnect the inlet hoses
AVOID DEATH
(Item 1) [Figure 20-60-3] from the pump inlet fitting.
Figure 20-60-4
D-1009-0409
WARNING
Never work on a machine with the lift arms up unless 1
N-17600
W-2059-0598
Disconnect the hose (Item 1) [Figure 20-60-4] from the
pump outlet to the control valve.
device. (See Engaging The Lift Arm Support Device on Remove the pump mounting bolts (Item 2) [Figure 20-
Page 10-20-1.) 60-4] (both sides).
Installation: Tighten the mounting bolts to 25 - 27 ft.-lb.
Raise the operator cab. (See Raising The Operator Cab (34 - 37 N•m) torque.
on Page 10-30-1.)
Remove the hydraulic pump.
WARNING
explosion or fire.
W-2103-0508
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HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 &
BELOW) (CONT’D)
1 2 3
4
5
6 7
10
8 6
5
13 14
11
12
TS-1022A
Ref. Description
1. Bolt
2. Washer
3. End Housing
4. O-Ring Seal
5. Seal
6. Ring
7. Body
8. Bearing Housing
9. Drive Gear
10. Idler Gear
11. Bolt
12. Washer
13. Cover
14. Seal
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BELOW) (CONT’D)
Disassembly
IMPORTANT
1
damage the system.
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 20- CD-15143
60-5].
Figure 20-60-6 Remove the mounting flange end housing (Item 1)

[Figure 20-60-8].
CD-15141
Remove the pump housing bolts (Item 1) [Figure 20-60-

6]
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BELOW) (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 back-up seals / O-ring seals (Item 2) [Figure
20-60-11] from the bearing housing.
Remove the gear / bearing housing assembly [Figure
20-60-9]. Figure 20-60-12
Figure 20-60-10
1
CD-15150
1
CD-15145
Remove the drive gear shaft seals (Item 1) [Figure 20-
60-12].
pump housing.
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BELOW) (CONT’D)
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.
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BELOW) (CONT’D)
Assembly
IMPORTANT
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
1 CD-15150
Always use new O-rings and seals when assembling the

hydraulic pump. CD-15152
Install the two seals (Item 1) [Figure 20-60-16] into the

mounting flange housing using the correct size driver Install the back-up seals / O-ring seals (Item 1) [Figure
tool. 20-60-18].
Install the inside seal with the lip facing the drive gear Install the large O-ring (Item 2) [Figure 20-60-18]
and the outside seal with the lip facing outward.
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BELOW) (CONT’D)
Assembly (Cont’d)
Figure 20-60-19
CD-15155
Install the end housing (Item 1) [Figure 20-60-21].
CD-15153 Install the four pump housing bolts [Figure 20-60-21].
Figure 20-60-22
Install the mounting flange housing on the pump housing
[Figure 20-60-19].
Figure 20-60-20
1 CD-15156
Tighten the bolts to 45 - 50 ft.-lb. (61 - 68 N•m) torque

CD-15154 [Figure 20-60-22].
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].
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HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N Figure 20-61-1
514449483 & BELOW)
Checking The Output Of The High Flow Pump

1
1
WARNING 1
1
1
Failure to use jackstands can allow the machine to 1
W-2017-0286
1
2
N-23027
NOTE: This procedure is the same for 863 and 863H in
the standard flow mode.
Remove the seven bolts (Item 1) [Figure 20-61-1] and
The tools listed will be needed to do the following cover (Item 2) [Figure 20-61-1].
procedure:
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.

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 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.
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HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N
514449483 & BELOW) (CONT’D)
Checking The Output Of The High FLow Pump

WARNING
(Cont’d)
Warm the fluid to 140° F (60° C) by turning the restrictor the lift arms are secured by an approved lift arm
control on the tester about 1000 PSI (6895 kPa). DO support device. Failure to use an approved lift arm
NOT exceed the system relief pressure. Open the support device can allow the lift arms or attachment
restrictor control and record the free flow (GPM) at full to fall and cause injury or death.
RPM. W-2059-0598
Push the mode switch (on the remote start switch) to Figure 20-61-3
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.
%= x100
FREE FLOW (GPM)
1
A low percentage may indicate a pump problem.

THE LOADER on Page 10-10-1.) N-19740

on Page 10-30-1.)
Drain the hydraulic reservoir (See Draining The Fluid
Figure 20-61-4
DANGER
1
P-90328
N-18594
AVOID DEATH
tubeline, hose, fitting, component or a part failure Loosen the clamps and disconnect the pump inlet hoses
can cause lift arms to drop. (Item 1) [Figure 20-61-4].
unless supported by an approved lift arm Remove the hydraulic hose (Item 2) [Figure 20-61-4]
support. Replace if damaged. from the pump.
D-1009-0409
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514449483 & BELOW) (CONT’D)
Figure 20-61-5
N-18595
Remove the inlet fitting (Item 1) [Figure 20-61-5] from

the pump.
Figure 20-61-6
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.-lb. (34 - 37
N•m) torque.
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514449483 & BELOW) (CONT’D)
1 2 3
4
5 7
6
10
9
6
5 9
4
12
11
13
14 15
16
17
18
20
15
14 13 19
21
23
22
24
25 26 TS-1078C
Ref. Description Ref. Description
1. Bolt 14. Seal

2. Washer 15. Ring
3. Cover 16. Body
4. O-Ring 17. Bearing
5. Seal 18. Drive Gear
6. Ring 19. Idler Gear
7. Body 20. Bearing
8. Dowel 21. Cover
9. Bearing 22. Seal
10. Drive Gear 23. Bolt
11. Idler Gear 24. Seal
12. Cover 25. Washer
13. O-Ring Seal 26. Bolt
863 Bobcat Loader

236 of 968
514449483 & BELOW) (CONT’D)
Disassembly
IMPORTANT
1
3
damage the system.
I-2003-0888 2
CD-15017
Figure 20-61-7
Remove the four pump housing bolts (Item 1) [Figure 20-
Mark
61-8] from the small gear pump end housing.
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 20-

61-7].
1
2
CD-15018

end housing.
Remove the back-up seal / O-ring seal (Item 2) [Figure

20-61-9] from the pump housing.
863 Bobcat Loader

237 of 968
514449483 & BELOW) (CONT’D)
Figure 20-61-10
CD-15021
1 Remove the drive and idler gear from the bearing

housing [Figure 20-61-12].
2 CD-15019
Figure 20-61-13
center housing.

20-61-10].
Figure 20-61-11
1
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

CD-15020 20-61-13].
Remove the bearing housing / gears assembly from the

863 Bobcat Loader

238 of 968
514449483 & BELOW) (CONT’D)
Figure 20-61-14
1
2
2 CD-15025
CD-15023 Remove the back-up seal / O-ring seal (Item 2) [Figure

20-61-16].
Remove the O-ring (Item 1) [Figure 20-61-14]. Figure 20-61-17
20-61-14].
Figure 20-61-15
CD-15026
Remove the bearing housing / gears assembly from the

1 large pump housing [Figure 20-61-17].
CD-15024
Remove the center housing (Item 1) [Figure 20-61-15]

from the large gear pump housing.
863 Bobcat Loader

239 of 968
514449483 & BELOW) (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
CD-15027 and correct size driver tool to remove it from the center
housing.
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.
863 Bobcat Loader

240 of 968
514449483 & BELOW) (CONT’D)
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 20-61-

23].
Check the surfaces in the gear area for scratches, wear

and etc.
Replace all parts as needed.
863 Bobcat Loader

241 of 968
514449483 & BELOW) (CONT’D)
Assembly
IMPORTANT 1

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

mounting flange housing using the correct size driver CD-15033
tool.
Install the inside seal with the lip facing the drive gear Install the bearing housing / gears assembly into the
and the outside seal with the lip facing outward. large pump housing [Figure 20-61-26].
Install the back-up / O-ring seal (Item 1) [Figure 20-61-

26].
863 Bobcat Loader

242 of 968
514449483 & BELOW) (CONT’D)
Assembly (Cont’d)
Figure 20-61-27
2
1
CD-15036
Install the mounting flange housing (Item 1) [Figure 20-

61-29] 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].

1
Figure 20-61-28
CD-15037
Install the hex head bolts (Item 1) [Figure 20-61-30] and

1 allen head bolts (Item 2) [Figure 20-61-30]. Finger
tighten only.
CD-15035
Install the center housing (Item 1) [Figure 20-61-28] on

the large pump housing.
863 Bobcat Loader

243 of 968
514449483 & BELOW) (CONT’D)
Assembly (Cont’d)
Figure 20-61-31
1
2
1
CD-15017
Install pump housing on the center housing [Figure 20-

61-33].
CD-15020
Install the drive and idler gears into the bearing housing Install the back-up seal / O-ring seal (Item 2) [Figure 20-
(Item 1) [Figure 20-61-31]. 61-33].
Figure 20-61-32 Install the end housing.
Install the four pump housing bolts.
Figure 20-61-34
1 2
CD-15019
Install the bearing housing / gears assembly into the

pump housing [Figure 20-61-32].
CD-15084

Tighten the small pump housing bolts to 20 - 25 ft.-lb. (27
Install the back-up seal / O-ring seal (Item 2) [Figure 20- - 34 N•m) torque [Figure 20-61-34].
61-32].
863 Bobcat Loader

244 of 968
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.-lb. (46 - 56 N•m) torque [Figure 20-
61-35].
863 Bobcat Loader

245 of 968
863 Bobcat Loader
246 of 968
HYDRAULIC PUMP (CAST IRON) (S/N 514449260 & Figure 20-62-1
ABOVE)
Check The Output Of The Hydraulic Pump Without

Power Bob-Tach
1
WARNING
W-2017-0286
P-34154
Disconnect the OUTLET hose (Item 1) [Figure 20-62-1]

WARNING from the pump.
Never work on a machine with the lift arms up unless Figure 20-62-2
W-2059-0598

procedure: 2 1
MEL1563 - Remote Start Tool

Lift and block the loader. (See LIFTING AND BLOCKING P-34153
Raise the lift arms and install an approved lift arm support Connect the INLET hose (Item 1) [Figure 20-62-2] from
device. (See Engaging The Lift Arm Support Device on the tester to the OUTLET fitting (Item 2) [Figure 20-62-1]
Page 10-20-1.) of the pump. Connect the OUTLET hose (Item 2) [Figure
20-62-2] from the tester to the hose (Item 1) [Figure 20-
Raise the operator cab. (See Raising The Operator Cab 62-1] which was disconnected from the pump.
on Page 10-30-1.)
Connect the remote start tool. (See REMOTE START on

Page 10-60-1.)
IMPORTANT
I-2024-0284
863 Bobcat Loader

247 of 968
HYDRAULIC PUMP (CAST IRON) (S/N 514449260 &
ABOVE) (S/N 514449260 & ABOVE) (CONT’D)

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
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) X100
FREE FLOW (GPM)
A low percentage may indicate a failed pump.
*See “Hydraulic System” on page SPEC-10-3 for system

relief pressure and full RPM.
863 Bobcat Loader

248 of 968
ABOVE) (CONT’D)
Check The Output Of The Hydraulic Pump With

Power Bob-Tach 1
WARNING
fall or move and cause injury or death. 2
W-2017-0286
P-26916

WARNING from the top of the Power Bob-Tach block.
W-2059-0598
The tools listed will be needed to do the following 2 1

procedure:

Page 10-20-1.) on the top of the Power Bob-Tach block. Connect the
OUTLET hose (Item 2) [Figure 20-62-5] from the tester
Raise the operator cab. (See Raising The Operator Cab to the hose (Item 1) [Figure 20-62-4] which was
on Page 10-30-1.) disconnected from the Power Bob-Tach block.

Page 10-60-1.) IMPORTANT
I-2024-0284
863 Bobcat Loader

249 of 968
ABOVE) (CONT'D)
Check The Output Of The Hydraulic Pump With DANGER

Figure 20-62-6
EXAMPLE: TESTER
CONNECTION
Reservoir
P-90328
AVOID DEATH
Hydraulic Pump tubeline, hose, fitting, component or a part failure
Out In can cause lift arms to drop.
Hydraulic Control
Valve • Keep out of this area when lift arms are raised
1 support. Replace if damaged.
BH-00196 D-1009-0409
Start the engine and run at low idle RPM. Make sure the WARNING
tester, the hoses are connected wrong. With the hoses Never work on a machine with the lift arms up unless
connected correctly, increase the engine speed to full the lift arms are secured by an approved lift arm
RPM*. support device. Failure to use an approved lift arm
Warm the fluid to 140° F (60° C) by turning the restrictor to fall and cause injury or death.
control (Item 1) [Figure 20-62-6] on the tester to about W-2059-0598
flow (GPM) at full RPM. Raise the lift arms and install an approved lift arm support
Push the maximum / variable flow switch (on the remote Page 10-20-1.)
light will come ON. Push the button (on the right control Stop the engine. Raise the seat bar.
go over main relief). Record the highest pressure (PSI) Lift and block the rear of the loader. (See LIFTING AND
and flow (GPM). The high pressure flow must be at least BLOCKING THE LOADER on Page 10-10-1.)
80% of free flow.
%= HIGH PRESSURE FLOW (GPM) X100 on Page 10-30-1.)
FREE FLOW (GPM)
Drain the hydraulic fluid from the reservoir. (See Draining
The Fluid Reservoir on Page 20-80-1.)
*See “Hydraulic System” on page SPEC-10-3 for system
relief pressure and full RPM. Remove the Power Bob-Tach block if equipped. (See
863 Bobcat Loader

250 of 968
ABOVE) (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
(37 - 50 N•m) torque.
Disconnect and cap the hoses from the outlet fitting (Item
1) [Figure 20-62-7] of the hydraulic pump. Figure 20-62-10
Figure 20-62-8
1 1
1
2
1
P-26348 P-26318
P-34155
Remove the hydraulic pump from the hydrostatic pump
[Figure 20-62-10].
Disconnect and cap the inlet hoses (Item 1) [Figure 20-
62-8] from the front of the hydraulic pump. Remove the coupler (Item 1) [Figure 20-62-10] from the
hydraulic shaft.
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.
863 Bobcat Loader

251 of 968
ABOVE) (CONT’D)
Identification
15
8
7
6
14
12 13
11
9 10
7
1 4 5
3
B-16050A
REF. DESCRIPTION REF. DESCRIPTION
1 RETAINING RING 8 DRIVE GEAR

2 PUMP END SECTION 9 IDLER GEAR
3 PRE-LOAD SEAL 10 PUMP CENTER SECTION
4 LOAD SEAL 11 WEAR PLATE
5 SECTION SEAL 12 SECTION SEAL
6 WEAR PLATE 13 PUMP END SECTION
7 PINS 14 BOLT (4)
15 BOLT (4)
863 Bobcat Loader

252 of 968
ABOVE) (CONT’D)
Disassembly And Assembly 1
IMPORTANT
damage the system.
I-2003-0888
P-26353
Figure 20-62-11
Remove the pump end section (Item 1) [Figure 20-62-
12].
1 Figure 20-62-13
P-26352
2
1
P-26351
Mark the pump sections for correct assembly [Figure 20- 2

62-11]. 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.-lb. (40,7 N•m) torque. Tighten
the four larger bolts (Item 2) [Figure 20-62-11] to 54 ft.-
lb. (73,2 N•m) torque.
863 Bobcat Loader

253 of 968
ABOVE) (CONT’D)
Disassembly And Assembly (Cont'd)
Figure 20-62-14 1
1 P-26358
2 Figure 20-62-16
P-26355
Remove the wear plate (Item 1) [Figure 20-62-13] & 1

[Figure 20-62-14] and section seal (Item 2) [Figure 20-
62-13] & [Figure 20-62-14] from the pump end section.
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 20-62-
14]. If excessive wear or damage is visible, the
pump must be replaced. P-26359
Remove the pump center section (Item 1) [Figure 20-62-

15] & [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.
863 Bobcat Loader

254 of 968
ABOVE) (CONT’D)
Figure 20-62-17
1
P-26391
Figure 20-62-20
P-26389
Figure 20-62-18
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
P-26390 ring (Item 1) [Figure 20-62-20] from the spline end of the
drive gear.
Remove the idler gear (Item 1) [Figure 20-62-17] &

[Figure 20-62-18].
NOTE: Inspect the idler gear (Item 1) [Figure 20-62-

pump must be replaced.
863 Bobcat Loader

255 of 968
ABOVE) (CONT’D)
Figure 20-62-21
P-26394

P-26392 toward gears.
Figure 20-62-24
Remove the drive gear (Item 1) [Figure 20-62-21].
NOTE: Inspect the drive gear (Item 1) [Figure 20-62-

1
P-26396
Figure 20-62-22
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] &

863 Bobcat Loader

256 of 968
ABOVE) (CONT’D)
Disassembly And Assembly (Cont'd) 1
Figure 20-62-25
1
2
P-26398
1
P-26374

P-26397 26]. If excessive wear or damage is visible, the
Remove the pre-load seal (Item 1) [Figure 20-62-25].
863 Bobcat Loader

257 of 968
863 Bobcat Loader
258 of 968
HYDRAULIC PUMP (CAST IRON HIGH FLOW) (S/N Figure 20-63-1
514449484-514450945)

Power Bob-Tach
1
WARNING
W-2017-0286
P-34690

WARNING from the pump.
W-2059-0598

procedure: 1
2
Page 10-20-1.) of the pump. Connect the OUTLET hose (Item 2) [Figure
20-63-2] from the tester to the hose (Item 1) [Figure 20-
Raise the operator cab. (See Raising The Operator Cab 63-1] which was disconnected from the pump.
on Page 10-30-1.)

Page 10-60-1.)
IMPORTANT
I-2024-0284
863 Bobcat Loader

259 of 968
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N Check The Output Of The Hydraulic Pump With
514449484-514450945) (CONT’D) Power Bob-Tach

Figure 20-63-3
WARNING
EXAMPLE: TESTER
CONNECTION Put jackstands under the front axles and rear corners
Reservoir of the frame before running the engine for service.
W-2017-0286
Out
Hydraulic Pump
In
Hydraulic Control
WARNING
Valve
1 the lift arms are secured by an approved lift arm
BH-00196 support device. Failure to use an approved lift arm
Sample tester connection shown [Figure 20-63-3]. W-2059-0598
Start the engine and run at low idle RPM. Make sure the The tools listed will be needed to do the following
tester is connected correctly. If no flow is indicated on the procedure:
connected correctly, increase the engine speed to full MEL1563 - Remote Start Tool
RPM*. MEL10103 - Hydraulic Tester
control (Item 1) [Figure 20-63-3] on the tester to about Lift and block the loader. (See LIFTING AND BLOCKING
1000 PSI (6895 kPa). DO NOT exceed system relief THE LOADER on Page 10-10-1.)
flow (GPM) at full RPM. Raise the lift arms and install an approved lift arm support
Push the maximum / variable flow switch (on the remote Page 10-20-1.)
light will come ON. Push the button (on the right control Raise the operator cab. (See Raising The Operator Cab
lever) for fluid flow to the quick coupler (fluid pressure will on Page 10-30-1.)
and flow (GPM). The high pressure flow must be at least Open the rear door of the loader.
80% of free flow.
HIGH PRESSURE FLOW (GPM) X100 Connect the remote start tool. (See REMOTE START on
%=
FREE FLOW (GPM) Page 10-60-1.)
*Refer to SPECIFICATIONS, Contents, Section SPEC-

01 for system relief pressure and full RPM.
863 Bobcat Loader

260 of 968
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N Figure 20-63-6
514449484-514450945) (CONT'D)
EXAMPLE: TESTER
Check The Output Of The Hydraulic Pump With CONNECTION
Reservoir
Figure 20-63-4
1 Hydraulic Pump
Out In
Hydraulic Control
Valve
2
1
BH-00196
P-34689 tester is connected correctly. If no flow is indicated on the
Disconnect the OUTLET hose (Item 1) [Figure 20-63-4] RPM*.
from the top of the Power Bob-Tach block.
Figure 20-63-5 control (Item 1) [Figure 20-63-6] on the tester to about
flow (GPM) at full RPM.
Push the maximum / variable flow switch (on the remote

2 1 start tool) to engage the front auxiliary hydraulics, the
light will come ON. Push the button (on the right control
and flow (GPM). The high pressure flow must be at least
80% of free flow.
%= HIGH PRESSURE FLOW (GPM) X100
P-26917 FREE FLOW (GPM)
Connect the INLET hose (Item 1) [Figure 20-63-5] from A low percentage may indicate a failed pump.
the tester to the OUTLET fitting (Item 2) [Figure 20-63-4]
on the top of the Power Bob-Tach block. Connect the *Refer to SPECIFICATIONS Section SPEC-01 for
OUTLET hose (Item 2) [Figure 20-63-5] from the tester system relief pressure and full RPM.
to the hose (Item 1) [Figure 20-63-4] which was
disconnected from the Power Bob-Tach block.
IMPORTANT
I-2024-0284
863 Bobcat Loader

261 of 968
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N Remove the hoses from the Power Bob-Tach block if
514449484-514450945) (CONT’D) equipped. (See Removal And Installation on Page 20-
120-1.)
Figure 20-63-7
DANGER
2 1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic P-34689
Disconnect and cap the outlet hose (Item 1) [Figure 20-
63-7] from the back of the hydraulic pump.
Disconnect and cap the hose (Item 2) [Figure 20-63-7]
D-1009-0409
from the high flow section of the hydraulic pump.
Figure 20-63-8
WARNING
1
W-2059-0598
Page 10-20-1.)
P-34688
Lift and block the rear of the loader. (See LIFTING AND Disconnect and cap the hoses from the inlet fitting (Item
BLOCKING THE LOADER on Page 10-10-1.) 1) [Figure 20-63-8] of the hydraulic pump.

on Page 10-30-1.)

863 Bobcat Loader

262 of 968
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N
514449484-514450945) (CONT’D)
Figure 20-63-9
1 1
P-28067

Installation: Tighten the mounting bolts to 27 - 37 in.-lb.

(37 - 50 N•m) torque.
Remove the hydraulic pump from the hydrostatic pump.
Remove the coupler and the O-ring.

pump.

hydraulic pump.
See Disassembly And Assembly on Page 20-63-7 for the

proper procedure.
863 Bobcat Loader

263 of 968
514449484-514450945) (CONT’D)
Identification
26
22
19 23
27
24 25
23
18 21
16 17
15 20 8
7
14
13
11 12
1
6 7 9 10
4 5
3
2
B-16051A
REF. DESCRIPTION REF. DESCRIPTION
1 RETAINING RING 14 PUMP CENTER SECTION

2 PUMP END SECTION 15 PRE-LOAD SEAL
3 PRE-LOAD SEAL 16 LOAD SEAL
4 LOAD SEAL 17 SECTION SEAL
5 SECTION SEAL 18 WEAR PLATE
6 WEAR PLATE 19 DRIVE GEAR
7 PINS 20 IDLER GEAR
8 DRIVE GEAR 21 PUMP SECTION
9 IDLER GEAR 22 WEAR PLATE
10 PUMP SECTION 23 PINS
11 WEAR PLATE 24 SECTION SEAL
12 SECTION SEAL 25 PUMP END SECTION
13 SPLINE SHAFT 26 BOLT (4)
27 BOLT (4)
863 Bobcat Loader

264 of 968
514449484-514450945) (CONT’D)
Disassembly And Assembly

1
IMPORTANT
damage the system.
I-2003-0888
P-26624
Figure 20-63-10
Remove the pump end section (Item 1) [Figure 20-63-
11].
1
P-26623
2
2
1 P-26622
Mark the pump sections for correct assembly [Figure 20-

63-10].
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.-lb. (40,7 N•m) torque. Tighten
the four larger bolts (Item 2) [Figure 20-63-10] to 54 ft.-
863 Bobcat Loader

265 of 968
514449484-514450945) (CONT’D)
Figure 20-63-12
1
1
P-26627
Figure 20-63-15
2 P-26625
Figure 20-63-13
3 1
1 P-26628
2
Remove the pump section (Item 1) [Figure 20-63-14] &
P-26626 [Figure 20-63-15] from the pump center section.
NOTE: Inspect the pumps center section (Item 1)

replaced.
toward gears.

863 Bobcat Loader

266 of 968
514449484-514450945) (CONT’D)
Figure 20-63-16
P-26631
Figure 20-63-19
P-26629
Figure 20-63-17
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] & pump must be replaced.
[Figure 20-63-17].

863 Bobcat Loader

267 of 968
514449484-514450945) (CONT’D)
Figure 20-63-20
P-26636
1
1
P-26635
2 Remove the load seal (Item 1) [Figure 20-63-22].
P-26633 Figure 20-63-23
Figure 20-63-21
1
P-26638
1
1
2
P-26637
P-26634 Remove the pre-load seal (Item 1) [Figure 20-63-23].

63-20] & [Figure 20-63-21] from the pump center
section.

toward gears.
863 Bobcat Loader

268 of 968
514449484-514450945) (CONT’D)
Figure 20-63-24
2 P-26657


Remove the pump center section (Item 1) [Figure 20-63- [Figure 20-63-26] and bushings (Item 4)
24] from the pump sections. [Figure 20-63-26]. If excessive wear or
Figure 20-63-25 replaced.
Figure 20-63-27
P-26655
P-26659
([Figure 20-63-26]) and section seal (Item 2) [Figure 20-
63-25] & ([Figure 20-63-26]) from the pump section. Remove the pump section (Item 1) [Figure 20-63-27]
from the pump end section.
863 Bobcat Loader

269 of 968
514449484-514450945) (CONT’D)
Figure 20-63-28
1
1
P-26662

P-26660 pump must be replaced.
NOTE: Inspect the pump section (Item 1) [Figure 20-

63-28]. If excessive wear or damage is visible,
the pump must be replaced.
Figure 20-63-29
P-26661

([Figure 20-63-30]).
863 Bobcat Loader

270 of 968
514449484-514450945) (CONT’D)
Figure 20-63-31
1
P-26666
Remove the drive gear (Item 1) [Figure 20-63-33] from

the pump end section.
P-26663
Figure 20-63-32 pump must be replaced.
Figure 20-63-34
P-26665
1 1
P-26664
P-26674
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 Remove the spline shaft (Item 1) [Figure 20-63-34] from
drive gear. the end of the drive gear.
NOTE: Inspect the spline shaft (Item 1) [Figure 20-63-

863 Bobcat Loader

271 of 968
514449484-514450945) (CONT’D)

1
Figure 20-63-35
P-26670
P-26669

2
P-26667 Figure 20-63-38
Figure 20-63-36
1
P-26672
1
1


toward gears.
863 Bobcat Loader

272 of 968
514449484-514450945) (CONT’D)
Figure 20-63-39
P-26673

863 Bobcat Loader

273 of 968
863 Bobcat Loader
274 of 968
HYDRAULIC PUMP (CAST IRON HI FLOW) clockwise to free flow. Shut the front auxiliary hydraulics
(514450846 & ABOVE) off.
Hydraulic Pump Test If flow and pressure specs are not obtained, go to the
Inline Standard Hydraulic Pump Test. (See Removal And
The tools listed will be needed to do the following Installation on Page 20-61-2.) If flow and pressure specs
procedure: are obtained continue on to the next paragraph.
MEL10103 - Hydraulic Tester With the engine running at low idle RPM. Press the Front
MEL10106 - Hydraulic Test Kit Auxiliary button. Engage the front auxiliary with the
trigger on the right handle. Make sure the tester is
Figure 20-64-1 connected correctly. If no flow is indicated on the tester,
the hoses are connected wrong. With the hoses
RPM*.
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.
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
2 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
P-16903 P-31821 the flow should be at 0 GPM. Turn the restrictor counter
clockwise to free flow. Shut the front auxiliary hydraulics
off.
Install a hydraulic tester (Item 1) [Figure 20-64-1] onto
the front auxiliary quick couplers. If the specs from above are reached, the high flow
hydraulic pump is OK.
This procedure will require a operator in the cab and one
operator running the tester. If the flow and pressure were not obtained, go to the
Inline High Flow Hydraulic Pump Test (See Checking The
Start the engine and run at low idle RPM. Press the Front Output Of The High Flow Pump on Page 20-61-1.)
Auxiliary button. Engage the front auxiliary with the
trigger on the right handle. Make sure the tester is *Refer to SPECIFICATIONS Contents Page SPEC-01 for
connected correctly. If no flow is indicated on the tester, system relief pressure and full RPM.
the hoses are connected wrong. With the hoses
RPM*.

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
863 Bobcat Loader
275 of 968
HYDRAULIC PUMP (CAST IRON HI FLOW) Figure 20-64-2
(514450846 & ABOVE) (CONT’D)
Inline Hydraulic Pump Test (Standard)

1
procedure:

MEL10106 - Hydraulic Test Kit 2
WARNING
Put jackstands under the front axles and rear corners P-34845

Disconnect the standard pump OUTLET hose (Item 1)
W-2017-0286
[Figure 20-64-2] from the tubeline.
Figure 20-64-3
Page 10-20-1.)
2 1
WARNING
P-34851
W-2059-0598
Connect the INLET hose (Item 1) [Figure 20-64-3] from
the tester to the OUTLET hose (Item 1) [Figure 20-64-2]
Raise the operator cab. (See Raising The Operator Cab of the pump. Connect the OUTLET hose (Item 2) [Figure
on Page 10-30-1.) 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.
863 Bobcat Loader

276 of 968
HYDRAULIC PUMP (CAST IRON HI FLOW) Record the flow (GPM) at 2700 PSI, this is the high
(514450846 & ABOVE) (CONT’D) pressure flow. The high pressure flow must be at least
80% of free flow.
Inline Hydraulic Pump Test (Standard) (Cont'd)
%= X 100
FREE FLOW (GPM)
IMPORTANT A low percentage may indicate a failed pump.
The hydraulic tester must be in the fully open *Refer to SPECIFICATIONS Contents Page SPEC-01 for
position before you start the engine. system relief pressure and full RPM.
I-2024-0284
Figure 20-64-4
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In Hydraulic Control
Valve
BH-196
Sample tester connection shown [Figure 20-64-4]].
RPM*.

1000 PSI (6895 kPa).
Open the restrictor control and record the free flow

(GPM) at full RPM.
863 Bobcat Loader

277 of 968
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
Inline Hydraulic Pump Test (High Flow)

WARNING
WARNING support device. Failure to use an approved lift arm
Put jackstands under the front axles and rear corners W-2059-0598
fall or move and cause injury or death. Figure 20-64-6
W-2017-0286

procedure:
MEL10103 - Hydraulic Tester 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 20-64-
6] 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.
Page 10-20-1.)
P-34851
on Page 10-30-1.)
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.
863 Bobcat Loader

278 of 968
HYDRAULIC PUMP (CAST IRON HI FLOW) Turn the restrictor control on the tester clockwise to 3000
(514450846 & ABOVE) (CONT’D) PSI and the flow should go to zero GPM. If the pressure
readings are not obtained go to the High Flow Relief
Inline Hydraulic Pump Test (High Flow) (Cont’d) Pump Adjustment (See Contents Page 20-61-6). If the
pressure readings are correct, continue on to the next
paragraph.
IMPORTANT Open the restrictor control and record the free flow
(GPM) at full RPM.
The hydraulic tester must be in the fully open Record the flow (GPM) at 2500 PSI, this is the high
position before you start the engine. pressure flow. The high pressure flow must be at least
I-2024-0284 80% of free flow.
Figure 20-64-8 HIGH PRESSURE FLOW (GPM)

%= X 100
FREE FLOW (GPM)
EXAMPLE: TESTER
CONNECTION
Reservoir
*Refer to SPECIFICATIONS Contents Page SPEC-01 for
system relief pressure and full RPM.
Hydraulic Pump
Out In Hydraulic Control
Valve
BH-196
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*.

1000 PSI (6895 kPa).
863 Bobcat Loader

279 of 968
(514450846 & ABOVE) (CONT’D)
High Flow Relief Adjustment Procedure

WARNING
The tools listed will be needed to do the following Never work on a machine with the lift arms up unless
procedure: the lift arms are secured by an approved lift arm
MEL10103 - Hydraulic Tester support device can allow the lift arms or attachment
MEL10106 - Hydraulic Test Kit to fall and cause injury or death.
W-2059-0598
Figure 20-64-10
WARNING
W-2017-0286 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
P-34847 1
Install a jumper hose (Item 1) [Figure 20-64-9] onto the

front auxiliary quick couplers.
P-34851
Page 10-20-1.)

the tester to the OUTLET hose (Item 1) [Figure 20-64-
10] 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.
863 Bobcat Loader

280 of 968
(514450846 & ABOVE) (CONT’D)
High Flow Relief Adjustment Procedure (Cont’d)
Figure 20-64-12
1
1
P-34919
Start the engine and run at low idle RPM. Press the Front
Auxiliary button. Press the High Flow button. Engage the
N-23027 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.
Remove the access cover mounting bolts (Item 1) and With the hoses connected correctly, increase the engine
the cover (Item 2) [Figure 20-64-12] from the frame. speed to full RPM*.
Figure 20-64-13 Warm the fluid to 140° F (60° C) by turning the restrictor
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
1 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.
If the specs from above are reached, the pump is OK.

P-34846
If the pump is unable to reach 3000 PSI the relief plug

(Item 1) [Figure 20-64-14] will need to be turned
Remove the cap (Item 1) [Figure 20-64-13] from the
clockwise a 1/4 turn and retested with the procedure
pump.
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 20-
100-2.) 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.
863 Bobcat Loader

281 of 968
(514450846 & ABOVE) (CONT’D)
High Flow Relief Valve Removal and Installation
1
WARNING 1
1
W-2017-0286
P-37082
Remove the access cover mount bolts (Item 1) and the
Remove the right rear tire. access cover (Item 2) [Figure 20-64-16] from the frame.
Figure 20-64-15 Figure 20-64-17
P-34847 P-34846
Install a jumper hose (Item 1) [Figure 20-64-15] onto the Remove the cap (Item 1) [Figure 20-64-17] from the
front auxiliary quick couplers. pump.
Page 10-20-1.)
WARNING
W-2059-0598
863 Bobcat Loader

282 of 968
(514450846 & ABOVE) (CONT’D)
1
High Flow Relief Valve Removal and Installation
(Cont’d) 2
Figure 20-64-18
3
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
Inspect the relief valve seat in the pump for damage or
wear.
Remove the Relief Plug (Item 1) [Figure 20-64-18] from
the pump. 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.)
863 Bobcat Loader

283 of 968
HYDRAULIC PUMP (CAST IRON HI FLOW) Remove the hoses from the Power Bob-Tach block. If so
(514450846 & ABOVE) (CONT’D) equipped.) (See Removal And Installation on Page 20-
120-1.)
Figure 20-64-20
DANGER 3
1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic P-34855
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].
D-1009-0409
Figure 20-64-21
WARNING
1
W-2059-0598
Page 10-20-1.) P-34852

Disconnect and cap the hoses from the inlet fitting (Item
Lift and block the rear of the loader. (See LIFTING AND 1) [Figure 20-64-21] of the hydraulic pump.
BLOCKING THE LOADER on Page 10-10-1.)

on Page 10-30-1.)

863 Bobcat Loader

284 of 968
(514450846 & ABOVE) (CONT’D)
Figure 20-64-22
1
P-34849

P-34854
(37 - 50 N•m) torque.
Disconnect the electrical connector (Item 1) [Figure 20-
64-22] from the high flow solenoid. Remove the hydraulic pump from the hydrostatic pump.
Remove the coupler and the O-ring.

pump.

hydraulic pump.
863 Bobcat Loader

285 of 968
(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 26
12. Section Seal
13. Spline Shaft
14. Pump Center Section
23
15. Pre-Load Seal 19 22
16. Load Seal
27
24 25
23
18 20 21
17
15 16
8
7
14
13
12
11
1
9 10
6 7
4 5
3
17. Section Seal 2

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)
B-16051A
863 Bobcat Loader

286 of 968
(514450846 & ABOVE) (CONT’D)

1
IMPORTANT
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.-lb.
2 (47 - 54 N•m).
Figure 20-64-26
P-34692
Mark the pump sections for correct assembly.
Remove the solenoid nut (Item 1) [Figure 20-64-24]. 1

P-34694
Remove the solenoid (Item 2) [Figure 20-64-24].
Installation: Tighten the solenoid nut to 48 - 72 in.-lb. (5 - Inspect the o-ring (Item 1) [Figure 20-64-26] and replace
8 N•m) as needed.
Inspect the o-ring and back-up ring (Item 2) [Figure 20-

64-26] and replace as needed.
863 Bobcat Loader

287 of 968
(514450846 & ABOVE) (CONT’D)
1
2
Figure 20-64-27
P-34696
Inspect the check valve (Item 1), spring (Item 2), and
plug (Item 3) [Figure 20-64-29] for damage and replace
P-34708 as needed.
Figure 20-64-30
Remove the cap (Item 1) [Figure 20-64-27].
Installation: Tighten the cap to 13 - 16 ft.-lb. (18 - 22

N•m) after the relief valve has been set.
Figure 20-64-28
2 1
P-34699
1
Remove the eight bolts (Item 1) [Figure 20-64-30].
Installation: Tighten the assembly bolts to 45 - 50 ft.-lb.

P-34695 (60 - 67 N•m).
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.)
863 Bobcat Loader

288 of 968
(514450846 & ABOVE) (CONT’D)
Figure 20-64-31 1
1
P-26627
Remove the pump center section (Item 1) [Figure 20-64-

33] & [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 20-64-
32] from the pump end section.
Figure 20-64-32
3 1
1 P-26628

2
P-34698 replaced.

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
863 Bobcat Loader

289 of 968
(514450846 & ABOVE) (CONT’D)
Figure 20-64-35
P-26631
Figure 20-64-38
P-26629

[Figure 20-64-36].
Figure 20-64-36 1
P-26632
1
Remove the drive gear (Item 1) [Figure 20-64-37] &

[Figure 20-64-38].


863 Bobcat Loader

290 of 968
(514450846 & ABOVE) (CONT’D)
1
Figure 20-64-39
P-26636
1
1
P-26635
2
P-26633 Figure 20-64-42
Figure 20-64-40 1
P-26638
1
1
2
P-26637

64-39] & [Figure 20-64-40] from the pump center
section.

toward gears.
863 Bobcat Loader

291 of 968
(514450846 & ABOVE) (CONT’D)
Figure 20-64-43
4
1
1
2
P-26657

NOTE: Inspect the pump center section (Item 3) and

Remove the pump center section (Item 1) [Figure 20-64- bushings (Item 4) [Figure 20-64-45]. If
43] from the pump sections. excessive wear or damage is visible, the
Figure 20-64-44
Figure 20-64-46
P-26655
P-26659

[Figure 20-64-45] and section seal (Item 2) [Figure 20- Remove the pump section (Item 1) [Figure 20-64-46]
64-44] & [Figure 20-64-45] from the pump section. from the pump end section.
863 Bobcat Loader

292 of 968
(514450846 & ABOVE) (CONT’D)
Figure 20-64-47
1
1
P-26662

Figure 20-64-50
NOTE: Inspect the pump section (Item 1) [Figure 20-
64-47]. If excessive wear or damage is visible,
the pump must be replaced.
Figure 20-64-48
1
P-26665
1
P-26664
Remove the retaining ring (Item 1) [Figure 20-64-50]

from the spline end of the drive gear.
P-26661

[Figure 20-64-49].
863 Bobcat Loader

293 of 968
(514450846 & ABOVE) (CONT’D)
Figure 20-64-51
P-26674
Remove the spline shaft (Item 1) [Figure 20-64-53] from

the end of the drive gear.
P-26663
NOTE: Inspect the spline shaft (Item 1) [Figure 20-64-
Remove the drive gear (Item 1) [Figure 20-64-51] from pump must be replaced.
Figure 20-64-54
Figure 20-64-52
1
1
P-26667
P-26666
Remove the wear plate (Item 1) and section seal (Item 2)

Remove the drive gear (Item 1) [Figure 20-64-52] from [Figure 20-64-54]

863 Bobcat Loader

294 of 968
(514450846 & ABOVE) (CONT’D)
Figure 20-64-55
P-26671
Remove the pre-load seal (Item 1) [Figure 20-64-57].
P-26668 Figure 20-64-58
Inspect the wear plate (Item 1) and the section seal (Item
2) [Figure 20-64-55]. 1

toward gears.
Figure 20-64-56 2
P-26673
P-26670
NOTE: Inspect the pump end section (Item 1) and
1 bushings (Item 2) [Figure 20-64-58]. If
excessive wear or damage is visible, the
P-26669
863 Bobcat Loader

295 of 968
863 Bobcat Loader
296 of 968
HYDRAULIC / HYDROSTATIC FILTER Raise the lift arms and install lift arm support device. (See
LIFT ARM SUPPORT DEVICE on Page 10-20-1.)
Housing Removal And Installation
on Page 10-30-1.)
DANGER Disconnect the wires (Item 1) [Figure 20-70-1] from the

hydraulic filter sender and switch.
Figure 20-70-2
2 3
P-90328 1
AVOID DEATH
N-19745
D-1009-0409
Disconnect the hose clamp and hose (Item 1) [Figure

20-70-2] from the filter housing.
WARNING Disconnect the hydraulic tubeline (Item 2) [Figure 20-70-
2].
the lift arms are secured by an approved lift arm Remove the four mounting bolts (Item 3) [Figure 20-70-
support device. Failure to use an approved lift arm 2].
to fall and cause injury or death. Installation: Tighten the mounting bolts to 25 ft.-lb. (34
W-2059-0598 N•m) torque.
Figure 20-70-1 Remove the filter housing / filter assembly.
N-19744
863 Bobcat Loader

297 of 968
863 Bobcat Loader
298 of 968
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].

on Page 50-100-1.)
Remove the bucket position valve (if so equipped). (See

Remove the select valve (if so equipped). (See Removal

1 And Installation on Page 20-100-2.)
Figure 20-80-2
N-19496
Remove the side cover from the loader frame. Pull the 2
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 20-80-

2].
Remove the hydraulic fill hose.
863 Bobcat Loader

299 of 968
HYDRAULIC FLUID RESERVOIR (CONT’D) Figure 20-80-5
Figure 20-80-3 1
2
N-19730
At the left motor cover hole, remove the drain hose

N-19728 (Item1) [Figure 20-80-5] from the tank.
Remove the supply hose (Item 2) [Figure 20-80-5] from

Remove the two hydraulic hoses (Item 1) [Figure 20-80- the tank.
3] from the reservoir.
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].

Remove the rear tank bracket (Item 1) [Figure 20-80-6]
Installation: Tighten the bolt to 16 - 20 ft.-lb. (21 - 27 from the loader.
N•m) torque.
Remove the mounting strap.
Slide the reservoir forward.
863 Bobcat Loader

300 of 968
HYDRAULIC FLUID RESERVOIR (CONT’D) Figure 20-80-8
Hydraulic Fluid Screen

on Page 10-30-1.)
Figure 20-80-7 1
N-17718
1
Remove the hydraulic fluid screen (Item 1) [Figure 20-
80-8] from the reservoir.
Wash the screen in clean solvent and air dry, before

N-19610 replacing.
Remove the two hose clamps (Item 1) [Figure 20-80-7]

and remove the hydraulic fill hose (Item 2) [Figure 20-80-
7] from the hydraulic reservoir.
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301 of 968
863 Bobcat Loader
302 of 968
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 30-40- 2
7.)
Figure 20-90-1
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

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.-lb. (6,78

N•m) torque.
Figure 20-90-2
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.-lb. (40,8 - 47,6
N•m) torque.
863 Bobcat Loader

303 of 968
BUCKET POSITION VALVE (CONT’D)
Solenoid Testing WARNING

Figure 20-90-4
W-2059-0598
Stop the engine.

on Page 10-30-1.)
Figure 20-90-5
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 7-10 ohm
and the other coils 5 - 8 ohm.
Replace the test meter with 12 volt power. You can see 1
Start the engine. Raise the lift arms and install an

N-23648
approved lift arm support device. (See LIFT ARM
SUPPORT DEVICE on Page 10-20-1.)
Disconnect the electric solenoid connector (Item 1)
[Figure 20-90-5].
DANGER
P-90328
AVOID DEATH
D-1009-0409
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304 of 968
BUCKET POSITION VALVE (CONT’D) Figure 20-90-8
Figure 20-90-6
1
1
2
N-23652
3
Remove the tubeline (Item 1) [Figure 20-90-8] from the
N-23650 B port to the control valve.
Figure 20-90-9
Installation: Tighten the nut to 60 in.-lb. (6,78 N•m)

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

N-23651 the D port on the bucket position valve.
D is top is base end of tilt.

Disconnect tubelines (Item 1) [Figure 20-90-7] from the
A port on the bucket position valve tee fitting.
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BUCKET POSITION VALVE (CONT’D) Disassembly And Assembly
Figure 20-90-10
1
1
N-19069
N-23654
Remove the mounting bolts (Item 1) [Figure 20-90-10]. Installation: Tighten the nut to 60 in.-lb. (6,78 N•m)
torque.
Installation: Tighten the mounting bolts and nuts to 15
ft.-lb. (20 N•m) torque. Figure 20-90-12
Remove the bucket position valve from the loader.

2
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.-lb.

(40,8 - 47,6 N•m) torque.
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Disassembly And Assembly (Cont’d)
Figure 20-90-13
N-18339
1 Remove the plug (Item 1) [Figure 20-90-15], and flow

N-19072 control spool (Item 2) [Figure 20-90-15].
Check the flow control spool for wear, check the O-ring
Remove the flow adjustment valve and O-ring (Item 1) on the plug and replace as needed.
[Figure 20-90-13].
Figure 20-90-16
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.
Figure 20-90-14
3
N-19042
Remove the tilt cylinder check valve (Item 1) [Figure 20-

1 90-16], spring (Item 2) [Figure 20-90-16] and plug (Item
N-19041 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].
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Figure 20-90-17
1
N-19046
Remove the plug (Item 1) [Figure 20-90-18], spring (Item

N-19045 2) [Figure 20-90-18] and unloading spool (Item 3)
[Figure 20-90-18].
Remove the plug [Figure 20-90-17]. Check all parts and replace as needed. Install a new O-
ring on the plug before installing.
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SELECT VALVE Figure 20-100-2
Checking The High Flow Pump Relief Valve (S/N

514450945 & Below)
3 1
IMPORTANT
2
I-2024-0284
B-15551
WARNING Start the engine and run at low idle RPM. Push the mode
Put jackstands under the front axles and rear corners switch (Item 1) [Figure 20-100-2] once (on the
of the frame before running the engine for service. instrument panel) to engage the front auxiliary hydraulics
Failure to use jackstands can allow the machine to momentarily, the light (Item 2) [Figure 20-100-2] will
fall or move and cause injury or death. 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

procedure:


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.
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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
2
2
2 P-9174 P13047 1 2
P-13046
If the relief pressure is not correct, stop the engine. Disconnect the controls harness at the left side steering
Remove and inspect the relief valve (Item 1) [Figure 20- lever connectors (Item 1) [Figure 20-100-4].
100-3]. Inspect the O-rings (Item 2) [Figure 20-100-3]
and back-up ring (Item 3) [Figure 20-100-3] for damage. Disconnect the controls harness at the select valve
connectors (Item 2) [Figure 20-100-4].
Replace the relief valve if required. This relief valve is not
adjustable. 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.

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SELECT VALVE (CONT’D) Figure 20-100-7
Removal And Installation (Cont’d) 1
Figure 20-100-5
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 Installation: Connect controls harness to select valve
disconnect the hose. solenoids. See Disassembly And Assembly on page 20-
100-4 for solenoid identification and correct controls
Disconnect the tubeline (Item 2) [Figure 20-100-5]. harness wire color.
Disconnect the hose (Item 3) [Figure 20-100-5].
Install caps and plugs on open connections.
Figure 20-100-6
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.
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IMPORTANT 1
damage the system. 2
I-2003-0888
P-9177
Figure 20-100-8
Figure 20-100-10
2
1
3
1
4 2
5 2
P-9168 2 2
P-9169
Clean the select valve to remove dirt before disassembly.
Remove the solenoid valve coils in [Figure 20-100-8]. Assembly: The coils largest opening (Item 1) [Figure
20-100-9] must position on the valve shoulder (Item 2)
NOTE: The controls wiring harness colors are listed [Figure 20-100-9]. Install the washer (Item 1) [Figure
below for identification during select valve 20-100-10] between the double coils. Install the coils and
assembly installation. tighten the nuts (Item 2) [Figure 20-100-10] to 5 ft.-lb.
(6,7 N•m) 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
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Figure 20-100-11
1 3
1 2
P-9171
2 Remove the relief valve (Item 1) [Figure 20-100-12].

3 P-9170 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 20-
Remove the 4-way solenoid valve (Item 1) [Figure 20- 100-12] and (Item 3) [Figure 20-100-12].
100-11].
Figure 20-100-13
Remove the 2-way solenoid valve (Item 2) [Figure 20-
100-11].
Remove the 2-way solenoid valves (Item 3) [Figure 20-

100-11].
Inspect the solenoid valves for contamination or damage.

Wash all parts in clean solvent. Use air pressure to dry 1
them. Install new O-rings and back-up washers.
5 4
Assembly: Put oil on O-rings and back-up washers. 2
Install and tighten the solenoid valves (Items 1&3)
[Figure 20-100-11] to 25 ft.-lb. (33,9 N•m) torque.
3
Tighten the solenoid valve (Item 2) [Figure 20-100-11] to
20 ft.-lb. (27,1 N•m) torque. 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.
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Figure 20-100-14
P-9175
Use a test meter to measure coil resistance [Figure 20-

P-9176 100-15]. Coil wires do not have polarity. Correct
resistance for the pressure relief (small) coil is 7 - 10 ohm
and the other coils 5 - 8 ohm.
The fitting (Item 2) [Figure 20-100-13] and [Figure 20-
100-14] has a poppet valve. The poppet valve allows flow Replace the test meter with 12 volt power. You can see
out of the select valve only. Inspect the poppet for and hear the spool shift.
smooth opening and closing.
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.-lb. (33,9 N•m) 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 20-100-
13]. Install the check valves and load shuttle (Item 1)
[Figure 20-100-13] and tighten to 20 ft.-lb. (27,1 N•m)
torque. Install the fitting (Item 2) [Figure 20-100-13] and
tighten to 35 ft.-lb. (47,4 N•m) torque.
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REAR AUXILIARY DIVERTER VALVE Figure 20-110-2
Disassembly
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888 2
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 4
1 1
N-0527 2
3
5 2
Clean the diverter block to remove dirt before
disassembly. Block ports are labeled for correct 2
assembly.
Remove the logic cartridge valves from block ports LC1

3
and LC2 (Item 1) [Figure 20-110-1]. 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.
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REAR AUXILIARY DIVERTER VALVE (CONT’D) Assembly
Inspection Put oil on O-rings and back-up washers.
Inspect cartridges, check valves, solenoid valves and Tighten the logic cartridge valves (Item 1) [Figure 20-
sealing washers for contamination or damage. Wash all 110-1] to 65 ft.-lb. (88 N•m) torque.
parts in clean solvent. Use air pressure for drying them.
Install new O-rings and back-up washers. Tighten the pilot check valves (Item 1) [Figure 20-110-2],
shuttle check valve (Item 2) [Figure 20-110-2] to 35 ft.-lb.
Inspect diverter block cavities for contamination. Wash (47 N•m) torque.
block in clean solvent. Use air pressure to dry.
Tighten the solenoid valves (Items 4 & 5) [Figure 20-110-
Solenoid Testing 3] to 12 ft.-lb. (16,3 N•m) torque. Install the sealing
washers (Item 2) [Figure 20-110-3] and coils (Item 3)
Figure 20-110-4 [Figure 20-110-3]. Tighten the nuts (Item 1) [Figure 20-
110-3] to 10 in.-lb. (1,13 N•m) torque.
P-9137

110-4]. Coil wires do not have polarity. Correct resistance
is 6 - 9 ohm.
Replace the test meter with 12 volt power. You can see
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POWER BOB-TACH BLOCK (6676547-ALUMINUM) Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
IMPORTANT Figure 20-120-1

damage the system.
I-2003-0888
DANGER 1
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.

P-90328
Figure 20-120-2
AVOID DEATH
• Keep out of this area when lift arms are raised 1
D-1009-0409
1
WARNING 1
N-23027
support device. Failure to use an approved lift arm Remove the seven access cover mount bolts (Item 1)
support device can allow the lift arms or attachment [Figure 20-120-2] and remove the access cover (Item 2)
to fall and cause injury or death. [Figure 20-120-2].
W-2059-0598

device. (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)
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POWER BOB-TACH BLOCK (6676547-ALUMINUM) Figure 20-120-5
(CONT’D)
Figure 20-120-3
2 N-22660
Remove the four mounting bolts (Item 1) [Figure 20-120-

5].
N-23030
(34 - 38 N•m) torque.
that goes to the control valve. Remove the POWER BOB-TACH BLOCK (6676547-
Aluminum).
that goes to the hydrostatic pump.
Figure 20-120-4
N-23029
Disconnect the two hydraulic hoses (Item 1) [Figure 20-

120-4] that go to the Bob-Tach cylinder.
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(CONT’D)
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
damage the system.
I-2003-0888
N-22661
Figure 20-120-6
Figure 20-120-8
P-16282
N-22662
Clean the diverter block (Item 1) [Figure 20-120-6] to

remove dirt before disassembly. Block ports are labeled Remove the plug (Item 1) [Figure 20-120-7] & [Figure
for correct assembly. 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.-lb. (30 N•m) torque.
Remove the 0.02 screened orifice (Item 2) [Figure 20-

120-8].
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319 of 968
(CONT’D)
Figure 20-120-9
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.-lb. (33,9 N•m).
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(CONT’D)
Figure 20-120-12
P-16255

1
P-16259 Installation: Put oil on O-ring. Tighten to 40 ft.-lb. (54
N•m).
Figure 20-120-13 Figure 20-120-15
P-16260
P-16251
Remove the relief valve (Item 1) [Figure 20-120-12] & Remove the P2 fitting (Item 1) [Figure 20-120-15].
[Figure 20-120-13].
Installation: Put oil on O-ring. Tighten to 40 ft.-lb. (54
Installation: Put oil on O-rings and back-up washers. N•m).
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(CONT’D)
Figure 20-120-16
1 P-16271
Figure 20-120-19
P-16269
Figure 20-120-17 1
P-16272
Remove the logic cartridge valve (Item 1) [Figure 20-

120-18] & [Figure 20-120-19].
P-16270
Remove the DR fitting (Item 1) [Figure 20-120-16] &
[Figure 20-120-17].
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(CONT’D)
Figure 20-120-20
1 1
P-16265
Remove plug (Item 1) [Figure 20-120-22].
P-16274 Installation: Put oil on O-rings and back-up washers.

Tighten to 108 - 120 in.-lb. (12,2 - 13,5 N•m).
Figure 20-120-21 Figure 20-120-23
P-16283
P-16263
Remove the P.O. check valve (Item 1) [Figure 20-120- Remove Plug (Item 1) [Figure 20-120-23].
20] & [Figure 20-120-21].
Installation: Put oil on O-rings and back-up washers. Tighten to 20 in.-lb. (27,0 N•m).
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(CONT’D)
Figure 20-120-24
P-16290
Remove the nut (Item 1) [Figure 20-120-26].
P-16268 Installation: Tighten to 48 - 60 in.-lb. (5,4 - 6,8 N•m).
Figure 20-120-27
Remove ROD end fitting (Item 1) [Figure 20-120-24].
Figure 20-120-25
1
P-16276
P-16267 Use a test meter to measure coil resistance [Figure 20-

120-27]. Coil wires do not have polarity. Correct
resistance is approximately 9 ohm.
Remove BASE end fitting (Item 1) [Figure 20-120-25].
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(CONT’D)
Figure 20-120-28
2
1 1
P-16335
Remove the check ball (Item 1) [Figure 20-120-29].
P-16277 Remove the spring (Item 2) [Figure 20-120-29].
Remove the solenoid valve (Item 1) [Figure 20-120-28].
Tighten the solenoid valve to 12 ft.-lb. (16,3 N•m) torque.
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POWER BOB-TACH BLOCK (6678554-CAST IRON) Figure 20-121-1
DANGER
1
P-26244
P-90328
AVOID DEATH Disconnect and cap the two solenoid connectors (Item 1)
• Disconnecting or loosening any hydraulic [Figure 20-121-1] from the loader harness.
support. Replace if damaged. IMPORTANT
D-1009-0409
WARNING tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
the lift arms are secured by an approved lift arm Figure 20-121-2
to fall and cause injury or death. 1
W-2059-0598

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

on Page 10-30-1.) 2
P-26908
Disconnect and cap the outlet hose (Item 1) [Figure 20-
121-2] from block.
Disconnect and cap the hose (Item 2) [Figure 20-121-2]

from block.
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POWER BOB-TACH BLOCK (6678554-CAST IRON)
(CONT’D)
Removal And Installation (Cont’d) IMPORTANT

Figure 20-121-3 When repairing hydrostatic and hydraulic systems,
damage the system.
1 I-2003-0888
1
Figure 20-121-5
1
1
P-26909

3]. 2
Installation: Tighten the mounting bolts to 25 - 28 ft.-lb. 1

(34 - 38 N•m) 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].
Figure 20-121-4
Check the O-ring (Item 3) [Figure 20-121-5] on the plug
1 Figure 20-121-6
P-26100
1
Clean the block (Item 1) [Figure 20-121-4] to remove dirt

before disassembly. Block ports are labeled for correct P-26105
assembly. Remove the plug (Item 2) [Figure 20-121-4].

Installation: Tighten the plug to 46 ft.-lb. (62,4 N•m)
torque.
Installation: Tighten the plug to 120 in.-lb. (13,6 N•m)
torque.
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(CONT’D)
1
Figure 20-121-7
P-26208
3
2
1
4
2 5 P-26112
1 3
Remove the pressure reducing valve plug (Item 1)
[Figure 20-121-8] & [Figure 20-121-9].
P-26107
Installation: Tighten the pressure reducing valve plug to
to 46 ft.-lb. (62,4 N•m) torque.
Remove the spring (Item 1) [Figure 20-121-7] and check
ball (Item 2) [Figure 20-121-7]. Remove the relief piston (Item 2) [Figure 20-121-9],
spring (Item 3) [Figure 20-121-9], ball seat spring guide
Check the O-ring (Item 3) [Figure 20-121-7] on the plug (Item 4) [Figure 20-121-9].
Check the O-ring (Item 5) [Figure 20-121-9] on the
Figure 20-121-8 pressure reducing valve plug and replace as needed.
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
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329 of 968
(CONT’D)
Figure 20-121-10
P-26116
Figure 20-121-13
1
P-26113
Figure 20-121-11 4
3 2
P-26117
3
Remove the nut (Item 1) [Figure 20-121-12] & [Figure

2 1 20-121-13].
P-26114
Installation: Tighten the nut to 5 ft.-lb. (6,8 N•m) torque.
Remove the plug (Item 1) [Figure 20-121-10] & [Figure Remove the first coil (Item 2) [Figure 20-121-13], spacer
20-121-11]. (Item 3) [Figure 20-121-13] and the second coil (Item 4)
[Figure 20-121-13].
torque. NOTE: Remember the coil orientation for ease of
installation.
Check the O-ring (Item 3) [Figure 20-121-11] and

replace as needed.
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(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.-lb. (27,1 N•m)

torque.
Figure 20-121-15
2
1
1
3 P-26309
Remove the plug (Item 1) [Figure 20-121-16] & [Figure

20-121-17].

2
torque.
Remove the dowel pin shuttle (Item 2) [Figure 20-121-

P-26122 17].

Check the O-rings and back-up washers (Item 1) [Figure replace as needed.
20-121-15] and replace as needed.

replace as needed.
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(CONT’D)
Figure 20-121-18
P-26128
Figure 20-121-21
1
P-26125
Figure 20-121-19
2 P-26129
2
1
20-121-21].
3 P-26127
torque.
20-121-19]. Check the O-ring (Item 2) [Figure 20-121-21] and
replace as needed.
torque.
Remove the pilot piston (Item 2) [Figure 20-121-19].

replace as needed.
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332 of 968
(CONT’D)
Figure 20-121-22
P-26133
Make sure orifice is clean and not plugged [Figure 20-

121-24].
P-26130
Figure 20-121-23
2
1
3 P-26132

20-121-23].

torque.
Remove the orifice (Item 2) [Figure 20-121-23] with a 5/

32 in. allen wrench.
Installation: Tighten the orifice to 5 ft.-lb. (6,8 N•m)

torque.
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333 of 968
(CONT’D)
Figure 20-121-25
P-26137
1 P-26134 Installation: Tighten the plug to 120 in.-lb. (13,6 N•m)

torque.
Figure 20-121-26 Figure 20-121-28
3
2 1
1
4 P-26136 2 P-26139
Remove the plug (Item 1) [Figure 20-121-25] & [Figure Remove the dowel pin orifice (Item 1) [Figure 20-121-
20-121-26]. 28].
Installation: Tighten the plug to 198 in.-lb. (22,4 N•m) Check the O-ring (Item 2) [Figure 20-121-28] and
torque. replace as needed.
Remove the relief spring (Item 2) [Figure 20-121-26].
Remove the ball seat spring guide (Item 3) [Figure 20-

121-26].

replace as needed.
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334 of 968
(CONT’D)
Figure 20-121-29
P-26141A
P-26140 Installation: Tighten the plug to 32 in.-lb. (3,6 N•m)

torque.
Figure 20-121-30 Figure 20-121-32
2
1
2
1
P-26141
3
P-26143
Remove the plug (Item 1) [Figure 20-121-29] & [Figure Remove the flow control spring (Item 1) [Figure 20-121-
20-121-30]. 32].
Installation: Tighten the plug to 32 in.-lb. (3,6 N•m) Remove the flow control (Item 2) [Figure 20-121-32].
torque.
Check the O-ring (Item 2) [Figure 20-121-30] and replace as needed.
replace as needed.
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FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly (518916011 & Above)
Removal And Installation (514449564 & Above) Figure 20-130-2
IMPORTANT 1

clean the work area before disassembly and keep all 2
parts clean. Always use caps and plugs on hoses, 4
damage the system. 3
I-2003-0888
Figure 20-130-1 P-34661
Figure 20-130-3
2 1
1
3
6 2
4 5
3
P-34899
P-34760
Disconnect the auxiliary tubelines (Item 1) [Figure 20-
130-1] and drain tubeline (Item 2) [Figure 20-130-1] from
the coupler block. Remove the male coupler (Item 1) [Figure 20-130-2] &
[Figure 20-130-3].
1] Installation: Tighten the male coupler (Item 1) [Figure
20-130-2] & [Figure 20-130-3] to 59 ft.-lb. (80 N•m).
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.-lb. (50 N•m).
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.-lb. (80 N•m).
Remove the fittings (Item 4) [Figure 20-130-2] & [Figure

20-130-3] check the O-rings (Item 5) [Figure 20-130-3]
Remove the springs (Item 6) [Figure 20-130-3].
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FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-130-6
(CONT'D)
Disassembly And Assembly (514449564 & Above) 1

(Cont’d)
Figure 20-130-4
1
1
P-34665
Check the O-rings (Item 1) [Figure 20-130-6] backup O-

rings (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 1
Figure 20-130-5
P-34664
Check the O-rings (Item 1) [Figure 20-130-7] backup O-

rings (Item 2) [Figure 20-130-7] for damage and replace
P-34701 as needed.
Press center of male couplers down and check the O-ring

(Item 1) [Figure 20-130-5] for damage and replace as
needed.
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HYDROSTATIC SYSTEM
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Hydrostatic Charge Pressure Sender Removal And Installation 30-30-1
SAFETY &
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1 MAINTENANCE
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 HYDROSTATIC

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-8 SYSTEM
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 ELECTRICAL
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 SYSTEM &
ANALYSIS
HYDROSTATIC MOTOR (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . 30-21-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-13
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-5 ENGINE
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-12 SERVICE
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1 SPECIFICATIO

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
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.
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HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart
WARNING
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4, 5
The loader does not move in a straight line. 2, 3, 5, 6, 7
The hydrostatic system is overheating. 8, 9, 10, 11
Service code HP 2 appears (Warnings, low charge pressure) or the warning light 8, 11, 12, 13, 14
comes on.

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.
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HYDROSTATIC SYSTEM INFORMATION (CONT’D) The functions of the replentishing valves are:
• To give replacement fluid to the low pressure side of

the hydrostatic circuit. Replacement fluid is needed
IMPORTANT because of normal internal leakage and the controlled
flow to the oil cooler for cooling; Function 1 [Figure
30-10-1].
When repairing hydrostatic and hydraulic systems, • To keep high pressure fluid out of the low pressure
clean the work area before disassembly and keep all side of the hydrostatic circuitry; Function 2 [Figure
parts clean. Always use caps and plugs on hoses, 30-10-1].
damage the system. See HYDROSTATIC MOTOR, Page 30-01 (M46 Pump)
I-2003-0888
or HYDROSTATIC MOTOR (TWO SPEED), Page 30-01
(M44 Pump) for valve location and repair information.
Replentishing The Valve Function
Figure 30-10-1
Function 1 Valve Moves for

Charge Oil
Replacement
Function 2 Valve Stays on Seat

to Hold High
Pressure for
Drive
B-2804
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HYDROSTATIC MOTOR Figure 30-20-1
DANGER 1
N-17874
P-90328
AVOID DEATH Disconnect the case drain hose (Item 1) [Figure 30-20-
• Disconnecting or loosening any hydraulic 1].
can cause lift arms to drop. Disconnect the high pressure hoses (Item 2) [Figure 30-
• Keep out of this area when lift arms are raised 20-1].
support. Replace if damaged. Figure 30-20-2
D-1009-0409
WARNING
1 2 1
W-2059-0598
Lift and block the loader. (See LIFTING AND BLOCKING N-17876
Raise the lift arms and install the lift arm support device. Remove the ten mounting bolts (Item 1) [Figure 30-20-
(See LIFT ARM SUPPORT DEVICE on Page 10-20-1.) 2].
Raise the operator cab. (See Raising The Operator Cab NOTE: The two bolts (Item 2) [Figure 30-20-2] mount
on Page 10-30-1.) the cam ring to the motor, and do not have to
be removed, to remove the motor from the
Remove the motor cover. loader.
Mark the hoses for correct installation. Remove the motor / cam ring section from the loader.
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HYDROSTATIC MOTOR (CONT’D)
Figure 30-20-3
P-5405
Remove the piston / roller section (Item 1) [Figure 30-20-

3] from the loader, if it was not removed with the motor /
cam ring.
To remove the motor carrier. (See Carrier Removal And

Installation on page 30-20-11.)
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3
1 2 3
5
6
4 7
8
9
12 4 10
11
13
15
23 14
26
27 25
28
29
16
22
24 21
20
19
18
30 17
C-3374A
Ref. Description Ref. Description

1. Distributor 17. Plug
2. Spring 18. O-Ring
3. Seal 19. Spring
4. O-Ring 20. Shim
5. Plug 21. Poppet
6. O-Ring 22. O-Ring
7. Spring 23. Seal
8. Washer 24. O-ring
9. Spool
10. 25. Seal
Spring 26. O-ring
11. Rear Housing 27. Cam
12. Plug
13. 28. Roller
O-Ring 29. Piston
14. O-Ring 30. Block
15. Stop Pin
16. Bolt
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HYDROSTATIC MOTOR (CONT’D) Figure 30-20-6
Disassembly
Figure 30-20-4 1
N-17863
Remove the cam ring (Item 1) [Figure 30-20-6] from the

N-17861 motor housing.
Figure 30-20-7
Remove the piston / roller section (Item 1) [Figure 30-20-
4] from the motor.
1
Figure 30-20-5
N-17864
Remove the stop pin (Item 1) [Figure 30-20-7] from the

N-17860 rear motor housing.
Remove the two cam ring mounting bolts (Item 1)

[Figure 30-20-5].
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HYDROSTATIC MOTOR (CONT’D) Remove the two O-rings, that are located under the
seals.
Figure 30-20-10
1
IMPORTANT 1

damage the system.
I-2003-0888
1
Figure 30-20-8
N-17869
Remove the nine springs (Item 1) [Figure 30-20-10] from

1 2 the distributor.
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

the distributor.
Remove the two O-rings, that are located under the

seals.
N-17866
Remove the two seals (Item 1) [Figure 30-20-9] from the

housing.
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Figure 30-20-12
2
1
P-5765
3 4
1 2
Apply low air pressure to each port in the cylinder block
N-17872 to remove the roller (Item 1) [Figure 30-20-14] and
piston / ring assembly (Item 2) [Figure 30-20-14].
Remove the plug (Item 1) [Figure 30-20-12], spring (Item NOTE: Put all the roller / piston assembly in their
2) [Figure 30-20-12], shim (Item 3) [Figure 30-20-12] original position.
and poppet (Item 4) [Figure 30-20-12].
Figure 30-20-13
1
4 2
2 3
N-17871
Remove the plug (Item 1) [Figure 30-20-13], springs

(Item 2) [Figure 30-20-13], spool (Item 3) [Figure 30-20-
13] and washer (Item 4) [Figure 30-20-13].
Inspect all parts and replace as needed.
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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].
N-17870
Check the distributor surface for scratches [Figure 30-

20-15].
Figure 30-20-16
P-5753
Check the cam ring inside surface for wear and scratches
[Figure 30-20-16].
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Assembly
IMPORTANT 1

damage the system.
I-2003-0888
N-17870
NOTE: Always use new O-rings and seals when
assembling the hydrostatic motor.
Install new O-rings and seals (Item 1) [Figure 30-20-19]
Figure 30-20-18 on the distributor.
Figure 30-20-20
2
1
1
P-5765
N-17869
Install the roller (Item 1) [Figure 30-20-18] in the piston
(Item 2) [Figure 30-20-18].
Put grease on the springs (Item 1) [Figure 30-20-20] to
Dip the roller / piston assembly into oil and install into the hold them in place.
bore in the cylinder.
Install the springs into the distributor.
Repeat for each roller / piston assembly.
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HYDROSTATIC MOTOR (CONT’D) Install the two O-rings into the housing.
Assembly (Cont’d) Figure 30-20-23
Figure 30-20-21
4
1 2 3 1
1
N-17866
N-17871
housing, over the top of the O-rings, with minimum
Install the spring (Item 1) [Figure 30-20-21], spool (Item distortion.
2) [Figure 30-20-21], washer (Item 3) [Figure 30-20-21]
and spring into the rear housing. Lightly smear grease over the seals.
Replace the O-ring (Item 4) [Figure 30-20-21] on the Figure 30-20-24

plug.
Install the plug into the rear housing and tighten to 18 -

3
22 ft.-lb. (25 - 30 N•m) torque. 2
Figure 30-20-22
N-17868
4 3 2 1 Install the stop pin (Item 1) [Figure 30-20-24] and tighten

to 7 - 9 ft.-lb. (10 - 12 N•m) torque.
N-17872 Install the distributor (Item 2) [Figure 30-20-24] into the

housing.
Install the poppet (Item 1) [Figure 30-20-22], the shim Align the distributor hole (Item 3) [Figure 30-20-24] with
(Item 2) [Figure 30-20-22], spring (Item 3) [Figure 30- the stop pin. When aligned correctly, the distributor can
20-22] into the rear housing. be depressed slightly.
Replace the O-ring (Item 4) [Figure 30-20-22] on the Lightly smear grease on the O-ring.
plug.
Install the plug into the rear housing and tighten to 9 - 11

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Assembly (Cont’d)
Figure 30-20-25
1
1
1
N-17860
Install the two cam ring mounting bolts (Item 1) [Figure

N-17862 30-20-27] and tighten to 50 ft.-lb. (67,8 N•m) torque.
Figure 30-20-28
Install the O-ring (Item 1) [Figure 30-20-25] on the rear
housing.
Figure 30-20-26
N-17861
Install the piston / roller section (Item 1) [Figure 30-20-

N-17863 28] in the motor.
Install the motor on the loader and tighten the mount

Install the cam ring (Item 1) [Figure 30-20-26] on the bolts to 110 ft.-lb. (149,2 N•m) torque.
rear housing and align the mounting bolt holes.
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.
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Carrier Removal And Installation
Figure 30-20-29
P-5467
Lift and block the loader. (See Contents Page 10-01.)
Raise the lift arm and install an approved lift arm support
20-1.)

on Page 10-30-1.)
Remove the fluid from the chaincase. (See Replacing

The Oil on Page 10-130-1.)
P-5489
Remove the front axle. (See DRIVE COMPONENTS on

Page 40-20-1.) NOTE: For easier access for the motor carrier coming
out and going into the chaincase, tie the front
If the motor carrier is removed from the right side, drive chain to the chaincase with a wire
remove the lift arm bypass control valve, (See Removal [Figure 30-20-30].
And Installation on Page 20-50-1.) and remove the
hydraulic control valve. (See Removal & Installation (S/N Slide the motor carrier out of the chaincase far enough to
514447863 & Below) on Page 20-41-3.) install a chain and chain hoist to the carrier [Figure 30-
20-30].
Remove the six mounting bolts (Item 1) [Figure 30-20-
29] from the carrier.
Installation: Tighten the mounting bolts to 330 ft.-lb.

(447 N•m) torque.
Slide the motor carrier toward the rear and remove the
rear drive chain.
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Carrier Parts Identification
1
2 3
5 5
6
7
8
TS-1227A
Ref. Description
1. Shaft
2. Bearing
3. Race
4. Housing
5. Seal (2)
6. Race
7. Bearing
8. Snap Ring
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Carrier Disassembly
Figure 30-20-31
P-5756
Remove the snap ring (Item 1) [Figure 30-20-33] and

P-5760 washer from the shaft.
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 30-20- Use a hydraulic press, remove the shaft from the housing
32]. [Figure 30-20-34].
Put a small amount of pressure on the shaft to release

the pre-load on the snap ring.
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HYDRAULIC MOTOR (CONT’D) Carrier Assembly
Carrier Disassembly (Cont’d) Figure 30-20-37
Figure 30-20-35
P-5764
P5761
The tool listed will be needed to the following procedure:
Install the bearing puller tool under the bearing flange, MEL1431 - Seal Driver Tool
use the hydraulic press to remove the bearing from the
shaft [Figure 30-20-35]. Install the first seal (Item 1) [Figure 30-20-37] into the
housing with the seal lip facing away from you.
Figure 30-20-36
Use the tool (Item 2) [Figure 30-20-37] as shown in the
figure.
Figure 30-20-38
2
1
2
P-5763

the housing.
P-5762
Check the bearing cup (Item 2) [Figure 30-20-36] (both

sides) and replace as needed. 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.
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Carrier Assembly (Cont’d)
Figure 30-20-39
1
1
P-5769
P-5767 Install the bearing (Item 1) [Figure 30-20-40] using the

tool (Item 2) [Figure 30-20-40] (MEL1431).
Install the bearing on the shaft [Figure 30-20-39]. After the bearing is seated. Install the washer and snap
ring on the shaft.
Use a pipe (Item 1) [Figure 30-20-39] with O.D. that
seats on the I.D. of the bearing. It may be necessary to use the tool to push the washer
and snap ring sown into position because of the pre-load
Install the shaft / bearing assembly into the housing. on the bearings.
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HYDROSTATIC MOTOR (TWO-SPEED) Figure 30-21-1
DANGER
1
1
N-22483
P-90328
AVOID DEATH Remove the motor cover mount bolts (Item 1) [Figure
• Disconnecting or loosening any hydraulic 30-21-1].
can cause lift arms to drop. Remove the motor cover from the loader.
unless supported by an approved lift arm Figure 30-21-2
D-1009-0409
WARNING
2
W-2059-0598
N-22484

THE LOADER on Page 10-10-1.) Disconnect the hydraulic hose (Item 1) [Figure 30-21-2]
that goes to the two-speed port on the two-speed / brake
Raise the lift arms and install the lift arm support device. block.
(See LIFT ARM SUPPORT DEVICE on Page 10-20-1.)
Raise the operator cab. (See Contents, Page 10-01.) that goes to the brake port on the two-speed / brake
block.
Drain the hydraulic reservoir. (See Raising The Operator
Cab on Page 10-30-1.) Disconnect the hydraulic hose (Item 3) [Figure 30-21-2]
that goes to the make-up port on the two-speed / brake
block.
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HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D) Figure 30-21-5
Figure 30-21-3
1
1
N-22488
Remove the hydraulic fitting (Item 1) [Figure 30-21-5]

N-22485 from the motor.
Figure 30-21-6
that goes to the case drain filter.
Figure 30-21-4
N-22487
2
Remove the 10 (12 mm) mount bolts (Item 1) [Figure 30-

N-22486 21-6] from the motor.
NOTE: The two smaller diameter bolts (8 mm), hold

Remove the hydraulic fitting (Item 1) [Figure 30-21-4] the cam ring to the motor and do not have to
from the motor. be removed for motor removal.
Remove the eight flange bolts (Item 2) [Figure 30-21-4] Remove the motor from the loader.
from the high pressure hoses on the motor.
Installation: Install the lower collar to the motor and

connect the high pressure hoses behind the collar, then
install the upper collar and tighten the bolts to 25 ft.-lb.
(34 N•m) torque.
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HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D)
Figure 30-21-7
N-22535
Installation: Replace the O-ring (item 1) [Figure 30-21-

7] and hold it in place with a light cover of lithium base
grease. Tighten the 10 mounting bolts to 110 ft.-lb. (149
N•m) torque.
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1. Motor
2. Distributor
3. Spring
4. Seal / O-Ring
5. Seal / O-Ring
6. Seal / O-Ring
1
7. Seal / O-Ring
8. Seal / O-Ring 8
9. Bushing 7
10. Roller
11. Piston 5
4 6
12. Block 3
13. Cam 2
14. Quad Ring
15. Plug
16. O-Ring 29 30
17. Locating Pin 28
18. Housing 27
9 25 26
19. Shim
20. O-Ring
16 32 25
21. Poppet 31
22. Spring
23. Plug 15
24. Bolt
25. Spring 10
26. Spool 34
39
27. Washer 33
28. O-Ring 11
29. Plug
30. Housing
18 38
31. Quad Ring 21 3637
32. Bushing 19 24 35
33. Snap Ring 17 22
20 48
34. Snap Ring
23
35. Spool 14 47 49
36. Spring 46
37. Washer 13 45
38. Quad Ring 12 44
39. Bolt 43
40. Shaft
41. Brake Disc-Outer
42. Brake Disc-Inner 42
41
43. Piston
44. O-Ring 40
45. Washer
46. Washer
47. Gasket
48. Cover
49. Bolt
B-16657A
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Disassembly
Figure 30-21-8
N-22491
Remove the cover plate gasket (Item 1) [Figure 30-21-

N-22489 10].
Remove the disc spring washer (Item 2) [Figure 30-21-

NOTE: Mark the motor, brake and motor carrier 10] and the disk spring (Item 3) [Figure 30-21-10] from
housings for proper alignment for ease of the brake housing.
assembly [Figure 30-21-8]
NOTE: Mark the top side of the disk spring for proper
Drain the oil from the motor casing. installation.
1 2
1
N-22490 N-22493
Remove the twelve mounting bolts (Item 1) [Figure 30- Remove the piston from the brake housing (Item 1)
21-9] from the brake cover plate. [Figure 30-21-11].
NOTE: Unscrew the bolts alternately, one turn at a NOTE: The use of air pressure through the brake line
time to release the preload in the end cap. connection (Item 2) [Figure 30-21-11] will aid
in piston removal.
Remove the cover plate from the brake housing.
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Figure 30-21-12
1
2
1
N-22496

N-22494 brake housing.
Figure 30-21-15
Remove the eight mounting bolts (Item 1) [Figure 30-21-
12] from the brake housing.
Remove the brake housing (Item 2) [Figure 30-21-12]

from the rear housing.
1
Figure 30-21-13
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.

housing.
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Figure 30-21-16
1
1
2
N-22502

N-22499 housing.
Installation: Tighten the plug to 18 - 22 ft.-lb. (25 - 30

Remove the two-sped spool (Item 1) [Figure 30-21-16] N•m) torque.
from the housing assembly.
Remove the plugs (Item 2) [Figure 30-21-18] from the
Figure 30-21-17 housing.
Installation: Tighten the plugs to 9 - 11 ft.-lb. (12 - 15

N•m) 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 30-
21-17] and the snap ring (Item 4) [Figure 30-21-17], and
N-22503
replace as needed.
NOTE: The spool (Item 1) [Figure 30-21-17] is marked Remove the flushing spool assembly (Item 1) [Figure 30-
with either an A or B. The spool must be 21-19] from the housing.
replace with a spool with the same mark.
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Figure 30-21-20
1 3
2 4
N-22506
Remove the poppet assembly (Item 1) [Figure 30-21-22]

N-22504 from the housing.
Figure 30-21-23
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 30-21-
20].
Inspect all parts and replace as needed.
Figure 30-21-21
1
1 2
3
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

housing.
Installation: Tighten the plug to 9 - 11 ft.-lb. (12 - 15

N•m) torque.
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Figure 30-21-24
1 1
N-22511
Remove the roller / piston assembly (Item 1) [Figure 30-

N-22508 21-26] from the cylinder block.
NOTE: Put all roller / piston assemblies back in the

Loosen the two (8 mm) cam ring mount bolts (Item 1) original bore.
[Figure 30-21-24].
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
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.

housing.
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Figure 30-21-28 1
N-22516
NOTE: The distributor removal, is best accomplished

N-22513 by lifting the housing (Item 1) [Figure 30-21-
30] 2 - 3 in. above a wooden surface, and
dropping the housing [Figure 30-21-30].
NOTE: The snap ring end of the shaft (Item 1) [Figure
30-21-28] goes up toward the cam ring end of Figure 30-21-31
the motor.
Figure 30-21-29
1
1
N-22521
N-22515 Remove the locating pin (Item 1) [Figure 30-21-31] from

the distributor.
Remove the distributor (Item 1) [Figure 30-21-29] from

the housing.
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Figure 30-21-32
1
1 2
N-22519
Remove the six seals [Figure 30-21-34] and the six

N-22522 back-up O-rings (Item 2) [Figure 30-21-34] from the
distributor.
Remove the twelve springs (Item 1) [Figure 30-21-32]

from the distributor.
Figure 30-21-33
N-22523
Remove the bushing (Item 1) [Figure 30-21-33] from the

distributor, if worn or scratched.
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Inspection
Figure 30-21-35
N-22510
2
Check the cam ring inside surface for wear and scratches
N-22498 [Figure 30-21-37].
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
Before the motor is assembled, check the following 1

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
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].
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HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D) Assembly
Inspection (Cont’d) Figure 30-21-40
Figure 30-21-39
1
N-22511
N-22514
NOTE: Always use new O-rings and seals when
assembling the motor and brake assemblies.
Check the brake shaft (Item 1) [Figure 30-21-39] for
wear and replace as needed. Dip the roller / piston assembly (Item 1) [Figure 30-21-
40] in oil and replace back in its original bore.
Check the brake shaft snap ring (Item 2) [Figure 30-21-
39] and replace as needed. Repeat the procedure for each roller / piston assembly.
Figure 30-21-41
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.
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Assembly (Cont’d)
Figure 30-21-42
1 1
N-22515
Install the distributor (Item 1) [Figure 30-21-44] in the

N-22525 housing.
Figure 30-21-45
Install a new bushing (Item 1) [Figure 30-21-42] in the
distributor if the old bushing was removed.
Figure 30-21-43
1 1
N-22516
Align the locating pin (Item 1) [Figure 30-21-45] in the

N-22522 housing with the alignment hole in the distributor, and tap
the distributor in place with a rubber mallet.
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].
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Assembly (Cont’d)
Figure 30-21-46
1 1
N-22509
Install the cylinder block assembly (Item 1) [Figure 30-

N-22513 21-48] to the brake shaft.
Install the cam ring to the rear housing and start the
Install the brake shaft (Item 1) [Figure 30-21-46] in the mount bolts and finger tighten.
housing.
Figure 30-21-49
Figure 30-21-47
1 1
N-22508
N-22512
Turn the motor so that it sets on the cam ring, and

Apply a light coating of grease, and install the O-ring cylinder block [Figure 30-21-49].
(Item 1) [Figure 30-21-47] to the housing.
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.-lb. (35 - 39 N•m) torque.
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Assembly (Cont’d)
Figure 30-21-50
1 N-18348
Measure the thickness of the individual brake disc’s

N-22499 [Figure 30-21-52] to determine the amount of wear on
each disc.
Install the new O-ring on the housing assembly (Item 1) The normal thickness of the individual brake disc is 0.039
[Figure 30-21-50] and lightly smear with grease. in. (1 mm).
Install the two speed spool (Item 2) [Figure 30-21-50]. If the individual disc’s thickness is 0.037 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 30-21-

53] and tighten evenly to 52 - 57 ft.-lb. (70 - 77 N•m)
torque.
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Assembly (Cont’d)
Figure 30-21-54
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 30-
21-55].
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Assembly (Cont’d)
Figure 30-21-58
2 1
N-22534
With the motor in a hydraulic press and the

N-22493 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 30-21-
Install the piston (Item 1) [Figure 30-21-58] in the brake 59] to the top of the piston (Item 2) [Figure 30-21-59].
housing.
Record the measurement to three decimal places.
NOTE: If the brake pack was not replaced, the
procedure described below for determining Remove the motor from the hydraulic press.
brake washer thickness, need not be
performed. Figure 30-21-60
Install the motor assembly in a hydraulic press. Apply a

downward force of 4500 lb. (20 Kn), on the brake piston
[Figure 30-21-58]. 1
NOTE: The 4500 lb. of force, is NOT the amount of

pressure required by the press. It is the 2
amount of downward force applied by the
press.
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.
N-22492
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. Install the brake plate (Item 1) [Figure 30-21-60].
1432 Install the end plate gasket (Item 2) [Figure 30-21-60].

1432
= 159 PSI
( d = 6 in. 2 (Squared) = 9
2 ) 9
Example: d = 6 in. (152 mm) piston diameter of the

press cylinder. Apply 159 PSI (1,096 kPa) pressure to
the press cylinder piston.
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Assembly (Cont’d)
Figure 30-21-61
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.-lb. (14 - 16 N•m) 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 30-

21-59]. 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 0.281 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.
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CHARGE PRESSURE
Hydrostatic Charge Pressure Sender Removal And

Installation
Figure 30-30-1
3 1
N-19742
To remove and install the charge pressure sender use

the following procedure.
Disconnect the wire (Item 1) [Figure 30-30-1] from the

sender.
Remove the hydraulics 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].
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HYDROSTATIC PUMP Figure 30-40-2
Replenishing / High Pressure Relief Valve
Figure 30-40-1
1
N-17228
Remove the high pressure relief valve from the pump

N-17227 [Figure 30-40-2].
Check the O-rings (Items 1 & 2) [Figure 30-40-2] for

There are four replenishing / high pressure relief valves damage and replace as needed.
(Item 1) [Figure 30-40-1] in the hydrostatic pump. Two
are located at the top of the pump and two at the bottom If the high pressure relief valve must be replaced, it must
of the pump. be replaced as a complete unit.
See Contents, Page 30-01 for valve function. The pressure setting for a new high pressure relief valve
is:
4721 PSI (S/N 514441939-514446864)
(S/N 514540074-514541034)
5000 PSI (S/N 514446895 & Above)
(S/N 514541035 & Above)
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HYDROSTATIC PUMP (CONT’D) Figure 30-40-5
Charge Pressure Relief Valve
IMPORTANT 1

damage the system.
I-2003-0888
N-17232
Figure 30-40-3
1 There are several different thickness of shims (Item 1)

[Figure 30-40-5] and they are used to adjust the charge
pressure.
The charge pressure should be set at 420 PSI (2896

kPa).
N-17230
Loosen the charge relief valve plug (Item 1) [Figure 30-

40-3].
Figure 30-40-4
N-17231
Remove the plug, spring and poppet [Figure 30-40-4].
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Figure 30-40-6
P-5557
1 Remove the washer and nut (Item 1) [Figure 30-40-8]

P-5552 from the hydrostatic pump drive shaft.
Installation: Tighten the nut to 175 - 200 ft.-lb. (237 - 271

Remove the hydrostatic pump / engine assembly from N•m) torque.
the loader. (See Removal And Installation on Page 70-
80-1.) Figure 30-40-9
Remove the belt shield clips (Item 1) [Figure 30-40-6]

and belt shield (Item 2) [Figure 30-40-6].
Figure 30-40-7
1 1
2
3
P-5657
Install the nut on the end of the pump drive shaft (without
washer.
P-5554
Use a puller (Item 1) [Figure 30-40-9] to remove the
pulley from the pump drive shaft.
Loosen the stop mounting bolts (Item 1) [Figure 30-40-
7].
Remove the spring tension bolt (Item 2) [Figure 30-40-

7].
Remove the drive belt (Item 3) [Figure 30-40-7].
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Figure 30-40-10
N-15343
1
Remove the mounting bolt (Item 1) [Figure 30-40-12] at

N-15341 the hydraulic pump end of the pump.
Remove the hydrostatic pump from the mounting bracket

Figure 30-40-11 and drive belt housing.
N-15342

10] and nuts (Item 1) [Figure 30-40-11].
Installation: Tighten the mounting bolts and nuts to 65 -

70 ft.-lb. (89 - 95 N•m) torque. Make sure the key (Item 2)
[Figure 30-40-10] is installed.
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HYDROSTATIC PUMP (CONT’D)
Parts Identification (Right Half)
8 5
7 4
6
9 3
2 1
13
14
10 15
17
11 12 19
21
23
25
27 16
18
29
20
22
24
26
3837
28
36 33
34
30 32
31
46
41 35 48
42 40
43
45
44 49
39 47 D-2427
Ref. Description Ref. Description Ref. Description Ref. Description

1. BOLT 14. O-RING 26. RETAINER 38. BOLT
2. END CAP 15. RELIEF VALVE 27. RETAINER 39. SHAFT
3. PLUG 16. PIN 28. PISTON ASSEMBLY 40. SNAP RING
4. O-RING 17. VALVE PLATE 29. PLATE 41. BEARING
5. PLUG 18. RETAINER 30. SWASHPLATE 42. SNAP RING
6. O-RING 19. WASHER 31. PIN 43. SNAP RING
7. O-RING 20. SPRING 32. HOUSING 44. PLUG
8. RELIEF VALVE 21. WASHER 33. PLUG 45. O-RING
9. BOLT 22. BLOCK 34. BEARING 46. BEARING
10. GASKET 23. RETAINER 35. SEAL 47. O-RING
11. BEARING 24. PIN 36. O-RING 48. PLATE
12. PLUG 25. WASHER 37. COVER 49. BOLT
13. O-RING
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HYDROSTATIC PUMP (CONT’D)
Parts Identification (Left Half)
4
16 8 6
13 11
14
12
10
1
2
17 3
23 5
15 9 7
24
18
19
21 22 26
20 28
30
32
34 25
36
38 27
29
31 47
33 46
35 45
37 44
51 48 43
39 40
52 49 42
50
53
60 54
55
56
61
62 55 54 64
65
57 66
59 58 63 D-2428A
Ref. Description Ref. Description Ref. Description Ref. Description Ref. Description
1. SNAP RING 17. BOLT 33. BLOCK 49. O-RING 65. O-RING
2. WASHER 18. PIN 34. WASHER 50. O-RING 66. RELIEF VALVE
3. SEAL 19. O-RING 35. SPRING 51. O-RING
4. SNAP RING 20. PLUG 36. WASHER 52. RELIEF VALVE
5. SNAP RING 21. BEARING 37. WASHER 53. PLUG
6. BEARING 22. O-RING 38. VALVE PLATE 54. PIN
7. SNAP RING 23. PLATE 39. PIN 55. O-RINGS
8. KEY 24. BOLT 40. GASKET 56. PIN
9. SHAFT 25. SWASH PLATE 41. BEARING 57. GEROTOR
10. HOUSING 26. WEAR PLATE 42. PLUG 58. SPACER
11. PLUG 27. PISTON ASSEMBLY 43. POPPET 59. O-RING
12. O-RING 28. PISTON RETAINER 44. SPRING 60. O-RING
13. BEARING 29. RETAINER 45. SHIM 61. PIN
14. SEAL 30. WASHER 46. O-RING 62. COUPLER
15. O-RING 31. PIN 47. PLUG 63. BOLT
16. COVER 32. RETAINER 48. PLUG 64. O-RING
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Hydraulic Pump Removal & Installation

2
Figure 30-40-13
2
1
N-17223
1 Remove the Hi-flow hydraulic pump (Item 1) [Figure 30-

N-17226 40-15] (if loader is so equipped) from the hydrostatic
pumps, by removing the two mounting bolts (Item 2)
[Figure 30-40-15].
Remove the standard flow hydraulic pump (Item 1)
[Figure 30-40-13] from the hydrostatic pumps, by Figure 30-40-16
removing the two mounting bolts (Item 2) [Figure 30-40-
13].
Figure 30-40-14
2
1
2
1
N-17356
Remove the gasket (Item 1) [Figure 30-40-16] and

N-17229 coupler (Item 2) [Figure 30-40-16] with the hydraulic
pump.
Remove the O-ring (Item 1) [Figure 30-40-14] and

coupler (Item 2) [Figure 30-40-14] with the hydraulic
pump.
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Disassembly
Pump Separation
Figure 30-40-17
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 2
1 N-17235
N-17233
Remove the two O-rings (Item 1) [Figure 30-40-20] from
the grooves in the gerotor spacer on the charge pump.
Remove the mounting bolts (Item 1) [Figure 30-40-17] &
[Figure 30-40-18]. Remove the O-rings (Item 2) [Figure 30-40-20] from the
charge pump housing end cap.
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2
Charge Pump Disassembly (Cont’d)
Figure 30-40-21
3
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)
N-17236 [Figure 30-40-23] for wear and replace as needed.
Figure 30-40-24
Figure 30-40-22
1 2
1
2
2
N-17186
N-17237
Remove the locating pin (Item 1) [Figure 30-40-24] from

Remove the gerotor assembly (Item 1) [Figure 30-40-21] the pump end cap.
& [Figure 30-40-22] from the charge pump.
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.

24] from the charge pump.
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1
Figure 30-40-25
N-17193
Check the valve plate [Figure 30-40-27] for wear and

3
N-17191 remove from charge pump.
Figure 30-40-28
Mark the charge pump (Item 1) [Figure 30-40-25] case
and the pump case (Item 2) [Figure 30-40-25] for proper
2
installation. 1
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 30-40-

28] 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.
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1
Figure 30-40-29
N-17199
Remove the ball guide retainer (Item 1) [Figure 30-40-

N-17197 31] from the cylinder block.
Figure 30-40-32
Remove the rotating group (Item 1) [Figure 30-40-29]
from the pump.
3
3
Figure 30-40-30
1 2 1
3
3
2
N-17200
Check the ball guide retainer (Item 1) [Figure 30-40-32]

N-17198 and washer (Item 2) [Figure 30-40-32] for wear and
replace as needed.
Remove the slipper guide and pistons (Item 1) [Figure Remove the four slipper hold down pins (Item 3) [Figure
30-40-30] from the cylinder block. 30-40-32] from the cylinder block.
Check the pistons (Item 2) [Figure 30-40-30] for wear Check the cylinder block for wear and replace as needed.
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1
Figure 30-40-33
N-17239
Use a seal puller and remove the seal (Item 1) [Figure

N-17201 30-40-35] from the pump housing.
Figure 30-40-36
Remove the thrust plate (Item 1) [Figure 30-40-33] from
the pump housing.
Figure 30-40-34
1
2
N-17240
3
Remove the snap ring (Item 1) [Figure 30-40-36] from
N-17481 the pump housing and remove the driveshaft and bearing
from the housing.
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.
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Figure 30-40-37
1 1
1 N-17243
Remove the four mount bolts (Item 1) [Figure 30-40-39]

N-17241 form the lower trunnion cover. Remove the cover.
Figure 30-40-40
the driveshaft and remove the bearing.
Figure 30-40-38
2
1
N-17244
Remove the O-ring (Item 1) [Figure 30-40-40] and

N-17242 bearing race (Item 2) [Figure 30-40-40] from the pump
housing.
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.
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Figure 30-40-41
1
1
2
N-17247
Remove the upper trunnion cover (Item 1) [Figure 30-40-

N-17245 43].
Figure 30-40-44
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 30-40-42
1
2
N-17250
1 1
Inspect the seal (Item 1) [Figure 30-40-44] in the upper

trunnion cover and replace as needed.
N-17246

form the pump housing and remove the steering bracket
(Item 2) [Figure 30-40-42].
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Figure 30-40-45
1 N-17251
2 Slide the swashplate from the side to side and remove

N-17248 the tapered roller bearing (Item 1) [Figure 30-40-47]
from the swashplate shaft.
Remove the O-ring (Item 1) [Figure 30-40-45] and Figure 30-40-48

bearing race (Item 2) [Figure 30-40-45] from the pump
housing.
1
Figure 30-40-46
1
N-17252
2
Tilt the swashplate (Item 1) [Figure 30-40-48] and
N-17249 remove the swashplate and lower bearing from the pump
housing.
Inspect the bearing race (Item 1) [Figure 30-40-46] and

the O-ring (Item 2) [Figure 30-40-46] and replace as
needed.
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Assembly
Figure 30-40-49
1
1
N-17249
Install the tapered bearing (Item 1) [Figure 30-40-51] on

N-17253 the swashplate shaft.
Figure 30-40-52
Install the lower bearing (Item 1) [Figure 30-40-49] on
the swashplate.
Figure 30-40-50
N-17248
Install the bearing race (Item 2) [Figure 30-40-51] and O-

N-17252 ring (Item 3) [Figure 30-40-51] as shown in [Figure 30-
40-52].
Install the swashplate and bearing into the pump housing

[Figure 30-40-50].
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HYSROSTATIC PUMP (CONT’D) Figure 30-40-55
Assembly (Cont’d)
Figure 30-40-53
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 O-

ring (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.-lb.
(24 - 30 N•m) torque.
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Assembly (Cont'd)
Figure 30-40-57
N-17241
Install the bearing and snap ring (Item 1) [Figure 30-40-

N-17243 59] on the pump shaft.
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.-lb.

(24 - 30 N•m) torque.
Figure 30-40-58
1
1
N-17240
Install the pump shaft into the pump housing [Figure 30-
40-60].
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.
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Assembly (Cont'd)
Figure 30-40-61
1 2 3
N-17198
Assemble the piston assemblies into the slipper guide

N-17200 [Figure 30-40-63]. Lubricate the pistons and cylinder
block bores and insert the piston assemblies into the
cylinder bores [Figure 30-40-63].
Install the four slipper pins (Item 1) [Figure 30-40-61]
into the cylinder block. 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
N-17197
Lay the pump housing on its side and install the cylinder
block, piston assembly into the housing.
N-17199 Place the pump on a work surface with the end cap
opening up [Figure 30-40-64].
Install the ball guide retainer and washer (Item 1) [Figure

30-40-62] onto the slipper holddown pins.
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Assembly (Cont'd)
Figure 30-40-65
1
2 1
N-17193
Coat the backside of the valve plate with petroleum jelly

N-17194 to hold it in position and install the valve plate onto the
charge pump, bronze face up [Figure 30-40-67]-.
Replace the needle bearing (Item 1) [Figure 30-40-65] The notch (Item 1) [Figure 30-40-67] on the valve plate
and valve plate locating pin (Item 2) [Figure 30-40-65] in must engage the locating pin.
the charge pump.
Figure 30-40-68
Figure 30-40-66
1
2
1
N-17192
N-17196
Coat a new end cap gasket (Item 1) [Figure 30-40-68]

The bearing cage (Item 1) [Figure 30-40-66] will with petroleum jelly and install onto the charge pump.
protrude from 0.08 - 0.10 in. (2,0 - 2,5 mm) from the
surface of the charge pump.
The valve plate locating spring pin (Item 2) [Figure 30-

40-66] will protrude from 1.65 - 0.185 in. (4,19 - 4,70 mm)
from the surface of the charge pump.
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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]. NOTE: The charge pump rotation is determined by
the position of the gerotor space and locating
When the charge pump is properly installed, the cylinder pin (Item 1) [Figure 30-40-71] in the pump end
block spring will hold the charge pump end cap away cap.
from the housing approximately 0.125 in. (3 mm).
Prior to assembly, lubricate the gerotor assembly with
Figure 30-40-70 clean hydraulic oil.
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.-lb. (47 - 61 N•m) torque.
Install the gerotor assembly (Item 1) [Figure 30-40-72]
into the charge pump housing.
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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
When the spacer is properly installed the surface of the
gerotor spacer and charge pump face are flush [Figure
Apply petroleum jelly to the gerotor drive pin (Item 1) 30-40-75].
[Figure 30-40-73] and install the gerotor pin into the
drive coupler (Item 2) [Figure 30-40-73]. Figure 30-40-76
NOTE: The gerotor drive coupler (Item 2) [Figure 30-

40-73] must be installed with the longer 3 1
portion down toward the rear of the charge
pump.
2 2
Figure 30-40-74
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]
N-17189 in the charge pump housing end cap.
Install the two aligning pins into the alignment holes (Item
Install the coupler and drive pin into the gerotor, be sure 3) [Figure 30-40-76] in the charge pump.
the pin engages the gerotor slot (Item 1) [Figure 30-40-
74].
Install the gerotor spacer (Item 2) [Figure 30-40-74] into

the charge pump end cap.
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Assembly (Cont'd)
Charge Pump Assembly (Cont’d) 1
Figure 30-40-77
N-17233
Figure 30-40-79
N-17234 1
Slide the two sections of the pumps together [Figure 30-

40-77].
N-17230
Install the four mounting bolts (Item 1) [Figure 30-40-78]

& [Figure 30-40-79] and tighten to 35 - 45 ft.-lb. (47 - 61
N•m) torque.
Check for proper internal assembly by slowly rotating the

pump shaft while tightening the mount bolts.
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DRIVE BELT Adjustment
Shield Removal And Installation Figure 30-50-3
Figure 30-50-1
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].
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DRIVE BELT (CONT’D) Tensioner Pulley Removal And Installation
Replacement Figure 30-50-5
Figure 30-50-4
1
P-5552
P-7894
Remove the belt shield clips (Item 1) [Figure 30-50-5].
Remove the belt shield. (See Shield Removal And Remove the belt shield (Item 2) [Figure 30-50-5].
Figure 30-50-6
Loosen the two stop mounting bolts (Item 1) [Figure 30-
50-3].
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 30-

50-6].
Remove the stop.
Remove the spring tension bolt (Item 2) [Figure 30-50-

6].
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DRIVE BELT (CONT’D) Figure 30-50-9
Tensioner Pulley Removal And Installation

1
Figure 30-50-7
P-5560
Remove the pulley / arm assembly (Item 1) [Figure 30-

P-5548 50-9] from the engine housing.
Remove the arm bushing (Item 2) [Figure 30-50-9].

Remove the end cap (Item 1) [Figure 30-50-7] from the Check for wear and replace as needed.
tensioner pulley arm.
Figure 30-50-10
Figure 30-50-8
1
1
P-5553
P-5555
Check the arm seal (Item 1) [Figure 30-50-10]. Replace

Remove the mounting bolt (Item 1) [Figure 30-50-8] from the seal as needed.
the tensioner pulley arm.
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DRIVE BELT (CONT’D) Tensioner Pulley Tension Spring
Tensioner Pulley Removal And Installation (Cont’d) Figure 30-50-13
Figure 30-50-11
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
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.
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OIL COOLER Figure 30-60-3
Removal And Installation With STC (Seal Tight

Connector)
IMPORTANT 1

damage the system.
I-2003-0888
P-24726

Figure 30-60-4
Figure 30-60-1
1
N-19346
2 3 P-24724
Slide the rubber sleeve in toward the radiator. The

Raise the rear grill [Figure 30-60-1]. connector will release [Figure 30-60-3] & [Figure 30-60-
4].
Figure 30-60-2
Disconnect the inlet and outlet hoses (Items 1 & 2)
[Figure 30-60-1] from the oil cooler (Item 3) [Figure 30-
60-1]
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].
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DRIVE SYSTEM
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-10-3
Pedal Disassembly And Assembly . . . . . . . . . . . . . . . . . . 40-10-2 SAFETY &
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-10-1 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 DRIVE
Rear Chaincase Cover Removal And Installation . . . . . . . 40-30-1 SYSTEM
DRIVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . 40-20-1
Axle, Sprocket And Bearings Removal And Installation. . . 40-20-3
Drive Chain Removal And Installation . . . . . . . . . . . . . . . . 40-20-8
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BRAKE Figure 40-10-3
Pedal Removal And Installation
Figure 40-10-1
1 1
N-19614

N-19612 40-10-3] from the parking brake.
Figure 40-10-4
on Page 10-30-1.)

1] from the foot rests.
Remove the foot rests.

1
Figure 40-10-2
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.
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BRAKE (CONT’D) Figure 40-10-6
Pedal Disassembly And Assembly
Figure 40-10-5 1
2
6
1
4
P-4156
2 Remove the harness mounting clamp (Item 1) [Figure

3
P-4189 40-10-6] from the pedal mounting bracket (Item 2)
[Figure 40-10-6].
Loosen and remove the mounting bolt (Item 1) [Figure Remove the sensor harness from the pedal mounting
40-10-5] and nut from the spring mounting bracket (Item bracket.
2) [Figure 40-10-5].
Remove the pedal mounting bolt (Item 6) [Figure 40-10-
Remove the brake pedal spring (Item 3) [Figure 40-10-5] 5], plastic spacers and bushing nut from the brake pedal.
from the tension spring mounting bracket (Item 2)
[Figure 40-10-5] and from the brake pedal mounting Remove the pedal from the pedal mounting bracket.
bracket (Item 4) [Figure 40-10-5].
[Figure 40-10-6] shows the parking brake disassembled
Remove the two mounting bolts, washers and nuts (Item to identify the existing parts in the brake assembly.
5) [Figure 40-10-5] from the brake pedal sensor.
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BRAKE (CONT’D) Raise the loader operator cab. (See Raising The
Operator Cab on Page 10-30-1.)
Disc Removal And Installation
Remove the bolts (Item 1) [Figure 40-10-7] from traction
lock solenoid.
DANGER Figure 40-10-8
4
P-90328
AVOID DEATH
3 2
unless supported by an approved lift arm N-19724

D-1009-0409
Remove the traction lock solenoid (Item 1) [Figure 40-
10-8], 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]

WARNING from the guides.
Installation: Inspect the solenoid mount gasket, replace

Never work on a machine with the lift arms up unless if damaged.
support device. Failure to use an approved lift arm See “Removal And Installation (Single Speed)” on
support device can allow the lift arms or attachment page 60-110-2 for complete disassembly and assembly
to fall and cause injury or death. procedures for the traction lock assembly.
W-2059-0598
Remove the crossmember pivot bolt (Item 5) [Figure 40-
10-8].
Figure 40-10-7
Figure 40-10-9
1
1
N-19618
N-19668
Raise the lift arms and install and approved lift arm
support device. (See Contents, Page 10-01.) Remove the bolt and nut (Item 1) [Figure 40-10-9] to
disconnect the lift pedal linkage from crossmember.
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Disc Removal And Installation (Cont’d)
Figure 40-10-10
N-19726
Remove the center cover mounting bolts (Item 1) [Figure

N-19669 40-10-12].
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]. Installation: Replace the chaincase cover gasket.
Tighten the bolts to 190 - 240 in.-lb. (21,5 - 27,1 N•m)
Disconnect the crossmember from the control valve. torque.
Figure 40-10-11 Figure 40-10-13
1 1
N-19725 P-7799
Remove the crossmember from the pivot [Figure 40-10- Remove the two nuts (Item 1) [Figure 40-10-13] from the
11]. disc bolts.
Installation: Check the nylon bushing (Item 1) [Figure

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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

P-7801 shaft.
Figure 40-10-17
Remove the two disc bolts (Item 1) [Figure 40-10-14 on
Page 5] from the disc. 3 3
Figure 40-10-15
2
P-13003
Installation: Bolting the disc to the snap ring provides

P-7800 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
A snap ring pliers with 90° tips are needed for removing 2) [Figure 40-10-17] and sprocket teeth (Item 3) [Figure
the brake disc snap ring. 40-10-17] after the brake disc is installed on the shaft.
Pull the disc away from snap ring.

the end of the carrier shaft.
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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

N-22536 11-3] from the brake / two-speed block.
Figure 40-11-4
Raise the operator cab. (See Raising The Operator Cab 1

on Page 10-30-1.)
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 40-

11-1] from the brake / two-speed block.
Figure 40-11-2
N-22539

1 40-11-4] from the brake solenoid.

40-11-4] from the two-speed solenoid.
N-22537

11-2] from the brake / two-speed block.
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BRAKE (TWO-SPEED) (S/N 514449389 & BELOW) Block Disassembly And Assembly
(CONT’D)
Figure 40-11-7
Block Removal And Installation (Cont’d)
Figure 40-11-5
1 1
1
1
N-22578
N-22576 Mark all hydraulic hoses for proper installation.
Remove the hydraulic fittings (Item 1) [Figure 40-11-7]

Disconnect the wire harness connector (Item 1) [Figure from the block.
40-11-5] from the make-up valve solenoid.
Figure 40-11-8
Figure 40-11-6
1 1 2
N-22579
N-22577
Remove the check valve (Item 1) [Figure 40-11-8] from

Turn the hydraulic fitting (Item 1) [Figure 40-11-6] to the two-speed valve.
allow for clearance to remove the mounting bolt.
Remove the check valve (Item 2) [Figure 40-11-8] from
Remove the two mounting bolts (Item 2) [Figure 40-11-6] the brake valve.
from the valve.
NOTE: The check valves (Items 1 & 2) [Figure 40-11-8]
Remove the brake / two-speed block from loader. are interchangeable.
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.
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(CONT’D)
Block Disassembly And Assembly (Cont’d)
Figure 40-11-9
1
N-22583
Use a test meter and test the solenoid [Figure 40-11-11]

for resistance.
N-22580
The resistance value for the solenoid coil can be found
on the electrical schematic. (See Solenoid Test on Page
Check the back-up washers (Item 1) [Figure 40-11-9] 60-10-8.).
and O-rings (Item 2) [Figure 40-11-9] for wear and
replace as needed. Figure 40-11-12
Figure 40-11-10
N-22582
N-22581
Remove the solenoid valve (Item 1) [Figure 40-11-12]
from the block.
Loosen the electrical solenoid nut (Item 1) [Figure 40-11-
10] from the make-up valve solenoid.
Assembly: Tighten the nut to 60 - 84 in.-lb. (6,78 - 9,49

N•m) torque.
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(CONT’D)
Figure 40-11-13
1
N-22586

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.-lb. (27,1 N•m) torque.
Figure 40-11-14
1 N-22587
Remove the two-speed solenoid nut (Item 1) [Figure 40-

11-16].
N-22585 Assembly: Tighten the nut to 60 - 80 in.-lb. (6,78 - 9,49

N•m) torque.

brake / two-speed block.
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(CONT’D)
Figure 40-11-17
N-22611
2 Assembly: Always install new O-rings. Tighten the

solenoid valve to 20 ft.-lb. (27,1 N•m) torque.
N-22610
Check the O-rings [Figure 40-11-19] and replace as
needed.
Use a test meter and test the solenoid (Item 1) [Figure
40-11-17] for resistance Figure 40-11-20
60-10-8.)
Figure 40-11-18
1
1
N-22587
Remove the brake solenoid nut (Item 1) [Figure 40-11-

20].

N•m) torque.
N-22588

from the block.
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(CONT’D)
Figure 40-11-21
N-22614

washers. Tighten the solenoid valve to 20 ft.-lb. (27,1
N-22613 N•m) torque.
Check the O-rings and back-up washers [Figure 40-11-

Use a test meter and test the solenoid (Item 1) [Figure 23] and replace as needed.
40-11-21] for resistance.
The resistance value for the solenoid can be found on the

electrical schematic. (See Solenoid Test on Page 60-10-
8.)
Figure 40-11-22
N-22612

from the block.
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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

P-34096 12-3] from the brake / two speed block.
Figure 40-12-4

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 40-

12-1] from the brake / two speed block.
Figure 40-12-2 2
P-34093

40-12-4] from the brake solenoid.

40-12-4] from the two speed solenoid.
1
1
P-34091

12-2] from the brake / two speed block.
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BRAKE (TWO-SPEED) (S/N 514449390 & ABOVE)
(CONT’D)
Block Removal And Installation (Cont'd)
Figure 40-12-5
P-34094

40-12-5] from the make-up valve solenoid.
Figure 40-12-6
P-34095

6] from the valve.
Remove the brake / two-speed block from the loader.
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(CONT’D)
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
P-34097 replace as needed.
Figure 40-12-10
Mark all hydraulic hoses and fittings for proper
installation.
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 40-12-

10] from the make-up valve solenoid.
Remove the brake solenoid nut (Item 2) [Figure 40-12-

P-34098 10] from the brake solenoid.

Remove the check valve (Item 1 & 2) [Figure 40-12-8] N•m) torque.
from the two-speed valve.
NOTE: The check valves (Items 1 & 2) [Figure 40-12-

8] are interchangeable.
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(CONT’D)
Block Disassembly And Assembly (Cont'd)
Figure 40-12-11
1 2
1 P-34101

from the block.
P-34112
Remove the brake solenoid (Item 1) [Figure 40-12-13]
from the block.
40-12-11] for resistance. Figure 40-12-14
60-10-8.)
Figure 40-12-12
N-22584
1
washers [Figure 40-12-14]. Tighten the solenoid valve to
20 ft.-lb. (27,1 N•m) torque.
P-34111
Use a test meter and test the brake solenoid (Item 1)

[Figure 40-12-12] for resistance.

60-10-8.)
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(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
Check the O-rings and replace as needed [Figure 40-12-

15]
Figure 40-12-16
1
P-34104
Remove the two speed solenoid nut (Item 1) [Figure 40-

12-18].

N•m) torque.
1 P-34102
Remove the plugs (Item 1) [Figure 40-12-16] from the

brake / two-speed block.
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(CONT’D)
Figure 40-12-19
N-22611
2
Assembly: Always install new O-rings. Tighten the
N-22610
Check the O-rings [Figure 40-12-21] and replace as
needed.
40-12-19] for resistance.

60-10-8.)
Figure 40-12-20
P-37979

from the block.
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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

Remove the tire / wheel assembly.
Installation: Tighten the wheel nuts to 105 - 115 ft.-lb. P-4848

(142 - 155 N•m) torque.
Remove the key (Item 1) [Figure 40-20-3] from the axle.
Remove the bolts (Item 1) [Figure 40-20-1] and plate.
Installation: Tighten the bolts to 175 - 190 ft.-lb. (240 -

260 N•m) torque.
Remove the two wheel studs (Item 2) [Figure 40-20-1]

across from each other.
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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
P-4817 [Figure 40-20-5].
Place the seal with the lip facing in [Figure 40-20-5].

Install a slide hammer (Item 1) [Figure 40-20-4] with a
screw tip end into the axle seal. Figure 40-20-6
Remove the axle seal.

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].
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DRIVE COMPONENTS (CONT’D)
Axle Seal Removal And Installation (Cont’d) WARNING

Figure 40-20-7
2 to fall and cause injury or death.
W-2059-0598

procedure:
MEL1242 - Port-a-Power
1 MEL1202B - Axle Bearing Service Set
NOTE: The procedure shown for removal and

P-10553 installation of the axle, sprocket and bearings
is for a front axle. This procedure will be the
same for the rear axle.
NOTE: S/N 514416546 & Above the axle (Item 1)
[Figure 40-20-7] finish specification was Raise the lift arms and install an approved lift arm support
changed to provide the correct surface for the device. (See LIFT ARM SUPPORT DEVICE on Page 10-
axle seal (Item 2) [Figure 40-20-7]. These 20-1.)
loaders MAY or MAY NOT have a wear ring
installed. When ordering the axle seal, check Lift and block the loader. (See LIFTING AND BLOCKING
to see of the axle uses a wear ring. THE LOADER on Page 10-10-1.)
Axle, Sprocket And Bearings Removal And Raise the operator cab. (See Raising The Operator Cab
Remove the front panel / steering lever assembly. (See

Lever Disassembly And Assembly on Page 50-110-1.)
DANGER Remove the front cover. (See Front Chaincase Cover
Remove the fluid from the chaincase. (See CHAINCASE

on Page 40-30-1.)
P-90328
AVOID DEATH
D-1009-0409
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DRIVE COMPONENTS (CONT’D)
Axle, Sprocket And Bearings Removal And

Installation WARNING
Figure 40-20-8 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
2 Figure 40-20-10
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.-lb. (644 - 710 N•m) torque. P-4849
Figure 40-20-9
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.-lb. (240 -

260 N•m) torque. P-4809
Remove the two wheel studs (Item 2) [Figure 40-20-9]

across from each other. Install a Port-a-Power ram between the two sprockets
[Figure 40-20-11].
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Installation (Cont’d)
Figure 40-20-12
P-4171
Press the splined end of the axle free from the bearing
1
[Figure 40-20-14].
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. NOTE: Hold on to the axle during installation as it will
slide freely after the bearing is pressed over
Remove the drive chain from the sprocket. 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
P-4175
Put a piece of tubing (Item 1) [Figure 40-20-15] that

contacts inner race of the bearing only.
P-4170
Press the bearing onto the mounting surface until the

bearing is fully seated [Figure 40-20-15].
A bearing puller (Item 1) [Figure 40-20-13] is needed to
do the following procedure:
Be sure the bearing puller makes good contact with the

inner race and press the bearing off the mounting surface
of the axle [Figure 40-20-13].
NOTE: Hold onto the axle during removal as it will
slide freely after the bearing is removed from
the mounting surface.
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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 1
slide hammer is also needed.
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.
Figure 40-20-17 3
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.
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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
To install the outer bearing cup, install the bearing cup
tool on the driver handle.
Install the installation tool (Item 1) [Figure 40-20-20] on
the threaded rod. Install the nut. Install the bearing cup into the axle tube, and put the tool
into the bearing cup.
Hold the inside nut (Item 3) [Figure 40-20-19] with a
wrench and tighten the outside nut [Figure 40-20-20].
Tighten the nut until the bearing cup is seated.
Remove the installation tools and threaded rod.
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DRIVE COMPONENTS (CONT’D) Remove the front (or rear) chaincase cover. (See Front
Chaincase Cover Removal And Installation on Page 40-
Drive Chain Removal And Installation 30-1.)
Remove the front (or rear) axle and sprocket. (See Axle,
DANGER Sprocket And Bearings Removal And Installation on
Page 40-20-3.)
Figure 40-20-22
Rear Chain
P-90328
AVOID DEATH
can cause lift arms to drop. Front Chain
P-7866
D-1009-0409
Remove the front (or rear) drive chain from the
chaincase.
The tool listed is needed for the following procedure:
WARNING MEL1037 - Chain Link Tool

Installation: If a new chain is installed, a connector link
must be used to connect the chain together.
DO NOT exceed the recommended torque. The tool
Install the new chain around the carrier shaft.
may fail under too much torque. Put cloth around the
tool to protect yourself from flying debris. Use MEL1037 Chain Link Tool and #100 chain adapter.
W-2233-0307
Figure 40-20-23
WARNING
W-2059-0598
Raise the loader lift arms and install an approved lift arm
support device. (See LIFT ARM SUPPORT DEVICE on B-13504
Page 10-20-1.)
Secure the tool and place the connector link and chain in
the tool as shown [Figure 40-20-23].
Turn the threaded rod of the tool and press the connector
Raise the loader operator cab. (See Raising The
link together on the chain [Figure 40-20-23]. Tighten the
Operator Cab on Page 10-30-1.)
threaded rod of the chain link tool to 180 ft.-lb. (176 N•m)
Drain the fluid from the chaincase. (See CHAINCASE on torque.
Page 40-30-1.)
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CHAINCASE
Front Chaincase Cover Removal And Installation WARNING

Figure 40-30-1
W-2059-0598
20-1.)
1 Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)
P-4800 Figure 40-30-2
Remove the parking brake pedal. (See Pedal Removal

Remove the mounting bolts from the front cover (Item 1)

[Figure 40-30-1].
Remove the cover.
Rear Chaincase Cover Removal And Installation 1
DANGER 1 N-19956
Disconnect the hydraulic hoses (Item 1) [Figure 40-30-

2].
Figure 40-30-3
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic 1
D-1009-0409
P-7935
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Remove the eight mounting bolts from the rear chaincase
cover (Item 1) [Figure 40-30-3].
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.
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MAINFRAME
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Bob-Tach Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-4 SAFETY &
Pivot Pin Bushing And Seal Replacement . . . . . . . . . . . . . . . . 50-40-5 MAINTENANCE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
CONTROL HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

Lever Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . 50-110-1
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Linkage Neutral Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-5
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . 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 MAINFRAME
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) . . 50-111-1
Actuators Disassembly And Assembly . . . . . . . . . . . . . . . . . 50-111-9
AHC Controller Removal And Installation . . . . . . . . . . . . . . . 50-111-4
Handle Control Unit Connector . . . . . . . . . . . . . . . . . . . . . . . 50-111-5
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/ PUSH

BUTTON FLOAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Actuators Disassembly And Assembly . . . . . . . . . . . . . . . . 50-112-11
Handle Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-7
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . 50-112-5
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS)

SELECTABLE HAND / FOOT CONTROL. . . . . . . . . . . . . . . . . . 50-114-1
Control Handle Disassembly and Assembly . . . . . . . . . . . . . 50-114-6
Control Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-114-8
Control Lever Removal And Installation. . . . . . . . . . . . . . . . . 50-114-6
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . 50-114-1
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MAIN FRAME (CONT’D)
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Crossbar Linkage Removal And Installation . . . . . . . . . . . 50-90-2
Lift Foot Pedal Linkage Removal And Installation . . . . . . . 50-90-3
Pedal Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Tilt Foot Pedal Linkage Removal And Installation . . . . . . . 50-90-4
CONTROL PEDALS (ACS). . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1

Foot Pedal Linkage Disassembly And Assembly. . . . . . . . 50-91-2
Foot Pedal Removal And Installation . . . . . . . . . . . . . . . . . 50-91-2
Foot Sensor Removal And Installation. . . . . . . . . . . . . . . . 50-91-1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Gas Cylinder Bracket Disassembly And Assembly . . . . . . 50-20-2
Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . 50-20-1
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Seat Belt Removal And Installation.. . . . . . . . . . . . . . . . . . 50-30-1
OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . 50-31-1

Back Removal And Installation . . . . . . . . . . . . . . . . . . . . . 50-31-4
Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . 50-31-3
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . 50-31-4
Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . 50-31-2
POWER BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Pivot Pin Bushing And Seal Replacement . . . . . . . . . . . . . 50-41-4
Power Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . 50-41-2
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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

SEAT BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Assembling Components . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2
Compression Spring Assembly And Assembly . . . . . . . . . 50-10-4
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SEAT BAR Figure 50-10-3
Figure 50-10-1
N-18572
Remove the seat bar mounting nuts (Item 1) [Figure 50-

N-19225 10-3] (both sides).
Installation: Tighten the nuts to 28 ft.-lb. (38 N•m)

Raise the seat bar (Item 1) [Figure 50-10-1]. torque.
Figure 50-10-2 Lower the operator cab. (See Lowering The Operator
Cab on Page 10-30-2.)
Figure 50-10-4
N-18463
Disconnect the seat bar sensor (Item 1) [Figure 50-10-2]

N-19224
from the cab harness.
Lower the seat bar. Remove the seat bar (Item 1) [Figure 50-10-4] from the
operator cab.
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.
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SEAT BAR (CONT’D) Seat Bar Mount (Item 1)
Mounting Bolt (Item 2)
Assembling Components Keyed Plastic Bushing (Item 3)
Seat Bar (Item 4)
Figure 50-10-5 Magnetic Bushing Assembly (Item 5)
Pivot Bushing (Item 6)
6 Sensor Bracket (Item 7)
4 5
Sensor Mounting Nut (Item 8)
Sensor Mounting Bolt (Item 9)
7 Mounting Nut (Item 10)
3
Installation: Tighten the mounting bolt (Item 2) [Figure
50-10-5] & [Figure 50-10-6] to 50 - 70 in.-lb. (5,6 - 7,9
2 N•m) torque.
9 8
1 10
N-19383
Figure 50-10-6
4 5 8
9
2 10
6
7
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].
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SEAT BAR (CONT’D) Seat Bar Mount (Item 1)
Mounting Nut (Item 2)
Assembling Components (Cont’d) Pivot Bushing (Item 3)
Spacer Bushing (Item 4)
Figure 50-10-7 Seat Bar (Item 5)
Keyed Plastic Bushing (Item 6)
5 Mounting Bolt (Item 7)
4
Installation: Tighten the mounting bolt (Item 7) [Figure
3 6 50-10-7] & [Figure 50-10-8] to 50 - 70 in.-lb. (5,6 - 7,9
N•m) torque.
2 7
N-19340
Figure 50-10-8
5
4 6
3
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].
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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 50-10-

10] 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.
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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

2 cylinder mounting bracket.
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

N-19651
window, the rear grill and rear grill mounts
(Item 2) [Figure 50-20-1] must be removed to
prevent window damage. Use a pliers to unlock cotter pin (Item 1) [Figure 50-20-3]
& [Figure 50-20-4 on Page 2].
on Page 10-30-1.)
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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
P-1008
N-19652
Remove the clevis (Item 1) [Figure 50-20-5] and washer
(Item 2) [Figure 50-20-5] from the end of the gas
NOTE: Cotter pin (Item 1) [Figure 50-20-4] is shown in cylinder.
locked position.
Remove the gas cylinder from the outer housing.
Remove the cotter pin.
Assembly: Install a replacement cylinder inside the
Remove the gas cylinder. 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.
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Figure 50-20-7
1
1
N-19365
1
Remove the cab nut and holddown plate (Item 1) [Figure
50-20-7] (both sides).

N•m) torque.
N-19623

[Figure 50-20-8].
Disconnect the operator cab ground wire (Item 2) [Figure

50-20-8].
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Figure 50-20-9
P-7713
Move the operator cab forward a small amount for

N-19647 clearance at the pivot mounting brackets [Figure 50-20-
11].
Install a sling (Item 1) [Figure 50-20-9] on the grab Install the pivot bolt, washer (one on each side) and nut
handles of the operator cab. Connect a chain hoist to the (Item 1) [Figure 50-20-11] (both sides).
sling.
Install the sling under the pivot bolt and pivot of the
Remove both gas cylinders. (See Gas Cylinder Removal 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

N-19620 operator cab from the loader [Figure 50-20-12].
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.-

Remove the pivot bolt (both sides).
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OPERATOR SEAT Seat Belt Removal And Installation.
Removal And Installation Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
on Page 10-30-1.) Figure 50-30-3
Figure 50-30-1
1
1
N-20729A
N-20729
Locate the seat belt bolts under seat pan insulation (Item
1 & 2) [Figure 50-30-3] and peel back or cut insulation to
Remove the seat mounting nuts (Item 1) [Figure 50-30- gain access to the head.
1] and washers from the operator seat mounting studs.
Figure 50-30-4
Installation: Tighten the mounting nuts to 20 ft.-lb. (27
N•m) torque.
NOTE: Ensure the washers are installed.
Figure 50-30-2
2
N-20655
Remove the two nuts (Item 1 & 2) [Figure 50-30-4].
Installation: Tighten nut (Item 1) [Figure 50-30-4] to 54

P-10564 P-10563 ft.-lb. (73 N•m) torque. Tighten nut (Item 2) [Figure 50-
30-4] to 34 ft.-lb. (46 N•m) torque.
Lower the cab and install one of the mounting washer Repeat for the other half of seat belt and guide.
and nut (Item 1) [Figure 50-30-2].
NOTE: With the seat removed the cab will raise.
Reverse the removal procedure to install the operator

seat.
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OPERATOR SEAT (SUSPENSION) Figure 50-31-3

on Page 10-30-1.)
Figure 50-31-1
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].
N-20647 Figure 50-31-4
Remove the four seat mounting nuts (Item 1) [Figure 50-

31-1] and washers from the operator seat mounting
studs.
Installation: Tighten the mounting nuts to 20 ft.-lb. (27

N•m) torque.
Figure 50-31-2
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.

seat.
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OPERATOR SEAT (SUSPENSION) (CONT’D)
Slide Rail Removal And Installation

on Page 10-30-1.)
Remove the operator seat. (See Removal And

Figure 50-31-5
1
1
2 2
1
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.
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OPERATOR SEAT (SIUSPENSION) (CONT’D) Figure 50-31-8
Cushion Removal And Installation
Figure 50-31-6
1
N-18581
Remove the cushion (Item 2) [Figure 50-31-7] from the

N-18579 seat frame (Item 1) [Figure 50-31-8].
Figure 50-31-9
Press the two buttons (Item 1) [Figure 50-31-6] &
[Figure 50-31-7] and lift the seat cushion.
Figure 50-31-7
2
1
N-18580
Inspect the seat ride adjustment [Figure 50-31-9].

N-18582
seat back.
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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. (See Removal And
1 Installation on Page 50-30-1.)
Figure 50-31-12
N-18583
1 2
Pull the seatback adjustment lever (Item 1) [Figure 50-

31-10] 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 50-

31-11] from the seat back and remove the back. Remove the seat shock retaining pin (Item 1) [Figure 50-
31-12] & [Figure 50-31-13] (both ends).
seat back. Remove the seat shock (Item 2) [Figure 50-31-12] &
[Figure 50-31-13].
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OPERATOR SEAT (SUSPENSION) (CONT’D)
Shock Removal And Installation (Cont’d)
Figure 50-31-14
N-18586
NOTE: The seat shock mounting studs (Item 1)

[Figure 50-31-14] are replaceable.

seat shock.
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BOB-TACH Figure 50-40-3
Figure 50-40-1
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
P-3911
Remove the tilt cylinder rod end.
P-7693 Remove the seals (Item 1) [Figure 50-40-4].
Remove the retainer bolt (Item 1) [Figure 50-40-2] from

the pivot pin.
Installation: Tighten the retainer bolt to 18 - 20 ft.-lb. (24

- 27 N•m) torque.
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BOB-TACH (CONT’D) Figure 50-40-7
Figure 50-40-5
P-7696
Install an adapter (Item 1) [Figure 50-40-7] into the Bob-

P-3910 Tach pivot pin.
Install the slide hammer into the adapter and pull the
Installation: Use two pieces of shim stock (light pivot pin from the lift arms/Bob-Tach.
cardboard), install the rod end of the tilt cylinder into the
Bob-Tach [Figure 50-40-5]. NOTE: Always inspect Bob-Tach pivot pin bushings
and seals in lift arm for wear or damage.
Be careful not to damage the seal during installation. Replace as needed.
NOTE: Removal procedure is show for the right side.

Left side procedure is the same.
Figure 50-40-6
P-7697

6] from the Bob-Tach pivot pin.
Installation: Tighten the bolt and retainer nut to 25 ft.-lb.

(34 N•m) torque.
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Bob-Tach Lever And Wedge
Use the following procedure to remove and install the

Bob-Tach lever, spring and wedge.
Figure 50-40-8
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 50-40-

9], washer (Item 2) [Figure 50-40-9] and spring (Item 3)
[Figure 50-40-9].

N•m) torque.
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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
P-7683
P-7952
Remove the spring, bolt and clevis assembly (Item 1)

[Figure 50-40-12]. Remove and replace the Bob-Tach stop (Item 1) [Figure
50-40-14] (both sides) if worn or damaged.
Remove the wedge from the Bob-Tach frame.
NOTE: The Bob-Tach stop (Item 1) [Figure 50-40-14]
Always replace bent or broken wedges. must contact the lift arm at the same time the
tilt cylinder reaches full extension. Use
Figure 50-40-13 available shims to adjust the Bob-Tach stop
and tilt cylinder sequence as closely as
possible.
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 in. 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 50-
40-13].
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Pivot Pin Bushing And Seal Replacement
Figure 50-40-15
P-7950
Use a driver to install new seals. The pivot pin can be

P-7948 used to locate seal [Figure 50-40-17].
Use a seal pick to remove seals (Item 1) [Figure 50-40-

15] 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].
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POWER BOB-TACH Figure 50-41-2
Figure 50-41-1
2 1
3
1
N-18545
Remove the pivot pin (Item 1) [Figure 50-41-2] from the

N-21401 tilt cylinder rod end (both sides).
Remove the tilt cylinder rod end from the Bob-Tach (both
Tilt the Bob-Tach forward, so it is parallel to the floor. Put sides).
blocks (approximately 3 in.) under each side of the Bob-
Tach [Figure 50-41-1]. Loosen the bolt (Item 2) [Figure 50-41-2] at the Bob-
Tach pivot pin.
Lower the Bob-Tach onto the blocks.
Installation: Tighten the bolt to 350 ft.-lb. (475 N•m)
Remove the hoses to the cylinder fittings [Figure 50-41- torque.
1].
Figure 50-41-3
NOTE: The hose with the 45° end (Item 1) [Figure 50-
41-1] is connected to the base end fitting on
the cylinder.
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.
Remove the retainer bolt (Item 3) [Figure 50-41-1] and 1

nut from the tilt cylinder rod end pin (both sides).

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.
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POWER BOB-TACH (CONT’D) Power Bob-Tach Lever And Wedge
Figure 50-41-4
N-21401
P-13099
Use the following procedure to remove and install the
Bob-Tach lever (Item 1) [Figure 50-41-5], spring and
Use a punch to drive the pivot pin and cap (Item 1) wedge.
[Figure 50-41-4] out of the Bob-Tach frame.
Figure 50-41-6
Remove the Bob-Tach pivot pin (both sides).
Remove the Bob-Tach from the lift arms.
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.
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POWER BOB-TACH (CONT’D) Figure 50-41-9
Power Bob-Tach Lever And Wedge (Cont’d)
Figure 50-41-7
4
3 2
1
N-20625
If the bolt (Item 1) [Figure 50-41-9], handle pivot (Item 2)

N-18560 [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.
Remove the Wedge (Item 1) [Figure 50-41-7].
Remove the bolt and replace the damaged parts as
Always replace bent or broken wedges. needed.
2
1 1
3
4
5
N-21401 N-18563
Remove the washers and bolts (Item 1) [Figure 50-41- Use a punch and hammer to drive the roll pin (Item 1)
8]. Tighten the bolts to 25 - 28 ft.-lb. (24 - 28 N•m) torque. [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 50-41-

8], washer (Item 3) [Figure 50-41-8], spring (Item 4)
[Figure 50-41-8] and lever (Item 5) [Figure 50-41-8].

N•m) torque.
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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
N-18557
N-18562
Remove the power Bob-Tach. (See Removal And
Reverse the removal procedure to install the Power Bob-
Tach lever and wedge [Figure 50-41-11]. Use a seal pick to remove seal (Item 1) [Figure 50-41-
12] on the Bob-Tach.
Remove and replace bushing (Item 2) [Figure 50-41-12]

with a driver tool and hammer.
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LIFT ARMS Figure 50-50-3
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 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
N-19654

2] from the front auxiliary quick coupler mounting bracket
(if so equipped).
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LIFT ARMS (CONT’D) Figure 50-50-5
Figure 50-50-4
2 1
1
P-7730
Remove the tilt cylinder (Item 1) [Figure 50-50-5] from

P-7726 the lift arms.
Remove the tilt tubelines from the lift arms and put the tilt
Wrap the lifting strap around the lift arm crossmember as cylinder on the floor.
shown in [Figure 50-50-4]. Connect both loops of the
lifting strap to a chain hoist. Figure 50-50-6
Raise the lift arms enough to remove the auxiliary

tubelines (if so equipped) from the lift arms [Figure 50-
50-5].
Raise the operator cab. (See Raising The Operator Cab 2 1

on Page 10-30-1.)
Remove the nut and retainer bolt (Item 1) [Figure 50-50-

4] from the pivot pin for the base of the tilt cylinder. 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


6] from the pivot pin for the lift cylinder rod end (both
sides).

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LIFT ARMS (CONT’D) Figure 50-50-8
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 50-

50-6].
2
Lower the lift arms with the chain hoist.
Figure 50-50-7
P-7732

8] from the loft arm pivot pin (both sides).

ft.-lb. (220 - 230 N•m) 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 50-
50-7] (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.
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REAR GRILL Figure 50-60-3
Figure 50-60-1 1
P-7946
Remove the cotter pin and the pivot pin (Item 1) [Figure
N-19411 50-60-3] (both sides).
Figure 50-60-4
Raise the rear grill [Figure 50-60-1].
Support the rear grill.
Figure 50-60-2
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.
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REAR DOOR Figure 50-70-2
Open the rear door.
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.
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REAR DOOR (CONT’D) Adjusting The Rear Door Latch (S/N 514449208 &
Below)
(Cont’d) Figure 50-70-4
Figure 50-70-3
2 1
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 N-19321
(Item 1) [Figure 50-70-3] and remove the hinge bolts.
Installation: Tighten the mounting bolts and nuts to 25 - The door latch (Item 1) [Figure 50-70-5] can be adjusted
28 ft.-lb. (34 - 35 N•m) torque. The door stop (Item 2) forward or backward for alignment with the door catch.
[Figure 50-70-3] is installed in the top hinge bolt.
Remove the rear door from the loader frame and lay it flat
on the floor.
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REAR DOOR (CONT'D) Adjusting The Striker (S/N 514449209 & Above)
Striker Removal And Installation (S/N 514449209 & Figure 50-70-7

Above)
Figure 50-70-6
1
P-31126
1
P-31126 Loosen the two striker assembly mount bolts (Item 1)
[Figure 50-70-7].
Remove the two striker mount bolts (Item 1) [Figure 50- Align the striker assembly in the center of the mounting
70-6]. 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 50-70-

7].
Close the rear door.
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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
Remove the lever (Item 1) [Figure 50-70-10] from the
rear door.
Disconnect the spring (Item 1) [Figure 50-70-8] from the
tailgate.
Remove the bolt and nut (Item 2) [Figure 50-70-8] from

the door latch.
Figure 50-70-9
P-31127
Remove the spring (Item 1) [Figure 50-70-9] from the

door handle.

door latch.
Remove the door latch (Item 3) [Figure 50-70-9] from the

lever.
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FUEL TANK Figure 50-80-3
Figure 50-80-1
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 Figure 50-80-4

installed over the drain plug.
Figure 50-80-2
P-7918
P-1619 Remove the bolts (Item 1) [Figure 50-80-4] from the

battery hold down plate.
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.)
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FUEL TANK (CONT’D) Fuel Level Sender
Figure 50-80-5
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 Figure 50-80-7
the battery hold down plate.
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].
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CONTROL PEDALS Pedal Adjustment
Figure 50-90-1 WARNING

1 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.
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.-lb. (28

- 34 N•m) torque.
Check the rubber bushing in the pedal for wear and

replace as needed.
Figure 50-90-2
N-19232

2] from the pedal mounting bracket.
Remove the pedal assembly from the loader.
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CONTROL PEDALS (CONT’D) Figure 50-90-3
Crossbar Linkage Removal And Installation
DANGER 1
P-24756
P-90328
Remove the crossbar pivot bolt (Item 1) [Figure 50-90-
AVOID DEATH 3].
tubeline, hose, fitting, component or a part failure Figure 50-90-4
D-1009-0409
1
WARNING
support device can allow the lift arms or attachment P-24758
W-2059-0598
Remove the bolt and nut (Item 1) [Figure 50-90-4] to
disconnect the lift pedal linkage from crossbar.
20-1.)
on Page 10-30-1.)
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CONTROL PEDALS (CONT’D) Lift Foot Pedal Linkage Removal And Installation
Crossbar Linkage Removal And Installation (Cont’d) Figure 50-90-7
Figure 50-90-5
1
P-24760
P-24757
disconnect the lift foot pedal linkage from the crossbar
Remove the hairpin clip and cross-pin from the control linkage.
valve lift spool (Item 1) [Figure 50-90-5].
Figure 50-90-8
Disconnect the crossbar from the control valve.
Figure 50-90-6 1
P-24759
1
P-24763 Remove the bolt (Item 1) [Figure 50-90-8] and nut from
the pedal linkage.
Remove the crossmember from the pivot [Figure 50-90- Installation: Tighten the bolt and nut to 21 - 25 ft.-lb. (28
6]. - 34 N•m) torque.
Installation: Check the nylon bushing (Item 1) [Figure

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CONTROL PEDALS (CONT’D)
Tilt Foot Pedal Linkage Removal And Installation
Figure 50-90-9
P-24761

disconnect the tilt foot pedal linkage from the control
valve.
Figure 50-90-10
P-26008
Remove the bolt (Item 1) and nut from the pedal linkage.

- 34 N•m) torque.
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CONTROL PEDALS (ACS) Figure 50-91-3
Foot Sensor Removal And Installation
Figure 50-91-1
2 1
P-21936
P-21927
Remove the two bolts (Item 1) [Figure 50-91-3] from the

1 P-21938 foot sensor shield.
Installation: Tighten the bolts to 80 - 90- in.-lb. (9,0 -

Pull the pin (Item 1) [Figure 50-91-1] holding the foot 10,2 N•m) torque.
pedal linkage to the sensor.
Figure 50-91-4
Disconnect the two connectors (Item 2) [Figure 50-91-1]
from the sensor and lock solenoid.
1
Figure 50-91-2
P-21924
Remove foot lock solenoid (Item 1) [Figure 50-91-4].

P-21935
Installation: Apply a drop of oil to the solenoid threads
and tighten the solenoid to 35 - 40 ft.-lb. (47 - 54 N•m)
Tilt the foot pedal up and remove the two nuts (Item 1) lubed torque.
[Figure 50-91-2].
Remove the two bolts (Item 2) [Figure 50-91-4] from the
Remove the foot pedal and sensor assembly from the bracket and sensor assembly.
loader.
N•m) torque.
Remove the sensor assembly.
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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

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

2
linkage to the sensor.
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 50-91-
8] 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.
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CONTROL PANEL Figure 50-100-1
WARNING 2

W-2017-0286
N-19662
WARNING Remove the engine speed control (Item 1) [Figure 50-

100-1]. (See Removal And Installation on Page 70-20-1.)
Loosen the jam nut from the bypass control knob (Item 2)
[Figure 50-100-1].
Remove the control knob, jam nut and rubber washer.
W-2059-0598
Disconnect the control harness wiring connector (Item 3)

[Figure 50-100-1] from the right side steering lever.
DANGER Figure 50-100-2
P-90328
AVOID DEATH
N-19667
support. Replace if damaged. NOTE: If the loader is equipped with rear auxiliary
D-1009-0409 hydraulics, also disconnect the electrical
connectors from the left side steering lever
Raise the lift arms and install an approved lift arm support (Item 1) [Figure 50-100-2].
20-1.)

on Page 10-30-1.)
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CONTROL PANEL (CONT’D) Figure 50-100-5

1
Figure 50-100-3
2 1
2
N-19665
1
Remove the control panel mounting bolts (Item 1)

N-19664 [Figure 50-100-5] from the right side of the control panel.
Installation: Tighten the control panel mounting bolts to

Scribe a mark across the top of the steering linkage bars 25 - 28 ft.-lb. (34 - 38 N•m) torque.
(Item 1) [Figure 50-100-3].
Remove the four steering linkage mounting bolts (Item 2)

[Figure 50-100-3].
Installation: Tighten the steering linkage mounting bolts

to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
Figure 50-100-4
N-19663

[Figure 50-100-4] from the right side control panel.

25 - 28 ft.-lb. (34 - 38 N•m) torque.
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Figure 50-100-6
1 1
N-19667
1
1
N-19666 [Figure 50-100-6] & [Figure 50-100-7] from the left side
of the control panel.

25 - 28 ft.-lb. (34 - 38 N•m) torque.
Remove the control panel from the loader.
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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
Disassemble the right and left steering shafts from the
cross shaft assembly.
Loosen both U-bolts (Item 1) [Figure 50-110-1] at the
steering lever (both sides). NOTE: Some loaders may have a sleeve (Item 1)
[Figure 50-110-2] between the bearing (Item 2)
Remove the steering cross shaft mounting bolts (Item 2) [Figure 50-110-2] and the bell crank (Item 3)
[Figure 50-110-1] (both sides). [Figure 50-110-2].
Installation: Tighten the mounting bolts to 25 ft.-lb. (40 Figure 50-110-3

N•m) torque.
Remove the steering cross shaft from the control panel. 1
N-17640
Check the bearings (Item 1) [Figure 50-110-3] for wear

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.
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CONTROL HANDLE (CONT’D) Linkage Removal And Installation
Lever Disassembly And Assembly (Cont’d) Figure 50-110-6
Figure 50-110-4
N-17601
2 P-13773
Remove the nut (Item 1) [Figure 50-110-6] from the end
of the centering spring shoulder bolt (Item 2) [Figure 50-
Check the end bearing (Item 1) [Figure 50-110-4] and 110-6].
fiber washer (Item 2) [Figure 50-110-4] and replace as
needed. Remove the shoulder bolt / spring assembly.
Figure 50-110-5 Installation: Tighten the centering spring shoulder bolt

and a NEW lock nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque.

1 Reservoir on Page 20-80-1.)
2 Figure 50-110-7
3
4 P-13774
NOTE: Some loaders may have a spacer (Item 1) 2

[Figure 50-110-5] between the bearing (Item 2) 1
[Figure 50-110-5] and the bell crank (Item 3)
[Figure 50-110-5].
N-19736
Check the fiber washer (Item 4) [Figure 50-110-5] and

replace all worn parts. Remove the hydraulic hoses (Item 1) [Figure 50-110-7].
Remove the hydraulic fitting (Item 2) [Figure 50-110-7]

from the pump.
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Linkage Removal And Installation (Cont’d) 2

5
1
Figure 50-110-8
1 2
3
2 4
3
N-17609
The centering plate / centering spring assembly consists

3 N-19737 of the following parts [Figure 50-110-10]:
Item Description
1 Bolt
Slide the plate (Item 1) [Figure 50-110-8] to the right and
2 Washer
remove it from the two guide pins (Item 2) [Figure 50-
3 Sleeve
110-8].
4 Bushing
5 Spring
NOTE: The two guide bushings (Item 3) [Figure 50-
110-8] will be loose and can fall out of the plate
as soon as it is removed from the guide pins. Figure 50-110-11
Figure 50-110-9
1
1
2
4
1
N-17607
2
3 N-17608
Check the wear on the centering blocks (Item 1) [Figure
50-110-11].
The centering plate / centering spring assembly consists
of the following parts [Figure 50-110-9]:
Item Description
1 Centering Spring Assembly
2 Guide Bushings
3 Lock Nut
4 Centering Plate
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Linkage Removal And Installation (Cont’d)
Figure 50-110-12
N-17611
Remove the linkage bar nut (Item 1) [Figure 50-110-14]

N-17606 from the torsion bushing.
The bolt is threaded into the linkage bar, remove the bolt
If the centering blocks need replacement, remove the from underneath the pintle arm.
bolts (Item 1) [Figure 50-110-12]. Remove the centering
blocks. Installation: Tighten the bolt to 11 - 13 ft.-lb. (21 - 25
N•m) torque, then tighten the nut (Item 2) [Figure 50-
Installation: Tighten the centering block bolts to 25 - 28 110-16 on Page 5] to 21 - 25 ft.-lb. (28 - 33 N•m) torque.
Figure 50-110-15
Figure 50-110-13
1
2
1
N-17612
N-19738
Remove the linkage bar (Item 1) [Figure 50-110-15] from

Check the surface of the four pintle cams (Item 1) the pintle arm. Remove the torsion bushing (Item 2)
[Figure 50-110-13]. [Figure 50-110-15].
If worn replace the cam. Remove the nuts (Item 1) [Figure 50-110-16 on Page 5]
from both shock absorber ball joint ends.
N•m) torque. Installation: Tighten the nuts to 25 - 28 ft.-lb. (34 - 38
N•m) torque.
Disconnect the shock absorbers from the linkage bars.
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CONTROL HANDLE (CONT’D)
Linkage Removal And Installation (Cont’d)

DANGER
Figure 50-110-16
2 P-90328
1
AVOID DEATH
N-17624
D-1009-0409
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.-lb. (21 - 25 WARNING

N•m) torque, the tighten the nuts to 21 - 25 ft.-lb. (28 - 33
N•m) torque. Never work on a machine with the lift arms up unless
The torsion bushings can now be removed from the support device. Failure to use an approved lift arm
steering bell cranks. support device can allow the lift arms or attachment
The linkage and the centering plate must be readjusted W-2059-0598
for neutral after the components have been reassembled.
See “Linkage Neutral Adjustment” on Page 50-110-5 for
Raise the lift arms and install an approve lift arm support
the neutral adjustment procedure.
20-1.)
Linkage Neutral Adjustment
WARNING Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
of the frame before running the engine for service. Connect the remote start switch. (See REMOTE START
Failure to use jackstands can allow the machine to on Page 10-60-1.)
W-2017-0286 Pre-load tension in the torsion bushings must be
removed before adjusting the steering linkage.
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CONTROL HANDLE (CONT’D) Figure 50-110-19
Linkage Neutral Adjustment (Cont’d)
Figure 50-110-17
2
1
3 1
N-17619
Move the right side steering lever to the rear and install a
N-17624 3 - 8 in. (10 mm) thick spacer (Item 1) [Figure 50-110-19]
between the pintle arm cam (Item 2) [Figure 50-110-19]
and the centering block (Item 3) [Figure 50-110-19].
Loosen the nut (Item 1) [Figure 50-110-17] (three to four
turns), then loosen the bolt. The bolt is threaded into the Figure 50-110-20
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.
Figure 50-110-18
3
1
2
N-17620
Move the right side steering lever forward and install a

2 15/16 in. (24 mm) thick spacer (Item 1) [Figure 50-110-
N-17613 20] between the centering plate (Item 2) [Figure 50-110-
20] and the mounting plate (Item 3) [Figure 50-110-20].
Loosen the nut (three to four turns), then loosen the bolt This will allow the pintle arms to move freely while
at the linkage bar (Item 1) [Figure 50-110-18]. The bolt is adjusting the steering linkage for full forward travel
threaded into the linkage bar (Item 2) [Figure 50-110- speed.
18]. The bolt must be loosened enough to allow the
torsion bushing to turn freely between the pintle arm and Remove the 3/8 in. (10 mm) thick spacer (Item 1) [Figure
the linkage bar. 50-110-19].
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Figure 50-110-21
N-17623
Move the left side steering lever to the full forward

N-17616 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
Check that the pintle arm mounting bolt (Item 1) [Figure clamping plier and clamp the two linkage bars together
50-110-21] is tight, 25 - 28 ft.-lb. (34 - 38 N•m) torque and [Figure 50-110-23].
that there is no play between the pintle arm and the
square pump shaft. Also check that the cam mounting Tighten the nuts and bolts to 25 - 28 ft.-lb. (34 - 38 N•m)
bolts (Item 2) [Figure 50-110-21] are tight, 45 - 50 ft.-lb. torque.
(62 - 68 N•m) torque.
Check the lever movement to make sure that the pintle
Figure 50-110-22 arm and the steering lever are both at full stroke at the
same time. This will allow for maximum forward speed.
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 50-110-

22] on each steering linkage bar.
N-17620
Remove the spacer (Item 1) [Figure 50-110-24].
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The following tool listed will be needed to so the following

procedure:
MEL1429A - Remote Start Switch 1
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
N-19736 the neutral position [Figure 50-110-26].
Tighten the bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque.

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.
NOTE: Bolt holes are slotted for pintle arm centering

adjustment.
Figure 50-110-26
N-17621
Adjust the left side centering block first [Figure 50-110-

26].
Start the engine and run at high RPM.
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Figure 50-110-28
N-19736
Tighten the two linkage bar bolts to 11 - 13 ft.-lb. (15 - 17

N-17618 N•m) torque, then tighten the two nuts to 21 - 25 ft.-lb. (28
- 33 N•m) torque at the pintle levers (Item 1) [Figure 50-
110-29].
Adjust the right side centering block [Figure 50-110-28].
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.-lb. (34 - 38 N•m) 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 N-17624
procedure again.
Stop the engine. Tighten the two linkage bar bolts to 11 - 13 ft.-lb. (15 - 17
N•m) torque, then tighten the two nuts to 21 - 25 ft.-lb. (28
- 33 N•m) torque at the steering cross shaft (Items 1 & 2)
[Figure 50-110-30].
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863 Bobcat Loader
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CONTROL HANDLE (ADVANCED HAND CONTROL) Figure 50-111-3
(AHC)
Components Identification
Figure 50-111-1
1
1
P-13797
2
ACH controller (Item 1) [Figure 50-111-3].
N-17774 N-17783 Figure 50-111-4
Control handle (Item 1) [Figure 50-111-1].
Handle control unit (Item 2) [Figure 50-111-1] (both 1

sides).
Figure 50-111-2
P-28360A
ACH error indicator (Item 1) [Figure 50-111-4].
NOTE: The AHC icon will illuminate when an error

occurs. The error is stored as a service code.
1 (See DELUXE INSTRUMENTATION SERVICE
N-19112 CODES on Page 60-80-1.)
Control Valve Actuators (Item 1) [Figure 50-111-2].
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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 General Fuel Level System Engine Oil Engine Air Filter
Hand Warning Voltage Pressure Coolant
Controls Temperature
B-16640
Attachment Two Speed Glow Plugs Seat Belt Hydraulic Hydraulic Oil Hydraulic
Control Charge Temperature Filter
Device Pressure
Advanced Hand Controls
Errors - lights solid with 3 beeps

32-31 - Tilt actuator fault
32-33 - Tilt actuator wiring fault
B-16624
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.)
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CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (CONT’D)
C-428
C-430
C-431
C-429
TS-1957
P/N PIN DESCRIPTION

P/N PIN DESCRIPTION
C-430 CONNECTOR, METRI-PACK
C-428 CONNECTOR, 8 WAY PLUG (LIFT) (TOP
Orange/White A SWITCHED BATTERY POWER
ACTUATOR)
Black B GROUND
Dk. Blue/White 1 LOW REFERENCE TO RESISTIVE INPUTS
C-431 MALE, 10-WAY
Lt. Green/White 2 SIGNAL FROM LIFT ACTUATOR
Brown/Dk A SIGNAL FROM LIFT CONTROL
Dk. Blue 3 HIGH REFERENCE TO RESISTIVE UNITS
Green
4 OPEN
HANDLE INPUT
Brown/White 5 LIFT SPOOL ACTUATOR MOTOR (-)
Purple/Yellow B FLOAT SWITCH ON/OFF
6 OPEN
Pink/Dk. Green C SIGNAL FROM TILT CONTROL
7 OPEN
HANDLE INPUT
Brown/Yellow 8 LIFT SPOOL ACTUATOR MOTOR (+)
Dk. Blue D TILT HIGH REFERENCE TO
RESISTIVE INPUTS C-429 CONNECTOR, 8 WAY PLUG (TILT) (BOT-
TOM ACTUATOR)
Dk. Blue/White E TILT LOW REFERENCE TO
RESISTIVE INPUTS Dk. Blue/White 1 LOW REFERENCE TO RESISTIVE INPUTS
Dk Blue/White F LIFT LOW REFERENCE TO Lt. Blue/White 2 SIGNAL FROM TILT ACTUATOR
RESISTIVE INPUTS Dk. Blue 3 HIGH REFERENCE TO RESISTIVE INPUTS
Dk. Blue G LIFT HIGH REFERENCE To 4 OPEN
RESISTIVE INPUTS Pink/White 5 TILT SPOOL ACTUATOR MOTOR (-)
Purple/White H BICS INPUT STATUS 6 OPEN
Purple/Red J AHC STATUS OUTPUT 7 OPEN
K OPEN Pink/Yellow 8 TILT SPOOL ACTUATOR MOTOR (+)
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CONTROL HANDLE (ADVANCE HAND CONTROL) Figure 50-111-7
(AHC) (CONT’D)
AHC Controller Removal And Installation
Figure 50-111-5
1
1
N-19643

7] 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
N-19642
Disconnect the wiring harness connectors from the

controller (Item 1) [Figure 50-111-6].
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CONTROL PANEL (ADVANCED HAND CONTROL) Figure 50-111-10
(AHC) (CONT’D)
Handle Control Unit Connector
Figure 50-111-8
1
2 3
P-13733
With a pointed tool, lift the tab (Item 1) [Figure 50-111-

1 10] and pull the wire from the connector.
N-17392
Assembly: Install the wires into the connector as listed
below [Figure 50-111-10]:
The wire connector (Item 1) [Figure 50-111-8] can be
removed from the handle control unit wires, use the 1 - Terminal - Red
following procedure. 2 - Terminal - Black
3 - Terminal - Green
Figure 50-111-9
1 1
P-13725 P-13732
Remove the wedge (Item 1) [Figure 50-111-9] from the

connector.
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(AHC) (CONT’D)
Control Handle Removal And Installation
Figure 50-111-11
3 2 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

Right Control Lever Switch Handle

1 - Terminal - Pink/Red
2 - Terminal - Pink/Black
1 3 - Terminal - Pink/Green
Left Control Lever Switch Handle

N-17786
1 - Terminal - Brown/Red
2 - Terminal - Brown/Black
Remove the handle control unit from the control lever. 3 - Terminal - Brown Green
(See AHC Controller Removal And Installation on Page
50-111-4.)
To remove the switch handle, the connector (Item 1)

[Figure 50-111-11] must be removed from the wires.
Figure 50-111-12
1
P-13725 P-13732

connector.
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CONTROL HANDLE (ADVANCED HAND CONTROL) Installation: The wire colors of the control lever harness
(AHC) (CONT’D) are as follows:
Control Handle Removal And Installation (Cont’d) Right Switch Handle
Figure 50-111-14 Ten-Pin Connector

A - Terminal - Orange
1 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
N-17779 C - Terminal - Pink/Lt. Green
Left Switch Handle

Disconnect the right switch handle connectors (Items 1 &
2) [Figure 50-111-14] from the loader wiring harness
Ten-Pin Connector
connectors.
B - Terminal - Dk. Blue
Figure 50-111-15
C - Terminal - White
D - Terminal - Blank
E - Terminal - Blank
1 F - Terminal - Yellow/Red
2 3 G - Terminal - Yellow/Green
4 H - Terminal - Blank
J - Terminal - Blank
Three-Pin Connector
A - Terminal - Brown/Red
B - Terminal - Brown/Black
C - Terminal - Brown/Lt. Green
Two-Pin Connector
N-17772
A - Terminal - Orange/Blue
B - Terminal - Orange/White
Disconnect the left switch handle connectors (Items 1, 2,
3 & 4) [Figure 50-111-15] from the loader wiring harness Five-Pin Connector
connectors. A - Terminal - Dk. Green
B - Terminal - Brown
Remove the connector locks and connectors from the C - Terminal - Blank
wires the remove the switch handle from the control D - Terminal - Yellow
handle. E - Terminal - Blank
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(AHC) (CONT’D)
Control Handle Removal And Installation (Cont’d)
Figure 50-111-16
2
2
N-17471
1
Installation: When installing the switch handle and

wiring harness assembly into the control handle, route
N-17382 the harness (Item 1) [Figure 50-111-18] to assure proper
return of the control handle to neutral position.
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
N-17383
Pull the switch handle and wiring harness assembly (Item

1) [Figure 50-111-17] from the control lever.
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(AHC) (CONT’D)
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 50-111-
N-18912 21].
Remove the mounting bracket (Item 3) [Figure 50-111-

Remove the actuator (Item 1) [Figure 50-111-19] from 21].
the hydraulic control valve. (See Actuator Removal And
Installation (In Loader) on Page 20-41-1.) Check the rubber strap, mounting shaft collar and
mounting bracket for wear and replace as needed.
Installation: Tighten the mount bolts to 90 - 100 in.-lb.
(130,2 - 11,3 N•m) torque. Figure 50-111-22
Figure 50-111-20
1
2
1 N-17742 N-17741
N-18940
Check the actuator wiring harness connector (Item 1)
[Figure 50-111-22] and replace if broken.
Check the mounting block (Item 1) [Figure 50-111-20]
and bolts for wear and replace as needed. 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].
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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)
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(AHC) (W/ PUSH BUTTON FLOAT)
Figure 50-112-1
1
1
P-13797
2
P-16536 N-22797 Figure 50-112-4
Handle sensor (Item 2) [Figure 50-112-1].

1
Figure 50-112-2
P-28360A
ACS error indicator (Item 1) [Figure 50-112-4].
NOTE: The ACS icon will illuminate when an error

1 occurs. The error is stored as a service code.
N-19112 (See DELUXE INSTRUMENTATION SERVICE
CODES on Page 60-80-1.)
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CONTROL HANDLE (ADVANCED HAND CONTROL) (ACH) (W/ PUSH BUTTON FLOAT) (CONT’D)
B-16640A
Device Pressure

To see what error occurred. Check the service code on the left instrument panel. (See Contents Page 60-01.)
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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 DESCRIPTION

P/N PIN DESCRIPTION
C-430 CONNECTOR, METRI-PACK
C-428 CONNECTOR, 8 WAY PLUG (LIFT) (TOP
Orange/White A SWITCHED BATTERY POWER ACTUATOR)
Black B GROUND Dk. Blue/White 1 LOW REFERENCE TO RESISTIVE INPUTS
C-431 MALE, 10-WAY Lt. Green/White 2 SIGNAL FROM LIFT ACTUATOR
Brown/Dk A SIGNAL FROM LIFT CONTROL Dk. Blue 3 HIGH REFERENCE TO RESISTIVE UNITS
Green
4 OPEN
HANDLE INPUT
Brown/White 5 LIFT SPOOL ACTUATOR MOTOR (-)
Purple/Yellow B FLOAT SWITCH ON/OFF
6 OPEN
Pink/Dk. Green C SIGNAL FROM TILT CONTROL
7 OPEN
HANDLE INPUT
RESISTIVE INPUTS C-429 CONNECTOR, 8 WAY PLUG (TILT) (BOT-
TOM ACTUATOR)
RESISTIVE INPUTS Dk. Blue/White 1 LOW REFERENCE TO RESISTIVE INPUTS
Dk Blue/White F LIFT LOW REFERENCE TO Lt. Blue/White 2 SIGNAL FROM TILT ACTUATOR
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(AHC) (W/ PUSH BUTTON FLOAT) (CONT’D)
Loosen the bottom bolts and remove the top bolt.

1
Figure 50-112-5
N-19643


N-22656
Remove the right front panel (Item 1) [Figure 50-112-5]

from the loader.
Figure 50-112-6
N-22673

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Handle Sensor Removal And Installation
Figure 50-112-8
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
N-22790
N-22801
Use an allen wrench, remove one of the two mounting

Disconnect the harness connector (Item 1) [Figure 50- screws (Item 1) [Figure 50-112-11] from the handle
112-9] from the handle sensor connector. sensor.
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CONTROL PANEL (ADVANCED HAND CONTROL) Figure 50-112-14
Handle Sensor Removal And Installation (Cont’d) 3
Figure 50-112-12
1
3
1 2
3 2
P-16576
Remove the handle sensor (Item 1) [Figure 50-112-14]

from the handle assembly.
P-16580 N-22793
NOTE: The sensor (Item 1) [Figure 50-112-14] can
only be replaced as a complete assembly.
Remove the two plastic spacers (Item 1) [Figure 50-112-
12] and the metal spacer (Item 2) [Figure 50-112-12] Check the spacers (Item 2) [Figure 50-112-14] and
from the handle sensor. screws (Item 3) [Figure 50-112-14] and replace as
needed.
Figure 50-112-13
Figure 50-112-15
1
1
P-16574
N-22799
Remove the top mounting bolt (Item 1) [Figure 50-112-

13] 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.
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Handle Sensor Connector
Figure 50-112-16
1
3
2
1
1 P-13733
With a pointed tool, lift the tab (Items 1) [Figure 50-112-

18] and pull the wire from the connector.
P-16578
removed from the handle sensor wires, use the following 1 - Terminal - Red
procedure. 2 - Terminal - Black
Figure 50-112-17
1 1
P-13725 P-13732
Remove the wedge (Items 1 & 2) [Figure 50-112-17]

from the connector.
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Control Handle Removal And Installation
Figure 50-112-19
3 2 1
P-13735
1
N-22794
Installation: Install the wires into the connector as listed
To remove the switch handle, the connector (Item 1)
[Figure 50-112-19] must be removed from the wires. Right Control Lever Switch Handle
1 - Terminal - Red/White
Figure 50-112-20 2 - Terminal - Black/White
3 - Terminal - Purple/White

2 - Terminal - Black/White
1
P-13725 P-13732

connector.
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CONTROL HANDLE (ADVANCED HAND CONTROL) Installation: The wire colors of the control lever harness
(AHC) (W/ PUSH BUTTON FLOAT) (CONT’D) are as follows:
Control Handle Removal And Installation (Cont’d) Right Switch Handle

B - Terminal - White
1 D - Terminal - White/Red
Three-pin connector
2
B - Terminal - Pink/Black
Left Switch Handle

Figure 50-112-23
Ten-Pin Connector
A - Terminal- Orange
2 C - Terminal - White
1 3 D - Terminal - Purple
4
F - Terminal - Tan
G - Terminal - Pink
H - Terminal - Blank
Three-Pin Connector
A - Terminal - Red/White
N-17772
B - Terminal - Black/White
C - Terminal - Purple/White
2) [Figure 50-112-22] from the loader wiring harness Two-Pin Connector
connectors. A - Terminal - Black
B - Terminal - Red
3 & 4) [Figure 50-112-23] from loader wiring harness Five-Pin Connector
wires to remove the switch handle from the control D - Terminal -Yellow
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(CONTROL HANDLE (ADVANCED HAND CONTROL) Figure 50-112-26
(AHC) (PUSH BUTTON FLOAT (CONT’D)
Control Handle Removal And Installation (Cont’d)
Figure 50-112-24
2 2
N-22794
1
wiring harness assembly in the control handle, route the
N-22783 harness (Item 1) [Figure 50-112-26] to assure proper
Roll the pistol grip handle cover (Item 1) [Figure 50-112-
24] down.

Figure 50-112-25
N-22784

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Figure 50-112-27
2
1
1
N-17742 N-17741

N-18940
below. The terminal numbers are written on the back of
Remove the actuator. (See Actuator Removal And the connector (Item 2) [Figure 50-112-29].
Installation (In Loader) on Page 20-41-1.)

and bolts for wear and replace as needed.
Figure 50-112-28
2
1
N-18941

28].

28].
Check the rubber strap, mounting shaft collar and

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CONTROL HANDLE (ADVANCED HAND CONTROL)

gauge)
2 - Terminal -Green - Larger diameter wire (16 gauge)
gauge)
4 - Terminal - Open
6 - Terminal - Open
7 - Terminal - Open
gauge)
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CONTROL HANDLE (ADVANCED CONTROL Handle Sensor Removal And Installation
SYSTEM) (ACS) ADVANCED HAND CONTROL
Figure 50-113-3
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
P-16572 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.
P-24909
Handle Sensor (Item 1) [Figure 50-113-2].
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CONTROL PANEL (ADVANCED CONTROL SYSTEM) Figure 50-113-7
(ACS) ADVANCE HAND CONTROL (CONT’D)
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
P-24910 sensor.
Installation: Tighten the handle sensor mounting screws

Using a small screwdriver remove the handle sensor to 32 - 28 in.-lb. (3,6 - 4,3 N•m) torque.
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].
Figure 50-113-6
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].
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CONTROL PANEL (ADVANCED CONTROL SYSTEM) EARLIER VERSION HAND CONTROLS ONLY;
(ACS) ADVANCE HAND CONTROL (CONT’D)
Figure 50-113-10
Figure 50-113-8
2
2
1
P-24914
P-24915 Remove the mounting bolt and nut (Item 1) [Figure 50-
113-10] from the control handle and shaft.
Figure 50-113-9 NOTE: Be careful not to loose the recessed nut on the
other side of the handle.

from the control handle.
Installation: Tighten the mounting bolt to 32 - 28 in-lb.

(3,6 - 4,3 N•m) torque.
Figure 50-113-11
1
5
P-24913
Remove the spacers (Item 1) [Figure 50-113-8] & 1

1
[Figure 50-113-9] while removing the mounting pin (Item
2) [Figure 50-113-8] 4
3
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]
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CONTROL HANDLE (ADVANCED CONTROL Figure 50-113-14
(CONT’D)
CURRENT VERSION HAND CONTROLS:

1
Figure 50-113-12
P-24909
Installation: When installing the handle sensor into the

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.-lb. (3,6 - 4,3 N•m)

torque.
Figure 50-113-13
1
3
4
3
2
P-24918


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.
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(CONT’D)
Control Handle Removal And Installation 1

Figure 50-113-15
N-17384
Remove the rubber handle cover (Item 1) [Figure 50-

113-17] from the handle.
P-24909 Figure 50-113-18
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
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.
P-16534 Installation: Tighten the allen head screws to 35 in.-lb.

(4 N•m) torque.
Remove the switch handle (Item 1) [Figure 50-113-16].
(See Switch Handle Removal And Installation on Page
60-121-8.)
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CONTROL HANDLE (ADVANCED CONTROL
(CONT’D)
Control Handle Disassembly and Assembly
Figure 50-113-19
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
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.
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(CONT’D)
Control Lever Removal And Installation
Figure 50-113-21
18.25”
1
1
B-16618
1
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]
N-22667 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
Disconnect the electrical connectors (Item 1) [Figure 50-
18.25 in. [Figure 50-113-23].
113-21] from the control lever switch handle.
Remove the lever from the cross shaft and control panel.
Remove the electrical connectors from the control lever
switch handle. (See Switch Handle Removal And
Figure 50-113-24
Figure 50-113-22
1
2
2
P-13734
N-22658 The control lever (Item 1) [Figure 50-113-24] must be

replaced as a complete unit.
Loosen the two u-clamps (Item 1) [Figure 50-113-22]
The connector clip (Item 2) [Figure 50-113-24] can be
nuts.
replaced separately from the control lever.
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(CONT’D)
Control Lever Boot
Figure 50-113-25
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 50-113-
7.)
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
6.)
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CONTROL HANDLE (ADVANCED CONTROL Handle Sensor Removal And Installation
SYSTEM) (ACS) SELECTABLE HAND / FOOT
CONTROL Figure 50-114-3
Figure 50-114-1
1 1
P-21864
Loosen the nuts (Item 1) [Figure 50-114-3].

seat. Be sure the control lever does not interfere with the
operator cab when lowering or raising the cab.
Figure 50-114-4
P-16572
Figure 50-114-2 1
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
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CONTROL (CONT’D)
Figure 50-114-5
1
P-21860
Remove the handle lock solenoid connector (Item 1)

2 [Figure 50-114-7] from the clip.
P-21836 NOTE: Pry out with a small screwdriver and push the
connector down.
Figure 50-114-8
114-5] from the handle sensor connector.
1
114-5] from the handle lock solenoid.
5
Figure 50-114-6 2
4
1
1 P-21862

50-114-8] from the handle sensor.
P-21861 Installation: Tighten the screws to 32 - 38 in.-lb. (3,6 -

4,3 N•m) torque.
Remove the handle sensor connector (Item 1) [Figure
While removing the mounting pin (Item 2) [Figure 50-
50-114-6] from the clip.
114-8] from the handle sensor, remove the one plastic
spacer (Item 3) [Figure 50-114-8], the spring (Item 4)
NOTE: Pry out with a small screw driver and push the
[Figure 50-114-8] and washer (Item 5) [Figure 50-114-
connector down.
8].
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CONTROL PANEL (ADVANCED CONTROL SYSTEM) Figure 50-114-10
(ACS) SELECTABLE HAND / FOOT CONTROL
(CONT’D)
7
3
EARLIER VERSION HAND CONTROLS ONLY;
1
Figure 50-114-9
4
3
5 6
8
2
P-21791

1 from the handle assembly.
NOTE: The handle senor (Item 1) [Figure 50-114-10]

P-21863
Check the spacer (Item 2) [Figure 50-114-10] and

screws (Item 3) [Figure 50-114-10], mounting pin (Item
Remove the top mounting bolt (Item 1) [Figure 50-114-9]
4) [Figure 50-114-10], spring (Item 5) [Figure 50-114-
from the handle sensor.
10], washer (Item 6) [Figure 50-114-10], bolt / nut (Item
7) [Figure 50-114-10], stop strap (Item 8) [Figure 50-
NOTE: Be careful not to loose the recessed nut on the
114-10] and replace as needed.
other side of the handle.

torque.
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CONTROL HANDLE (ADVANCED CONTROL 7) [Figure 50-114-12], stop strap (Item 8) [Figure 50-
SYSTEM) (ACS) SELECTABLE HAND / FOOT 114-12] and replace as needed.
CONTROL (CONT’D)
Figure 50-114-13
CURRENT VERSION HAND CONTROLS:
Figure 50-114-11
1
1
P-21878
Figure 50-114-14
P-21880

50-114-11]from the handle sensor.

torque.
Figure 50-114-12
4
3 8
1
1
P-21799
Installation: When installing the handle sensor into the

4
3 wire harness (Items 1) [Figure 50-114-13] & [Figure 50-
114-14] to assure proper return of the control handle
neutral.
5 6
2 NOTE: The calibration procedure must be followed
P-21882
when replacing handle sensor, actuator or
ACS Controller (See Actuators Disassembly
Remove the handle sensor (Item 1) [Figure 50-114-12] and Assembly on Page 60-122-11.)

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 50-114-
12], washer (Item 6) [Figure 50-114-12], bolt / nut (Item
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CONTROL (CONT’D)
Control Handle Removal And Installation 1

Figure 50-114-15
1
N-17384
Remove the rubber handle cover (Item 1) [Figure 50-

114-17] from the handle.
P-21879 Figure 50-114-18
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.
P-16534 Installation: Tighten the allen head screws to 35 in.-lb.

(4 N•m) torque.
Remove the switch handle (Item 1) [Figure 50-114-16].
(See Switch Handle Removal on Page 60-122-6.)
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CONTROL HANDLE (ADVANCED CONTROL Control Lever Removal And Installation
CONTROL (CONT’D) Figure 50-114-21
Control Handle Disassembly and Assembly
Figure 50-114-19 1
1
1
2
N-22667
2
Disconnect the electrical connectors (Item 1) [Figure 50-
1 N-17394 114-21] from the control lever switch handle.
Remove the electrical connectors from the control lever

Remove the handle sleeve (Item 1) [Figure 50-114-19]
switch handle. (See Switch Handle Removal on Page 60-
and bushings (Item 2) [Figure 50-114-19] from the
122-6.)
handle.
Check all parts for wear and replace as needed.
Figure 50-114-20
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.
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CONTROL (CONT’D)
Figure 50-114-22
2
1
P-13734
The control lever (Item 1) [Figure 50-114-24] must be

N-22658 replaced as a complete unit.
The connector clip (Item 2) [Figure 50-114-24] can be

Figure 50-114-23
replaced separately from the control lever.
18.25”
B-16618
Loosen the two u-clamps (Item 1) [Figure 50-114-22]

nuts.

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 in. [Figure 50-114-23].
Remove the control lever from the cross shaft and control
panel.
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CONTROL (CONT’D)
Control Lever Boot
Figure 50-114-25
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
6.)
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ELECTRICAL SYSTEM & ANALYSIS
ADVANCED CONTROL SYSTEM (ACS) ADVANCED HAND

CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-122-1
ACS Controller Removal And Installation . . . . . . . . . . . . 60-122-4 SAFETY &
Actuators Disassembly and Assembly. . . . . . . . . . . . . . 60-122-11 MAINTENANCE
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
DRIVE
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 ELECTRICAL
Controller, Connector And Wire Identification . . . . . . . . . 60-123-4 SYSTEM AND
ANALYSIS
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) . . . . . . . . . 60-120-1

Actuators Disassembly And Assembly . . . . . . . . . . . . . . 60-120-9
AHC Controller Removal And Installation . . . . . . . . . . . . 60-120-4
Handle Control Unit Connector . . . . . . . . . . . . . . . . . . . . 60-120-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-3
Switch Handle Removal And Installation . . . . . . . . . . . . . 60-120-6
Trouble shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-2
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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
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). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-6
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Rectifier (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-5
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . 60-30-5
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-5
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
ALTERNATOR (90 AMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-1

Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . 60-31-1
Alternator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-1
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-7
Alternator Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-9
Charging System Check . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-2
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-7
High Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-4
ALTERNATOR (90 AMP) (CONT’D) . . . . . . . . . . . . . . . . . 60-31-4
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . 60-31-6
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-8
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-8
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-8
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-8
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing The Electrical System . . . . . . . . . . . . . . . . . . . . 60-20-3
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . 60-20-4
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544 of 968
BOBCAT CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

Identification Chart (S/N 514450763 & Below) . . . . . . . . . . . . . . 60-70-1
Identification Chart (S/N 514450764 & Above) . . . . . . . . . . . . . . 60-70-2
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 Bypass 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 . . . . . . . . . . . . . . . . . . . . . 60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Relay Switches Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
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LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-60-2
SEAT BAR SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

BICS™ Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-4
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
STARTER (VALEO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-1

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-1
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . 60-41-4
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-7
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-9
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-3
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Description Of The Control System (Two-Speed) . . . . . . 60-110-3
Inspecting The Control System (Two-Speed) . . . . . . . . . 60-110-3
Removal And Installation (Single Speed). . . . . . . . . . . . . 60-110-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
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RED = RED
BATTERY FEED 1000-1999 RED, RED/WHT, RNG
GROUND 2000-2999 BLK
RNG = ORANGE
BLK = BLACK CAB FRONT LIGHT
ACCESSORY 2740
2750
863 WIRING SCHEMATIC
LBL = LIGHT BLUE CONNECTORS 2760
MONITORING 3000-3999 LBL DBL = DARK BLUE HARNESS 6718870
LGN = LIGHT FRONT WORKLIGHTS
S/N 514440001-45999
HYDRAULIC 4000-4999 LGN
WIRES CONNECT BY LETTER GREEN 2750 B B 2750
C435
ACROSS CONNECTORS ATTACHMENT CONTROLS 5000-5999 YEL
DGN = DARK
S/N 514540001-40999 A B LIGHTS 6000-6999 PNK GREEN
6110 A A 6110
YEL = YELLOW
S/N 514640001-40999 B A ACCESSORIES 7000-7999 WHT
PNK = PINK 6120 A A 6120
C434
ENGINE 8000-8999 TAN
(PRINTED NOVEMBER 2002) SOME CONNECTOR
BODIES NOT SHOWN
COMMUNICATION 9000-9999 PUR
WHT = WHITE
BRN = BROWN
2760 B B 2760
V-0003 FOR DRAWING CLARITY TAN = TAN

PUR = PURPLE
LEFT PANEL
GRY = GRAY
9340 D HEADLIGHTS
FUEL SENDER 2910 G GROUND

FUSE 5 FUSE 1 FUSE 9
20-270 ohm UNSWITCHED 1210 E PROTECTED POWER
TRACTION HEATER
FRONT &
30A 25A REAR SWITCH 25A 1910 F COMPUTER POWER
MARKER
FUSE 6 LIGHT POWER FUSE 10 K
TAILGATE/
A B FUSE 2 LIGHT 9210 SYSTEM Rx
2650 FUEL PULL FR & MK LT ATTCHMNT
2640
C442 30A 15A 25A
9110 H SYSTEM Tx
9300 A CLOCK/LATCH
A B FUSE 3 FUSE 11
WORK LIGHTS
2630 2600 FUSE 7
REAR LT ALT & KITS 9310 B DATA
2620 15A
FUEL SENDER GLOW FUEL TRACTION 25A CONNECTS TO 9330 J START
2610 STARTER
HARNESS FUSE 8 FUSE 4 PLUG PULL PULL FUSE 12 C407
HARNESS 6716419 ON THIS PAGE
9320 C BUZZER
3100
3110
6719422 COMPUTER ACC PLUGS
RIGHT
TAILLIGHT 2610 6320
25A 25A
C407
A 9320 + BUZZER
A B C
2930 -
LEFT
2640 6330 C406 RIGHT PANEL
MAIN FRAME
TAILLIGHT 6100 8 8 6100
A B C
9340 11 11 9340
RIGHT 9200 10 10 9200 9330 J START

WORK 2620 6200 9 9 B
HARNESS 6719112 9100 9310 DATA
3100
3110
9100
6210
C408
LIGHT
2900 4 4 2900 9300 A CLOCK/LATCH
1900 2 2 1900 9120 H SYSTEM Tx
LEFT WORK
2630 6210 1200 1 1 1200 9220 K SYSTEM Rx
LIGHT
C405
3700 A A AIR FILTER 9350 12 12 9350 1920 F COMPUTER POWER
3710 B B SWITCH 3900 5 5 3900 1220 E PROTECTED POWER
7100 3920 7 7 3920 2920 G GROUND
BACKUP 3910 6 6 3910 9350 D KEY/ENTER SWITCH
2650
ALARM
HYD FILTER 2740 3 3 2740 C OPEN
2600
7100
6200
6310
TO OPTIONS
(BACKUP HARNESS 6717247 2910
ALARM 2900 2920
SWITCH) t 2930
B F G D E C H A HYD TEMP SENDER
C404 3300 C C 3300
538-1824 ±30 ohm 3900
C
C103 SEAT
C102
3310 D D 3310 B
B A A+ 3920 BAR
3400 A A 3400 HYD CHARGE PRESS A
3910
B F G D E C H A 3420 E E 3420
C SENDER 0.5-7.5 V
3410 F F 3410 B - MAIN

2000 CAB
9340
2900
9350
9200
9100
1900
1200
3900
3920
3910
FRAME
7100
HYD OIL FILTER
ENGINE
3430 B B 3430
PRESSURE SWITCH
2600
6600
6500
6400
7100
6200
6310
HARNESS 6719082 J2
RIGHT HANDLE
E3
D2
D1
A1
A2
A3
D3
C3
C2
C1
B3
B2
B1
E1
E2
F2
F3
F1
J4
3020
6310 N E1 4300 4300 B B WHT
6200 S
3110 J1 J2
D D
+
A 3500 3310 3010 E3 4320 4320 WHT/RED
PWM
SEATBAR SENSOR
SEATBAR SENSOR
FUEL SENDER SPARE ANAL OG
ENG COOLAN T SPARE ANAL OG
SPARE DIGITIAL
SENSOR SIGN AL
C 7100 R R 7100 E2 C C
SEATBAR
3410 4310
GROUND
ENG OIL PRESSURE 4310 WHT/BLK
SUPPLY
IN 1
IN 2
IN 1
3900
3910
3920
3520
A1
A2
A3
A1
A2
A3
SENDER 0.5-7.5 V - 6400 W 3710
B 3510 K3
6500 P TWO
TEMP SENDER
J1
HYD TEMP
SENDER
C409
SIGNAL
A1 F F SPEED
OPEN
OPEN
4910 4910 WHT/LGN
OPEN
3100
3200
3300
B1
B2
B3
B1
B2
B3
6600 V
ENGINE COOLANT
t
3010 F2 G G
HYD CHARGE
HYD CHARGE
PRESSURE +
3200
DIGITAL IN 2
PRESSURE
SENDER DETENT
SIGNAL
SPARE
OPEN
OPEN
OPEN
E3 J3 J4 B1 E E
3400
3420
3430 4920 4920 DGN
C1
C2
C3
C1
C2
C3
500-3000 ± 30 ohm
3210 3020 H H 3020
3420 C2 K2 K K
RH TWO SPEED
BATTERY IN (1 )
BATTERY IN (2 )
BATTERY IN (3 )
LH AUX RIGH T
UNSWITCHED
UNSWITCHED
UNSWITCHED
BRAKE SW
C1 C1 J
4910
4810
4500
1110
1120
1130
3400
BLACK
WHITE
4930 4930 J
A1
A2
A3
A1
A2
A3
IN
YEL
J1
J2
3610 SKI
SPEED SENSOR (VR) 3300 B3 D1 4940 4940 H H LGN CONTROL
3600
LH AUX LEFT
ENG SPEED +
PRESSURE +
RH FRON T
BRAKE SW
E2
SYSTEM Tx
SYSTEM R x
PRESSURE
DETEN T
3700
GROUND
GROUND
A
ENG OIL
ENG OIL
B3 A RNG
SIGNAL
OPEN
1400 1490
4920
4820
1400
OU T
2100
2110
OPEN
B1
B2
B3
(hall)
9100
9200
3500
3520
B1
B2
B3
D1
D2
D3
D1
D2
D3
3100 B1
F F BRAKE SWITCH
FUEL PULL RELAY
RH SKI D OWN
FILTER SIGN AL
LH SKI D OWN
HYD CHARGE
EHC INPU T
HEADLIGH T
FUEL HOLD
COMPUTER
FEEDBAC K
ENG SPEED
FUEL PULL
KEY/ENTER
SIGNAL (vr)
AIR FILTER
K
SWITC H
SWITC H
D1 A3
POWER
SIGNAL
3500 K 3500 3500 4500 1450
4930
4830
9400
GLOW PLUGS
8800
8110
8150
1900
9350
9340
C1
C2
C3
3600
3700
3430
C1
C2
C3
E1
E2
E3
E1
E2
E3
C403
0.4 ohm 3520 L L 3520 3520 D2 K1
STARTER REL AY
EHC OUTPU T
HR
SIGNAL (hall )
PROTECTED
GLOW PL U G
C C B2 H
ENG SPEED
BRAKE PULL
8560 3200 3200 3200
Dealer Copy -- Not for Resale
GROUNDS
LH SKI U P
H
RH SKI U P
GROUND
SENSOR
POWER
RELAY
RELAY
OPEN
OPEN
LEFT HANDLE
1200
2900
4940
4840
9410
3010
8210
4110
8510
D1
D2
D3
F1
F2
F3
F1
F2
F3
D1
D2
D3
3600 M M 3600 3600 E1 C3 9400 J J
0.4 ohm
X X F3 D3 9400 1480 A A RNG
PWM SIGN AL
GLOW PL U G
BRAKE PULL
HR
FEEDBAC K
FEEDBAC K
FEEDBAC K
8570
STARTER
PWM +
PWM -
4310
4320
4300
E1
E2
E3
8250
4150
8550
B B C3 D2 4840 C C
E1
E2
E3
2300 2300 4840 WHT SKI
C410
0.4 ohm J J A1 C2 4830 4830 B B DBL CONTROL
HR
WHITE
8580 8500 8500 G W 6400 A3 B2 4820 4820 G G
BLACK
YEL/LGN
J4
PADDLE
J3
P 6500 F1 A2 4810 4810 F F YEL/RED MOMENTARY
0.4 ohm
SPOOL LOC K
FRONT BASE
FRONT R OD
V 6600 D3 G2 4430 K K
REAR WKL T
MARKER L T
RELAY
RELAY
HR
4340
4330
4360
OPEN
8590
F1
F2
F3
6210
6320
F1
F2
F3
T T A2 G1 4440 E
E
800 SERIES
TRACTION HOL D
U 8250 J1 4460 D D
REAR BASE
REAR ROD
RESERVED
RESERVED
RESERVED
(R TURN)
(L TURN)
(HORN)
4440
4430
4200
G1
G2
G3
G 8500 J2
G1
G2
G3
4450
FUEL SHUT OFF B BRN
D 8200 J3 4480
C412 C411
TURN
D
RELAY OUTPU T
TWO SPEED
YEL
ATTACHMEN T
BICS LOC K
ACCESSOR Y
POSITION
BUCKET
KEY INPU T
TO OPTIONS SIGNAL
CONTROL
2800 8100 8100 E S 6200 F2
TRAVEL
4330
4410
4420
4350
H1
H2
H3
8000
9800
4730
H1
H2
H3
(ACCESSORY A DGN
1800 A N 6310 F1 4340 CONNECTOR)
ALTERNATOR C
SPARE OUTPU T 1
SPARE OUTPU T 2
RED TO BLK=
REAR BLEED
HIGH FL OW
D E
DIVERTER
8200 8100 H1 4410
RESERVED
(ATT ACC )
3.2 ohm
4460
4450
4470
E
J1
J2
J3
J1
J2
J3
S 8250 U A 1800 F3 4360
1020
G EXC TO OPTIONS
(SERIAL RIGH T)
H2 A
(SERIAL LEFT)
4420 (ACCESSORY RNG/DBL
FUTURE
FUTURE
1010 1800
CAN SHIELD
CAN HIGH
CAN L OW
OPEN
K1
K2
K3
CONNECTOR) B
9500
9600
9700
H3 4350 RNG/WHT HORN
K1
K2
K3
BAT
G3 4200
STARTER 2600 REAR ROD
G3
G1
G2
M
B3
D3
B1
B2
H3
C1
E1
H1
C3
C2
D1
E3
D2
E2
A1
A2
A3
K1
K2
K3
H2
J3 F3
F2
F1
J1
J2
J3
2300 CONNECTS TO
S
C413
C407 TO OPTIONS 4430 A A 7.5 ohm nominal
1010 8200 2800 (ACCESSORY
ON THIS PAGE BROWN TIE STRAP at 12 VDC
CONNECTOR)
2430 B B
R
8250
C407 C427 120 ohm REAR BASE
4110
4730
8250
8000
8150
8110
6320
6210
8210
2100
8550
8510
2110
4150
4390
1110
1120
1130
9500
9600
9700
9800
C414
4440 A A 7.5 ohm nominal
A E F H G C B A D ACD & REMOTE START
WHITE TIE STRAP 2440 B B at 12 VDC
CONNECTOR
2090
2090
LOCATED AT REAR OF HIGH FLOW
MACHINE
C415
6400
6500
6600
6300
4730
BLUE TIE STRAP 2460 B B at 12 VDC

6000
GROUNDS D C B A G F E DIVERTER
2480
TO OPTIONS TO OPTIONS
C426 4450 A A 7.5 ohm nominal
C416
2460 (ACCESSORY (ACCESSORY
at 12 VDC
CONNECTOR) CONNECTOR) YELLOW TIE STRAP 2450 B B
2360
2450
D C B A G F E
2440 2400 C401 C402 REAR AUX RELIEF
C417
2430
B A D C B A GREEN TIE STRAP at 12 VDC
B A 2480 B B
9800
9700
9600
9500
2710
1160
1710
2340
FRONT ROD
2330 C458
4330 A A
C418
3.3 ohm nominal
2730
1140
1700
1150
2100
2720
1720
2420 B A 2330 B B at 10 VDC

2410 FRONT BASE
2380 4340 A A
C419
3.3 ohm nominal
2370 2390 2340 B B at 10 VDC
2360 HYD LOCK VALVE
2350 HYDRAULIC
4410 A A
C420
MAKE-UP 9.8 ohm nominal
2200 2410 B B at 12 VDC
2000 TILT SPOOL LOCK
4370 A A
C421
2300 1800
FUSE 11 7.7 ohm nominal
2740 1720 25A 2370 B B
2730 1700 1055
LIFT SPOOL LOCK
8000
6310
8500
8550
8510
4110
4150
4100
6000
6300
6320
2120
2720 FUSE 12
USED IN AHC A A
8100
8150
8110
6200
6210
8200
8210
25A 4380
C422
AHC POWER
1140
2710 EQUIPPED 1730 7.7 ohm nominal

2110 LOADERS ONLY SWITCHED REAR TRACTION 2380 B B
1150
1160
MARKER LIGHT GLOW
FUSE 10 POWER FUEL STARTER LOCK
ATTACHMENT LIGHT PLUG
25A PULL BUCKET POSITION
1710
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A
1130
1110
1120
C423
HEATER 4420 A A 6.7 ohm nominal
30 85 2420 B B at 12 VDC
25A 30 85 30 85 30 85 30 85 30 85 85 30 UNSW
POWER
FUSE 1 TWO SPEED
2020
2030
1330
1050
2000
2010
1350
2040
2050
1320
2010
2020
1030
2060
1060
2030
2040
2050
2060
25A
1360
RELAY GROUNDS 2000-2060
4350 A A
C441
ARE CONNECTED IN SERIES FUSE 9
5.5 ohm nominal
2350 B B at 12 VDC
30A 15A 15A
1070
BATTERY FUSE 6 FUSE 2 FUSE 3 30A 25A SINGLE SPEED TRACTION LOCK

1050 FUSE 4
FUSE 5
- + 1300 TWO SPEED BRAKE LOCK
100A 1030 WHT TO BLK =
4200 A A HOLD A
C425
C425
0.26 ohm
1010 1060
2200 C C RED TO BLK= B 9.8 ohm
1310 10.9 ohm
4100 B B PULL C
1040
V-0003 (10-4-02)
Printed in U.S.A.
547 of 968
ELECTRICAL SYSTEM INFORMATION

S/N 514440001-45999
S/N 514540001-40999
S/N 514640001-40999
(PRINTED OCTOBER 2002)
V-0003

WITH ADVANCED HAND CONTROL OPTION
S/N 514440001-43831
S/N 514540001-40110
S/N 514640001-40215
V-0004

WITH ADVANCED HAND CONTROL OPTION
S/N 514443832-45999
S/N 514540111-40999
S/N 514640216-40999
V-0119

WITHOUT ACS OPTION
S/N 514446001-514450763
S/N 514541001-514541103
S/N 514641001-514641254
V-0120

WITH ACS OPTION
S/N 514446001-514450763
S/N 514541001-514541103
S/N 514641001-514641254
V-0216

WITHOUT ACS OPTION
V-0214

WITH ACS OPTION
V-0215
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ELECTRICAL SYSTEM INFORMATION (CONT’D)
OPTIONS

OPTIONS
V-0020
OPTIONS
V-0021

OPTIONS
S/N 514446001-46746
S/N 514541001-41027
S/N 514641001-41068
V-0121

OPTIONS
V-10123
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WARNING
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. 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
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0807
PROBLEM CAUSE
Battery will not take charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9
863 Bobcat Loader

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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.
863 Bobcat Loader

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ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 60-10-2
Description
Figure 60-10-1
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 1
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.
P-28475
the fuse holder is located in the engine compartment,

below the engine harness connector (Item 1) [Figure 60-
10-2] & [Figure 60-10-3].
863 Bobcat Loader

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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.
N-19659
The electrical system is also protected by fuses and

relays under the fuse panel cover (Item 1) [Figure 60-10-
4] located in the cab on the steering control panel.
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ELECTRICAL SYSTEM INFORMATION (CONT’D) The location and sizes are shown in [Figure 60-10-6] &
[Figure 60-10-7].
Fuse Location
Ref Description Amp
Figure 60-10-6 F1 Heater 25
F2 Front & Marker Lights 15
F3 Rear Lights 15
F4 Bobcat Controller 25
F5 Traction 30
F6 Fuel Shutoff 30
F7 Not Used --
F8 Not Used --
F9 Unswitched Attachment 25
F10 Switched Attachment 25
F11 Alternator & Kits 25
F12 AHC Power 25
Relay Switches Location
Remove the cover to check or replace the relays.

N-19660
The location is shown in [Figure 60-10-6] & [Figure 60-
F5 F1 E C B
10-7].
D F9
Ref Description Ref Description
F2 F10
B Switch Power F Glow Plugs
F6
C Rear Lights G Fuel Shutoff
D Front & Marker Lights H Traction
F7 F3 F G H J F11 E Not Used J Starter
F8 F4 F12
Fuses Relays Fuses

N-18465A
Figure 60-10-7
1
N-19661
Remove the cover to check or replace the fuses.
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Solenoid Test
Figure 60-10-8
P-9175

10-8]. 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.
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863 Bobcat Loader
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863 Bobcat Loader
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BATTERY Figure 60-20-2
1
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 P-28431
and wash eye with clean, cool water for at least 15
minutes.
Remove the bolt from the cable clamp (Item 1) [Figure
If electrolyte is taken internally drink large quantities 60-20-2] and loader frame.
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. Figure 60-20-3
W-2065-0807
Open the rear door.

2
Figure 60-20-1
1
P-28429
Disconnect the positive (+) cable (Item 1) [Figure 60-20-

3]from the battery.
P-28429 Remove the battery holddown clamp (Item 2) [Figure 60-

20-3].
Disconnect the negative (-) cable (Item 1) [Figure 60-20-
Remove the battery from the loader.
1] from the battery.
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BATTERY (CONT’D) Figure 60-20-6
Figure 60-20-4
P-28431
Installation: The short negative cable must be

P-9589 connected at the cable clamp and ground bolt (Item 1)
[Figure 60-20-6] to insure proper system ground and
cable routing.
Figure 60-20-5
Connect and tighten the battery cables. Connect the
negative (-) cable last to prevent sparks.
P-9590
Installation: Always clean the terminals and cable ends

when installing a new battery as shown in [Figure 60-20-
4] & [Figure 60-20-5].
When installing the battery in the loader, do not touch any

metal parts with the battery terminal posts.
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BATTERY (CONT’D)
Servicing The Electrical System
WARNING

In case of eye contact get prompt medical attention
minutes.
If electrolyte is taken internally drink large quantities

prompt medical attention.
W-2065-0807
Figure 60-20-7
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.
Put Battery Saver P/N 6664458 or grease on the battery

terminals and cable ends to prevent corrosion.
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BATTERY (CONT’D) If it is necessary to use a booster battery to start the
engine, BE CAREFUL! There must be one person in the
Using A Booster Battery (Jump Starting) operator’s seat and one person to connect and
disconnect the battery cables.
The ignition must be in the OFF position. The booster
WARNING battery to be used must be 12 volt.
Figure 60-20-8

minutes.
2
prompt medical attention. 4
W-2065-0807
P-10813
WARNING
Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery 3 1
make final connection (negative) at machine frame.
Do not jump start or charge a frozen or damaged

battery. Warm battery to 60°F (16°C) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
P-7661
lean over battery while boosting, testing or charging.
Battery gas can explode and cause serious injury. Connect the end of the first cable (Item 2) [Figure 60-20-
W-2066-0705 8] 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 60-

IMPORTANT 20-8] 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.
Damage to the alternator can occur if:
• Engine is operated with battery cables
Keep cables away from moving parts. Start the engine.
disconnected.
• Battery cables are connected when using a fast
After the engine has started, remove the ground (-) cable
charger or when welding on the loader. (Remove
(Item 4) [Figure 60-20-8] first.
both cables from the battery.)
• Extra battery cables (booster cables) are
Remove the cable from the starter.
connected wrong.
I-2023-1285
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ALTERNATOR (55 AMP) If the reading is low, remove the screws and pull the
regulator cover away from the alternator and continue
Alternator Output Test testing (below).
Rectifier (Diode) Test
WARNING NOTE: The alternator is removed from the loader for

clarity purposes.
Put jackstands under the front axles and rear corners Disconnect the negative (-) cable from the battery.
Failure to use jackstands can allow the machine to Install the wires in their original location on the back of
fall or move and cause injury or death. the alternator.
W-2017-0286
Figure 60-30-2
Output
Terminal
Disconnect the negative (-) cable from the battery.
Figure 60-30-1
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 If the reading is within 45-55 amps @ 2600 RPM replace
the ammeter. the rectifier (diode) assembly or replace the alternator.
Connect the positive (+) side of the ammeter to the If the reading is low, do the Alternator Regulator Test.
output terminal on the alternator (Item 1) [Figure 60-30-
1].
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.
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ALTERNATOR (55 AMP) (CONT’D) Figure 60-30-4
Alternator Regulator Test
WARNING
When an engine is running in an enclosed area, fresh Ground
Brush Stud
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust Terminal
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-0807
1 P-1364
Figure 60-30-3
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.
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2
IMPORTANT
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
1
both cables from the battery.)
• Extra battery cables (booster cables) are N-19698
connected wrong.
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.
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.

[Figure 60-30-5].
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ALTERNATOR (55 AMP) (CONT’D) Stator Continuity Test
Disassembly Figure 60-30-8
Figure 60-30-7
1. Nut 10. Case Half (Rear)
2. Pulley 11. Condenser Assembly
3. Fan 12. Strap
4. Bolt 13. Regulator
5. Case Half (Front) 14. Brush
6. Bearing 15. Cover
7. Rotor
8. Stator
9. Rectifier (Diode)
2 3
1 8
5 7 P-1369
6
4
Use an ohmmeter to test the stator.
Touch the probes to two of the bare stator wires [Figure

12 60-30-8].
13 Move one of the probes to the third wire.
The readings should be the same.

14
11 If there is no continuity, replace the stator.
10
9
Stator Ground Test
15 C-3312 Figure 60-30-9
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

P-1386
hammer.
Unsolder the stator leads from the rectifier. Remove the Touch one probe to a bare stator lead and the other
stator. probe to the bare metal surface of the stator [Figure 60-
30-9].
There should be no continuity.
Replace the stator if there is continuity.
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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
Figure 60-30-10 shows no continuity or continuity in both
directions, replace the rectifier assembly.
Figure 60-30-12
P-1365
Touch the probes to the slip rings (Item 1) [Figure 60-30-

P-1373
10].
The ohmmeter should read between 3.0-33.0 ohms. 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.
Reverse the probes to check the diode in the other
Rotor Ground Test 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].
Touch one probe to the diode and the other to the
There should be no continuity. connected heat sink and read the meter [Figure 60-30-
13].
Replace the rotor if there is continuity.
direction.
There should be continuity in one direction only.

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ALTERNATOR (55 AMP) (CONT’D)
Assembly
Figure 60-30-14
P-1808
Reverse the order of disassembly.
Place the rotor in soft jaws when tightening the shaft nut.
Tighten to 50 ft.-lb. (68 N•m) torque [Figure 60-30-14].
Install the rear case half and the remaining parts.
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ALTERNATOR (90 AMP) Alternator Identification
Adjusting The Alternator Belt Figure 60-31-2
Stop the engine.
Open the rear door. 2

Figure 60-31-1 1
P-24416A
2
4
1
1
3 P-24417
Figure 60-31-3
4
P-24611 P-24614
Loosen the alternator mounting bolt (Item 1) [Figure 60-

31-1].
3
Loosen the adjustment bolt (Item 2) [Figure 60-31-1].
Move the alternator until the belt has 5 - 16 in. (8,0 mm)
movement at the middle of the belt span with 15 lb. (66
N) of force. 1
1 1
Tighten the adjustment bolt and mounting bolt. 2 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]
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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.
Inspect the alternator wiring harness and connectors at

IMPORTANT alternator. Harness and connectors must be clean and
tight.
• Engine is operated with battery cables Check the fuse for the alternator in the fuse panel. If fuse
disconnected. is burned, fond the cause and repair / replace. If fuse is in
• Battery cables are connected when using a fast doubt, remove it and check for continuity.
both cables from the battery.) Check the electrolyte level in the battery. Add distilled
• Extra battery cables (booster cables) are water as needed. (Does not apply to maintenance free
connected wrong. batteries.)
I-2023-1285
Verify the charge of the battery. Make sure the battery is
fully charged.
Disconnect the battery cables (negative first, then

WARNING 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.
minutes.
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.)
prompt medical attention.
2. If the test light lights up, there is a short (drain) in the
W-2065-0807
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 machine frame.
Do not jump start or charge a frozen or damaged

battery. Warm battery to 60°F (16°C) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Battery gas can explode and cause serious injury.

W-2066-0705
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Charging System Check (Cont’d)
Figure 60-31-4
2 P-24616
Turn the engine on with the remote start tool and run at
P-24621 idle. With a voltmeter, check the voltage between the B+
terminal and ground at the starter [Figure 60-31-5].
3. Disconnect the alternator B+ terminal (Item 1) [Figure The voltage must be higher than 13.5 volts but lower than
60-31-4] and L & S terminal connector (Item 2) n 14.7 volts at 70° F (Alternator Temperature).
[Figure 60-31-4] and if the test light goes out, the
alternator is faulty. If the test light stays on, find the If the voltage is higher than 14.7 volts proceed to See
short in the system and repair it. High Voltage Test on Page 60-31-4.
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
Open the rear door. (See REAR DOOR on Page 50-70- volts, proceed with the See ALTERNATOR (90 AMP)
1.) (CONT’D) on Page 60-31-4.
Connect the remote start tool to the loader. (See

REMOTE START on Page 10-60-1.)
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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 4] off the alternator.
Figure 60-31-6
Figure 60-31-8
1
P-24568
1
2
P-24617
P-24569 P-24619
Turn engine OFF and remove the L & S terminal

connector (Item 1) [Figure 60-31-6] off the alternator. Check the continuity between the “S” terminal (Item 1)
[Figure 60-31-8] and the positive (+) terminal on the
Turn the remote start tool key to the ON position. battery or starter terminal (Item 2) [Figure 60-31-8].
There should be continuity. If no continuity, replace wire
Figure 60-31-7 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.
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ALTERNATOR (90 AMP) (CONT’D) Raise the lift arms and install an approved lift arm support
Removal And Installation 20-1.)
Place jackstands under the rear of the loader. Open the rear door.
DANGER 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.
P-90328
IMPORTANT
AVOID DEATH Damage to the alternator can occur if:
• Disconnecting or loosening any hydraulic • Engine is operated with battery cables
tubeline, hose, fitting, component or a part failure disconnected.
can cause lift arms to drop. • Battery cables are connected when using a fast
• Keep out of this area when lift arms are raised charger or when welding on the loader. (Remove
unless supported by an approved lift arm both cables from the battery.)
support. Replace if damaged. • Extra battery cables (booster cables) are
D-1009-0409 connected wrong.
I-2023-1285
Figure 60-31-10
WARNING
1
support device can allow the lift arms or attachment 2
W-2059-0598
Figure 60-31-9 3
P-24611
Remove the adjustment bolt (Item 1) [Figure 60-31-10]

1 from the mounting bracket.
Remove the alternator belt (Item 2) [Figure 60-31-10]

2 from the alternator pulley.
Remove the mounting bolt (Item 3) [Figure 60-31-10].
P-24621
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Rectifier Continuity (Diode) Test

1
Figure 60-31-11
1
2 3 1
1
P-24527
Touch the probes to the terminals (Item 1) [Figure 60-31-

1 P-24416 13] of each diode and read the meter.

Remove the two screws (Item 1) [Figure 60-31-11], nut / direction.
washer (Item 2) [Figure 60-31-11] and the plastic cover
(Item 3) [Figure 60-31-11] from the alternator. Meter readings should be different when probes are
reversed.
NOTE: In the diode tests there should be continuity in
one direction only. Meter readings should be Figure 60-31-14
different when robes are reversed. If the diode
being tested shows no continuity or
continuity in both directions, replace the
rectifier assembly.
Figure 60-31-12
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 Reverse the probes to check the diode in the other

direction.
NOTE: Use the diode function (Item 1) [Figure 60-31- Meter readings should be different when probes are
12] on the multimeter. reversed.
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ALTERNATOR (90 AMP) (CONT’D) Disassembly
Alternator Regulator Test Figure 60-31-17
Figure 60-31-15 1. Alternator 11. Bearing

2. Nut 12. Stator
3. Pulley 13. Bracket
4. Spacer 14. Sleeve
5. Bolt
15. Regulator
6. Bracket
7. Bolt 16. Rectifier
8. Bearing 17. Cover
9. Retainer 18. Spacer
2 10. Rotor 19. Nut
7
1
6
1
4 7 13 14
P-24533
2 3 12 5
Touch one probe to the “L” terminal (Item 1) [Figure 60-
11
31-15] and the other probe to the ground (Item 2) [Figure 10
60-31-15].
9
8
Figure 60-31-16
19
18
16
15
17
C-3529
Disassemble the alternator. (See Parts Identification

[Figure 60-31-17].)
Remove the rear cover.

P-24535
Remove the four bolts holding halves together.
Reverse the probes to check in the other direction
Pry the halves apart (Use a press if needed).
[Figure 60-31-16].
Use a soft jaw vise to hold rotor while removing pulley
There should be continuity in one direction only. Meter
nut.
readings should be different when probes are reversed. If
there is no continuity or continuity in both directions,
Remove front case half from the rotor using a plastic
replace regulator.
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.
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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 If there is no continuity replace the rotor.
60-31-18].
Rotor Ground Test
Move one of the probes to the third wire.
The readings should be the same. Figure 60-31-21
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].
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 60-
31-19].
Replace the stator if there is continuity.

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ALTERNATOR (90 AMP) (CONT’D)
Assembly
Reverse the order of disassembly.
Do not assemble the rear case half.
Figure 60-31-22
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.-lb. (98
± 20 N•m) torque.
Install the rear case half and the remaining parts.
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STARTER (NIPPONDENSO) Figure 60-40-3
Figure 60-40-1
1 1
N-20399
Remove the lower mounting bolt (Item 1) [Figure 60-40-

N-19699 3].
Figure 60-40-4
Open the rear door.
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 60-
40-4].
1
Remove the starter.
N-19700
Disconnect the wires (Item 1) [Figure 60-40-2] from the

starter solenoid.
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STARTER (NIPPONDENSO) (CONT'D)
1. Felt Washer
2. Bearing
3. Armature
8
4. Bearing
5. Field Windings 10
6 7 9
Housing Assy.
6. Cover 11. Brushes
7. Brush Holder 12. Cover
8. Cover 5 13. Gasket
9. Bolt 14. Screw
10. Bolt 15. Pinion Shaft
4
16. Nut
3 17. Washer
18. Nut
19. Washer
1 20. Roller
11
17 13
12
16
18 14
15
20 19 11
22 21
18
25 16
24
17
23
35 21. Retainer
22. Pinion
23. Ball
34 24. Spring
33 25. Housing
26. Screw
31 27. Washer
28. O-ring
28 29. Housing
27 30 32 30. Gear
26 31. Spring
32. O-ring
33. Drive
34. Spring
35. Shaft
29
D-2297A
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STARTER (NIPPONDENSO) (CONT'D) Figure 60-40-7
Figure 60-40-5
B-14442
Remove the field windings housing from the magnetic

B-14441 switch [Figure 60-40-7].
Figure 60-40-8
Disconnect the wire from the magnetic switch [Figure
60-40-5].

N•m) torque. Securely put the rubber boot over the 1
terminal.
Figure 60-40-6
B-14468
Assembly: When installing the field windings housing to

the magnetic switch, engage the tab (Item 1) [Figure 60-
40-8] 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.-lb.

(6,8 - 11,8 N•m) torque.
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Figure 60-40-9
B-14444
Remove the armature from the field windings [Figure 60-

B-14443 40-11].
NOTE: Use a plastic hammer to tap the field windings

Remove the screws from the cover over the brushes. housing, when necessary to remove the
armature.
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 60-
40-12].
Negative Brush Holder Hole
B-14466 Assembly: Tighten the screws to 60 - 104 in.-lb. (6,8 -
11,8 N•m) torque.
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].
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Figure 60-40-13
B-14448
Remove the steel ball from the overrunning clutch

B-14446 [Figure 60-40-15].
Figure 60-40-16
Remove the drive end frame from the magnetic switch
[Figure 60-40-13].
Figure 60-40-14
B-14449
Remove the pinion (Item 1) [Figure 60-40-16] from the

B-14447 drive end frame.
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.)
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STARTER (NIPPONDENSO) (CONT'D) External Pinion
Disassembly And Assembly (Cont'd) Figure 60-40-19
Figure 60-40-17
B-14452
B-14450
If the pinion is installed on the drive end frame (externally
attached to overrunning clutch shaft), it will be necessary
Remove the retainer and rollers from the drive end frame to remove the pinion prior to removing the overrunning
[Figure 60-40-17]. clutch.
Figure 60-40-18 Push down on the drive end frame [Figure 60-40-19].
Figure 60-40-20
Collar
B-14451
B-14453
Remove the return spring from the magnetic switch
[Figure 60-40-18].
While pressing down on the starter pinion, tap the collar
Assembly: Reverse the order of disassembly. Before using a pipe (Item 1) [Figure 60-40-20].
reassembling, put grease on the following parts:
Overrunning Clutch
Retainer and Rollers
Steel Ball
Return Spring
Armature Bearing
Felt Washer
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STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-23
External Pinion (Cont’d)
Figure 60-40-21
B-14456
Armature Winding Ground Test: Use a circuit tester,

B-14454 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
Remove the snap ring (Item 1) [Figure 60-40-21]. armature is grounded and must be replaced.
After the snap ring is removed, the pinion, overrunning Figure 60-40-24
clutch, shaft, washer, and spring can be removed.
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,
B-14455 replace the armature.
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.
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Inspection And Repair (Cont'd)
ARMATURE (Cont'd)
1
Figure 60-40-25
B-14460
Measure the segment mica depth (Item 1) [Figure 60-40-

27].
B-14458 Service Limit - 0.008 in. (0,2 mm)
If it is worn, undercut the segment mica.

Commutator Run-Out Test: Check the commutator run-
out as shown in [Figure 60-40-25]. Check the commutator surface for burned spots which
usually indicates an open-circuit, and correct it using
Service Limit - 0.02 in. (0,5 mm) #400 sand paper.
If the commutator exceeds the service limit, repair as Figure 60-40-28

needed.
Figure 60-40-26
B-14461
B-14459 Check the bearings for wear and damage [Figure 60-40-
28].
Measure the commutator outer diameter [Figure 60-40- If the bearings are worn or damaged, they should be
26]. replaced.
Service Limit - 1.38 in. (35 mm)
If it is worn, replace the armature.
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ARMATURE (Cont’d)
Figure 60-40-29
Press
Bearing B-14463
Field Windings Continuity Test: Use a circuit tester, touch

Armature one probe to the wire and the other probe to the brush
[Figure 60-40-31]. There should be continuity. If there is
B-14439 no continuity, the field windings are open-circuited.
Replace the field windings.

Use a press as shown in [Figure 60-40-29], replace the
worn or damaged bearing(s). BRUSH AND BRUSH HOLDER:
FIELD WINDINGS: Figure 60-40-32
Figure 60-40-30
B-14464
B-14462
Measure the brush length.
Check the field windings for wear and damage. Service Limit - 0.512 in. (13 mm)
Check all the connections for clean and tight solder If it exceeds the limit, replace the brush holder or field
joints. windings assembly.
Field Winding Ground Test: Use a circuit tester, touch Check brush springs, for damage or rust. Replace as
needed.
one probe to the field winding end of the brush and the
other probe to the surface of the field windings housing Brush Holder Insulation Test: Use a circuit tester, touch
[Figure 60-40-30]. There should be no continuity. If there one probe to the positive brush holder plate and the other
is continuity, the field windings are grounded. probe to the holder plate [Figure 60-40-32]. There
should be no continuity. If there is continuity, replace or
Replace the field windings. repair.
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OVERRUNNING CLUTCH: C 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: C....C-Terminal to which the wire from the field windings
is connected.
NOTE: Each test should be performed a short time (3
to 5 seconds) to prevent the magnetic switch 50....50-Terminal to which the wire from the starting
winding from burning. Each test should be switch or stator relay is connected.
performed with 12 volts.
Pull-In Test: Connect the wires as shown in [Figure 60-

40-34]. When connecting Terminal C and M.T. are
closed, the pinion should engage.
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STARTER (NIPPONDENSO) (CONT’D)
No Load Test
Figure 60-40-37
Ammeter
50
M.T.
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
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863 Bobcat Loader
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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

A-1992 Removal And Installation on Page 60-20-1.)
Disconnect the S terminal on the starter (Item 1) [Figure

The key switch must be in the OFF position. 60-41-3].
The battery must be at full charge. Hold-In Test: Use circuit tester, touch one probe to the S
terminal (Item 1) [Figure 60-41-3] and one probe to the
The cable connections on the battery must be clean and mounting bolt (Item 2) [Figure 60-41-3] on the magnetic
tight. switch (solenoid). If there is no continuity replace the
magnetic switch (solenoid).
Connect a jumper wire between S terminal and BAT
terminal [Figure 60-41-1]. 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
Cranking
P-34674
Motor
Disconnect the negative cable from the battery. (See

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]. Pull-In Test: Use circuit tester, touch one probe to the S
terminal (Item 1) and one probe to the starter motor
If the starter turns, the defect is in the solenoid. 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.
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STARTER (VALEO) (CONT’D)
Figure 60-41-5
4
2
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.-lb. (24,4 - 32,5

N•m) 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

Reverse the removal procedure to install the starter.
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STARTER (VALEO) (CONT’D)
1. Starter 30
2. Shaft 13. Lever
3. Gear 14. Gear
4. Washer 15. Bracket
5. Shaft 16. Spring
6. Stop Ring 34 17. Gear
33
7. Lever 18. Stop
8. Holder 19. Stop Ring
13
9. Spring 20. Ball
10. Spring 21. Armature
36 22. Washer
11. Plate
8* 11* 23. Seal
12. Seal 9*
10* 24. Yoke
31
32 7*
21
15
14 19
16 20
17
19 18
5 8
14
6
29
1 4
3
28
2
27
35
25. Holder
26. Bracket
26 27. Ring
22
28. Bolt
29. Bolt
23 25 30. Switch
31. Seal
23 32. Bolt
33. Washer
34. Nut
24 35. Boot
36. Bracket
* Not serviceable parts B-16488
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STARTER (VALEO) (CONT’D) Figure 60-41-8
Disassembly and Assembly
Figure 60-41-6
1
1
1
2
P-34596
Remove the bolts (Item 1) [Figure 60-41-8] from the

P-34594 brush cover (Item 2) [Figure 60-41-8].
Remove the cover (Item 2) [Figure 60-41-8].

Remove the cable (Item 1) [Figure 60-41-6] from the
magnetic switch. Figure 60-41-9
Installation: Tighten the bolts to 63 - 129 ft.-lb. (7,1 - 2

14,6 N•m) 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 NOTE: The brushes are non-replaceable. If the

brushes are worn order a new brush holder
(for the negative brushes) and yolk (for the
Remove the armature, yoke, brush holder and rear positive brushes).
bracket assemblies (Item 1) [Figure 60-41-7] from the
front assembly (Item 2) [Figure 60-41-7]. Remove the brush holder (Item 3) [Figure 60-41-9] from
the end of the armature.
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].
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].
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Disassembly and Assembly (Cont'd)

1
Figure 60-41-10
2
3
2 P-34600
Inspect the magnetic switch (Item 1) [Figure 60-41-12],

P-34598 the spring (Item 2) [Figure 60-41-12],and the plunger
(Item 3) [Figure 60-41-12] for wear and replace as
needed.
Remove the armature (Item 1) [Figure 60-41-10] from
the frame. 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

magnetic switch.
Installation: Tighten bolts to 34 - 69 ft.-lb. (3,8 - 7,8 N•m)

torque.
Remove the front assembly (Item 2) [Figure 60-41-11]

from the magnetic switch (Item 3) [Figure 60-41-11].
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Disassembly and Assembly (Cont'd)
Figure 60-41-14
1
3
2
2 2 4
P-34604
1 Remove the snap ring (Item 3) [Figure 60-41-15] &

P-34602 [Figure 60-41-16]
Remove the retainer (Item 2) [Figure 60-41-15] &

Remove the rubber retainer (Item 1) [Figure 60-41-14]. [Figure 60-41-16] and pinion (Item 1) [Figure 60-41-15]
& [Figure 60-41-16].
Remove the planetary gears (Item 2) [Figure 60-41-14]
and inspect for damage. Remove the spring (Item 4) [Figure 60-41-16].
Figure 60-41-15 Installation: Inspect all parts for wear and replace as
needed.
3 2
P-34603
Press down on the pinion (Item 1) [Figure 60-41-15] &

[Figure 60-41-16] and retainer (Item 2) [Figure 60-41-
15] & [Figure 60-41-16].
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Inspection And Repair
Figure 60-41-17
N-00997
Armature Winding Continuity Test: Use a circuit tester,

B-14455 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,
Inspect the brush cover for discoloration, indication the replace the armature.
starter has been overheated.
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 run-

out as shown in [Figure 60-41-20].
Service Limit - 0.003 in. (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.
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Figure 60-41-21
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 60-41-
21]. Field Winding Ground Test: Use a circuit tester, touch
one probe to the field winding end of the brush and the
Service Limit - 0.012 in. (0,3 mm) other probe to the surface of the frame [Figure 60-41-
22]. There should be no continuity. If there is continuity,
If it is worn, replace the armature. the field windings are grounded.
Check the commutator surface for burned spots which Replace the frame.
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.
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STARTER (VALEO) (CONT’D) No Load Test
Inspection and Repair (Cont'd) Figure 60-41-25
Figure 60-41-24 Ammeter
S
M.T.
Starter B-14440
N-15006
The following test should be done after reassembling the
starter:
Inspect the brushes for wear and damage.
Clamp the starter in a vise. Using a 12 volt battery and
Replace the brush holder and yoke if the brushes need ammeter, connect the positive wire of the battery, and the
replacement. ammeter to the terminal [Figure 60-41-25]. Connect the
negative wire to the starter body. Using a jumper wire,
Check brush spring, for damage or rust. Replace as connect the S terminal to the main terminal.
needed.
The starter should show smooth and steady rotation
Brush Holder Insulation Test: Use a circuit tester, touch immediately after the pinion is engaged, it should draw
one probe to the positive brush holder plate and the other less than the specified current.
probe to the holder plate [Figure 60-41-24]. There
should be no continuity. If there is continuity, replace or Service Limit - 1150 Amp. Maximum @ Stall Condition
repair.
Clean all parts and apply high temperature grease to the
armature bearing, return spring, steel ball, over running
clutch, and idler gear rollers.
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863 Bobcat Loader
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INSTRUMENT PANEL Figure 60-50-1
Left Panel 2
The left instrument panel is the same for both Standard 1

3
and the Deluxe Instrument Panels [Figure 60-50-1]. 6 7 8
4 5
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 60-50- 13
1]. If more than one SERVICE CODE is present, the 9 10 11 12
codes will scroll on the HOURMETER / CODE DISPLAY. 14 B-15551
Ref No Description Function / Operation

1 TEMPERATURE GAUGE Shows the engine coolant temperature.
2 HOURMETER / CODE DISPLAY / HOURMETER - Records operating hours of loader. CODE DISPLAY -
GLOWPLUG COUNTDOWN Displays numeric SERVICE CODES* relating to the loader monitoring system.
COUNTDOWN - Glow Plug time remaining.
3 FUEL GAUGE Shows the amount of fuel in the tank.
4 LIGHTS / HOLD FOR CODES LIGHTS - Press once for FRONT LIGHTS. Press a second time for FRONT
AND REAR lights. Press a third time to turn all lights off. HOLD FOR CODES -
Press and hold two seconds for display of SERVICE CODES* (Item 2) [Figure
60-50-1]. (CODES* show only when there is an error found by loader
monitoring system.)
5 BUCKET POSITIONING (Option) Press to engage the BUCKET POSITIONING function. Press again to
disengage. Press and hold 2 seconds to view BASE or SHTDN
( SHUTDOWN) feature in HOURMETER / CODE DISPLAY.
ATTACHMENT AUXILIARY HYDRAULICS
6 HIGH FLOW (Option) Press to engage the HIGH FLOW auxiliary hydraulics. Press again to
disengage.
7 MAXIMUM FLOW / VARIABLE FLOW Press once to engage the VARIABLE FLOW auxiliary hydraulics. Press a
second time to engage MAXIMUM FLOW. Press a third time to disengage all
auxiliary hydraulics. [VARIABLE FLOW allows for slow-to-fast movement of
auxiliary functions (The farther you move the switch, the faster the movement
of auxiliary functions.) MAXIMUM FLOW allows for only fast movement.]
8 AUXILIARY PRESSURE RELEASE 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.
10 SEAT BAR The light comes ON when the seat bar is down.
11 LIFT & TILT VALVE The light comes ON when the seat bar is down and the PRESS TO OPERATE
Button is pressed. The lift and tilt functions can be operated when the light is
ON.
12 TRACTION The light comes ON when the seat bar is down, engine is running, and the
parking brake is released. The loader can be moved forward or backward
when the light is ON.
13 TRACTION LOCK OVERRIDE (Functions Only When Seat Bar Is Raised And The Engine Is Running)
Press to unlock the brakes. Allows you to use the steering levers to
move the loader forward or backward when using the backhoe
attachment or for loader service. (See TRACTION LOCK OVERRIDE
Page 60-01). Press a second time to lock the brakes.
14 ALARM The ALARM beeps when there is an Error, WARNING or SHUTDOWN
condition.
* See ELECTRICAL SYSTEM SERVICE MANUAL for further description of SERVICE CODES.
SHUTDOWN feature only in Deluxe Right Panel or Factory Option with Standard Panel.
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INSTRUMENT PANEL IDENTIFICATION (CONT’D) Figure 60-50-2
Right Panel - Standard Instrument Panel (With Key 15 17 19 21 23 25 27

Switch)
The right instrument panel shown [Figure 60-50-2] is the

Standard Panel.
16 18 20 22 24 26 28
The table below shows the Icons and other components or

of the Right Standard Panel.
B-15552
OPTION ICON/
REF. FUNCTION ALARM CODE CONDITION DESCRIPTION
OR STD. LIGHT
Advanced Hand Opt. ON 3 Beeps * Error Error with Advanced Hand Controls (AHC).
15 Controls (AHC)
or
Advanced Opt. ON 3 Beeps * Error Error with Advanced Control System (ACS).
Control System
(ACS)
Attachment Control Std. ON --- - --- Electrical controlled attachment is present.
Device (ACD) Std. FLASHING 3 Beeps * Error Error with Attachment Control Device (ACD).
16
General Std. ON 3 Beeps * Error Error with one or more engine or hydraulic functions.
Warning Std. ON 3 Beeps * WARNING Engine speed high or in shutdown.
17 Std. FLASHING Continuous * ◆SHUTDOWN Engine speed very high. Engine will stop in 10 seconds.
High Std. ON --- - --- Light is ON when High Range is activated.
Range Std. ON 3 Beeps * Error Solenoid error.
18
Fuel Std. ON 3 Beeps * Error Fuel level sender system fault.
Level Std. FLASHING 3 Beeps * WARNING Fuel level low.
19
Glow Std. ON --- - --- Glow plugs are energized.
Plugs Std. FLASHING 3 Beeps * Error Error with glow plugs.
20
System Voltage Std. ON 3 Beeps * WARNING Voltage low, high or very high.
21
Seat Belt Std. ON --- - --- Light stays on for 45 seconds to remind operator to fasten seat belt.
22
Engine Std. ON 3 Beeps * Error Engine Oil Pressure sender out of range.
Oil Pressure Std. ON 3 Beeps * WARNING Engine oil level low.
23 Std. FLASHING Continuous * ◆SHUTDOWN Engine oil pressure very low. Engine will shutdown in 10 seconds.
Hydrostatic Std. ON 3 Beeps * Error Hydraulic oil pressure sender out of range.
Charge Std. ON 3 Beeps * WARNING Hydraulic oil pressure low.
24 Pressure Std. FLASHING Continuous * ◆SHUTDOWN Hydraulic charge pressure very low. Engine will stop in 10 seconds.
Engine Std. ON 3 Beeps * Error Engine coolant sender out of range.
Coolant Std. ON 3 Beeps * WARNING Engine coolant temperature high.
25 Temperature Std. FLASHING Continuous * ◆SHUTDOWN Engine coolant temperature very high. Engine will stop in 10 seconds.
Hydraulic Std. ON 3 Beeps * Error Hydraulic oil temperature out of range.
Oil Std. ON 3 Beeps * WARNING Hydraulic oil temperature high.
26 Temperature Std. FLASHING Continuous * ◆SHUTDOWN Hydraulic oil temperature very high. Engine will stop in 10 seconds.
Engine Std. ON 3 Beeps * Error Air filter switch not connected.
Air Filter Std. FLASHING 3 Beeps * WARNING Air filter with high restriction.
27
Hydraulic Std. ON 3 Beeps * Error Hydraulic filter switch not connected.
Filter Std. FLASHING 3 Beeps * WARNING Hydraulic filter with high restriction.
28
29 Key Switch - - - - - Used to start and stop the engine.
(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
863 Bobcat Loader
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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 B-16656

you to select items from the Display Panel and scroll
through screens.
The first screen you will see on your new loader will be as
Figure 60-50-3 shown in [Figure 60-50-4].
When this screen is on the display you can enter the

password and start the engine or change the Display
Panel setup features.
1 3
NOTE: Your new loader (with Deluxe Instrument
2 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
4 SERVICE MANUAL.) Keep your password in a
safe place for future needs.
6 5 B-15553 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]
4. Keypad: The numeric keypad (Item 4) [Figure 60-50-
3] has two functions: Press and hold the START Button (Item 6) [Figure 60-
50-3] until the engine starts.
(a) To enter a number code (password) to allow
starting the engine (Keyless Start). 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.
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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 Description
B-16655
LOCK / UNLOCK: Allows machine to be
locked / unlocked. You must lock machine
Use the Keypad to select the number of the language to activate security system.
[Figure 60-50-5]. When system is unlocked, the user can
press RUN / ENTER then press START
Press EXIT. The screen will return to [Figure 60-50-4]. to begin operation.
You can then enter the password and start the engine. A valid password will need to be entered
at startup to run a locked machine.
TOOL / SETUP: Access system options.
Use to set clock, check system warnings,

select language, set passwords, etc.
HELP: Access help on current menu
? item.
EXIT EXIT returns you to previous level menu.
11:23 CLOCK / JOB CLOCK: Press to clear or
0.0 lock job clock; TOOL / SETUP to set time.
UP ARROW: Goes backward one
screen. DOWN ARROW: Goes forward
one screen.
OUTLINE ARROWS: No screen avail-
able (backward / forward).
SELECTION ARROW: Use to select

menu item.
Goes to the NEXT screen series.
NEXT EXAMPLE: The next Active Warning
screen.
INFO Goes to more information about an
attachment.
YES/NO Answer yes/no to current setup question.
CLEAR Removes previously installed password.
SET Set accepts current installed password.
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INSTRUMENT PANEL (CONT’D) Passwords
Deluxe Panel Setup For security purposes, your dealer may change the
Display Options password and also set it in the locked mode. Your
dealer will provide you with the password.
Owner Password:
Press Allows for the full use of the loader and to setup the
TOOL/SETUP 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.
User Password:
Allows starting and operating the loader; cannot
Press change password or any of the other setup
LOADER FEATURES
features.
Changing The Password

Right Instrument Panel
Display Screen
Press
DISPLAY OPTIONS
Press
TOOL / SETUP
Press PASSWORD
UTILITIES
Press
ADJUST CONTRAST
Press
Press MODIFY OWNER
or
UP or Down MODIFY USER
Arrow to
change contrast.
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.
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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
Enter Password on Hydraulic Charge Pressure
Keypad Hydraulic Oil Temperature
System Voltage
Engine Speed
Press Enter to
Continue
The Display Panel is easy to use. Continue to set
your own preferences for running / monitoring your
Re-enter new Bobcat Loader.
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.
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INSTRUMENT PANEL (CONT’D)
Option And Field Accessory Panels
1 2 3 4 5 6
POWER
WIPER
FRONT
WIPER
REAR
USED
PLUG
USED
USED
NOT
NOT
NOT
SIDE
CONSOLE
9
TURN SIGNAL
7 INDICATORS 10 11
8 HAZARD ROTATING
POWER
BOB-TACH NOT USED LIGHTS BEACON
Early Models
FRONT
CENTER 12 9
PANEL 11
POWER TURN SIGNAL ROTATING
BOB-TACH INDICATORS
13 10 BEACON
Later Models 8 HAZARD
PARKING
NOT USED BRAKE LIGHTS
7 14
ADVANCED
CONTROL NOT USED
SYSTEM (ACS) b-16642 -
b-16641
b-15891 updated
Side Console
Ref.
No. Description Function / Operation
1 POWER PLUG Provides a 12V receptacle for accessories.
2 NOT USED ---
3 FRONT WIPER 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.
4 REAR WIPER Press the bottom of the switch to start the rear wiper. Press the top of the
switch to provide washer fluid to clean the rear window.
5 NOT USED ---
6 NOT USED ---
Front Center Panel
7 ADVANCED CONTROL
Press the top to select Hand Controls; bottom to select Foot Controls.
SYSTEM (ACS)
8 NOT USED ---
9 TURN SIGNAL
Indicates left or right TURN SIGNALS are ON.
INDICATORS
10 HAZARD LIGHTS Press the left side to turn the HAZARD LIGHTS ON; right side to turn OFF.
11 ROTATING BEACON Press the left side to turn the ROTATING BEACON ON; right side to turn OFF.
12 POWER BOB-TACH 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.
13 PARKING BRAKE Press the top to engage the PARKING BRAKE; bottom to disengage.
14 NOT USED ---
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INSTRUMENT PANEL (CONT’D) Ignition Switch Removal And Installation (Standard
Panel)
Standard Panel Removal And Installation (Right Side)
Figure 60-50-8
Figure 60-50-6
N-20140
P-21769
Disconnect the key switch wiring harness (Item 1)[Figure

Remove the three mounting bolts (Item 1) [Figure 60-50- 60-50-8] from the back of the control panel.
6].
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
1
P-21769
Remove the ignition key (Item 1) [Figure 60-50-9] from

the switch. Remove the ignition switch retaining nut (Item
N-20158 2) [Figure 60-50-9] from the switch.
Pull the right instrument panel down and disconnect the

the panel.
Remove the panel from the loader cab.
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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

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)
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 60-50-

11].
Installation: Be careful to not overtighten the instrument

panel mounting bolts to prevent stripping of the threaded
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INSTRUMENT PANEL (CONT’D) Alarm Removal and Installation
Standard & Deluxe Panel Removal And Installation Remove the left side instrument panel.
(Left Side)
Figure 60-50-16
Figure 60-50-14
N-20144
N-18409
Remove the retaining nut (Item 1) [Figure 60-50-16]

Remove the three mounting bolts (Item 1) [Figure 60-50- from the loader alarm.
14].
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 Bulb Removal And Installation
Remove the left side instrument panel. (See Standard &
Figure 60-50-15 Deluxe Panel Removal And Installation (Left Side) on
Page 60-50-10)
Figure 60-50-17
2
1 1
N-20165
Pull the left instrument panel down and disconnect the

N-20145
the loader alarm.
Remove the two light bulb covers (Item 1) [Figure 60-50-
Disconnect the wire harness connector (Item 2) [Figure 17] from the back of the instrument panel.
60-50-15] from the loader instrument panel.
NOTE: The wiring harness (Item 3) [Figure 60-50-15] is

an optional accessory harness.
Remove the instrument panel from the loader.
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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.
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LIGHTS Figure 60-60-3
Front Removal And Installation
Open the rear door.
Disconnect the negative (-) cable from the battery. (See

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
N-19349
Remove the bulb assembly (Item 1) [Figure 60-60-2]

from the light housing by turning bulb assembly a 1/4
turn.
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LIGHTS (CONT’D) Figure 60-60-5
Rear Removal And Installation
Figure 60-60-4
1 2
N-19339
Using care press the rear light and housing from the door
N-19655 [Figure 60-60-5].
Reverse this procedure for installation.

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.
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BOBCAT CONTROLLER
Identification Chart (S/N 514450763 & Below)
TS-01941
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BOBCAT CONTROLLER (CONT’D)
Identification Chart (S/N 514450764 & Above)
41 50 41
50
40 31 40 31
30 21 30 21
20 11 20 11
10 1 10 1
9 8 7 6 5 4 3 2 9 8 7 6 5 4 3 2
J1 J2
Controller
Harness Connector View Harness Connector View
41 50 41 50
31
J1 40 31 J2 40
21 30 21 30
11 20 11 20
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
V-171/V-17
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BOBCAT CONTROLLER (CONT’D)
Identification Chart (S/N 514450764 & Above) (Cont’d)
Harness Connector View
41 50
J1
1400 8000 X 9800 X X 3420 7200 3520 X
31 X 8150 1130 9700 X 8550 3500 2100 6320 8110

40
21 X 4150 3010 9600 4730 4470 X 1120 4450 8210
30
11 X 8250 1110 9500 3400 6510 4200 4460 6210 8800
20
X X 3430 4910 X X X 6410 8510 4110
1 2 3 4 5 6 7 8 9 10
Harness Connector View
41 4410 9410 4640 9340 3920 4500 X 3300 X X

50
31 X 4420 X 9350 3910 J2 4840 X 2110 X 4940
40
21 4340 4430 9400 1900 3900 4830 X 3100 4320 4930
30
11 9110 4440 X 1200 9200 4820 X 3700 4310 4920
20
4360 X 4330 2900 9100 4810 9210 3200 4300 3600
1 2 3 4 5 6 7 8 9 10
V-172
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BOBCAT CONTROLLER (CONT’D) Figure 60-70-2

1 1
WARNING
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.
1 Installation: Tighten the connector bolts to 30 - 35 in.-lb.

(3,39 - 3,96 N•m) torque.
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
20-1.) 1
1
Lift and block the rear of the loader. (See LIFTING AND

on Page 10-30-1.)
S/N 514450764 & Above P-34842
Remove the left front side panel mount bolts (Item
1)[Figure 60-70-1].
Loosen the harness connectors mounting bolts (Item 1)
Remove the left front side panel. [Figure 60-70-3] from the Bobcat controller.
Remove the connectors.
NOTE: The connectors are keyed and will only plug

in one way.
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BOBCAT CONTROLLER (CONT'D)
Figure 60-70-4
P-34843
Loosen the three mounting bolts (Item 1) [Figure 60-70-

4] of the system controller.
Installation: Tighten the nuts to 12 - 14 ft.-lb. (17 - 19,2

N•m) torque.
Remove the system controller.
Reverse the above procedure to install the system

controller.
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DELUXE INSTRUMENTATION SERVICE CODES on Page 1] (See DELUXE INSTRUMENTATION
SERVICE CODES on Page 60-80-1.) for two seconds to
The hourmeter display on the Left Instrument Panel can view SERVICE CODES in the HOURMETER / CODE
change from engine hours to SERVICE CODES (See at DISPLAY display (Item 6) [Figure 60-50-1 on Page 1]
right.). These CODES help your dealership analyze (See DELUXE INSTRUMENTATION SERVICE CODES
monitored functions of your Bobcat loader. Some service on Page 60-80-1.). If more than one SERVICE CODE is
procedures must be performed ONLY BY QUALIFIED present, the codes will scroll on the HOURMETER /
BOBCAT SERVICE PERSONNEL. CODE DISPLAY.
The following word errors may also be displayed:
REPLY One or both instrument panel(s) not
communicating with the controller.
The Prefix, in the left two columns, followed by a Suffix, in INPUT The controller not communicating with the
the right two columns, will indicate a Function Error. left instrument panel.
CODE The controller is asking for a password.
EXAMPLE: 01-17 Plugged Air Filter (Deluxe Panel Only)
ERROR The wrong password was entered.
(Deluxe Panel Only)
Press and hold LIGHTS Button (Item 5) [Figure 60-50-1
SERVICE CODES
PREFIX FUNCTION SUFFIX ERROR DESCRIPTION
01 Air filter 02 Error ON (Detects ON when should be OFF)
02 Hydraulic Charge Filter 03 Error OFF (Detects OFF when should be ON)
03 Battery Voltage 04 In Error
04 Engine Oil Pressure 05 Short to Battery (Detects 12V & should not be)
05 Hydraulic Charge Pressure 06 Short To Ground
06 Engine Speed 07 Open Circuit (Not Grounded)
07 Hydraulic Oil Temperature 09 Low
08 Engine Coolant Temperature 10 High
11 Extremely High
09 Fuel Level
13 No Signal
11 Seat Bar Sensor
14 Extremely Low
12 Front Auxiliary PWM Switch (Proportional Control)
15 In Shutdown
13 Fuel Shutoff Solenoid - Secondary
16 Not Connected
14 Fuel Shutoff Solenoid - Primary 17 Plugged
15 Traction Lock Solenoid - Primary 18 Out Of Range
16 Traction Lock Solenoid - Secondary 21 Out of Range High
17 Lift and Tilt Valve Solenoid (Above detectable range of sensor)
18 Spool Lock Solenoid 22 Out Of Range Low
19 Bucket Positioning Solenoid (Below detectable range of sensor)
20 Two-Speed Solenoid (If Equipped) 23 Not Calibrated
21 Glow Plugs 28 Failure
22 Starter Output 31 Tilt Actuator Fault
32 Tilt Actuator Wiring Fault
23 Solenoid for Rear Female Coupler
33 Tilt Handle Wiring Fault
24 Solenoid for Rear Male Coupler
34 Tilt Actuator Not Calibrated
25 Rear Auxiliary Relief Solenoid
35 Tilt Handle Not Calibrated
26 Solenoid for Front Female Coupler
36 Lift Actuator Fault
27 Solenoid for Front Male Coupler 37 Lift Actuator Wiring Fault
28 Diverter Valve Solenoid 38 Lift Handle Wiring Fault
29 High Flow Auxiliary Solenoid 39 Lift Actuator Not Calibrated
31 Recovery Mode Failure (Loss of Power) 40 Lift Handle Not Calibrated
32 Advanced Hand Controls (AHC) 41 Invalid Frequency From Advanced Hand Controls (AHC)
Advanced Control System (ACS) 48 Multiple Controllers Present -Error
(Selectable Foot / Hand Controls 49 Lift Actuator Short To Ground
33 Constant Data (Stored Loader Information) 50 Tilt Actuator Short To Ground
34 Deluxe Panel Not Downgraded in Error 51 Lift Actuator Short To Battery
35 Two Speed Fan 52 Tilt Actuator Short To Battery
36 Attachment Control Device (ACD) Controller 53 Lift Handle/Pedal Short To Ground
80 ACD Output A 54 Tilt Handle/Pedal Short To Ground
81 ACD Output B 55 Lift Handle/Pedal Short To Battery
82 ACD Output C 56 Tilt Handle/Pedal Short to Battery
83 ACD Output D 57 Lift Actuator Reduced Performance
84 ACD Output E 58 Tilt Actuator Reduced Performance
85 ACD Output F 59 Lift Actuator Wrong Direction
60 Tilt Actuator Wrong Direction
86 ACD Output G
61 Handle Lock Short To Ground
87 ACD Output H
62 Handle Lock Short To Battery
Multiple SERVICE CODES and / or Abnormal Symptoms can be caused by
63 Pedal Lock Short To Ground
corroded or loose ground connection. Flashing instrument panel lights, alarm
64 Pedal Lock Short To Battery
beeping, front & rear lights flashing, low battery voltage, loose battery
65 Sensor Supply Voltage Out Of Range
connectors, could also indicate a poor ground. Check all grounds before
performing other diagnostics 66 Battery Out Of Range
67 Switch Moved While Operating
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BICS™ SYSTEM 2. Raise the Seat Bar fully. All four BICS lights (Items 1,
2, 3, & 4) [Figure 60-90-1] [PRESS TO OPERATE
Inspecting The BICS™ Controller (Engine STOPPED - LOADER, SEAT BAR, LIFT & TILT VALVE and
Key ON) TRACTION*] on left instrument panel should be OFF
[Figure 60-90-1].
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.
Inspecting The Traction Lock (Engine RUNNING)

1 2 3 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
WARNING the PRESS TO OPERATE LOADER Button.
AVOID INJURY OR DEATH 7. Engage the parking brake pedal and move the
The Bobcat Interlock Control System (BICS) must steering levers slowly forward and backward. The
deactivate the lift, tilt and traction drive functions. If it TRACTION lock should be engaged.
does not, contact your dealer for service. DO NOT
modify the system. NOTE: * The TRACTION light on the left instrument
W-2151-0394 panel will remain OFF until the engine is
started, the PRESS TO OPERATE LOADER
Button is pressed and the parking brake is
1. Sit in the operator's seat. Turn key ON (Standard
disengaged.
Panel), press RUN / ENTER Button (Deluxe Panel,
lower the Seat Bar and disengage the parking brake
Inspecting The Lift Arm Bypass Control
pedal. Press the PRESS TO OPERATE LOADER
Button. Three BICS lights (Items 1, 2, & 3) [Figure 60-
8. Raise the lift arms 6 feet (2 meters) off the ground.
90-1] [PRESS TO OPERATE LOADER, SEAT BAR,
Stop the engine.
and LIFT & TILT VALVE] on left instrument panel
should be ON [Figure 60-90-1].
Turn the lift arm bypass control knob clockwise 1/4 turn.
Pull up and hold the lift arm bypass control knob until the
lift arms slowly lower.
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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.
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BICS™ SYSTEM (CONT'D)
WARNING
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION#
All indicator lights flashing. 5
One of the indicator lights flashing. 1
Intermittent indicator lights. 2, 3, 4
SOLUTION SUGGESTIONS
1. Refer to BICS™ troubleshooting 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.
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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 6
location of BICS™ lights and Icons. Have service
procedures performed ONLY BY QUALIFIED BOBCAT
SERVICE PERSONNEL.
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 60-90-
2]. If more than one SERVICE CODE is present, the 2 4
3
codes will scroll on the HOURMETER / CODE DISPLAY. 1 B-15551
Effect on SERVICE CODES Means System Error

Indicator Operation of (See Your Bobcat Dealer for Service)
Light ON Light OFF
Light Loader When No. of Service
Light is OFF Causes
Flashes Code
1 PRESS TO PRESS TO Lift, tilt and ---- ---- ----
OPERATE OPERATE traction
LOADER Button LOADER Button functions will
is pressed. is not pressed. not operate.
2 Seat Bar is Seat Bar is up. Lift and tilt 2 11-05 Seat Bar sensor circuit shorted to battery
down. functions will voltage*.
not operate. 3 11-06 Seat Bar sensor circuit shorted to ground.
3 Control valve Control valve Lift, tilt and 1 17-07 Valve output circuit is open.
can be used. cannot be used. traction 2 17-05 Valve output circuit shorted to battery voltage*.
functions will 3 17-06 Valve output circuit shorted to ground.
not operate.
3 17-06 Controller not grounded or intermittent ground.
4 Loader can be Loader cannot Loader cannot 1 16-07 Traction lock hold solenoid circuit is open.
moved forward & be moved be moved 2 16-05 Traction lock hold solenoid circuit shorted to
backward forward and forward and battery voltage*.
backward. backward. 3 16-06 Traction lock hold solenoid circuit shorted to
ground.
5 15-02 Traction lock pull solenoid circuit is shorted to
battery voltage* - ERROR ON (Should be OFF).
6 15-03 Traction lock pull solenoid circuit ERROR OFF
(Should be ON).
SEAT BAR 2 LIFT & TILT VALVE 3 TRACTION 4 03-09
Continuous System voltage low
Flashing 03-10 System voltage high
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.
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SEAT BAR SENSOR
WARNING
assistance in locating and correcting BICS system Check for correct function after adjustments, repairs
W-2004-1285
PROBLEM SOLUTION #
Indicator light does not come ON when seat bar is lowered. 1, 2, 3, 4, 5
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.
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SEAT BAR SENSOR (CONT'D) Figure 60-100-3
Test
Figure 60-100-1
1
P-4698
If there is no power light (Item 1) [Figure 60-100-3] on

N-18463 the sensor tester, check the tester or wiring harness.
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
N-19558 sensor.
Disconnect the Sensor Tester.

Connect the Sensor Tester (Item 1) [Figure 60-100-2]
inline, to the seat bar sensor connectors. See inset Replace the Seat Bar Sensor. (See Removal And
[Figure 60-100-2]. Installation on Page 60-100-3.)
Turn the key to the ON position. DO NOT START THE If the above test passes, run the seat bar sensor BICS
ENGINE. 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.
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SEAT BAR SENSOR (CONT'D) Figure 60-100-7

2
Figure 60-100-5 1 3
N-19383
Remove the keyed plastic bushing (Item 1) [Figure 60-

N-19224 100-7], magnetic bushing assembly (Item 2) [Figure 60-
100-7] and sensor bracket (Item 3) [Figure 60-100-7].
Remove the seat bar (Item 1) [Figure 60-100-5] from the

loader. (See Removal And Installation on Page 50-10-1.)
Figure 60-100-6 IMPORTANT

Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095
Installation: Be sure the tabs on the pivot bushing are

3 positioned in the slotted hole (Item 1) [Figure 60-100-7]
of the seat bar
Inspect all parts for damage and wear and replace if

1 necessary.
Reverse the removal procedure to install the seat bar

sensor.
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.-lb.

(5,6 - 7,9 N•m) torque.
Remove the sensor mounting bolt (Item 3) [Figure 60-

100-6] and nut.
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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
BICS™ Circuit Test the Present position.
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
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.
The BICS™ seat bar indicator light (Item 1) [Figure 60-
Disconnect the seat bar sensor connector (Item 1) 100-10] should illuminate.
[Figure 60-100-8].
Figure 60-100-11
Figure 60-100-9
1
2
P-4699
P-4703
Move the toggle switch (Item 1) [Figure 60-100-11] on

Connect Sensor Tester (Item 1) [Figure 60-100-9] inline the sensor tester to the Absent position.
to the seat bar sensor connectors.
The Seat Bar light (Item 1) [Figure 60-100-10] should go
Turn the key to the ON position. DO NOT START THE off.
ENGINE.
If the above test fails, there is a problem with the Bobcat
If there is no power light on the sensor tester, check the controller or the wiring harness.
tester or wiring harness.
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TRACTION LOCK
WARNING
assistance in locating and correcting BICS™ system Check for correct function after adjustments, repairs
W-2004-1285
PROBLEM SOLUTION #
Traction lock stays engaged. 1, 2, 3, 4, 5, 6, 7
Intermittent activation of traction lock. 8, 9, 10
1. Make sure brake pedal is not engaged.
2. Maneuver loader to allow brake discs to move and remove pressure on the brake wedge so it
can retract.
3. If all lights indicate the brake should be released, but it doesn’t, check the brake 25 amp fuse.
4. When checking fuse, also check other fuses. Check the fuse block for correct orientation and
location of fuses. (See Electrical System Information, Page 60-01.)
5. To test the solenoid, the pull coil should be 0.4 - 0.5 ohm and the hold coil 10.5 - 11.0 ohm.
6. Check brake solenoid and cover mounting hardware for the correct torque.
7. Remove brake cover and check wedges for binding in the wedge guides.
8. Check wire connections for loose connector body.
9. Check for loose or bent pins in connectors.
10. Check for loose spade connectors in fuse holder.
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TRACTION LOCK (CONT’D) Figure 60-110-2
Removal And Installation (Single Speed)
2
1
WARNING
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 3
qualified technician. Use only genuine Bobcat N-19724
Company parts if repair is necessary.
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 60-
110-2] 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

on Page 10-30-1.)
3
1] from the electric solenoid mounting bracket.
Installation: Tighten the mounting bolts to 25 - 28 ft.-lb. N-20148

(34 - 38 N•m) torque.
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 60-

110-3] on the traction lock shaft (Item 4) [Figure 60-110-
3]. Install the collar (Item 2) [Figure 60-110-3] and
compression spring (Item 1) [Figure 60-110-3]
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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.
Inspecting The Control System (Two-Speed)

IMPORTANT
Figure 60-110-5
Failure to use Loctite® may allow the traction lock
assembly to loosen up which can cause damage to
the traction lock system.
I-2090-1095
Figure 60-110-4
4
2
3
2
1
1 N-18409
N-20211
Remove the shaft mounting bolt (Item 1) [Figure 60-110- 1 2 3 4

4], spring (Item 2) [Figure 60-110-4] and washer (Item 3) B-15551G
[Figure 60-110-4] from the assembly shaft (Item 4)
[Figure 60-110-4]. Remove the wedge (Item 5) [Figure
Fasten the seat belt, disengage the parking brake pedal,
60-110-4] and inspect all; parts for damage or wear.
press the PRESS TO OPERATE LOADER Button (Item
Replace if necessary.
1) [Figure 60-110-5] and raise the Seat Bar fully. Move
the steering levers slowly forward and backward. The
Installation: Thoroughly clean and dry the shaft
TRACTION lock (Item 2) [Figure 60-110-5] should be
mounting bolt (Item 1) [Figure 60-110-4], the shaft (Item
engaged. Lower the Seat Bar. Press the PRESS TO
4) [Figure 60-110-4] and wedge (Item 5) [Figure 60-110-
OPERATE LOADER Button (Item 1) [Figure 60-110-5].
4]. Use Loctite® 242 when assembling these parts to the
traction lock assembly.
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.
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TRACTION LOCK (CONT’D)
Inspecting The Control System (Two-Speed) (Cont’d)
Figure 60-110-6
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.
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ADVANCED HAND CONTROL SYSTEM (AHC) Figure 60-120-3
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 60-120-

1].
1
Handle Control Unit (Item 2) [Figure 60-120-1] (both
sides).
Figure 60-120-2
P-28360A
ACH error indicator (Item 1) [Figure 60-120-4].
NOTE: The AHC icon will illuminate when an error

1 (See Contents, Page 60-01.)
N-19112
863 Bobcat Loader

641 of 968
ADVANCED HAND CONTROL SYSTEM (ACH) (CONT’D)
B-16640
Device Pressure

To see what error occurred. Check the service code on the left instrument panel. (See DELUXE INSTRUMENTATION
SERVICE CODES on Page 60-80-1.)
863 Bobcat Loader

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ADVANCED HAND CONTROL SYSTEM (AHC) (CONT’D)
C-428
C-430
C-431
C-429
TS-1957
P/N PIN DESCRIPTION P/N PIN DESCRIPTION

C-430 CONNECTOR, METRI-PACK C-428 CONNECTOR, 8 WAY PLUG (LIFT) (TOP
Brown/Dk A SIGNAL FROM LIFT CONTROL Dk. Blue 3 HIGH REFERENCE TO RESISTIVE INPUTS
Green 4 OPEN
HANDLE INPUT Brown/White 5 LIFT SPOOL ACTUATOR MOTOR (-)
Purple/Yellow B FLOAT SWITCH ON/OFF 6 OPEN
Pink/Dk. Green C SIGNAL FROM TILT CONTROL 7 OPEN
HANDLE INPUT
C-429 CONNECTOR, 8 WAY PLUG (TILT) (BOT-
RESISTIVE INPUTS
TOM ACTUATOR)
RESISTIVE INPUTS
Lt. Blue/White 2 SIGNAL FROM TILT ACTUATOR
Dk Blue/White F LIFT LOW REFERENCE TO
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ADVANCE HAND CONTROL SYSTEM (AHC) Figure 60-120-6
(CONT’D)
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
WARNING 1
the lift arms are secured by an approved lift arm N-23236

W-2059-0598
Figure 60-120-7
Figure 60-120-5
3 2
1
N-23235
N-23234

Loosen the three bottom bolts (Item 1) [Figure 60-120- 7] from the controller.
5].
Remove the two top bolts (Item 2) [Figure 60-120-5], lift

and remove the right front panel (Item 3)[Figure 60-120-
5] from the loader.
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(CONT’D)
AHC Controller Removal And Installation (Cont’d)
Figure 60-120-8
1 1
1
P-13725 P-13732

connector.
N-23237
Figure 60-120-11
Remove the controller from the loader (Item 1) [Figure
60-120-8].
Handle Control Unit Connector

3 2
Figure 60-120-9 1
P-13733

1 Assembly: Install the wires into the connector as listed

N-17392 below [Figure 60-120-11]:
1 - Terminal - Red
The wire connector (Item 1) [Figure 60-120-9] can be 2 - Terminal - Black
removed from the handle control unit wires, use the 3 - Terminal - Green
following procedure.
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(CONT’D)
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-13725 P-13732

connector.
Figure 60-120-14
3 2 1
1
1
P-13735
N-23243

To remove the switch handle the connector (Item 1) [Figure 60-120-14] and pull the wire from the connector.
[Figure 60-120-12] must be removed from the wires, use
the following procedure. Installation: Install the wires into the conductor as listed
Right Control Lever Switch Handle

3 - Terminal - Pink/Green

1 - Terminal - Brown/Red
2 - Terminal - Brown/Black
3 - Terminal - Brown Green
863 Bobcat Loader

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ADVANCED HAND CONTROL SYSTEM (AHC) Installation: The wire colors of the control lever harness
(CONT’D) are as follows:
Switch Handle Removal And Installation (Cont’d) Right Switch Handle

1
Three-Pin Connector
2 B - Terminal - Pink/Black
Left Switch Handle

Ten-Pin Connector
connectors.
Figure 60-120-16
D - Terminal - Blank
F - Terminal - Yellow/Red
4 G - Terminal - Yellow/Green
1 H - Terminal - Blank
Three-Pin Connector
A - Terminal - Brown/Red
B - Terminal - Brown/Black
C - Terminal - Brown/Lt. Green
3
2
Two-Pin Connector
N-23245
A - Terminal - Orange/Blue
B - Terminal - Orange/White
3 & 4) [Figure 60-120-16] from the loader wiring harness Five-Pin Connector
wires the remove the switch handle from the control D - Terminal - Yellow
863 Bobcat Loader

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(CONT’D)
Switch Handle Removal And Installation (Cont’d)
Figure 60-120-17
2
2
N-17471
1

wiring harness assembly into the control handle, route
Roll the grip handle cover (Item 1) [Figure 60-120-17]
down.

Figure 60-120-18
N-17383

1) [Figure 60-120-18] from the steering lever.
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(CONT’D)
Remove the actuator. (See Actuator Removal And

Installation (In Loader) on Page 20-41-1.) 2
Figure 60-120-20
1 N-17742 N-17741


on the next page. The terminal numbers are written in the
N-18940 back of the connector (Item 2) [Figure 60-120-22].

Figure 60-120-21
2
1
N-18941

21].

21].

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ADVANCED HAND CONTROL SYSTEM (AHC)
(CONT’D)

gauge)
2 - Terminal - Green - Larger diameter wire (16
gauge)
gauge)
4 - Terminal - Open
6 - Terminal - Open
7 - Terminal - Open
gauge)
863 Bobcat Loader

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ADVANCED HAND CONTROL SYSTEM (AHC) (W/ Figure 60-121-3
PUSH BUTTON FLOAT)
Figure 60-121-1
1
1
P-13797
2
P-16536 N-22797 Figure 60-121-4
Steering Lever / Control Handle (Item 1) [Figure 60-121-

1].
Handle Control Unit (Item 2) [Figure 60-121-1]. 1
Figure 60-121-2
P-28360A

1 (See Contents, Page 60-01.)
N-19112
863,863H Bobcat Loader

651 of 968
(ADVANCED HAND CONTROL SYSTEM (ACH) (W/ PUSH BUTTON FLOAT) (CONT’D)
B-16640A
Device Pressure

B-16299

652 of 968
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

C-430 CONNECTOR, METRI-PACK C-428 CONNECTOR, 8 WAY PLUG (LIFT) (TOP
Brown/Dk A SIGNAL FROM LIFT CONTROL Dk. Blue 3 HIGH REFERENCE TO RESISTIVE INPUTS
Green 4 OPEN
HANDLE INPUT Brown/White 5 LIFT SPOOL ACTUATOR MOTOR (-)
Purple/Yellow B FLOAT SWITCH ON/OFF 6 OPEN
Pink/Dk. Green C SIGNAL FROM TILT CONTROL 7 OPEN
HANDLE INPUT
C-429 CONNECTOR, 8 WAY PLUG (TILT) (BOT-
RESISTIVE INPUTS
TOM ACTUATOR)
RESISTIVE INPUTS
Lt. Blue/White 2 SIGNAL FROM TILT ACTUATOR
Dk Blue/White F LIFT LOW REFERENCE TO

653 of 968
ADVANCE HAND CONTROL SYSTEM (AHC) (W/ Figure 60-121-6
PUSH BUTTON FLOAT) (CONT’D)

WARNING 1
the lift arms are secured by an approved lift arm N-23236

W-2059-0598
Figure 60-121-7
Figure 60-121-5
3 2
1
N-23235
N-23234

Loosen the three bottom bolts (Item 1) [Figure 60-121- 7] from the controller.
5].
Remove the two top bolts (Item 2) [Figure 60-121-5], lift

and remove the right front panel (Item 3)[Figure 60-121-
5] from the loader.

654 of 968
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].
N-23237 Figure 60-121-10
Remove the controller from the loader (Item 1) [Figure

60-121-8].
Handle Control Unit Removal And Installation

1
WARNING P-18142

121-10] from the handle control unit connector.
W-2059-0598

on Page 10-30-1.)

655 of 968
Figure 60-121-11
1 2
P-16580 P-18138
Remove the two plastic spacers (Item 1) [Figure 60-121-

13] and the metal spacer (Item 2) [Figure 60-121-13]
P-18143 from the control unit.
Figure 60-121-14
Remove the handle control unit connector (Item 1)
[Figure 60-121-11] from the clip.
NOTE: Pry out with a small screwdriver and push the

connector down.
Figure 60-121-12
1 P-16574
1
Remove the top mounting bolt (Item 1) [Figure 60-121-
14] 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.

656 of 968
ADVANCED HAND CONTROL SYSTEM (AHC) (W/ Handle Control Unit Connector
Figure 60-121-17
Figure 60-121-15
1
1
3
P-16578
3 2
P-16576 The wire connector (Item 1) [Figure 60-121-17] can be
removed from the handle control unit wires, use the
following procedure.
Remove the handle control unit (Item 1) [Figure 60-121-
15] from the handle assembly. 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 P-13732
1
Remove the wedge (Items 1) [Figure 60-121-18] from

the connector.
P-18141
Installation: When installing the control unit into the

proper return of the control handle to neutral.

657 of 968
Handle Control Unit Connector (Cont’d)
Figure 60-121-19
3 2
1
1
1 P-13725 P-13732

connector.
P-13733
Figure 60-121-22

1 - Terminal - Red
2 - Terminal - Black 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

Right Steering Lever Switch Handle

3 - Terminal - Pink/Green
Left Steering Lever Switch Handle

1
2 - Terminal - Black/White
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:

658 of 968
ADVANCED HAND CONTROL SYSTEM (AHC) (W/ Installation: The wire colors of the control lever harness
PUSH BUTTON FLOAT) (CONT’D) are as follows:
Switch Handle Removal And Installation (Cont’d) Right Switch Handle

1 E - Terminal - Dk. Green
K - Terminal Blank
Three-pin connector
2 B - Terminal - Pink/Blank
Left Switch Handle

Figure 60-121-24
Ten-Pin Connector
A - Terminal- Orange
4 D - Terminal - Purple
1 F - Terminal - Tan
G - Terminal - Pink
H - Terminal - Blank
K - Terminal Blank
3
2 Three-Pin Connector
A - Terminal - Red/White
N-23245
B - Terminal - Black/White
C - Terminal - Purple/White
2) [Figure 60-121-23] from the loader wiring harness. Two-Pin Connector
A - Terminal - Black
Disconnect the left switch handle connectors (Items 1, 2, B - Terminal - Black
3 & 4) [Figure 60-121-24] from loader wiring harness
connectors. Five-Pin Connector
A - Terminal - Dk. Green
Remove the connector locks and connectors from the B - Terminal - Brown
wires to remove the switch handle from the steering C - Terminal - Blank
handle. D - Terminal -Yellow

659 of 968
ADVANCED HAND CONTROL SYSTEM (AHC) (PUSH Figure 60-121-27
BUTTON FLOAT (CONT’D)
Switch Handle Removal And Installation (Cont’d)
Figure 60-121-25
2 2
P-18139
1
wiring harness assembly into the steering handle, route
Roll the pistol grip handle cover (Item 1) [Figure 60-121-
25] down.

Figure 60-121-26
N-22784


660 of 968
ADVANCE HAND CONTROL SYSTEM (AHC) (W/ Figure 60-121-30

Installation (In Loader) on Page 20-41-1.) 2
Figure 60-121-28
1
N-17742 N-17741


N-18940 the connector (Item 2) [Figure 60-121-30].

Figure 60-121-29
2
1
N-18941

29].

29].


661 of 968
ADVANCED HAND CONTROL SYSTEM (AHC) (W/

gauge)
2 - Terminal -Green - Larger diameter wire (16 gauge)
gauge)
4 - Terminal - Open
6 - Terminal - Open
7 - Terminal - Open
gauge)

662 of 968
ADVANCED CONTROL SYSTEM (ACS) ADVANCED Figure 60-122-3
HAND CONTROL
Figure 60-122-1
1
2
1
P-21767
ACS Controller (Item 1) [Figure 60-122-3].
P-16536 P-24909 NOTE: The calibration procedure must be followed

Control Handle (Item1) [Figure 60-122-1]. Calibration Of The ACS System on Page 60-
123-15.)
NOTE: The calibration procedure must be followed Figure 60-122-4

Calibration Of The ACS System on Page 60-
123-15.)
Figure 60-122-2 1
P-21769A

1 occurs. The error is stored as a service code.
P-24203
(See DELUXE INSTRUMENTATION SERVICE
CODES on Page 60-80-1.)

123-15.)
863 Bobcat Loader

663 of 968
ADVANCED CONTROL SYSTEM (ACS) ADVANCED
HAND CONTROL (CONT'D)
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 illuminate the icon.
The following list shows the probable causes when the icon is illuminated.
Control Warning Voltage Pressure Coolant
System Temperature
Attachment Hydraulic Hydraulic Oil Hydraulic

Two Speed Glow Plugs Seatbelt Filter
Control Charge Temperature
Device Pressure
Advanced Control System

Errors - lights soild with 3 beeps 32-54 - Tilt handle/pedal short to ground
32-04 - ACS in error 32-55 - Lift handle/pedal short to battery
32-23 - ACS not calibrated 32-56 - Tilt handle/pedal short to battery
32-31 - Tilt actuator fault 32-57 - Lift actuator reduced performance
32-34 - Tilt actuator not calibrated 32-58 - Tilt actuator reduced performance
32-35 - Tilt handle/pedal not calibrated 32-59 - Lift actuator wrong direction
32-36 - Lift actuator fault 32-60 - Tilt actuator wrong direction
32-39 - Lift actuator not calibrated 32-61 - Handle lock short to ground
32-62 - Handle lock short to battery
32-40 - Lift handle/pedal not calibrated 32-63 - Pedal lock short to ground
32-49 - Lift actuator short to ground 32-64 - Pedal lock short to battery
32-50 - Tilt actuator short to ground
32-65 - Sensor supply voltage out of range
32-51 - Lift actuator short to battery
32-66 - Battery out of range
32-52 - Tilt actuator short to battery
32-67 - Switch flipped while operating
32-53 - Lift handle/pedal short to ground
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Controller, Connector And Wire Identification
G H
J J1 J3
F K
E A
D B
J3 C H
G
F J
J2
K
F E
G D A
E H B
A C
B J2
D
J1
C
J3
J1 J2

J1 CONNECTOR, METRI-PACK J3 CONNECTOR, METRI-PACK
Orange A 5V HALL EFFECT SUPPLY Red A TILT ACTUATOR FORWARD
Orange B SWITCHED AHC POWER Red/White B UNSWITCHED AHC POWER
Green c HAND/FOOT INPUT Red/White C UNSWITCHED AHC POWER
Purple D CAN SIGNAL HIGH AHC Black D LIFT ACTUATOR REVERSE

Purple E CAN SIGNAL LOW AHC Green E HANDLE LOCK POWER
Purple F CAN SHEILD AHC Red F LIFT ACTUATOR FORWARD
Black G AHC GROUND Green G PEDAL LOCK POWER
Black H AHC GROUND Black H AHC GROUND
J2 CONNECTOR, METRI-PACK Black J AHC GROUND
A OPEN Black K TILT ACTUATOR REVERSE
B OPEN
C OPEN
D OPEN
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
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665 of 968
ACS Controller Removal And Installation
Figure 60-122-5
1
P-21840

P-21839
Loosen the bottom bolts and remove the top bolt. NOTE: The calibration procedure must be followed
Remove the right front panel (Item 1) [Figure 60-122-5] ACS Controller. (See Calibration Of The ACS
from the loader. System on Page 60-123-15.)
Figure 60-122-6
P-21843

[Figure 60-122-6] from the controller.
863 Bobcat Loader

666 of 968
Figure 60-122-8
1
3
1 2
1 P13733

P16578
removed from the handle sensor wires, use the following 1-Terminal - Red
procedure. 2-Terminal - Black
3-Terminal - Green
Figure 60-122-9
1
1
P13725 P13732

connector.
863 Bobcat Loader

667 of 968
Switch Handle Removal
NOTE: Switch handle can be removed and installed

while in loader.
Figure 60-122-11
1
3
2
P-13735
2 1 Using a pointed tool, press down on the tab (Item 1)

Figure 60-122-14
P-24909


122-11] from the blank handle connector.
1
Figure 60-122-12
P-13725 P-13732

harness connector (Black) that connects to the blank
1 handle connector (Item 2) [Figure 60-122-11].
P-13725 P-13732

harness connector (Gray) that connects to the handle
sensor connector.
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668 of 968
Switch Handle Removal (Cont'd)
Figure 60-122-15
2
1
4
1 3
3
P-34035
2
1
3 & 4) [Figure 60-122-17] from the loader wiring harness
P-13735 connectors.
Use a pointed tool, press down on the tab (Item 1)

Figure 60-122-16
P-34034

connectors.
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669 of 968
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 60-122- Figure 60-122-21
18] down.

Figure 60-122-19 Tape 1/2 of Wires

Tape back 1/2 of Wires
P-24233
P-21699
1
When installing the new switch handle, tape the wire

terminals together.
N-22784 The switch handle comes with a 6 in. 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
Pull the switch handle and wiring harness assembly (Item through handle and control lever tube.
NOTE: Leave all the other heat shrink tube on the
Cut the wires (Item 2) [Figure 60-122-19] below the wires for protection.
switch handle and remove switch handle.
Tape half of the wires back and half forward [Figure 60-
NOTE: Only cut the wires if the switch handle is bad 122-21] to keep the harness small enough to route
and needs replacement. If the switch handle is through the control lever tube.
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.
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ADVANCED CONTROL SYSTEM (ACS) ADVANCED Inspect the wire terminal tabs (Item 2) [Figure 60-122-
HAND CONTROL (CONT'D) 23] 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 Connector
1 A-Terminal - Orange
B-Terminal - White
C-Terminal - White/Black
D-Terminal - White/Red
E-Terminal - Dk. Green
F-Terminal - White/Lt. Green
G-Terminal - Yellow/Red
H-Terminal - Lt. Green
J-Terminal - Yellow
K-Terminal - Orange/Black
Three-Pin Connector
P-21700 A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White
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
Ten-Pin Connector
casting, along side the handle sensor and into the control
A-Terminal - Orange
lever tube.
B-Terminal - Dk. Blue
C-Terminal - White
NOTE: Do not pull the wire harness tight, allow a
D-Terminal - Purple
small amount of slack or slight bend at the
E-Terminal - Yellow/Red
handle pivot area. Verify the control handle
F-Terminal - Tan
returns to neutral position.
G-Terminal - Pink
H-Terminal - Orange/Black
Figure 60-122-23
J-Terminal - Blank
K-Terminal - Blank
Three-Pin Connector
A-Terminal - Red/White
2 C-Terminal - Purple/White
Two-Pin Connector
A-Terminal - Black
B-Terminal - Red
1
Five-Pin Connector
A-Terminal - Dk. Green
B-Terminal - Brown
P-21695
C-Terminal - Blank
D-Terminal - Yellow
Remove tape from wires for installation and install the 6 E-Terminal - Blank
in. of heat shrink tube (Item 1) [Figure 60-122-23]
approximately 3 in. into the control lever. Apply heat to
the exposed heat shrink tube.
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Switch Handle Installation (Cont'd)
Figure 60-122-24
1 1
3
2
P-13735
Install the wires into the connectors as listed below:

2
P-34034 Left and Right Control Lever Switch Handle [Figure 60-
122-26]
1-Terminal - Red/White
Figure 60-122-25 2-Terminal - Black/White
3-Terminal - Purple/White
Figure 60-122-27
1
1
3
2
P-34035
Connect the handle harness connectors (Item 1) [Figure

P-13735
60-122-24] & [Figure 60-122-25] to the loader harness
connectors.
Left and Right Control Lever Switch Handle [Figure 60-
122-27]
1-Terminal - Yellow/Red
2-Terminal - Open
3-Terminal - Orange/Black
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ADVANCED CONTROL SYSTEM (ACS) ADVANCED Actuators Disassembly and Assembly
Switch Handle Installation (Cont'd) Installation (In Loader) on Page 20-41-1.)
Figure 60-122-28 Figure 60-122-29
P-21804
N-18940
Connect the handle harness connector to the sensor and Check the mounting block (Item 1) [Figure 60-122-29]
blank handle connector [Figure 60-122-28]. and bolts for wear and replace as needed.
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HAND CONTROL (CONT’D)
Figure 60-122-30
1
N-17741
N-17742


the connector (Item 2) [Figure 60-122-30].

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)

when replacing a handle sensor, actuator or
ACS controller. (See Calibration Of The ACS
System on Page 60-123-15.)
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ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Foot sensor (Item 2) [Figure 60-123-2].
HAND / FOOT CONTROL
Components Identification when replacing handle sensor, foot pedal
The Advanced Control System (ACS) is a selectable foot Calibration Of The ACS System on Page 60-
/ hand control system. 123-15.)
The ACS system allows the operator to quickly switch
Figure 60-123-3
between foot and hand control modes.
Figure 60-123-1
2 1
P-24203
P16536 P-21879 Control Valve Actuators (Item 1) [Figure 60-123-3].
Control Handle (Item 1) [Figure 60-123-1]. NOTE: The calibration procedure must be followed
Handle sensor (Item 2) [Figure 60-123-1]. sensor, actuator or ACS Controller. (See
NOTE: The calibration procedure must be followed 123-15.)
sensor, actuator or ACS Controller. (See Figure 60-123-4
123-15.)
Figure 60-123-2
1
1 P-21767
ACS Controller (Item 1) [Figure 60-123-4].

P-21938 P-21939
Foot control / sensor assembly (Item 1) [Figure 60-123- sensor, actuator or ACS Controller. (See
2]. Calibration Of The ACS System on Page 60-
123-15.)
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ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND / FOOT CONTROL (CONT'D)
Components Identification (Cont'd)
Figure 60-123-5
P-21769A

(See Calibration Of The ACS System on Page
60-123-15.)
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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.
Control Warning Voltage Pressure Coolant
System Temperature
Attachment Hydraulic Hydraulic Oil Hydraulic

Two Speed Glow Plugs Seatbelt Filter
Control Charge Temperature
Device Pressure
Advanced Control System

Errors - lights soild with 3 beeps 32-54 - Tilt handle/pedal short to ground
32-04 - ACS in error 32-55 - Lift handle/pedal short to battery
32-23 - ACS not calibrated 32-56 - Tilt handle/pedal short to battery
32-31 - Tilt actuator fault 32-57 - Lift actuator reduced performance
32-34 - Tilt actuator not calibrated 32-58 - Tilt actuator reduced performance
32-35 - Tilt handle/pedal not calibrated 32-59 - Lift actuator wrong direction
32-60 - Tilt actuator wrong direction
32-36 - Lift actuator fault 32-61 - Handle lock short to ground
32-39 - Lift actuator not calibrated 32-62 - Handle lock short to battery
32-40 - Lift handle/pedal not calibrated 32-63 - Pedal lock short to ground
32-49 - Lift actuator short to ground 32-64 - Pedal lock short to battery
32-51 - Lift actuator short to battery 32-65 - Sensor supply voltage out of range
32-50 - Tilt actuator short to ground 32-66 - Battery out of range
32-52 - Tilt actuator short to battery 32-67 - Switch moved while operating
32-53 - Lift handle/pedal short to ground
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HAND / FOOT CONTROL(CONT'D)
Controller, Connector And Wire Identification
G H
J J1 J3
F K
E A
D B
J3 C H
G
F J
J2
K
F E
G D A
E H B
A C
B J2
D
J1
C
J3
J1 J2

J1 CONNECTOR, METRI-PACK J3 CONNECTOR, METRI-PACK
Orange A 5V HALL EFFECT SUPPLY Red A TILT ACTUATOR FORWARD
Orange B SWITCHED AHC POWER Red/White B UNSWITCHED AHC POWER
Green c HAND/FOOT INPUT Red/White C UNSWITCHED AHC POWER
Purple D CAN SIGNAL HIGH AHC Black D LIFT ACTUATOR REVERSE

Purple E CAN SIGNAL LOW AHC Green E HANDLE LOCK POWER
Purple F CAN SHEILD AHC Red F LIFT ACTUATOR FORWARD
Black G AHC GROUND Green G PEDAL LOCK POWER
Black H AHC GROUND Black H AHC GROUND
J2 CONNECTOR, METRI-PACK Black J AHC GROUND
A OPEN Black K TILT ACTUATOR REVERSE
B OPEN
C OPEN
D OPEN
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
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ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Figure 60-123-8
ACS Controller Removal And Installation
Figure 60-123-6
1
P-21840

P-21839
Loosen the bottom bolts and remove the top bolt. NOTE: The calibration procedure must be followed
Remove the right front panel (Item 1) [Figure 60-123-6] ACS Controller. (See Calibration Of The ACS
from the loader. System on Page 60-123-15.)
Figure 60-123-7
P-21843

[Figure 60-123-7] from the controller.
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Figure 60-123-9
2 3
1
P-13733

P-16578
removed from the handle sensor wires, use the following 1-Terminal - Red
procedure. 2-Terminal - Black
3-Terminal - Green
Figure 60-123-10
1
1
P-13725 P-3732

connector.
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Switch Handle Removal
NOTE: Switch handle can be removed and installed

while in loader.
Figure 60-123-12
3 1
2
1
P-13735

1
2
Figure 60-123-15
P-21879


123-12] from the handle lock solenoid connector.
Figure 60-123-13
1
1
P-13725 P-13732

harness connector (Black) that connects to the handle
lock solenoid connector.
1
1
P-13725 P-13732

harness connector (Gray) that connects to the handle
sensor connector.
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Figure 60-123-16
2 3
4
1
3 1
2 P-34035
1
3 & 4) [Figure 60-123-18] from the loader wiring harness
P-13735 connectors.
Use a pointed tool, press down on the tab (Item 1)

Figure 60-123-17
P-34034

connectors.
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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 60-123- Figure 60-123-22
19] down.

Tape 1/2 of Wires
Figure 60-123-20
Tape back 1/2 of Wires
P-24233
1 P-21699
When installing the new switch handle, tape the wire

terminals together.
N-22784 The switch handle comes with a 6 in. 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
Pull the switch handle and wiring harness assembly (Item through handle and control lever tube.
NOTE: Leave all the other heat shrink tube on the
Cut the wires (Item 2) [Figure 60-123-20] below the wires for protection.
switch handle and remove switch handle.
Tape half of the wires back and half forward [Figure 60-
NOTE: Only cut the wires if the switch handle is bad 123-22] to keep the harness small enough to route
and needs replacement. If the switch handle is through the control lever tube.
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.
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ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Inspect the wire terminal tabs (Item 2) [Figure 60-123-
HAND / FOOT CONTROL (CONT'D) 24] 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
1 B-Terminal - White
C-Terminal - White/Black
D-Terminal - White/Red
E-Terminal - Dk. Green
F-Terminal - White/Lt. Green
G-Terminal - Yellow/Red
H-Terminal - Lt. Green
J-Terminal - Yellow
K-Terminal - Orange/Black
Three-Pin Connector
P-21700 A-Terminal - Red/White
C-Terminal - Purple/White
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
Ten-Pin Connector
casting, along side the handle sensor and into the control
A-Terminal - Orange
lever tube.
B-Terminal - Dk. Blue
C-Terminal - White
NOTE: Do not pull the wire harness tight, allow a
D-Terminal - Purple
small amount of slack or slight bend at the
E-Terminal - Yellow/Red
handle pivot area. Verify the control handle
F-Terminal - Tan
returns to neutral position.
G-Terminal - Pink
H-Terminal - Orange/Black
Figure 60-123-24
J-Terminal - Blank
K-Terminal - Blank
Three-Pin Connector
A-Terminal - Red/White
2 C-Terminal - Purple/White
Two-Pin Connector
A-Terminal - Black
B-Terminal - Red
1
Five-Pin Connector
A-Terminal - Dk. Green
B-Terminal - Brown
P-21695
C-Terminal - Blank
D-Terminal - Yellow
Remove tape from wires for installation and install the 6 E-Terminal - Blank
in. of heat shrink tube (Item 1) [Figure 60-123-24]
approximately 3 in. into the control lever. Apply heat to
the exposed heat shrink tube.
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Figure 60-123-25
1 1
3
2
P13735
1 Install the wires into the connectors as listed below:
P-34034 Left and Right Control Lever Switch Handle [Figure 60-
123-27]
1-Terminal - Red/White
Figure 60-123-26 2-Terminal - Black/White
3-Terminal - Purple/White
Figure 60-123-28
1
1
3
2
P-34035
Connect the handle harness connectors (Item 1) [Figure

P13735
60-123-25] & [Figure 60-123-26] to the loader harness
connectors.
Left and Right Control Lever Switch Handle [Figure 60-
123-28]
1-Terminal - Yellow/Red
2-Terminal - Open
3-Terminal - Orange/Black
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ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Actuators Disassembly and Assembly
Remove the control panel.
Figure 60-123-29 Installation (In Loader) on Page 20-41-1.)
Figure 60-123-30
P-21804
N-18940
Connect the handle harness connectors to the sensor
and lock solenoid connectors [Figure 60-123-29].
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ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Handle Lock Solenoid Removal And Installation
Figure 60-123-32
Figure 60-123-31
2
P-21836
1
N-17742
N-17741 Disconnect the harness connector (Item 1) [Figure 60-
Check the actuator wiring harness connector (Item 1) Disconnect the harness connector (Item 2) [Figure 60-
[Figure 60-123-31] and replace if broken. 123-32] from the handle lock solenoid connector.
Installation: Install the wires into the connector as listed Figure 60-123-33
the connector (Item 2) [Figure 60-123-31].

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)
1
P-21832
ACS controller. (See Contents, Page 60-01) Remove the two screws (Item 1) [Figure 60-123-33]
holding the handle lock solenoid to the handle.

4,3 N•m) torque.
Remove handle lock solenoid assembly from handle.
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ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Handle Lock Solenoid Connector
Figure 60-123-36
Handle Lock Solenoid Disassembly And Assembly
Figure 60-123-34
1
1
2
P-21787
P-21787 The wire connector (Item 1) [Figure 60-123-36] can be

removed from the solenoid, use the following procedure.
Remove solenoid (Item 1) [Figure 60-123-34] from the Figure 60-123-37
solenoid mount (Item 2) [Figure 60-123-34].
Installation: Apply a drop of oil to the solenoid threads

and tighten solenoid to 35 - 40 ft.-lb. (47 - 54 N•m) lubed
torque.
Figure 60-123-35
1
1
P-21800 P-21801
1
connector.
P-21789
Check the O-ring (Item 1) [Figure 60-123-35] for

damage. Replace as necessary.
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ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Switchable Hand / Foot Controls Calibration
HAND / FOOT CONTROL (CONT'D) Procedure
Handle Lock Solenoid Connector (Cont’d) Figure 60-123-39
Figure 60-123-38
1 3
2
1 1
P-24182
P-21802
Switch the rocker switch (Item 1) [Figure 60-123-39] to
the hand control mode.

below [Figure 60-123-38].
1 - Terminal - Black
2 - Terminal - Open
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

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.)
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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].
B-16626 Turn the ignition key off (keyless panel power off).
Figure 60-123-43
Figure 60-123-41
Then Turn Key On
or
Press RUN / ENTER
B-16626
B-16627
Turn the ignition key on (keyless panel choose RUN /

With the seat bar down, turn the ignition key on (keyless ENTER) [Figure 60-123-43].
panel choose RUN / ENTER) [Figure 60-123-40] and
push the PRESS TO OPERATE button (Item 1) [Figure NOTE: Do Not start engine.
60-123-41] to unlock the hand controls.
NOTE: Do not start the engine.
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ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Hand Controls Only Calibration Procedure
Figure 60-123-45
Switchable Hand / Foot Controls Calibration
Procedure (Cont'd)
Figure 60-123-44 Stroke Both Handles Fully In and Hold Them
B-16628
1
With the seat bar down and the ignition key off (keyless
B-16627 panel power off), fully stroke both control handles in
toward the center of the cab and hold the handles there
[Figure 60-123-45].
Push the PRESS TO OPERATE button (Item 1) [Figure
60-123-44] to begin the calibration. 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 or
beep three times. The calibration process
generates two codes 32-35 (tilt handle not Press RUN / ENTER
calibrated) and 32-40 (lift handle not
calibrated). Ignore these two codes, this is
normal during the calibration procedure.
Release the control handles.

B-16626
NOTE: After pushing the PRESS TO OPERATE

button, the handle position does not affect the Turn the ignition key on (keyless panel choose RUN /
calibration process. 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.
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ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Foot Sensor Disassembly And Assembly
Figure 60-123-48
Hand Controls Only Calibration Procedure (Cont'd)
Figure 60-123-47
1 P-24269
1
B-16627 Remove the two bolts (Item 1) [Figure 60-123-48] from

the end of the foot sensor.
Push the PRESS TO OPERATE button (Item 1) [Figure Installation: Tighten the bolts to 90 in.-lb. (10,2 N•m)
60-123-47] to begin the calibration. torque. Apply Loctite® 242 to the threads.
NOTE: The ACS icon will light up and if you listen Figure 60-123-49
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 5
and a function is operated.
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. 3

2
NOTE: After pushing the PRESS TO OPERATE 1 P-24270
button, the handle position does not affect the
calibration process.
Remove the boot retainer (Item 1) [Figure 60-123-49],
NOTE: The ACS controller cycles the actuators, boot (Item 2) [Figure 60-123-49], spool stop plate (Item
records the values and optimizes the system 3) [Figure 60-123-49], O-ring (Item 4) [Figure 60-123-
automatically in approximately 5 seconds. 49].
Calibration is complete. 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.
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Foot Sensor Connector
Figure 60-123-50 1
3 1
2
P-24274

P-24271
removed from the sensor wires, use the following 1 - Terminal - Red
procedure. 2 - Terminal - Black
Figure 60-123-51
P-24272 P-24273

connector.
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Foot Lock Solenoid Removal And Installation
Figure 60-123-53
P-21790
Check the O-ring (Item 1) [Figure 60-123-55] for

1
damage. Replace as necessary
P-21938
Foot Lock Solenoid Connector
Remove the two bolts (Item 1) [Figure 60-123-53] from The wire connector (Item 2) [Figure 60-123-55] can be
the foot sensor shield. removed from the solenoid wires, use the following
procedure.
Installation: Tighten the bolts to 32 - 38 in.-lb. (3,6 - 4,3
N•m) torque.
Figure 60-123-54
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.-lb. (47 - 54 N•m)
lubed torque.
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Foot Lock Solenoid Connector (Cont’d)
Figure 60-123-56
1 3
2
P-21802
1
1
P-21800 P-21801
connector. 1 - Terminal - Black
2 - Terminal - Open
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ELECTRICAL / HYDRAULIC CONTROLS
REFERENCE
Controls Identification Chart
Attachment
xxxxxxxxx Harness
Switch Solenoid Number Attachment Harness
Terminal
Number Activated Connector
Left Side Activated Right Side
Control Handle Control Handle
Switches RH HFH Fourteen Pin Switches
Connector Viewed
1 1 1 1, 8 K from front
2 2 2 2 K (pin side of
connector)
*3 1 1 1, 8 K of loader.
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
B-16449
B-16447 10, 11, 12, - -- -- K
B-16448
13, 14 Early
Version
2 1
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.
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ELECTRICAL / HYDRAULIC CONTROLS
REFERENCE (CONT’D)
Controls Identification Chart (Cont’d)
Solenoid Hydraulic Wiring

Number Coupler Number
4 8
2 6 Front
3 3 1 Female 4330
1 (Rod)
Front
2 Male 4340
(Base)
3 (Top) Diverter 4450
Bleed - Rear
4 (Bottom) 4480
Male & Female
9 8
Rear
5 Female 4430
7 8 (Rod)
6 6
2 Rear
3
5 6 Male 4440
H
(Base)
1
7 (Bottom) Diverter 4450
High
8 (Middle) 4460
Flow
Bleed - Rear
9 (Top) 4480
Male & Female
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.
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ENGINE SERVICE
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
SAFETY &
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1 MAINTENANCE
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 DRIVE
ENGINE AND ENGINE MOUNTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Engine Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-7
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
ENGINE
Fuel Injector Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12
SERVICE
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

Speed Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-2
Speed Control Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-3
FLYWHEEL AND HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

Flywheel Housing Removal And Installation . . . . . . . . . . . . . . . . . . . 70-90-1
Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
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ENGINE SERVICE (CONT’D)
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
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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 CAUSE
Slow cranking speed. 1, 2, 3, 4
Engine will not start. 2, 5, 6, 7, 8, 9, 11, 12,13, 14, 15, 16, 17, 19, 27, 28, 29
Difficult to start. 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25,27, 28, 29
No power for engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29,
Engine is mis-firing. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue/white exhaust. 4, 10, 15, 16, 17, 21, 23,27, 29, 30, 47, 46
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 39, 48
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 49
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 49
Vibration. 2, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure warning. 4, 33, 36
Overheating. 10, 12, 13, 15, 16, 20, 21, 32, 40, 44, 47
Too much crankcase pressure. 22, 27, 29, 46
Poor compression. 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 49
Start and stop. 9, 10, 11

1. Battery capacity low. 26. Incorrect high pressure fuel pipes.
2. Bad electrical connection. 27. Worn cylinder bores.
3. Faulty starter motor. 28. Worn valve and seats.
4. Incorrect grade of oil. 29. Broken, worn, or sticking piston rings.
5. Low cranking speed. 30. Worn valve stems or guides.
6. Fuel tank empty. 31. Worn or damaged bearings.
7. Faulty stop control operation. 32. Not enough oil in the oil pan.
8. Plugged fuel line. 33. Switch / sensor is defective.
9. Plugged fuel filter. 34. Oil pump worn.
10. Restriction in the air cleaner. 35. Pressure relief valve is sticking open.
11. Air in the fuel system. 36. Pressure relief valve is sticking closed.
12. Faulty fuel injection pump. 37. Broken relief valve spring.
13. Faulty fuel injectors. 38. Faulty suction pipe.
14. Broken injection pump drive. 39. Plugged oil filter.
15. Incorrect injection pump timing. 40. Piston seizure.
16. Incorrect valve timing. 41. Incorrect piston height.
17. Poor compression. 42. Faulty engine mounting.
18. Plugged fuel tank vent. 43. Incorrect alignment of flywheel.
19. Incorrect grade of fuel. 44. Faulty thermostat.
20. Exhaust pipe restriction. 45. Plugged oil cooler.
21. Cylinder head gasket leaking. 46. Plugged PCV System.
22. Overheating. 47. Damaged valve stem oil deflectors.
23. Cold running. 48. Plugged oil pump pipe strainer.
24. Incorrect tappet adjustment. 49. Broken valve spring.
25. Sticking valves.
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ENGINE SPEED CONTROL Installation: Tighten the bolts evenly until the speed
control lever moves backward and forward at a
Removal And Installation comfortable tension.
Figure 70-20-58 Figure 70-20-60
1 2
P-4731 P-5375
Raise the lift arms and install an approved lift arm support Remove the speed control lever (Item 1) [Figure 70-20-
device. (See LIFT ARM SUPPORT DEVICE on Page 10- 60] and mounting bracket (Item 2) [Figure 70-20-60].
20-1.)
Figure 70-20-61
Raise the operator cab. (See OPERATOR CAB on Page
10-30-1.)

3
58].
Figure 70-20-59
1 2
2 P-5378
Remove the retainer pin (Item 1) [Figure 70-20-61] and

pivot pin (Item 2) [Figure 70-20-61] from the speed
control arm (Item 3) [Figure 70-20-61] to disconnect the
speed control cable clevis.
P-5368
NOTE: Do not lubricate the speed control parts when
assembling.
Mark the front of the stop bracket (Item 1) [Figure 70-20-
59] and remove the stop bracket
Installation: It is important for the front and rear stop on

the bracket to be located correctly.
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ENGINE SPEED CONTROL (CONT’D) Figure 70-20-63
Speed Control Cable

2
Figure 70-20-62
3
1
1
4
P-5545
Remove the u-bolt (Item 1) [Figure 70-20-63] from the

N-20414 cable.
NOTE: The throttle mount bracket bolts (Item 2)

NOTE: Do not lubricate the speed control parts when [Figure 70-20-63] can be removed to assist u-
assembling. bolt removal.
Raise the lift arm and install an approved lift arm support Remove the nut (Item 3) [Figure 70-20-63] to disconnect
device. (See LIFT ARM SUPPORT DEVICE on Page 10- the cable from the linkage.
20-1.)
Remove the speed control cable.
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 70-20-62] from the

cable.
Open the rear door.
NOTE: Engine is shown removed from loader for

clarity.
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ENGINE SPEED CONTROL (CONT’D)
Speed Control Linkage
Figure 70-20-64
4 5
1
P-5544
Loosen the bolt (Item 1) [Figure 70-20-64] to remove the

linkage rod (Item 2) [Figure 70-20-64].
Disconnect the cable nut (Item 3) [Figure 70-20-64].
Remove the nut (Item 4) [Figure 70-20-64] from the pivot

bolt (Item 4) [Figure 70-20-63].
Remove the bellcrank linkage (Item 5) [Figure 70-20-64]

and spring.
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MUFFLER Figure 70-30-3
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.
1 Remove the muffler.
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
P-7900
Remove the three bolts and nuts (Item 1) [Figure 70-30-

2] from the muffler exhaust flange.
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AIR CLEANER Figure 70-40-6
Housing Removal And Installation
Figure 70-40-4 1
2
N-19673
Disconnect the sensor wiring harness connector (Item 1)

N-19671 [Figure 70-40-6] from the air cleaner.
Remove the air cleaner housing from the loader.

Loosen the hose clamp (Item 1) [Figure 70-40-4] and
disconnect the inlet hose from the air cleaner.
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
N-19672

5].
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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 30-
60-1.)
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

1] 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
Before installing the oil cooler, check the seals (Item 1)

[Figure 70-50-4] at both sides of the oil cooler mounting
1 1 frame. Replace the seals as needed.
2
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.
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COOLING FAN Figure 70-60-3
Drive Tension Pulley Removal And Installation
Figure 70-60-1
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].
Figure 70-60-2 4 3
2
1 5
N-303A
P-0581
Remove the bolt (Item 1) [Figure 70-60-3] & [Figure 70-

60-4].
Remove the thrust washer (Item 2) [Figure 70-60-4], O-

rings (Item 3) [Figure 70-60-4] and spring (Item 4)
P-4956 [Figure 70-60-4].
Check all parts for damage or wear and replace them as

Remove the spacers, bolt and washers from the arm needed.
[Figure 70-60-2].
NOTE: When making any repairs, replace the bronze
Installation: Put a small amount of grease around the bushing (Item 5) [Figure 70-60-4] with a new
outside edge on the grease rings (Item 1) [Figure 70-60- style nylon bushing. Clean all parts and
2] between ring and bearing. assemble dry. Do not lubricate. (See Parts
Manual for correct part numbers.)
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COOLING FAN (CONT'D) Figure 70-60-6
Gearbox / Blower Housing Removal And Installation
20-1.)

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 Disconnect the wiring harness connectors (Item
Cylinder Removal And Installation on Page 50-20-1.) 1)[Figure 70-60-6].
Installation: Tighten the mounting bolts to 80 - 90 in.-lb. Remove the harness clamp (Item 2) [Figure 70-60-6].
(9 - 10 N•m) torque.
Move the electrical harness down for clearance at the
Remove the hydraulic fluid reservoir. (See Removal And blower housing.
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(Cont'd) 1
Figure 70-60-7
Oil Level
1 P7936-
Remove the sealant from the blower housing and loader

frame (Item 1) [Figure 70-60-9].
N-19736
Remove fuel fill hose (Item 2) [Figure 70-60-9] and the
fuel vent hose.
Remove the belt shield (Item 1) [Figure 70-60-7] from
the fan drive. 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
P-7775

10] and spacer tubes (two outside housing and two
inside housing).
1
NOTE: Remove the two rear mounting bolts first.
Installation: Use sealant on each end of the inside

P-7774 spacer tubes to prevent the tubes from falling out of the
housing during installation. Tighten the mounting bolts to
25 - 28 ft.-lb. (34 - 38 N•m) torque.
Remove the fan drive belt (Item 1) [Figure 70-60-8].
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(Cont'd)
Figure 70-60-11
P-7776
The blower housing must be moved away from the loader

frame if the side grills need to be replaced [Figure 70-60-
P-7773 12].
To replace the side grill, remove the four mounting

Slide the blower housing forward and remove the fan / screws (Item 1) [Figure 70-60-12] from the blower
fan gearbox assembly. Remove the blower housing housing.
[Figure 70-60-11].
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.)
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Blower Removal And Installation
Figure 70-60-13
CD-9953
Remove the fan from the tapered shaft [Figure 70-60-

CD-9952 15].
Figure 70-60-16
Remove the lock nut and spacer [Figure 70-60-13].

N•m) torque.
1
Figure 70-60-14
1
2
CD-9954
To remove the blower housing mounting plate, remove

1
the six bolts (Item 1) [Figure 70-60-16].
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.
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COOLING FAN (CONT'D)
Gearbox Parts Identification
18
1 6
2
3 4
7 4
5
22
4
12
13 9
14
10
*16
21
11
15
17
20 12
1. Seal 11. Nut 3

2. Snap Ring (Small) 12. Gear
3. Shims (1.0 in. O.D.) 13. Washer
14. Screw
4. Bearing
15. Square Shim
5. Shaft (Long) 4
*16. Short Housing
6. Shims (2.0 in. O.D.) 17. Bolt
7. Long Key 18. Snap Ring (Large) 13
8. Shaft (Short) 19. Cap
9. Short Key 20. Long Housing Assy.
10. Long Housing 21. Short Housing Assy.
14
22. Fill Plug
18
19
*Individual Part not available
TS-1002A
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Gearbox Disassembly
Figure 70-60-17
Part Number
2 Tag
-
P2983
3
1 Remove the four mounting bolts and the part number tag
P-37891 [Figure 70-60-18].
Remove the oil from the gearbox.

NOTE: When repairing the gearbox order the
following as needed:
1. Complete Assembly
2. Long Housing Assembly
WARNING
3. Long Housing
4. Short Housing Assembly (See Note Below) AVOID INJURY OR DEATH
5. Internal Parts Wear safety goggles to prevent eye injury when
drilling or grinding.
NOTE: The short housing is only available as an W-2108-1186
assembly. (See Gearbox Parts Identification

on page 70-60-6) (Order parts from Bobcat Figure 70-60-19
Parts Sales.)
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 in. (13 mm) hole in the seal. Use a slide
hammer tool to remove the seal [Figure 70-60-19].
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Gearbox Disassembly (Cont'd)
Figure 70-60-20
P-2966
Remove the screw and washer from the shaft [Figure

P-2964 70-60-22].
Figure 70-60-23
Remove the small snap ring [Figure 70-60-20].
Figure 70-60-21
P-3004
P-2963 Support the lower flange and press the shaft from the
bearing [Figure 70-60-23].
Remove the small shims [Figure 70-60-21]. NOTE: The gear and the other bearing (pulley end)
will be removed with the shaft.
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Figure 70-60-24
P-2996
Drill an 1/8 in. (3 mm) hole in the seal. Use a slide

P-3298 hammer tool to remove the seal [Figure 70-60-26].
Figure 70-60-27
Support the bearing and press the shaft from the bearing
[Figure 70-60-24].
Short Housing
WARNING
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
P-2997
Remove the end cap [Figure 70-60-25].
Use care not to damage the housing.
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Figure 70-60-28
P-2973
Remove the snap ring from the cap end of the housing
P-2969 [Figure 70-60-30].
Figure 70-60-31
Remove the large shims from the housing [Figure 70-60-
28].
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
P-2978 housing, use a non metal object to tap the
bearing from the housing.
Remove the screw and washer (Item 1) [Figure 70-60-

29] from the shaft.
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Figure 70-60-32
P-2972
Remove the key (Item 1) [Figure 70-60-34] from the

P-3088 shaft.
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].
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Gearbox Assembly
NOTE: See Gearbox Parts Identification on page 70-

60-6 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.
P-2960
NOTE: For procedures requiring the use of #242
Loctite® adhesive, thoroughly clean and dry
affected parts before the application of #242 Install the long housing on the shaft [Figure 70-60-36].
Loctite®.
Be sure the bearing is seated in the bore at the lower end
Long Housing of the housing.
Figure 70-60-35 Figure 70-60-37
P-2961 P-2962
Press a bearing on the short keyed end of the long shaft Install a bearing on the long keyed end of the shaft
[Figure 70-60-35]. [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].
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Gearbox Assembly (Cont'd)
Figure 70-60-38
P-2965
Install the gear key in the flange end of the shaft [Figure
P-2963 70-60-40].
Figure 70-60-41
Install on the bearing, the same number and size shims
that were removed during disassembly [Figure 70-60-
38].
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
P-2964 against the bearing [Figure 70-60-41].
Install the small snap ring in the groove above the shims
[Figure 70-60-39].
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Figure 70-60-42
P-2969
Install the large shims on the bearing (flanged end)

P-2966 [Figure 70-60-44].
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].
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Figure 70-60-46
P-2976
1
Install the shaft in the housing, tapered end in the bearing
P-2971 at the round flange end of the housing [Figure 70-60-48].
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.
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Figure 70-60-50
P-2978
Install the washer (Item 1) [Figure 70-60-52] on the

P-2974 shaft. Put liquid adhesive (Loctite® #242) on the screw
threads and install the screw [Figure 70-60-52].
Install a bearing on the gear end of the shaft [Figure 70-

60-50].
Figure 70-60-51
P-2973
Install the snap ring in the groove above the bearing

[Figure 70-60-51].
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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 in. (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.-lb. (34 - 38 N•m)

torque.
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Gearbox, Checking Backlash (Cont'd)
Figure 70-60-56
2 1
1.000”
(25,4mm)
P-37893
1 Using a magnetic based dial indicator mounted on a

P-37894 bench vise, touch the dial stem on the bolt (Item 1)
[Figure 70-60-58].
Install the long key (Item 1) [Figure 70-60-56] and the Hold the locking pliers against the long housing and
pulley (Item 2) [Figure 70-60-56]. rotate the pulley back and forth to read the dial gauge
[Figure 70-60-58].
Install a bolt in the set screw hole to maintain a 1.000 in.
(25,4 mm) distance from the shaft center to the bolt head If the backlash is GREATER than 0.008 in. (0,203 mm),
(to be used with a dial indicator)[Figure 70-60-56]. do the following:
Figure 70-60-57 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 in. (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
P-37892 large shim(s) of the same thickness between the snap
ring and the bearing on the tapered end of the shaft.
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].
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Gearbox Checking Backlash (Cont'd) LONG HOUSING
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.-lb. (34 - 38 N•m)

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.
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ENGINE COMPONENTS AND TESTS Figure 70-70-3
Engine Compression, Checking

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
N-19024
Remove the electrical connection (Item 1) [Figure 70-70-

1] from the fuel shut off solenoid.
Figure 70-70-2
N-19022
Install the compression adapter tool (Item 1) [Figure 70-

70-3] & [Figure 70-70-4] into the glow plug hole and
2
tighten to 15 - 18 ft.-lb. (20 - 24 N•m) torque.
N-19021
Remove the high pressure fuel line (Item 1) [Figure 70-

70-2] from the fuel pump and the fuel injector.
Installation: Tighten the fuel line nuts to 10 - 12 ft.-lb.
(13,5 - 16,5 N•m) torque.
Disconnect the glow plug harness (Item 2) [Figure 70-
70-2] from the glow plug.
Remove the glow plug from the cylinder head.
Installation: Tighten the glow plugs to 15 - 18 ft.-lb. (20 -
24 N•m) torque.
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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

N-19023 plug.
Connect the test meter lead to the terminal of the glow

Connect the compression gauge to the adapter [Figure plug as shown in figure [Figure 70-70-7].
70-70-5].
Touch the other lead from the test meter to the base of
Turn the engine with the starter at 200 to 300 RPM. Run the glow plug as shown in figure [Figure 70-70-7].
the test for each cylinder two times at 5 to 10 seconds
each time and take the average reading. The reading must be approximately 0.2 ohms.
The correct compression to the engine is 320-392 PSI If the resistance is zero ohms the glow plug has a short
(2206-2703 kPa) with no more than 10% difference circuit and must be replaced.
between the cylinders.
If the resistance is infinite, the coil of the glow plug is
Glow Plug, Checking broken and the glow plug must be replaced.
Figure 70-70-6
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 70-
70-6].
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Fuel Shut-Off Solenoid, Checking

1
Figure 70-70-8
N-19026
1
The reading must be approximately 02.8 ohms.
N-19024
If the resistance is zero ohms the solenoid has a short
circuit.
Remove the screw (Item 1) [Figure 70-70-8] from the
electrical connection on the fuel shut off solenoid. 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
Figure 70-70-9 Solenoid Removal and Installation” on Page 70-70-4)
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].
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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
Figure 70-70-11 the performance of the engine.
IMPORTANT
1 Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
Figure 70-70-13
3 3
N-19027

11].

2 2
(13,5 - 16,3 N•m) torque.
Remove the fuel shut-off solenoid from the engine.

1
Figure 70-70-12
P-5282
1
Remove the fuel tubeline (Item 1) [Figure 70-70-13] to
the fuel injection pumps (Item 2) [Figure 70-70-13].
Disconnect the respective high pressure fuel line (Item 3)

[Figure 70-70-13] from the injection pump to be removed
and fuel injector.
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 70-70-
12] must engage the fuel control rack.
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Fuel Injection Pump Removal (Cont'd)
2
IMPORTANT
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 70-70-

16].
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
1 injection pump.
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 70-70-

15] from the injection pump.
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Fuel Injection Pump Removal (Cont'd)
Figure 70-70-18 Tappet
MC-2175
Measure the distance between the engine block surface

P-5278 (without shim) and surface of the tappet [Figure 70-70-
20].
Install the tappet into its respective bore [Figure 70-70- Installation dimension of the injection pump is 2.32 in. (59
18]. mm).
EXAMPLE:
Fuel Injection Pump Timing
Specifications:
The fuel injection pump does not need to be timed if the
tappet, shim(s) and the camshaft are not changed. Installation Depth 2.32 in. (59 mm)
Measured Depth a 2.25 in. (57,55 mm)
Figure 70-70-19 Difference 0.07 in. (1.78 mm)
Determine the number of shim(s) needed to get the

1 correct installation height.
Install the appropriate number of shims(s) on the engine

block surface.
P-5284
Install a depth micrometer (Item 1) [Figure 70-70-19].
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Fuel Injection Pump Installation
Figure 70-70-21
2
1
P-5288
Use the centering pin (Item 1) [Figure 70-70-23] to

P-5287 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.)
Remove the plug from the engine block. Install control
rack locating pin (Item 1) [Figure 70-70-21]. (See “Deutz Figure 70-70-24
Engine Tools Identification Chart” on Page 70-100-1 for
correct tool.)
Figure 70-70-22 2 3
1
1
2
P-5289
Install the centering pin (Item 1) [Figure 70-70-24] into

P-5286 the injection pump and into the control lever (Item 2)
[Figure 70-70-24]. Align the marks (Item 3) [Figure 70-
70-24] on the pump body and the control lever. Make
Move the control rack until the slot (Item 1) [Figure 70- sure the control lever is in the center position.
70-22] is in the center of the injection pump bore.
Tighten the locating pin (Item 2) [Figure 70-70-22].
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Fuel Injection Pump Installation (Cont'd)
Figure 70-70-25
P-5280
2
1 Install the high pressure fuel line.

P-5294
Tighten the fuel line nut to 10 - 12 ft.-lb. (13,5 - 16,5 N•m)
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 Figure 70-70-28
rack.
Install the two nuts (Item 1) [Figure 70-70-25].
Tighten the mounting nuts to 15 ft.-lb. (21 N•m) torque

[Figure 70-70-25].
Figure 70-70-26
1
P-5285
Install new washers (Item 1) [Figure 70-70-28] on the

2 fuel line fastening bolt.
Install the fuel line on the injection pumps and tighten to

1 20 - 23 ft.-lb. (27 - 31 N•m) torque.
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].
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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.-lb. (21 N•m)

torque.
1 Figure 70-70-31
P-5280
Disconnect the respective high pressure fuel line from 1

fuel injector to be removed and fuel injection pump.
Use a flare nut wrench (Item 1) [Figure 70-70-29] to 2

loosen the high pressure fuel line nut.
Remove the high pressure fuel line.
P-5290
Installation: Tighten the fuel line nut to 10 - 12 ft.-lb.
(13,5 - 16,5 N•m) torque.
Remove the fuel injector (Item 1) [Figure 70-70-31] and
washer (Item 2) [Figure 70-70-31] from the cylinder
head.
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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

MC-2177
procedure:
OEM1064 - Injection Nozzle Tester Check nozzles spray pattern [Figure 70-70-33]:
OEM1065 - Accessory Set
The spray pattern must be uniform from all four holes of
Figure 70-70-32 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
W-2072-0807
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Fuel Injector Disassembly
Figure 70-70-34
CD-15334
The nozzle needle and body [Figure 70-70-36] are

CD-15332 lapped together and can not be exchanged with other
nozzle parts.
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,

1 wash the injector nozzle parts again in clean
2 diesel fuel. Blow dry with compressed air. Re-
3 do the procedure again. Replace the injectors
4 as needed. Wash all new injectors in clean
5 diesel fuel before installation.
6
Figure 70-70-37
CD-15333
Disassemble the parts as shown in [Figure 70-70-35].
1. Nozzle Cap Nut

2. Injector Nozzle
3. Adapter
4. Thrust Pin
5. Spring
6. 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].
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Fuel Injector Assembly
Figure 70-70-38
CD-15338
Install the thrust pin with the centering collar facing

CD-15336 toward the compression spring [Figure 70-70-40].
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].
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Fuel Injector Assembly (Cont'd)
Figure 70-70-42
CD-15342
Tighten the cap nut to 35 ft.-lb. (47 N•m) torque [Figure

CD-15340 70-70-44].
Check the injector nozzle on the nozzle tester before

Install the injector nozzle, make sure the center bore fits installation. (See “Deutz Engine Tools Identification
over the centering pins of the adapter [Figure 70-70-42]. 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].
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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:
MEL1552 - Torx Bit Check the timing belt, sprockets and tensioner for wear,
cracks or damage [Figure 70-70-46].
Figure 70-70-45
Check the timing belt in detail for the following conditions,
replace as needed.
1. Oil deposits
2
2. Hardened back rubber surfaces
3. Cracked
1 4. Badly worn teeth
5. Missing tooth
P-5292A 6. Side of belt badly worn
7. Side of belt cracked
Timing Belt Removal
3 Remove the bolts (Item 1) [Figure 70-70-45] from the

P-5292 timing belt inspection cover.
Remove the torx bolt (Item 2) [Figure 70-70-45].

timing belt inspection cover. Remove the cover (Item 3) [Figure 70-70-45].
Remove the torx bolt (Item 2) [Figure 70-70-45].
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ENGINE COMPONENTS AND TESTS (CONT'D) Timing Belt Installation
Timing Belt Removal (Cont’d) Figure 70-70-49
Figure 70-70-47
3
1
1
1
2
P-9575
P-5295
NOTE: Remove the fuel injectors from the cylinder
head. (See “Fuel Injector Removal and
Remove the bolts (Item 1) [Figure 70-70-47] from the v- Installation” on Page 70-70-9) This will let the
belt pulley (Item 2) [Figure 70-70-47]. crankshaft turn easier for timing belt
installation.
Remove the V-belt pulley.
The camshaft plug is located at the rear of the engine
Remove the bolts (Item 3) [Figure 70-70-47] from the block (Item 1) [Figure 70-70-49] on the fuel injection
timing belt cover. 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
P-5299
Loosen the belt tensioner mounting bolt (Item 1) [Figure

70-70-48].
P-9573
Loosen the belt tensioner.

Install the timing tool (Item 1) [Figure 70-70-50] and
Remove the timing belt. tighten.
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Timing Belt Installation (Cont'd)
Figure 70-70-51
1
2
P-5301
Loosen the nut at the camshaft gear [Figure 70-70-53].

P-9577 P-9578 (See “Deutz Engine Tools Identification Chart” on Page
70-100-1 for correct tool.)
The crankshaft plug is located at the front of the engine Install the new timing belt.
block (Item 1) [Figure 70-70-51] on the exhaust manifold
side. Figure 70-70-54
Remove the plug.
Figure 70-70-52
P-5630
Measure the distance from the edge of the belt to the

B-14401 front cover surface [Figure 70-70-54].
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.
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Figure 70-70-55
N-18867
Remove the belt tension tool.

P-5632
Initially tighten camshaft bolt to 22 ft.-lb. (30 N•m) [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 70- Figure 70-70-58
70-55].
1
Figure 70-70-56
1 N-18866
N-18863 With a torque degree wheel (Item 1) [Figure 70-70-58]

tighten the camshaft bolt an additional 210°.
Install the belt tension tool (Item 1) [Figure 70-70-56]. Remove the camshaft and crankshaft locating pins.
(See “Deutz Engine Tools Identification Chart” on Page
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.-lb. (45 N•m) torque.
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Figure 70-70-59
1
N-18853
Check the position of the belt tension tool (Item 1)

N-18864 [Figure 70-70-61] on the belt.
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,
N-18852 repeat the installation procedure starting with
[Figure 70-70-49].
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.
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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 70-70-

25 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 P-9566

tighten the bolts to 30 - 36 ft.-lb. (41 - 49 N•m) torque.
Figure 70-70-64 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

• 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
P-5292 (Item 1) [Figure 70-70-65].
NOTE: Do not lose the rubber seal gasket on the

Install the timing belt inspection cover (Item 1) [Figure solenoid connector.
70-70-64] and tighten the bolts.
Remove the bolts (Item 2) [Figure 70-70-65] holding the
belt shield. Move the shield away from the work area.
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Timing Belt, Replacement In the Loader (Cont'd)
Figure 70-70-66
2 1
N-20431
Remove the camshaft access plug (Item 1) [Figure 70-

P-9563 70-68].
Figure 70-70-69
Loosen the alternator adjustment bolt (Item 1) [Figure
70-70-66] and remove the alternator belt.
Remove the crankshaft pulley bolts (Item 2) [Figure 70-

70-66]. Remove the pulley.
Figure 70-70-67 1
P-9577
2
Remove the crankshaft access plug (Item 1) [Figure 70-
70-69].
1
NOTE: The plug is located on the front of crankcase,
P-9564 below the turbocharger and just above the
right side front engine mount.
Remove the throttle linkage bolts (Item 1) [Figure 70-70-

67]. Lower the throttle linkage.
Remove the four belt cover bolts (Item 2) [Figure 70-70-

67]. Remove the front and rear belt covers.
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Figure 70-70-70 1
P-9605
• For Broken Belt Replacement Only

P-9570
• Remove the number four cylinder fuel injector. (See
“Fuel Injector Removal and Installation” on Page 70-
Rotate the crankshaft in correct rotation as shown in 70-9)
figure [Figure 70-70-70] until the notch in the camshaft
can be seen through the access hole. • Rotate the crankshaft and use a wire (Item 1) [Figure
70-70-72] in the fuel injector hole to indicate piston is
NOTE: The crankshaft must be turned in correct moving upward, to top dead center (T.D.C.).
rotation. Turn clockwise as viewed from the
timing belt end of engine as shown. NOTE: The crankshaft must be turned in correct
rotation. Turn clockwise as viewed from the
Figure 70-70-71 timing belt end of engine.
Figure 70-70-73
P-9573
P-9578
Install the camshaft timing tool (Item 1) [Figure 70-70-71]
and tighten. (See “Deutz Engine Tools Identification
Chart” on Page 70-100-1 for correct tool.) • Install the crankshaft timing tool (Item 1) [Figure 70-
70-73] 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 70-70-

73] and tighten. (See “Deutz Engine Tools Identification
Chart” on Page 70-100-1 for correct tool.)
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Figure 70-70-74
1 P9576 P-9574
Install the belt tension tool as shown in [Figure 70-70-

P-9565 76]. (See “Deutz Engine Tools Identification Chart” on
Page 70-100-1 for correct tool.)
Remove the tensioner bolt (Item 1) [Figure 70-70-74] Figure 70-70-77

and the tensioner. Remove the timing belt.
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 70-
70-77]. Obtain a scale reading of 3.0-3.5. Tighten the
idler tension pulley mount bolt to 33 ft.-lb. (45 N•m)
torque.
P-9571
Install the camshaft gear tool (Item 1) [Figure 70-70-75].

(See “Deutz Engine Tools Identification Chart” on Page
Loosen the camshaft gear [Figure 70-70-75].
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Figure 70-70-78
P-9570A
Make four complete crankshaft revolutions in the

P-9569 direction of engine rotation. Bring the mark on the
crankshaft pulley back to the same position as before
[Figure 70-70-80].
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.
NOTE: If the specified scale reading is not obtained,
Tighten camshaft bolt to 22 ft.-lb. (30 N•m) torque as repeat the procedure.
shown in figure [Figure 70-70-78]. Mark the camshaft
bolt and tighten an additional 210°. Remove the belt tension tool.
Figure 70-70-79 • For Broken Belt Replacement Only
• Install the push rods and rocker arms / brackets.

Replace all damaged parts. (See Contents, Page 70-
01.)
• Set the valve clearance. (See “Valve Clearance
1 Adjustment” on Page 70-70-24)
• Install the valve cover and gasket. Tighten the bolts to
75 in.-lb. (8,5 N•m) torque.
Install the crankshaft and camshaft access plugs.
Install the belt covers and four mounting bolts.
Install the throttle linkage and bolts.

P-9565A
Install the crankshaft pulley and bolts. Tighten the bolts to
30 - 36 ft.-lb. (41 - 49 N•m) torque.
Remove the camshaft and crankshaft timing tools (Item
1) [Figure 70-70-71] & [Figure 70-70-73]. Install the alternator belt. Adjust the belt tension.
Mark the crankshaft pulley hub (Item 1) [Figure 70-70- Install the belt shield and bolts.
79].
Plug in the fuel solenoid connector and tighten the screw.
Reconnect the negative (-) battery cable.
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Valve Clearance Adjustment
Figure 70-70-81
P-5633
Loosen the locknut and turn the set screw until the
P-5297 clearance is correct.
Intake - 0.012 in. (0,3 mm)
Make the valve clearance adjustment with engine Exhaust - 0.020 in. (0,5 mm)
stopped and cold.
Tighten the locknut to 13 - 16 ft.-lb. (18 - 22 N•m) torque.
Remove the valve cover (Item 1) [Figure 70-70-81].
When installing the valve cover bolts, tighten them to 75

in.-lb. (8,5 N•m) torque.
Figure 70-70-82
CRANKSHAFT POSITION CRANKSHAFT POSITION
ONE TWO
Turn crankshaft Turn crankshaft further by
until valves one complete revolution
of cylinder No. 1 Overlap
(360°)
DO NOT ADJUST 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

over-lap [Figure 70-70-82].
Turn the crankshaft by one complete revolution (360°)

and set the other valves.
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Valve Timing, Checking
Figure 70-70-84
P-9563
At the crankshaft pulley bolt, install a torque wrench and

P-9575 turn the engine in the direction of rotation to 30 ft.-lb. (40
N•m) torque [Figure 70-70-86].
Remove the camshaft access plug (Item 1) [Figure 70- Remove the torque wrench, DO NOT change the
70-84]. crankshaft position.
Figure 70-70-85
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].
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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 70-

70-87].
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 70-70-87]

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.
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ENGINE COMPONENTS AND TESTS (CONT'D) Remove the plug (Item 1) [Figure 70-70-88] and remove
the thermostat and spring assembly (Item 1) [Figure 70-
Thermostat, Oil Pressure Control Valves And Heater 70-89] from the engine block. (See [Figure 70-70-90] for
Connections detail parts.)
Figure 70-70-88 Installation: Install the plug and tighten to 82 ft.-lb. (111
N•m) torque.
Remove the plug and O-ring (Item 2) [Figure 70-70-88]

1 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.)
Installation: Install the plug and tighten to 82 ft.-lb. (111

N•m) torque.
Remove the adapter fitting (Item 3) [Figure 70-70-88]

2 plug and O-ring (Item 3) [Figure 70-70-89]. (See [Figure
70-70-92] for detail parts.)
Installation: Install the fitting and/or plug and tighten to

82 ft.-lb. (111 N•m) 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
5 [Figure 70-70-93] for detail parts.)
N-18909
Installation: Install the plug and tighten to 82 ft.-lb. (111
N•m) torque.
Figure 70-70-89 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
1 parts.)
Installation: Install the fitting and/or plug and tighten to 82

NOTE: Be sure the valve and spring (Item 6) [Figure

70-70-89] is installed as shown in [Figure 70-
3 70-89].
5
B-14310
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Thermostat, Oil Pressure Control Valves And Heater

Connections (Cont'd)
1
Figure 70-70-90
N-18870
NOTE: The adapter fitting (Item 1) [Figure 70-70-92] is

removed when a cab heater is installed on the
N-18868 loader. The port it comes from on the engine
block is the oil out let port to the heater.
Remove the thermostat spring (Item 1) [Figure 70-70-90] Installation: (See (Item 3) [Figure 70-70-88] for location
from the thermostat (Item 2) [Figure 70-70-90], inspect on the engine block.)
all parts and replace as needed.
Figure 70-70-93
Installation: (See (Item 1) [Figure 70-70-88] for location
on the engine block.)
Figure 70-70-91 1
3
3
1
2
N-18871
Replace the O-ring (Item 1) [Figure 70-70-93]. Remove

N-18869 the spring (Item 2) [Figure 70-70-93] from the oil
pressure control valve (Item 3) [Figure 70-70-93].
Remove the spring (Item 1) [Figure 70-70-91] from the The spring is marked with a red mark, for proper
oil pressure control valve (Item 2) [Figure 70-70-91]. installation. If the red mark is missing, the spring coil
Replace the O-ring (Item 3) [Figure 70-70-91]. diameter is 0.055 in. (1,4 mm).
The spring is marked with a yellow mark, for proper Installation: (See (Item 4) [Figure 70-70-88] for location
installation. If the yellow mark is missing, the spring coil on the engine block.)
diameter is 0.047 in. (1,2 mm).

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ENGINE COMPONENTS AND TESTS (CONT'D)
Thermostat, Oil Pressure Control Valves And Heater

Connections (Cont'd)
Figure 70-70-94
N-18872

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 0.039 in. (1,0 mm).

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ENGINE AND ENGINE MOUNTS Figure 70-80-2
NOTE: The engine and hydrostatic pumps will be

removed as an assembly.
2
20-1.)
2
Place the loader on jackstands. (See LIFTING AND 1
Raise the operator cab. (See OPERATOR CAB on Page

10-30-1.) N-19664
Remove the rear tires. (Both Sides.)

Mark the steering linkages (Item 1) [Figure 70-80-2].
Figure 70-80-1 Remove the four steering linkage bolts (Item 2) [Figure
70-80-2] and separate the linkages.
Installation: Tighten the nuts and bolts to 25 - 28 ft.-lb.

(34 - 38 N•m) 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) 2
[Figure 70-80-1]. (Both Sides.)
N-19740
Drain the fluid from the hydraulic reservoir. (See Removal
Disconnect the inlet hose (Item 2) [Figure 70-80-3] that

comes from the reservoir to the pump.
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ENGINE AND ENGINE MOUNTS (CONT’D) Figure 70-80-6
Removal And Installation (Cont'd)
Figure 70-80-4
1
1
N-19956
N-19742 Remove the four high pressure hoses (Item 1) [Figure

70-80-6] from the hydrostatic pump.
Disconnect the charge pressure hose (Item 1) [Figure
Figure 70-80-7
70-80-4] from the charge pressure sendor.
IMPORTANT
parts clean. Always use caps and plugs on hoses, 1
damage the system.
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.
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 70-80-

5], (that was disconnected earlier) between the engine
and the pump.
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ENGINE AND ENGINE MOUNTS (CONT'D) Figure 70-80-10
Figure 70-80-8
1
N-19983
1
Disconnect the engine electrical harness (Item 1) [Figure
N-19952 70-80-10] from the loader harness.
Figure 70-80-11
Remove the engine mount bolt (Item 1) [Figure 70-80-8]
at the left front engine mount.
Installation: Tighten the mounting bolt to 61 - 69 ft.-lb.

(83 - 94 N•m) 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.-lb.

(83 - 94 N•m) torque.
At the engine compartment, remove the battery. (See

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Figure 70-80-12
N-19982
1
Disconnect and cap the engine oil to cooler hoses (Item

N-19959 1) [Figure 70-80-14].
Remove the engine air cleaner. (See Housing Removal

Disconnect and plug the fuel return line (Item 1) [Figure And Installation on Page 70-40-1.)
70-80-12].
Remove the engine muffler. (See Removal And
Figure 70-80-13 Installation on Page 70-30-1.)
Figure 70-80-15
1 1
1 2
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].
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1
Figure 70-80-16
2 2
1
P-7917
3 Use the dimensions from [Figure 70-80-19 on Page 6] to

N-19989 make engine removal and installation brackets.
Install the lift bracket (Item 1) [Figure 70-80-18] on the

Disconnect the positive battery cable (Item 1) [Figure 70- engine.
80-16] from the starter.
Tighten the bolts (Item 2) [Figure 70-80-18] until the lift
Disconnect the negative battery cable (Item 2) [Figure bracket is held firmly against the valve cover.
70-80-16] from the starter.
NOTE: Bolts required are two 12 x 80 mm x 1.75
Remove the left rear engine mounting bolt (Item 3) thread.
[Figure 70-80-16] and nut.

- 94 N•m) torque.
Figure 70-80-17
N-19990
Remove the right rear engine mounting bolt (Item 1)

[Figure 70-80-17] and nut.

- 94 N•m) torque.
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ENGINE AND ENGINE MOUNTS (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 1/4” (4)
Thick Gusset
4.0
2.0 (102) 1.0 1.375
(25) 16.0 0.66 (16,8)
(51) (406) (35,0)
4.5
0.5 1.0 (25) (114) 8.525
(12,7) (218)
0.375 1.125 1.125
(9,5) 4.0 (28,6) (28,6)
1.75
Use Two 3/8”x1-1/4” Bolts (102) (44,5)
for Drilled and Tapped Holes
(2) 2x2x1/4 0.775

2.0 (51) Gusset (19,7)
9.0 17.750 9/16
1.0 (229) Dia. Hole (2)
(25)
4.25 2-1/2x2-1/2x22
(108)
1/4” Thick
0.5 0.6875 3/8 Dia. Hole (4)
(12,7) (17,5) Gusset
45°
1.75 MC-1799A
(44,5)
MC-1799A
Figure 70-80-20 Connect a chain hoist to the ring (Item 1) [Figure 70-80-
20] on the lift bracket.
1 Remove the engine / hydrostatic pump assembly from

the loader [Figure 70-80-20].
NOTE: Residue remaining in the engine oil cooler

may contaminate the engine oil and damage
the engine. In the event of severe engine oil
contamination, oil cooler replacement is
recommended. Drain and flush the cab heater
and plumbing thoroughly.
P-24730
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Engine Mount Replacement HEAVY DUTY

ENGINE Engine
MOUNT Mounting
Figure 70-80-21 Bracket
Washer
2
1
Loader Engine
3 Frame Mount
5 Spacer
Snubbing
Washer
TS-1520
6
7 Install the new engine mount as shown in the cut away

MC-1771 side view [Figure 70-80-22].
Tighten the mounting bolts to 61 - 69 ft.-lb. (83 - 94 N•m)

Use the following procedure to install new engine torque.
mounts:
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
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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. The ring gear (Item 1) [Figure 70-90-2] on the flywheel is
an interference fit. Heat the ring gear enough to expand it
Remove the drive belt. (See DRIVE BELT on Page 30- and hit it with a hammer to remove it evenly.
50-1.)
Clean the outer surface of the flywheel to give it a smooth
Figure 70-90-1 fit.
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 30-
50-1.)
Remove the hydrostatic pump. (See Hydraulic Pump

Removal & Installation on Page 30-40-7.)
P-5558
Remove the belt tension pulley assembly. (See Tensioner
Pulley Removal And Installation on Page 30-50-2.)
flywheel. Remove the starter. (See Removal And Installation on
Page 60-40-1.)
Installation: Tighten the flywheel bolts as follows:
Initial Torque 22 ft.-lb. (30 N•m) Figure 70-90-3
1st. Step Angle 60°
2nd Step Angle 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].
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RPM SENSOR Figure 70-91-2
Adjustment
Figure 70-91-1 1
2 1
P-4317
Turn the RPM sensor and the jam nut out from the
P-4313 flywheel. Set a clearance of 0.050 in. (1,27 mm) between
the jam nut and the housing with a feeler gauge (Item 1)
[Figure 70-91-2].
When reinstalling the RPM sensor, turn the RPM sensor
(Item 1) [Figure 70-91-1] in until it makes contact with Hold the sensor and retighten the jam nut.
the engine flywheel.
NOTE: New RPM sensors have a plastic tip which is
Turn the jam nut (Item 2) [Figure 70-91-1] until it used as a gauge during installation. The
contacts the flywheel housing. The jam nut should not be plastic tip is designed to come off after the
tightened, it needs to turn with the RPM sensor when the engine is started.
sensor is turned back out for adjustment.
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RECONDITIONING THE ENGINE
Deutz Engine Tools Identification Chart
B-16718
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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 rocker arms and brackets [Figure 70-100-
Remove the fuel injection pumps. (See Fuel Injection 2].
Pump Removal on Page 70-70-4.)
Figure 70-100-3
Remove the fuel injectors. (See Fuel Injector Removal
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.
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Disassembly (Cont'd)
Figure 70-100-4
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
CD-15471
CD-15515
Remove the oil pump [Figure 70-100-7].

Remove the oil pressure control valve [Figure 70-100-5].
Remove the oil pump relief valve (Item 1) [Figure 70-
Remove the plugs or fittings from the engine block. 100-7].
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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
Figure 70-100-9 Piston, Checking on Page 70-100-35.)
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

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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 70-
100-30.)
Figure 70-100-13
1
CD-15526
Remove the main bearing caps bolts [Figure 70-100-15].
CD-15525 Remove the main bearing caps.
Remove the crankshaft.

Install the timing tool (Item 1) [Figure 70-100-13] for the
camshaft. To check the crankshaft specifications. (See Crankshaft,
Checking on Page 70-100-31.)
Remove the thrust washer from the camshaft [Figure 70-
100-13]. Remove the upper half of the main bearings.
Remove the timing tool.
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Figure 70-100-16
CD-15531
Install the oil pressure control valve and compression

CD-15527 spring [Figure 70-100-18].
Install the plug.

Remove the tappets from the engine block [Figure 70-
100-16]. Figure 70-100-19
Assembly
Figure 70-100-17
CD-15532
Install new seals on the fittings and/or plugs.

CD-15528
Install all the fittings and/or plugs and tighten to 82 ft.-lb.
(111 N•m) torque [Figure 70-100-19].
Install the thermostat and compression spring [Figure
70-100-17].
Install the plug and tighten to 82 ft.-lb. (111 N•m) torque.
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Assembly (Cont'd)
Figure 70-100-20
CD-15539
Install a new seal on the plug and install in the block.

CD-15537 Tighten the plug to 21 ft.-lb. (28 N•m) torque [Figure 70-
100-22].
Install the plug and tighten to 37 ft.-lb. (50 N•m) torque Figure 70-100-23
[Figure 70-100-20].
Figure 70-100-21
CD-15540
CD-15538 Install the tappets [Figure 70-100-23].
Install the oil pressure switch and tighten to 115 in.-lb. (13
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Assembly (Cont'd)
Figure 70-100-24
CD-15542
Install the thrust washer with the lubricating groove

CD-15435 toward the crankcase [Figure 70-100-26].
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 70-
100-24].
Figure 70-100-25
1
CD-15543
Install the camshaft timing tool (Item 1) [Figure 70-100-

27].
CD-15541 Tighten the camshaft thrust washer bolt to 15 ft.-lb. (21

Install the camshaft [Figure 70-100-25]. Remove the timing tool.
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Assembly (Cont'd)
Figure 70-100-28
CD-15546
Install the thrust bearings halves on the main bearing cap

CD-15544 [Figure 70-100-30].
Measure the width of the thrust washers / main bearing

Install the upper main bearing halves [Figure 70-100- cap [Figure 70-100-30].
28].
Figure 70-100-29
CD-15545
Install the other main bearing half into the main bearing
caps [Figure 70-100-29].
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Assembly (Cont'd)
Figure 70-100-31
CD-15547
CD-15549
Install the main bearing locating sleeves [Figure 70-100-

CD-15548 32].
Figure 70-100-33
Measure the bearing journal width at the crankshaft
(inset) [Figure 70-100-31].
Specifications:
Journal Width 1.378 - 1.379 in.
Std. (35,0 - 35,04 mm)
Limit for O/S 1.395 in. (35,44 mm)
Determine the end play for the crankshaft [Figure 70-

100-31].
Specifications:
Std. End Play 0.004 - 0.010 in.
(0,1 - 0,273 mm) CD-15550
Wear Limit 0.016 in. (0,4 mm)
Install the crankshaft into the engine block [Figure 70-

Use new thrust washer as needed to get the correct end 100-33].
play.
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Assembly (Cont'd)
Figure 70-100-34
CD-15553
Install the main bearing caps / main bearing assembly

CD-15551 [Figure 70-100-36].
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
Tighten the main bearing cup bolts as follows [Figure 70-
100-37]:
Install the main bearing / thrust washer assembly [Figure
70-100-35]. Initial Torque 37 ft.-lb. (50 N•m)
1st Step Angle 60°
NOTE: The main bearing cap No. 1, at the flywheel
end, the chamfer must be towards the 2nd Step Angle 45°
flywheel end.
863 Bobcat Loader

785 of 968
Assembly (Cont'd)
Figure 70-100-38
CD-15557
Measure the distance between the top edge of the

CD-15555 crankpin (TDC) and cylinder head sealing surface at
every cylinder [Figure 70-100-40].
Put sealing compound on the rear cover [Figure 70-100- Figure 70-100-41
38].
Figure 70-100-39
CD-15558
CD-15556 Compare actual dimension with the dimension listed

[Figure 70-100-41]:
Install the rear cover complete with a new rear seal Specifications:
[Figure 70-100-39].
Piston Class A 7.732 - 7.736 in.
(196,39 - 196,49 mm)
NOTE: Make sure the rear cover oil pan surface
aligns with the engine block surface.
NOTE: If the crankshaft is undersize, 0.005 in. (0,125
Tighten the bolts to 15 ft.-lb. (21 N•m) torque [Figure 70- mm) must be added to the dimension listed.
100-39].
863 Bobcat Loader

786 of 968
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]. NOTE: The flywheel symbol on the piston must be
toward the flywheel.
Figure 70-100-43
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 Install the connecting rod cap on the connecting rod,
[Figure 70-100-43]. make sure the numbers are aligned [Figure 70-100-45].
863 Bobcat Loader

787 of 968
Assembly (Cont'd)
Figure 70-100-46
CD-15565
Put sealing compound on the front cover sealing surface

CD-15563 [Figure 70-100-48].
NOTE: Make sure the camshaft / centrifugal governor

Tighten the connecting rod bolts as follows [Figure 70- connecting is clean and free of oil.
100-46]:
Figure 70-100-49
Initial Torque 22 ft.-lb. (30 N•m)
1st Step Angle 60°
2nd Step Angle 60°
Figure 70-100-47
CD-15566
Install the front cover with the new shaft seals on the
CD-15564 NOTE: Make sure the oil pan sealing surface on the
front cover aligns with the sealing surface on
the block [Figure 70-100-49].
Check that the connecting rods can be easily moved
back and forth on the crankpin [Figure 70-100-47].
863 Bobcat Loader

788 of 968
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.-lb. (21 N•m) torque Install the camshaft bolt [Figure 70-100-52].
[Figure 70-100-50].
Figure 70-100-53
Figure 70-100-51
CD-15469
CD-15568
Tighten the camshaft bolt finger tight only [Figure 70-

Install the crankshaft gear on the crankshaft [Figure 70- 100-53]. Camshaft gear must still turn freely.
100-51]. Make sure the mating surfaces are clean and
free of oil.
Install the bolt and tighten to 243 - 295 ft.-lb. (330 - 400
N•m) torque.
863 Bobcat Loader

789 of 968
Assembly (Cont'd)
Figure 70-100-54
CD-15472
Tighten the oil pump bolts to 16 ft.-lb. (22 N•m) torque

CD-15470 [Figure 70-100-56].
Install the engine timing belt. (See Timing Belt Installation

Install a new gasket on the oil pump [Figure 70-100-54]. 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 70-100- Put spacers on sealing surface of the engine block and
55]. set dial indicator gauge to 0 [Figure 70-100-57]. (See
Deutz Engine Tools Identification Chart on Page 70-100-
1. for correct tool.)
863 Bobcat Loader

790 of 968
Assembly (Cont'd)
Figure 70-100-58
CD-15475
Compare the measurements with the specifications to

CD-15474 determine the correct cylinder head gasket.
Specifications:
Position the dial gauge on the piston [Figure 70-100-58].
Marking of Cylinder
Figure 70-100-59 Piston Projection Head Gasket [Figure 70-100-60]
0.023 - 0.027 in. (0,59 - 0,69 mm) 1 Notch

0.027 - 0.030 in. (0,69 - 0,76 mm) 2 Notches
0.030 - 0.033 in. (0,76 - 0,83 mm) 3 Notches
1
1 Figure 70-100-61
Piston pin axis

B-14695
Measure at the gauge points (Item 1) [Figure 70-100-

59].
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].
863 Bobcat Loader

791 of 968
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

CD-15477 the correct sequence [Figure 70-100-64].

Install the cylinder head gasket [Figure 70-100-62]. 1st Stage Torque 59 ft.-lb. (80 N•m)
Gasket is marked TOP. 2nd Stage Torque 118 ft.-lb. (160 N•m)
3rd Stage Torque 90°
Make sure the sealing surfaces of the cylinder head
gasket is free of oil.
Figure 70-100-65
Install the cylinder head.
Measure the cylinder head bolts.

Std. Length 5.90 ± 0.03 in. (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 70-100-

63].
Install the head bolts.
863 Bobcat Loader

792 of 968
Assembly (Cont'd)
Figure 70-100-66
CD-15483
Install the valve cover gasket [Figure 70-100-68]. Install

CD-15481 the valve cover. Tighten the bolts to 75 in.-lb. (8,5 N•m)
torque.
Install the rocker arms / bracket assembly [Figure 70- Install new intake manifold gasket.
100-66].
Install the intake manifold and tighten the bolts to 15 ft.-
Figure 70-100-67 lb. (20 N•m) torque.
Install new exhaust manifold gaskets.
Install the exhaust manifold and tighten the bolts to 30 ft.-

lb. (40 N•m) torque.
Figure 70-100-69
CD-15482
Tighten the rocker arm bracket bolts to 15 ft.-lb. (21 N•m)

torque [Figure 70-100-67].
Set the valve clearance. (See Valve Clearance

Adjustment on Page 70-70-24.)
CD-15484
Install a new seal on the fuel lift pump [Figure 70-100-

69].
863 Bobcat Loader

793 of 968
Assembly (Cont'd)
Figure 70-100-70
CD-15487
Tighten the lift pump bolts to 15 ft.-lb. (21 N•m) torque

CD-15485 [Figure 70-100-72].
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]. Install the fuel injectors. (See Fuel Injector Removal and
Figure 70-100-71
Install the fuel injector pumps. (See Fuel Injection Pump
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].
863 Bobcat Loader

794 of 968
Assembly (Cont’d)
Figure 70-100-74
B-14696
Install the oil pan bolts and tighten to 15 ft.-lb. (21 N•m)
CD-15489 torque as shown in [Figure 70-100-76].
Install the oil pan plug and tighten to 40 ft.-lb. (55 N•m)
Install the oil suction pipe and tighten the bolts to 16 ft.-lb. torque.
(22 N•m) torque [Figure 70-100-74].
Install the flywheel. (See Flywheel Removal And
Figure 70-100-75 Installation on Page 70-90-1.)
Install the turbocharger. (See Turbo Charger Removal

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.-lb.

(0,5 N•m) torque.
863 Bobcat Loader

795 of 968
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-79
Cylinder, Checking
Figure 70-100-77
b 1
a 2
1 2
B-14697A
B-14697
Check the cylinders with engine block longitudinal (a)

CD-15319 and transverse (b) axis and in three planes [Figure 70-
100-79].
Clean the engine block and inspect for damage. Specification
Install the main bearing caps [Figure 70-100-77]. Cylinder Bore 3.58 + 0.0008 in.
(91 + 0,02 mm)
Tighten the main bearing cap bolts as follows: Wear Limit 3.59 in. (91,1 mm)

1st Stage Angle 60°
2nd Stage Angle 45°
Figure 70-100-78
CD-15421
Using a dial indicator gauge check the cylinders [Figure

70-100-78].
863 Bobcat Loader

796 of 968
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
Remove all the camshaft bearing bushings using a
camshaft bushing removal tool as needed [Figure 70-
Check the camshaft bearing bushings at points (1) and 100-82].
(2) in the planes of (a) and (b) [Figure 70-100-80].
Figure 70-100-83
Figure 70-100-81
(228,1±0,3 mm)
(117,1±0,3 mm)
(118,9±0,3 mm)
(2,5±0,3 mm)
0.098±0.012in.
4.681±0.012in.
0.019±0.012in.
8.98±0.012in.
4.61±0.012in.
(0,5±0,3 mm)
0
0
A B
B-14699
CD-15350
Use the dimensions in figure [Figure 70-100-83] to install

Check the camshaft bushings using a gauge [Figure 70- the camshaft bushings.
100-81].
Inner Diameter 2.126 + 0.002 in.

(54 + 0,054 mm)
863 Bobcat Loader

797 of 968
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 Figure 70-100-87
the oil lube hole aligns with the oil hole in the engine
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].
863 Bobcat Loader

798 of 968
Control Rod Guide Bushing Removal (Cont'd)
Figure 70-100-88
CD-15414
Install the puller into the bore until the pin engages
CD-15412 [Figure 70-100-90].
Figure 70-100-91
Remove the cover [Figure 70-100-88].
Figure 70-100-89
CD-15415
CD-15413 Install the spacer tool in position. Pull the pipe from the
lower press fit [Figure 70-100-91].
Drill a 7/32 in. (5,5 mm) hole on one side of the pipe NOTE: Do Not pull pipe completely out.
[Figure 70-100-89].
Remove the spacer tool.
NOTE: Carefully clean the engine block after drilling.
863 Bobcat Loader

799 of 968
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
Install the guide on the arbor assembly with the chamfer
pointing toward the crankcase [Figure 70-100-95].
Using the tool, drive the guide bushing out [Figure 70-
100-93].
863 Bobcat Loader

800 of 968
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

Figure 70-100-97
CD-15424
Remove the guide bushing at the flywheel end of the

CD-15422
Drive the bushing into the engine block as far as it will go

[Figure 70-100-97].
863 Bobcat Loader

801 of 968
Figure 70-100-100
CD-15427
Fasten the arbor assembly and guide bushing to the

CD-15425 engine block [Figure 70-100-102].
Figure 70-100-103
Assemble the arbor without the spacer [Figure 70-100-
100].
Figure 70-100-101
CD-15428
Drive in the guide bushing as far as it will go, at the

CD-15426 flywheel end [Figure 70-100-103].
Install the guide bushing on the arbor assembly with the

chamfer pointing toward the crankcase [Figure 70-100-
101].
863 Bobcat Loader

802 of 968
Figure 70-100-104
CD-15431
Put sealing compound on the new cover [Figure 70-100-

CD-15429 106].
Figure 70-100-107
Remove the arbor assembly [Figure 70-100-104].
Figure 70-100-105
CD-15432
CD-15430 Install the new cover flush with the engine block [Figure
70-100-107].
Install the new pipe in the block as far as it will go with the
arbor assembly [Figure 70-100-105].
863 Bobcat Loader

803 of 968
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 Figure 70-100-111
bushings [Figure 70-100-108].
Figure 70-100-109
CD-15439
CD-15434 Clean the seal seating surface [Figure 70-100-111].

Inspect the cover for damage, replace as needed.
Compress the starter spring. Install the parallel pin into

the recess for the control rod travel limitation [Figure 70-
100-109].
Check to make sure it is flush with the surface.
863 Bobcat Loader

804 of 968
RECONDITIONING THE ENGINE (CONT'D) Crankshaft, Checking
Rear Cover Seal Removal And Installation (Cont’d) Figure 70-100-114
Figure 70-100-112
(20,4 ± 0,2 mm)

0.803 ± 0.008 in. CD-15443
B-14700
Put the crankshaft on v-blocks.
When installing the new shaft seal, use the dimension Check the main bearing journals:
shown in [Figure 70-100-112].
Specifications:
Figure 70-100-113
Journal Dia. 2.755 -0.0004 in.
-0.0012
(70 -0.0001 mm)
-0.03
Each Undersize 0,010 in. (0,25 mm)
Undersize Limit 2.736 -0.0004 in.
-0.0012
(69,51 -0.01 mm)
-0.03
Journal Oval
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.)
863 Bobcat Loader

805 of 968
Crankshaft, Checking (Cont’d)
Figure 70-100-115
CD-15445
Use a dial indicator and check crankshaft for out of

CD-15444 roundness [Figure 70-100-116].
Specifications:
Specifications: Out of Roundness 0.002 in. (0,05 mm)
Journal Width 1.378 + 0.0016 in. Max
(35 + 0.04 mm)
Each Oversize 0.016 in. (0,4 mm) Figure 70-100-117
Oversize Limit 1.395 in. (35,44 mm)
Check the connecting rod journals [Figure 70-100-115].

Pin Dia. 2.16 -0.0004
-0.0012 in.
(55 -0.01 mm)
-0.03
Undersize Limit 2.146 -0.0004
-0.0012 in.
(54,5 -0.01 mm)
-0.03
Wear Limit Pin 0.0004 in. (0,01 mm)
Oval
CD-15446
Check the surface of the crankshaft seal area [Figure

70-100-117].
Recondition the crankshaft as needed.
863 Bobcat Loader

806 of 968
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-120
Connecting Rod, Checking
Figure 70-100-118
1 2 a
CD-15448
Replace small end bushing as needed [Figure 70-100-

B-14701 120].
Specifications:
When checking the connecting rod large and small end,
measure at the points (1) and (2) and in planes (a) and Bore for Small End 1.299 + 0.0008 in.
(b) [Figure 70-100-118]. Bushing (33 + 0,02 mm)
O.D. of Small End 1.299 +0.0004
Figure 70-100-119 Bushing +0.0027 in.
(33 +0,110 mm)
+0,070
Figure 70-100-121
CD-15447
Check the small end bushing [Figure 70-100-119].
Specifications: CD-15449
I.D. of Small End Bushing 1.18 + 0.00014
+ 0.00009 in.
30 + 0,035 Press in the small end bushing, make sure the lubrication
+ 0,025 mm holes are in alignment [Figure 70-100-121].
Wear Limit Bushing
Clearance 0.003 in. (0,08 mm)
863 Bobcat Loader

807 of 968
Connecting Rod, Checking (Cont'd)
Figure 70-100-122
CD-15452
Tighten the connecting rod cap nuts as follows [Figure

CD-15450 70-100-124].

After pressing in the small end bushing, bore the bushing 1st Step Angle 60°
to the following dimensions [Figure 70-100-122]. 2nd Step Angle 60°
Specifications:
I.D. of Small End 1.181 +0.00014
Bushing +0.00009 in.
(30 + 0,035 mm)
+ 0,025
Figure 70-100-123
2908 2908
CD-15451
Install the correct cap on the correct rod [Figure 70-100-

123].
863 Bobcat Loader

808 of 968
RECONDITIONING THE ENGINE (CONT'D) Piston, Checking
Connecting Rod, Checking (Cont’d) Figure 70-100-126
Figure 70-100-125
B-8194
CD-15454
Remove the piston rings from the piston [Figure 70-100-
126].
Measure the big end bore [Figure 70-100-125]. If the
measurement is the same as the specific valve, the Remove the piston from the connecting rod.
necessary preload on the bearing halves will be
obtained. (See Connecting Rod, Checking on Page 70-100-33. to
check connecting rod specifications.)
Specifications:
Big End I.D. 2.303 + 0.0008 in. Figure 70-100-127
(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. 2.1655 - 2.167 in.

(55,004 - 55,04 mm)
Each Undersize 0.010 in. (0,25 mm)
Limit For Undersize 2.148 - 2.1472 in.
(54,504 - 54,54 mm) B-8231
Radial Clearance 0.005 in. (0,12 mm)

Wear Limit
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 0.004 in. (0,10 mm)
Over a Distance of 3.94 in. (100 mm)
Squareness Check- 0.002 in. (0,05 mm)
Tolerance
863 Bobcat Loader

809 of 968
RECONDITIONING THE ENGINE (CONT'D)
Piston, Checking (Cont’d)

Specifications:
Figure 70-100-128 Wear Limit
1st Ring 0.008 in. (0,2 mm)
2nd Ring 0.006 in. (0,16 mm)
3rd Ring 0.005 in. (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 B-8230
1st Ring Gap 0.012 - 0.020 in. (0,3 - 0,5 mm)
2nd Ring Gap 0.031 - 0.039 in. (0,8 - 1,0 mm)
Check piston pin for wear [Figure 70-100-130].
3rd Ring Gap 0.018 - 0.028 in. (0,45 - 0,7 mm)
Specifications:
Figure 70-100-129 Piston Pin 1.118 - 0.0002 in. (30,0 - 0,005 mm)
O.D.
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

863 Bobcat Loader

810 of 968
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
3 TS-1927
CD-15456
Figure 70-100-133 Install the snap ring into the piston [Figure 70-100-134].
1 Figure 70-100-135
3
TS-1928A
CD-15457
1st Ring - Is a double tapered ring, (Item 1) [Figure 70-
100-132] & [Figure 70-100-133]. It is installed on the
piston with the mark TOP facing the combustion NOTE: The snap ring gap must be towards the piston
chamber. crown (Item 1) [Figure 70-100-135].
2nd Ring - Is a rectangular ring, (Item 2) [Figure 70-100-

132] 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.
863 Bobcat Loader

811 of 968
Piston Installation On the Connecting Rod (Cont'd)
Figure 70-100-136
2908 2908
CD-15451
Figure 70-100-139
CD-15458
1
Install the piston on the connecting rod [Figure 70-100-

136].
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.
N-19068 Figure 70-100-140
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].

863 Bobcat Loader
812 of 968
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

Specifications:
damaged, replace the cylinder head.
Wear Limits
Using a valve spring tool, remove the spring locks, valve Intake Valve 0.005 in. (0,12 mm)
spring cap, valve spring and valve [Figure 70-100-141]. Exhaust Valve 0.006 in. (0,15 mm)
(See Deutz Engine Tools Identification Chart on Page 70-
100-1. for correct tool.) 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 0.314 - 0.0006 in.

(7,98 - 0,015 mm)
Std. Exhaust Valve 0.313 - 0.0006 in.
(7,96 - 0,15 mm)
863 Bobcat Loader

813 of 968
RECONDITIONING THE ENGINE (CONT'D) Valve Seats, Checking
Valves, Checking (Cont’d) Figure 70-100-145
Figure 70-100-144
Angle
Thickness
Diameter CD-15463
B-8202
Measure the valve seat width [Figure 70-100-145].
Measure the valve rim thickness [Figure 70-100-144].

Specifications:
Specifications (BF4M1011F): Width (Intake) 0.062 ± 0.016 in. (1,58 ± 0,4 mm)
Intake Valve 0.055 in. (1,4 mm) (Exhaust) 0.067 ± 0.016 in. (1,7 ± 0,4 mm)
Exhaust Valve 0.05 in. (1,2 mm)
Figure 70-100-146
Measure the valve head diameter [Figure 70-100-144].
Specifications (BF4M1011):
Intake Valve 1.594 ± 0.004 in. (40,1 ± 0,1 mm)
Exhaust Valve 1.374 + 0.004 in. 34,9 + 0,01 mm)
Specifications (BF4M1011F):
Intake Valve 1.594 ± 0.004 in. (40,1 ± 0,1 mm)
Exhaust Valve 1.374 ± 0.004 in. 34,9 ± 0,01 mm)
Valve seat angle [Figure 70-100-144].
Specifications (BF4M1011F):
Intake Valve 30° CD-15464
Exhaust Valve 45°
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 in. (1,3 ± 0,13 mm)
Recondition the valve seats and valve guides if worn.
863 Bobcat Loader

814 of 968
Valve Spring, Checking
Figure 70-100-147
Inclination
Free Length
CD-15323
Square
Install the valve seal on the protective sleeve and push
B-8208 the seal down [Figure 70-100-149].
Remove the protective sleeve.

Measure valve spring free length [Figure 70-100-147].
Figure 70-100-150
Specifications:
Valve Spring Dia. 0.132 in. (3,35 mm)
Free Length 1.74 in. (44,3 mm)
Valve Spring Dia. 0.134 in. (3,40 mm)
Free Length 1.547 in. (39,3 mm)
Inclination 0.126 in. (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 70-100-

148].
Install the protective sleeve or masking tape on the valve

stem grooves [Figure 70-100-148].
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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
Check for wear at the following locations and replace as

Use the valve spring tool, install the valve spring lock needed [Figure 70-100-154]:
[Figure 70-100-152].
Journals
Repeat the above procedure to install all the valves. Adjusting Bolt
Rocker Arm Contact Face
Bore
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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]. Remove the engine shut-down solenoid [Figure 70-100-
157].
Figure 70-100-156
Figure 70-100-158
CD-15331
CD-15344
Install the rocker arms on the bracket.

Disconnect the governor spring [Figure 70-100-158].
Install the snap ring [Figure 70-100-156].
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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 70-100-

159] 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].
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Figure 70-100-164
CD-15353
Remove the shut-down lever with spacer bushings

CD-15351
[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].
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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 speed control lever and spacer bushing
[Figure 70-100-172].
Remove the dowel pin [Figure 70-100-170].
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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 NOTE: On later model Deutz engines the breather is
the height from the cover [Figure 70-100-174] and make located in the valve cover. The breather vent
a record of this for assembly. shown in photo [Figure 70-100-176] is used in
both engines.
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Front Cover Assembly
Figure 70-100-177 2
1 3
6
0-0,39 in.
5 4 (0-1 mm)
B-14704
If the torque control was disassembled, do the following

CD-15365 procedure to assemble:
Turn (Item 1) [Figure 70-100-179] into (Item 2) [Figure

Inspect the front cover for damage [Figure 70-100-177]. 70-100-179] to leave a protrusion of 0 - 0.039 in. (0 - 1
mm).
Replace the front cover as needed.
Tighten the lock nut (Item 3) [Figure 70-100-179] to 12
Figure 70-100-178 ft.-lb. (16 N•m) torque.
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.-lb. (6 N•m) torque.
Figure 70-100-180
B-14703
Inspect the individual parts of the torque control

assembly [Figure 70-100-178].
CD-15371
Install the torque control into the front cover [Figure 70-
100-180].
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Front Cover Assembly (Cont'd)
Figure 70-100-181
CD-15375
Tighten the clamp nut to 88 in.-lb. (10 N•m) torque

CD-15373 [Figure 70-100-183].
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 70-
100-184]. (See Deutz Engine Tools Identification Chart
Measure the thread reach [Figure 70-100-182]. on Page 70-100-1. for correct tool.)
Specifications:
Thread Reach 0.252 ± 0.019 in.
(6,4 ± 0,5 mm)
NOTE: Dynamometer testing may be necessary

depending on engine performance.
Install the clamp and nut [Figure 70-100-182].
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Front Cover Assembly (Cont'd) 0.79 ± 0.039 in.

(20 ± 1 mm)
Figure 70-100-185
B-14706
Adjust the minimum speed screw to 0.79 ± 0.039 in. (20 ±

CD-15377 1,0 mm) [Figure 70-100-187].
Tighten the lock nut to 40 in.-lb. (4,5 N•m) torque.

Do Not put oil on the crankshaft seal.
Figure 70-100-188
Press the crankshaft seal into the front cover [Figure 70-
100-185].
Figure 70-100-186
0.236 ± 0.039 in.

(6 ± 1 mm)
CD-15380
Install the spacer bushing and spring on the shut down

B-14705 shaft [Figure 70-100-188].
Adjust the distance of the shut-down stop screw to 0.236

± 0.039 in. (6 ± 1 mm) [Figure 70-100-186].
Tighten the lock nut to 40 in.-lb. (4,5 N•m) torque.
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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 70-100-
CD-15382 192].
Put grease on the O-ring and install on the shaft [Figure

70-100-190].
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Figure 70-100-193
B-14708
When installing the speed control lever, make sure it is

CD-15386 installed in the correct direction [Figure 70-100-195].
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
CD-15387 70-100-196].
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].
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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 70-100-

198]. Replace as needed.
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Figure 70-100-201
1
2
CD-15396
Install shims of at least 0.011 in. (0,3 mm) thickness at

CD-15394 points (Items 1 & 2) [Figure 70-100-203].
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.-lb. (9,2
N•m) torque.
CD-15395
NOTE: The longer space (Item 1) [Figure 70-100-204]
on the governor lever shaft goes toward the
Inspect roller lever, shaft and idling lever wear [Figure cover when being installed.
70-100-202].
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Figure 70-100-205
CD-15400
1 Assemble the roller lever with the idling lever and shaft
CD-15398 [Figure 70-100-207].
Figure 70-100-208
Measure the ball bearing (Item 1) [Figure 70-100-205],
by lightly pressing the roller lever.
Set the dial gauge to zero.
Figure 70-100-206 1
N-18859
CD-15401
Install the complete governor lever shaft assembly into

1 the front cover.
CD-15399 Tighten the bolts to 81 in.-lb. (9,2 N•m) torque [Figure

70-100-208].
Place dial indicator on ball bearing (Item 1) [Figure 70- NOTE: The longer space (Item 1) [Figure 70-100-208]
100-206]. on the governor lever shaft goes down toward
the cover when installed.
Make record of the two readings.
The required tolerance is 0.0019 in. (0,05 mm).
It is possible to install extra shims at (Items 1 & 2)

[Figure 70-100-203] to get the required measurement.
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Figure 70-100-209
CD-15405
Install a greased O-ring on the shut down solenoid

CD-15402 [Figure 70-100-211].
Figure 70-100-212
Connect the governor spring [Figure 70-100-209].
Figure 70-100-210
CD-15406
CD-15403 Install the shut down solenoid into the front cover [Figure
70-100-212].
Install the cover with new gasket. Tighten the bolts to 40 Tighten the bolts to 79 in.-lb. (9 N•m) torque.
in-lb. (4,5 N•m) torque [Figure 70-100-210].
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RECONDITIONING THE ENGINE (CONT'D) Turbo Charger Removal and Installation
Front Cover Assembly (Cont'd) Figure 70-100-215
Figure 70-100-213
P-7780
CD-15407
Remove the exhaust pipe (Item 1) [Figure 70-100-215].
Install new O-ring on the breather vent [Figure 70-100- Figure 70-100-216
213].
Figure 70-100-214
3
4 1
P-7779
CD-15408 Disconnect the air cleaner hose (Item 1) [Figure 70-100-

216], inspect the air intake system.
Install the breather vent into the front cover. Tighten the Remove the oil tubeline (Item 2) [Figure 70-100-216]
bolts to 75 in.-lb. (8,5 N•m) torque [Figure 70-100-214]. and clean the inside of the line with solvent or air, to
remove contaminated oil.
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RECONDITIONING THE ENGINE (CONT'D) Drain the engine oil from the crankcase again, replace
the engine oil and filter. (See Replacing Oil And Filter on
Turbo Charger Removal And Installation (Cont’d) 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
P-5292
P-7343

Remove the oil tubeline (Item 1) [Figure 70-100-217], procedure:
clean the inside of the line with solvent or air to remove
contaminated oil. MEL 1522 Torque Multiplier Support Device
MEL 1526 Torque Multiplier
Remove the exhaust manifold nuts (Item 3) [Figure 70-
100-216]. If the v-belt pulley is installed, remove the four bolts and
remove the pulley (Item 1) [Figure 70-100-218].
Installation: Tighten the nuts to 22 ft.-lb. (30 N•m)
torque. Figure 70-100-219
Remove the hose clamps (Item 4) [Figure 70-100-216].
Remove the turbocharger from the intake manifold hose. 1
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 10-
130-1.)
P-13135A
Start the engine and run at idle until oil pressure is
assured.
Install the tool (Item 1) [Figure 70-100-219] on the
Work the unit until operating temperature of engine is crankshaft hub using the v-belt pulley bolts.
maintained for approximately 15 minutes.
Install the crankshaft gear mounting bolt (Item 2) [Figure
Idle and cool the down engine approximately 3 to 4 70-100-219] and tighten to 95 ft.-lb. (130 N•m) torque.
minutes, and stop the engine.
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Crankshaft Gear Mounting Bolt Torque Procedure

(Cont'd)
Figure 70-100-220
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 70-100-

222] & [Figure 70-100-223].
P-13136
NOTE: If the torque multiplier tool (Item 1) [Figure 70-

100-221] has a degree wheel, the crankshaft
bolt does not have to be marked.
Install the torque multiplier tool (Item 1) [Figure 70-100-

221], with the socket, into the tool.
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HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SERVICE . . . . . . . . . . . . . . . . . . . . . . . 80-90-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
SAFETY &
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . 80-10-2 MAINTENANCE
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 DRIVE
Engine Coolant Bypassing The Heater Valve . . . . . . . . . 80-50-11 SYSTEM
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . 80-50-12
Poor A/C Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-13
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1
Compressor Clutch Disassembly. . . . . . . . . . . . . . . . . . . 80-110-2
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1
HVAC
EVAPORATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-190-1
EVAPORATOR / HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . 80-160-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 80-160-2
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-180-1

GENERAL AIR CONDITIONING SERVICE GUIDELINES . . . 80-60-1

Component Replacement And Refrigeration Leaks. . . . . . 80-60-3
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
Compressor Oil Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
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HEATING, VENTILATION, AIR CONDITIONING (CONT’D)
HEATER / AC FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-210-1

Wire Connector Removal And Installation . . . . . . . . . . . . 80-210-4
HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-220-1

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-220-1
PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1

PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1

RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1

REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Cleaning The Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
Compressor Drive Belt Inspection . . . . . . . . . . . . . . . . . . . 80-40-2
Filter Elements Removal And Installation . . . . . . . . . . . . . 80-40-2
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . 80-100-1

Charging Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-4
Charging Procedure With A Manifold Gauge Set . . . . . . 80-100-3
Reclamation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 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
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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.
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AIR CONDITIONING SYSTEM FLOW (CONT'D)
Chart
Thermostat
Cold Air
Evaporator
5
Evaporator
4
Expansion Valve
Blower
6
1 Compressor
2 Condenser
Pressure
Switch
Sight
Glass
Fan
Desiccant
3 Receiver Drier
Status Of R134a_______________________________________________
High Pressure Gas Low Pressure Liquid
High Pressure Liquid Low Pressure Gas
b-16691
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COMPONENTS Figure 80-20-3
Identification
Figure 80-20-1 2
N-22134
Receiver / Drier: The receiver / drier (Item 1) [Figure 80-

N-22252 20-3] is the unit that receives the liquid refrigerant from
the condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
Compressor: The compressor (Item 1) [Figure 80-20-1] extra liquid refrigerant until it is needed by the evaporator.
is the pump that circulates the refrigerant throughout the
system. It raises the pressure of the refrigerant for heat Figure 80-20-4
transfer through the condenser and evaporator.
NOTE: The A/C system (Compressor) is

recommended to be turned on for at least 5
minutes weekly throughout the year to
lubricate the internal components. 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 80-20-
4] 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.
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COMPONENTS (CONT'D) Figure 80-20-7
Identification (Cont'd)
Figure 80-20-5
1
1
2
N-22087
Evaporator Coil: The evaporator coil (Item 1) [Figure 80-

N-22121 20-7] cools and dehumidifies the air before it enters the
cab.
Heater / Evaporator Unit: The heater / evaporator unit Thermostat: The thermostat (Item 2) [Figure 80-20-7]
(Item 1) [Figure 80-20-5] is located behind the loader controls the temperature of the evaporator coil.
cab. The unit delivers the cold air for the A/C and warm
air for heat into the cab. The unit contains the blower, Heater Coil: The heater coil (Item 3) [Figure 80-20-7]
heat & A/C coils, thermostat and expansion valve. supplies the warm air into the cab by passing air through
the coil.
Figure 80-20-6
Figure 80-20-8
N-22150
N-22100
Expansion Valve: The expansion valve (Item 1) [Figure

80-20-6] controls the amount of refrigerant entering the Heater / Evaporator Blower: The blower (Item 1) [Figure
evaporator coil. 80-20-8] is used to push air through the heater and
evaporator coils and into the cab.
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COMPONENTS (CONT'D) Figure 80-20-11
Identification (Cont'd)
Figure 80-20-9
1
2 4
N-22134
3
Pressure Switch: The pressure switch (Item 1) [Figure

N-22261 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)
Control Panel: The panel (Item 1) [Figure 80-20-9] has or less on the high side, which indicates loss of
three separate components. 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 80-20-

9] 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
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.
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SAFETY Figure 80-30-2
Safety Equipment
Figure 80-30-1
P16399
R-134a inside a canister or in an A/C system is a liquid

P16398 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
In servicing A/C and heater systems you will be exposed should flood the area with cool water and SEEK
to high pressures, temperatures and several chemical MEDICAL ATTENTION FAST! It is a good idea to wear
hazards. Moving belts and pulleys are normal shop gloves [Figure 80-30-2] to prevent frost bite if you should
hazards. get refrigerant on your hands.
In addition to exercising caution in your work, DO WEAR

SAFETY GLASSES OR A FACE SHIELD [Figure 80-
30-1] 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.
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REGULAR MAINTENANCE Figure 80-40-3
Cleaning The Condenser
Open the rear door. 1
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.
Slide the hydraulic cooler (Item 2) [Figure 80-40-3]

toward the rear of the loader.
2
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].
Figure 80-40-2 1
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.
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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
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].
N-22064
Remove the filter cover and filter (Item 1) [Figure 80-40-

7] from the loader.
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REGULAR MAINTENANCE (CONT’D) Figure 80-40-10
Filter Elements Removal And Installation (Cont’d)
Figure 80-40-8 1
1
N-22061
Remove the recirculating filter (Item 1) [Figure 80-40-10]

N-22063 from the rear of the cab.
Figure 80-40-11
Remove the filter (Item 1) [Figure 80-40-8] from the
cover.
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.
N-22153
Remove the two retaining knobs (Item 1) [Figure 80-40-

9] 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.
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BASIC TROUBLESHOOTING Figure 80-50-3
Cleaning The A/C Evaporator Coil & Heater Coil
20-1.)

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

4].
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.
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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

5].
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]
N-22123 from the Evaporator / Heater Unit rear cover.
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].

form the Evaporator / Heater Unit rear cover.
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BASIC TROUBLESHOOTING (CONT'D) Checking The Electrical System
Cleaning The A/C Evaporator Coil & Heater Coil Check to see if the compressor clutch is engaging.
(Cont'd)
With an operator in the loader seat and the cab door
Figure 80-50-9 open, turn the loader key switch to RUN (Standard Panel)
OR press the RUN / ENTER Button (Deluxe Panel),
without starting the loader.
1
Figure 80-50-10
N-22127 2 1
With air or water clean the heater coil (Item 1) [Figure

N-22284
80-50-9] and evaporator unit (Item 2) [Figure 80-50-9].
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
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.
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Checking The Electrical System (Cont’d)
20-1.)

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.
N-23040 If there is power at the clutch, reconnect the wiring

harness to the compressor clutch.
Disconnect the loader harness (Item 1) [Figure 80-50- Figure 80-50-15

12] from the compressor clutch wire.
Figure 80-50-13
2
1
1
N-22256
N-23041 Disconnect the loader harness (Item 1) [Figure 80-50-

15] from the pressure switch (Item 2) [Figure 80-50-15].
With a multimeter, check the resistance to the

compressor clutch (Item 1) [Figure 80-50-13].
If there is no resistance value, replace the compressor

clutch. (See Removal And Installation on Page 80-110-
1.)
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Checking The Electrical System (Cont’d)
Figure 80-50-16
N-22258
Disconnect the thermostat wiring connector (Item 1)

N-22257 [Figure 80-50-18] from the loader wiring harness.
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

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.

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.
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Checking The Electrical System (Cont'd)
Figure 80-50-20
N-22129

N-22259 [Figure 80-50-22] from the loader wiring harness.
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.

1
If there is a resistance value, check the blower fan.
Figure 80-50-21
N-22260
2


N-22130

the left side cab access cover.
Remove the access cover (Item 2) [Figure 80-50-21]

from the loader.
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Figure 80-50-24
N-22262
Remove the control panel and wiring harness from the

N-22260 cab [Figure 80-50-26].
Figure 80-50-27
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.

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. The voltage should

be 12 volts.
1
N-22261

from the cab control panel.
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Figure 80-50-28
H C
M B
L
N-22264
At the loader cab, disconnect the loader harness (Item 1)

N-22288 [Figure 80-50-29] from the A/C switch.
Check the harness for voltage. The voltage should be

If there is voltage at the wiring harness, check the blower about 12 volts.
switch (Item 1) [Figure 80-50-28] for resistance.
With the switch in the OFF position, there should be zero harness for broken wires.
resistance between terminals.
Figure 80-50-30
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].
With the switch in the 2 position, there should be 2

resistance between C terminal and the B terminal. And 1
also between the C and the M terminal frame [Figure 80-
50-28].
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 there is voltage at the wiring harness, check the A/C
If the above resistance tests are good, check the A/C switch (Item 1) [Figure 80-50-30] for resistance.
switch.
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.

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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
N-22290

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


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Figure 80-50-35
N-22175
1
To check the resistance of the white wire, turn the

N-22175 potentiometer control (Item 1) [Figure 80-50-37] to the
full Heater position.
To check the resistance of the white wire, turn the Figure 80-50-38
potentiometer control (Item 1) [Figure 80-50-35] to the
full A/C position [Figure 80-50-35].
Figure 80-50-36
A C
A C
B
N-22290
B
Check the resistance between the wire terminal A and
N-22290 wire terminal B frame [Figure 80-50-38] should be
around 39 k Ohm’s.
The resistance between the wire terminal A and wire Check the resistance between the wire terminal C and
terminal B frame [Figure 80-50-36] should be around 49 wire terminal B frame [Figure 80-50-38] should be
k Ohm’s. around 49 k Ohm’s.
Check the resistance between the wire terminal C and If the resistance is not found replace the potentiometer.
wire terminal B frame [Figure 80-50-36] should be
around 39 k Ohm’s.
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BASIC TROUBLESHOOTING (CONT'D) Engine Coolant Bypassing The Heater Valve
Compressor Drive Belt Inspection: Raise the lift arms and install an approved lift arm support
It is a food rule to inspect (weekly) the compressor drive 20-1.)
belt for tension and wear.
Figure 80-50-40
Open the rear door.
Figure 80-50-39
2 3
1
N-22284
N-23037 Push the A/C switch (Item 1) [Figure 80-50-40] to the

OFF position. Turn the fan switch (Item 2) [Figure 80-50-
40] to the High Speed position. Turn the temperature
Check the tension on the compressor belt (Item 1) control (Item 3) [Figure 80-50-40] to the High A/C
[Figure 80-50-39]. position, with the loader ignition switch OFF.
The belt tension should be set by measuring the belt Raise the operator cab. (See Raising The Operator Cab
deflection, which should be 0.16 in. (4 mm) with a on Page 10-30-1.)
deflection load of 3.5 - 4 lb. (1,6 - 1,8 kg) force.
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.
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BASIC TROUBLESHOOTING (CONT'D) Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Engine Coolant Bypassing The Heater Valve (Cont'd)
Figure 80-50-41 REMOTE START on Page 10-60-1.)
Figure 80-50-43
1
1
N-22131
N-22131
Check the heater hose (Item 1) [Figure 80-50-41] for

temperature. Place the remote start tool on the left fender of the loader,
so the heater valve can be clearly seen. Watch the valve
If the hose is hot, the heater valve is leaking by, and shaft (Item 1) [Figure 80-50-43], as the key of the remote
needs to be replaced. start switch is turned to the ON position without starting
the loader. The heater valve should rotate. Place a mark
Heater Valve Not Opening Or Closing on the loader shaft.
Raise the lift arms and install an approved lift arm support Turn the remote start key to the OFF position and remove
device. (See LIFT ARM SUPPORT DEVICE on Page 10- the remote start tool from fender.
20-1.)
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.
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
2 3 loader. The heater valve should rotate.
1
If it does not rotate, check the potentiometer for proper
function. (See Checking The Electrical System on Page
N-22284 80-50-3.)
Replace the heater valve. (See Removal and Installation

Push the A/C switch (Item 1) [Figure 80-50-42] to the
on Page 80-220-1.)
OFF position. Turn the fan switch (Item 2) [Figure 80-50-
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.
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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 80-
40-1.)
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 Bypassing The Heater
Valve on Page 80-50-11.)
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GENERAL AIR CONDITIONING SERVICE Compressor Oil Check
GUIDELINES
The compressor oil should be checked as follows when
Compressor Oil oil is being added to an in service loader.
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
1 insure return of oil to the compressor.
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
Remove the compressor from the loader. (See Removal
with 150-170 cc's of PAG oil (Poly Alkelene Glycol).
Unlike engine oil, it is not necessary to frequently check
or change the compressor oil.
It is necessary to check, replenish or replace the

compressor oil in the following cases:
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.
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GENERAL AIR CONDITIONING SERVICE Figure 80-60-4
GUIDELINES (CONT'D)
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
N-22245 through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-60-
4] several times by hand.
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
P-16534A 1
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.-lb.

(13 - 15 N•m) torque.
N-22245
Add new compressor oil through the suction side

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.
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GENERAL AIR CONDITIONING SERVICE
GUIDELINES (CONT'D)
Component Replacement And Refrigeration Leaks
Figure 80-60-6
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.
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SYSTEM TROUBLESHOOTING CHART
Blower motor does not operate

Possible Cause Inspection Solution
1. Blown fuse. Inspect the fuse / wiring. Replace fuse / repair wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or connector.
connection.
3. Fan motor malfunction. Check the lead wires form the motor with a circuit Replace Motor.
tester.
4. Resistor malfunction. Check resistor using a circuit tester. Replace Resistor.
5. Fan motor switch Check power into and out of the fan switch. Replace Fan Switch.
malfunction.
Blower motor operates normally, but air flow is insufficient
1. Evaporator inlet obstruction. Check evaporator for plugging. Remove obstruction and clean
evaporator fins with air or
water.
2. Air leak. Check to make sure air hoses are properly hooked Repair of adjust.
to Louvers, and air ducts.
3. Defective thermo. switch Check thermostat using a circuit tester. Replace thermostat.
(frozen evaporator).
4. Plugged cab filters Check cab filter condition. Clean or replace filters.
Insufficient cooling although air flow and compressor operation are normal
1. System low on refrigerant. The high side pressure will be low and bubbles Repair any leaks and recharge
may be present in sight glass on receive drier. the refrigerant to the correct
level.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
The compressor does not operate at all, or operates improperly
1. Loose drive belt. The belt is vibrating or oscillating. Adjust tension.
2. Internal compressor The compressor is locked up and the belt slips. Replace compressor.
malfunction.
Magnetic clutch related
3. Low battery voltage. Clutch slips. Recharge the battery.
4. Faulty coil. Clutch slips. Replace the magnetic clutch.
5. Oil on the clutch surface. Clutch slips. Replace or clean the clutch
surface.
6. Open oil. Clutch does not engage and there is no reading Replace clutch.
when a circuit tester is connected between the coil
and terminals.
7. Broken wiring or poor Clutch will not engage. Inspect the ground and Repair.
ground. connections.
8. Wiring harness Test the conductance of the pressure switch, Check operation.
components. thermostat, Relay, etc.
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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.

Low pressure side The low pressure side pressure normally becomes too
Too high. high when the high pressure side pressure is too high. As
this is explained below, the following inspection is only
used when the low pressure side is too high.
1. Expansion valve Frost is present on the suction hose. Replace expansion valve.
opens too far.
2. Defective The high and low pressure side gauge pressures Replace compressor.
compressor. equalize when the magnetic clutch is engaged.
Low pressure side
Too low.
1. Low refrigerant The high side pressure will be low and bubbles may be Repair any leaks and recharge
charge. present in sight glass on receive drier. the refrigerant to the correct
level.
2. Clogged or closed The expansion valve’s inlet side is frosted. Moisture or Clean or replace the expansion
expansion valve. other Contaminants can be the cause. Valve.
3. Restriction between Frost on the line between drier and expansion valve. A Flush system or replace hose.
drier and expansion Negative low pressure reading may be shown.
valve.
4. Thermostat The evaporator is frozen. Adjust thermostat’s
malfunction. temperature setting or probe
placement or replace
thermostat.
5. Restriction in Excessive frost on receiver drier. Replace receiver drier.
receiver drier.
High pressure side
Too high.
1. Poor condenser Dirty or clogged condenser fins. Condenser fans not Clean fins, and/or repair the
performance. Operating. fan.
2. Excessive The high pressure side pressure will be high. Use refrigerant recovery
refrigerant. equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
3. Excessive oil charge. The high pressure side will be high. 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.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with
Refrigerant.
5. Restriction in drier, High pressure side will be high, and low pressure side Evacuate and flush system
condenser or high will be low. replacing defective parts.
pressure line.
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Gauge Pressure Related Troubleshooting (Cont'd)

High pressure side Too
low.
1. Low refrigerant charge. The high side pressure will be low and bubbles may be Repair any leaks and
present in sight glass on receive drier. recharge the refrigerant to
the correct level.
System pressures Equal
1. Clutch not operating. See magnetic clutch related topics above.
2. Compressor not Equal high and low pressures. Replace compressor.
pumping.
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Troubleshooting Tree
B-21491
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Troubleshooting Tree (Cont’d)
B-21491A
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B-21492
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B-21493
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TEMPERATURE / PRESSURE
Chart
NORMAL EVAPORATOR RANGE NORMAL CONDENSER RANGE

TEMP F. PSIG TEMP F. PSIG
16 15.69 93 110.20
18 17.04 94 112.10
20 18.43 95 114.10
22 19.87 100 124.30
24 21.35 102 128.50
26 22.88 104 132.90
28 24.47 106 137.30
30 26.10 108 141.90
32 27.79 110 146.50
34 29.52 112 151.30
36 31.32 114 156.10
38 33.17 116 161.10
40 35.07 118 166.10
42 37.03 120 171.30
44 39.05 122 176.60
45 40.09 124 182.00
50 45.48 126 187.50
55 51.27 128 193.10
60 57.47 130 198.90
65 64.10 135 213.70
70 71.19 140 229.40
75 78.75 145 245.80
80 86.80 150 263.00
85 95.40 155 281.10
90 104.40 160 300.10
91 106.30 165 320.10
92 108.20 170 340.80
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.
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AIR CONDITIONING SERVICE
Chart
Service Company/Phone Number:

Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:
Pre Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature At Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:
Explain Services Required:
Post Service Conditions 15 Minutes 30 Minutes Notes

Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:
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863 Bobcat Loader
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SYSTEM CHARGING AND RECLAMATION
Reclamation Procedure
Figure 80-100-1
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
1 contact with a flame, R134a refrigerant gives a toxic
gas.
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 N-23026
your reclaimed R-134a in your reclaimer, and
further contamination to other A/C systems
Connect the Refrigerant Identifier to the low pressure
that are reclaimed and charged from your
hose [Figure 80-100-3].
MEL1581 Recovery / Recycling / Recharging
Machine.
Connect the Refrigerant Identifier to its power source.
Figure 80-100-2
Follow the steps displayed on the refrigerant identifier
screen.
1 Allow two minutes for the refrigerant identifier to display

the type of refrigerant and air content. An alarm will
sound if potentially flammable hydrocarbons are present
and will also indicate on the visual display.
Disconnect the refrigerant identifier from the loader A/C.
If the refrigerant is dangerous or flammable, it must be

evacuated from the A/C system into a separate container
and properly and safely disposed of.
If R134a is found, evacuate the system.

N-22293
Remove the protective cap (Item 1) [Figure 80-100-2]

from the low pressure hose.
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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. 2
1
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. N-22380
• Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances. Connect the Red hose (Item 1) [Figure 80-100-5] to the
• NEVER SMOKE when there is the possibility of high pressure port and open the valve.
even small amounts of 134A in the air.
Any servicing work that involves release or addition Connect the Blue hose (Item 2) [[Figure 80-100-5] to the
of 134A to the system must be done by a competent low pressure port and open the valve.
refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration Figure 80-100-6
equipment.
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-

100-4] to evacuate the system.
Connect the reclaimer to the loader A/C charge ports.
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Reclamation Procedure (Cont’d)
Figure 80-100-7
1
N-22382
Check to see that the hand valves (Item 1) [Figure 80-

N-22381 100-8] are closed on the manifold gauge set.
If there is any refrigerant in the A/C system, it must be

NOTE: The reclaimer unit, has a complete step by recovered by an approved A/C reclamation procedure.
step set of instructions [Figure 80-100-7] to (See Reclamation Procedure on Page 80-100-1.)
follow for reclamation and recharging of the
A/C system. A trained technician should Connect the gauges to the loader A/C charge ports.
follow these instructions as they may very
slightly depending on the model and brand of Figure 80-100-9
reclaimer used.
Charging Procedure With A Manifold Gauge Set
support device. (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)

on Page 10-30-1.) 2
1
WARNING N-22382

refrigerant can cause severe injuries to eyes. In Connect the Red hose (Item 1) [Figure 80-100-9] to the
contact with a flame, R134a refrigerant gives a toxic high pressure port and open the valve.
gas.
W-2371-0500 Connect the Blue hose (Item 2) [Figure 80-100-9] to the
low pressure port and open the valve.
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SYSTEM CHARGING AND RECLAMATION (CONT'D) Charging Procedure
Charging Procedure With A Manifold Gauge Set Figure 80-100-12

(Cont’d)
Figure 80-100-10
N-22382
N-23042 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.
Connect the Yellow hose (Item 1) [Figure 80-100-10] to
the vacuum pump. If the pressure drops, this may be an indication of a leak
in the A/C system.
Figure 80-100-11
Determine the problem with the A/C system and repair it.
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.
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Charging Procedure (Cont'd)

3
Figure 80-100-13
1 N-23044
Place a refrigerant container with R134a (Item 1) [Figure

N-22385 80-100-14] on a charging scale (Item 2) [Figure 80-100-
14] and zero out the scale.
A thermistor vacuum gauge (Item 1) [Figure 80-100-13] Connect the yellow hose (Item 3) [Figure 80-100-14]
may be necessary to use to determine the critical from the manifold gauge set to the valve on the
vacuum level during evacuation. It is a solid state refrigerant tank.
instrument that constantly monitors and visually indicates
the vacuum level. 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.
Run the vacuum pump for at least 45 minutes to insure 1

that all the moisture is boiled out of the system.
Stop the vacuum pump and close the Iso-valve on the

vacuum pump. N-23044
Close both hand valves on the manifold gauge set and

remove the yellow hose from the vacuum pump that goes Open the valve on the refrigerant container (Item 1)
to the manifold gauge set. [Figure 80-100-15] and open the low pressure hand
valve (Blue) (Item 2) [Figure 80-100-15] on the manifold
Remove the vacuum pump and thermistor vacuum gauge set. Allow the vacuum to pull in the refrigerant until
gauge. the pressure stabilizes.
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SYSTEM CHARGING AND RECLAMATION (CONT'D)
Charging Procedure (Cont'd)

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.

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 lb. (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.)
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COMPRESSOR Cap and plug the compressor hoses and the fittings with
with the proper A/C caps and plugs.
Figure 80-110-2
WARNING
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500 1
Page 10-20-1.)
N-22377
on Page 10-30-1.)
Remove the compressor mount bolt (Item 1) [Figure 80-
Evacuate the A/C system. (See SYSTEM CHARGING 110-2].
AND RECLAMATION on Page 80-100-1.)
Remove the compressor from the loader.
Figure 80-110-1
N-22379A
Remove the compressor adjustment bolt (Item 1) [Figure

80-110-1].
Installation: Tighten the compressor adjustment bolt to

Remove the compressor belt.
Mark the compressor hoses for proper installation.
Remove the compressor hoses (Item 2) [Figure 80-110-

1] from the compressor.
Installation: Tighten the compressor hoses to 22 ft.-lb.

(29,8 N•m) torque.
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COMPRESSOR (CONT'D) Figure 80-110-5
Compressor Clutch Disassembly
Figure 80-110-3 1.32”
1.32”
1.32”
2
1
1 N-22275
The armature plate puller, (Item 1) [Figure 80-110-5] can

N-22244 be constructed by drilling three 10 mm holes in a flat
circular plate, located 1.32 in. apart [Figure 80-110-5].
Remove the center armature bolt (Item 1) [Figure 80- Figure 80-110-6
110-3].
Installation: Tighten the armature bolt to 8 - 10 ft.-lb. (12

- 14 N•m) torque.
Figure 80-110-4
2 N-22278
Attach the puller to the armature plate using three 8 mm

bolts (Item 2) [Figure 80-110-5].
N-22277 Turn the bolts into the three 8 mm holes (Item 2) [Figure
80-110-4] on the armature plate as shown in [Figure 80-
110-6].
To remove the armature plate (Item 1) [Figure 80-110-4]
from the clutch face, you must make an armature plate
puller.
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Compressor Clutch Disassembly (Cont'd)
Figure 80-110-7
1
N-22283

N-22279 the pulley assembly.
Figure 80-110-10
Attach a slide hammer puller (Item 1) [Figure 80-110-7]
to the armature puller disk.
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 80-110-
8].
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)
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Figure 80-110-11
1
N-22373
Slide the wire grommet (Item 1) [Figure 80-110-13] from

N-22370 the wire holder.
Figure 80-110-14
Remove the pulley from the compressor [Figure 80-110-
11].
Figure 80-110-12
N-22374
Remove the coil lead wire (Item 1) [Figure 80-110-14]

N-22371 from the wire holder on the compressor.
The pulley assembly and bearing [Figure 80-110-12]

must be replaced as a complete unit.
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Figure 80-110-15
N-22375
1
The compressor [Figure 80-110-16] must be replaced as

N-22372 a complete unit.
Remove the three coil mount bolts (Item 1) [Figure 80-

110-15] from the compressor.
Installation: Tighten the mount bolts to 2.9 - 4.3 ft.-lb. (4

- 6 N•m) torque.
Remove the coil from the compressor.
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863 Bobcat Loader
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CONDENSER
Remove the refrigerant from the A/C system. (See

WARNING
SYSTEM CHARGING AND RECLAMATION on Page 80- In the event of a leak, wear safety goggles. Escaping
100-1.) refrigerant can cause severe injuries to eyes. In
Open the rear door of the loader. 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
N-22976
Remove the two retaining clips (Item 1) [Figure 80-120-

1] 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.
P-28470
Mark the two A/C hoses (Item 1) [Figure 80-120-2] for

proper installation.
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CONDENSER (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
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RECEIVER / DRIER Figure 80-130-2
Page 10-20-1.) 1

on Page 10-30-1.)
3
SYSTEM CHARGING AND RECLAMATION on Page 80-
100-1.)
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
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

N-22134 system 1 fl. oz. (30 cc) of PAG oil must be
added to the system when recharging.
Mark the A/C hoses (Item 1) [Figure 80-130-1] for proper Figure 80-130-3
installation.
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 80-
130-2] for proper installation
WARNING
refrigerant can cause severe injuries to eyes. In N-22135
gas.
W-2371-0500 Remove the two mount bolts (Item 1) [Figure 80-130-3]
from the receiver / drier mount bracket.
Remove the bracket from the top of the hydraulic filter

bracket.
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863 Bobcat Loader
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PRESSURE RELIEF VALVE Figure 80-140-2
Figure 80-140-1
N-22206
The pressure relief valve [Figure 80-140-2] is designed

N-22205 to open and release the A/C charge if the pressure
reaches 535 PSI (3689 kPa)
The pressure relief valve (Item 1) [Figure 80-140-1] is This will cause the A/C system to shut down, saving the
located on the drier assembly. 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.
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PRESSURE SWITCH Figure 80-150-2
Page 10-20-1.)

1
on Page 10-30-1.)
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 80-

150-1] from the pressure switch wire harness.
NOTE: The pressure switch can be changed without

evacuating the A/C system.
WARNING
gas.
W-2371-0500
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PRESSURE SWITCH (CONT’D)
Shreader Valve Removal And Installation
Figure 80-150-3
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.
Page 10-20-1.)

on Page 10-30-1.)

SYSTEM CHARGING AND RECLAMATION on Page 80-
100-1.)
Remove the pressure switch.
With a tire valve core removal tool, remove the valve core
from the hose.
Replace with a new core.
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EVAPORATOR / HEATER UNIT Figure 80-160-3
20-1.)

on Page 10-30-1.)
Evacuate the A/C system. (See SYSTEM CHARGING 1

Figure 80-160-1
N-22129

[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
Figure 80-160-2
N-22119

2
4].
N-22130

the left side cab access cover.
Remove the access cover (Item 2) [Figure 80-160-2]

from the loader.
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EVAPORATOR / HEATER UNIT (CONT'D) NOTE: Mark the lines before removal for proper
installation.
Installation: Tighten the A/C hoses to 22 ft.-lb. (29,8
Figure 80-160-5 N•m) torque.
Cap and plug the hoses and the expansion valve fittings
Figure 80-160-7
N-22120

1
5].
N-22128
WARNING Remove the heater hoses (Item 1) [Figure 80-160-7]

from the heater coil.
refrigerant can cause severe injuries to eyes. In Installation: Tighten the Heater hoses to 22 ft.-lb. (29,8
contact with a flame, R134a refrigerant gives a toxic N•m) torque.
gas.
W-2371-0500 Remove the evaporator / heater unit from the loader
Figure 80-160-6 Disassembly And Assembly
Figure 80-160-8
1 1
N-22126
Remove the Evaporator / Heater Unit from the rear of the N-22065
cab and place it on the fenders of the loader supported
by blocking [Figure 80-160-6].
Remove the eight mount bolts (Item 1) [Figure 80-160-8]
Remove the two A/C hoses (Item 1) [Figure 80-160-6] from the Evaporator / Heater Unit rear cover.
from the expansion valve.
Remove the rear cover from the unit.
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THERMOSTAT Figure 80-170-3
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.

Figure 80-170-1
N-22072
2
Remove the thermostat from the unit [Figure 80-170-3].
Figure 80-170-4
1
A
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 1
housing.
Figure 80-170-2
N-22072A

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.
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EXPANSION VALVE Figure 80-180-2
NOTE: The expansion valve can be changed without

removing the evaporator / heater unit from the
loader.
1
device. (See LIFT ARM SUPPORT DEVICE on Page 10- 2
20-1.)

on Page 10-30-1.)
Evacuate the A/C system.(See SYSTEM CHARGING N-22073A

Remove the two evaporator fittings (Item 1) [Figure 80-

180-2] from the expansion valve.
WARNING Installation: Tighten the two evaporator fittings to 22 ft.-

refrigerant can cause severe injuries to eyes. In Remove the two mount bolts (Item 2) [Figure 80-180-2].
gas. Remove the expansion valve from the loader.
W-2371-0500
Figure 80-180-3
Figure 80-180-1
1
1
N-22074A
N-22150
Cap and plug the evaporator tubelines (Item 1) [Figure

80-180-3] and the expansion valve fittings with the
Remove the two A/C hoses (Item 1) [Figure 80-180-1]
proper A/C caps and plugs.
from the expansion valve.
NOTE: Mark the lines before removal for proper

installation.
Installation: Tighten the two A/C hose fittings to 22 ft.-lb.

(29,8 N•m) torque.
Cap and plug the hoses and the expansion valve fittings
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EXPANSION VALVE (CONT'D) Figure 80-180-5
Figure 80-180-4
1
1 N-22085
The expansion valve [Figure 80-180-5] is replaced as a

N-22074A complete unit.

from the expansion valve mount.
Remove the expansion valve mount from the unit.
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EVAPORATOR Figure 80-190-3
20-1.)

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.) N-22075
Figure 80-190-1
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 80-
180-1.)
1
N-22076
Figure 80-190-2
Remove the two retaining clips (Item 1) [Figure 80-190-

4] that connect the evaporator coil, to the heater coil.
Remove the evaporator coil from the unit.
N-22074
Remove the expansion valve mount bracket (Item 1)

[Figure 80-190-2] from the unit.
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EVAPORATOR (CONT'D)
Figure 80-190-5
N-22078
Inspect the evaporator coil [Figure 80-190-5] for leaks,

Clean with low water or air pressure.
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HEATER COIL Figure 80-200-2
Removal And Installation With A/C
20-1.)

on Page 10-30-1.)

cab. (See Removal And Installation on Page 80-160-1.)
Figure 80-200-1 1
N-22086

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

1
Remove the two heater hoses from the heater coil.
Cap the hoses and the heater coil with hydraulic caps N-22087
and plugs to prevent oil loss from the system.
Installation: Tighten the two heater hose fittings to 22 ft.- Remove the two retaining clips (Item 1) [Figure 80-200-
lb. (29,8 N•m) torque. 3] that connect the evaporator coil, to the heater coil.

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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
Figure 80-200-4 20-1.)

on Page 10-30-1.)
1 1 Remove the heater unit from the back of the cab. (See
Figure 80-200-6
2
2
N-22089
1
and remove the mount plate from the end of the unit.

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
Remove the two heater hoses from the heater coil.
Cap the hoses and the heater coil with hydraulic caps
Installation: Tighten the two heater hose fittings to 22 ft.-


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.
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HEATER COIL (CONT’D)
Removal And Installation Without A/C (Cont’d)
Figure 80-200-7
1
1
N-22093

and remove the mount plate from the end of the unit.

that support the heater coil tubelines to the unit.
Figure 80-200-8
N-22094

from the heater coil.
Remove the heater coil from the unit.
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HEATER / AC FAN Figure 80-210-3
20-1.) 1
on Page 10-30-1.)

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 N-22098
disconnecting the heater or A/C plumbing.
The unit is removed here for photo clarity.
If the metal is not cut out of the housing, mark the area
Figure 80-210-1 (Item 1) [Figure 80-210-3] and remove it with metal
shears.
Figure 80-210-4
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.
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.
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HEATER / AC FAN (CONT'D) Figure 80-210-7
Figure 80-210-5
1
2
N-22107
Check the blower housing (Item 1) [Figure 80-210-7]

N-22100 and fan mount (Item 2) [Figure 80-210-7] for wear and
replace as needed.
Remove the three mount bolts (Item 1) [Figure 80-210-5] Figure 80-210-8
from the blower fan housing.
Remove the blower fan housing from the evaporator / 1

heater unit.
Figure 80-210-6
2
N-22108
1
1
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.
2 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.

from the fan motor mount.
Remove the fan motor mount.
Remove the fan motor assembly from the housing.
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HEATER / AC FAN (CONT'D) Figure 80-210-10
Figure 80-210-9
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].
N-22112
Remove the outside blower wheel clamp (Item 1) [Figure

80-210-10] & [Figure 80-210-11] from the blower wheel.
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HEATER / FAN (CONT’D) Wire Connector Removal And Installation
Disassembly And Assembly (Cont’d) Figure 80-210-14
Figure 80-210-12
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
N-22104
Remove the plastic wedge (Item 1) [Figure 80-210-14] &

[Figure 80-210-15] from the center of the blower fan
N-22116 motor wiring connector.
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.
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HEATER / FAN (CONT’D)
Wire Connector Removal And Installation (Cont’d)
Figure 80-210-16
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 the connector.
Figure 80-210-17
N-22106
The wiring code for the blower fan connector [Figure 80-
210-17] is:
Number on Connector Wire Color
1 Orange
2 Red
3 Yellow
4 Black
5 Open
6 Open
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863 Bobcat Loader
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HEATER VALVE Figure 80-220-3
Removal and Installation
Figure 80-220-1
N-22133
Figure 80-220-4
N-22131

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
2 model loaders are equipped with heater
valves that allowed the loader wiring harness
(Item 1) [Figure 80-220-4] to be connected
N-22132 directly to the rear of the valve.

Remove the two hydraulic hoses (Item 1) [Figure 80- from the heater valve mount bracket.
220-2] from the heater valve.
Remove the heater valve and mount bracket from the
Cap the hoses and the heater valve with hydraulic caps loader.
Disconnect the loader wiring harness (Item 2) [Figure

80-220-2] from the heater valve.
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HEATER VALVE (CONT'D) Figure 80-220-7
Figure 80-220-5
1
1
N-22157
Remove the three mounting bolts (Item 1) [Figure 80-

N-22155 220-7] from the heater valve mount plate.
Figure 80-220-8
from the heater valve actuator.
Figure 80-220-6
2 1
N-22158
Remove the mount plate (Item 1) [Figure 80-220-8] from

N-22156 the heater valve bracket.
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.
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HEATER VALVE (CONT'D) Figure 80-220-10
Figure 80-220-9
N-22160
1
Remove the heater valve mount bracket (Item 1) [Figure
N-22159 80-220-10] from the heater valve.

9] from the heater valve.
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863 Bobcat Loader
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SPECIFICATIONS
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-70-1
Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . SPEC-70-1
U.S. To Metric Conversion . . . . . . . . . . . . . . . . . . . . . . SPEC-70-2 SAFETY &
MAINTENANCE
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Camshaft and Bearings . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Crankshaft and Main Bearings. . . . . . . . . . . . . . . . . . . SPEC-20-4
Cylinder Head and Block . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 DRIVE
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4 SYSTEM
Piston and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Valve and Valve Guide and Seat Insert . . . . . . . . . . . . SPEC-20-2
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . SPEC-50-1

Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-2
O-ring Face Seal Connection. . . . . . . . . . . . . . . . . . . . SPEC-50-1
O-ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-3
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-5
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . SPEC-50-1
Tubelines And Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
HYDRAULIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . SPEC-60-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1
LOADER SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2 SPECIFICATIONS
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Loader Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
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 Service Manual
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863 Bobcat Loader
SPEC-02 Service Manual
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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 Service Manual
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LOADER SPECIFICATIONS (CONT’D)
Performance
863 863H
Rated Operating Capacity (SAE) 1900 lb. (862 kg)
Tipping Load (SAE Rating) 3800 lb. (1724 kg)
Operating Weight 7045 lb. (3196 kg) 7090 lb. (3216 kg)
SAE Breakout Force-Lift 3700 lb. (16458 N)
-Tilt 3800 lb. (16902 N)
Axle Torque 6100 ft.-lb. (8272 N•m)
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 Direction and speed controlled by two hand levers.

Loader Hydraulics Lift and Tilt 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 Hand lever throttle: Key-type starter switch and shutdown.
Starting Aid Glow Plugs – Automatically activated by Standard Or Deluxe Instrumentation.
Service Brake 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.–lb. (239 N•m)
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 Closed
Air Cleaner Dry replaceable cartridge w/ safety element
Ignition Diesel-Compression
Low Idle 1125-1175 RPM
High Idle 2530-2690 RPM
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Hydraulic System
863 863H
Pump 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 3000PSI (206 Bar)
Filters (Charge & Implement) Full flow replaceable, 3 micron synthetic media element doubleacting;
Hydraulic Cylinders Tilt cylinder has cushioning feature on dump & rollback
Bore Diameter - Lift Cylinder (2) 2.50 (63,5)
- Tilt Cylinder (1) 3.50 (88,9)
Rod Diameter -Lift Cylinder (2) 1.75 (44,5)
- Tilt Cylinder (1) 1.57 (39,9)
Stroke - 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.

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Drive System
863 863H
Main Drive Hydrostatic 4 wheel drive
Transmission Infinitely variable tandem hydrostatic piston pumps, driving 2 fully reversing
hydrostatic motors
Final Drive #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 Gal. (95 L)

Engine / Cooling Oil W/ Filter 16 qt. (15,1 L)
Hydraulic / Hydro. Reservoir 4.7 Gal. (17,8 L)
Hydraulic / Hydro. System 10.7 Gal. (40,5 L)
Chaincase Reservoir 11 Gal. (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.
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ENGINE SPECIFICATIONS
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
General
Displacement 177.7 cu. in (2912 cu. cm.)

Bore 3.58 (91)
Stroke 4.41 (112)
Crankshaft Rotation (Facing Flywheel) Counterclockwise
Ignition 4 Stroke Diesel-Compression
Combustion System Direct Injection
Compression Ratio 17-1
Compression 320-392 PSI (2206-2703 kPa) (22-27 bar)
Firing Order 1-3-4-2
Fuel System
Fuel Injection Pump Pressure (5 Revolutions) Min. 4350 PSI (29993 kPa) (300 bar)
Injection Pump Testing Tightness 2175 PSI-145 PSI permissible drop / min. (14997 kPa-1000
kPa) (150 bar - 10 bar)
Injection Nozzle Opening Pressure 3625 PSI + 116 (24994 kPa + 800 kPa) (21-0 bar + 8 bar)
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ENGINE SPECIFICATIONS (CONT’D)
parentheses.
Valve and Valve Guide and Seat Insert
Valve Clearance (Intake) Oil Temp Below 176° F (80° C) 0.012 (0,3)
Valve Clearance (Exhaust) Oil Temp Below 176° F (80° C) 0.020 (0,5)
Valve Guide I.D. 0.315±0.0010 (8,0±0,025)
Valve Seat Insert O.D. (Intake) 1.680±0.0002 (42,67±0,005)
Valve Seat Insert O.D. (Exhaust) 1.460±0.0002 (37,075±0,006)
Valve Seat Insert Bore (Intake) 1.677±0.001 (42,6±0,03)
Valve Seat Insert Bore (Exhaust) 1.457±0.001 (37,0±0,03)
Valve Stem Diameter (Intake) 0.314-0.0006 (7,98-0,015)
Valve Stem Diameter (Exhaust) 0.313-0.0006 (7,96-0,015)
Valve Stem Clearance (Intake) 0.0008-0.0023 (0,02-0,06)
Wear Limit 0.005 (0,12)
Valve Stem Clearance (Exhaust) 0.0016-0.003 (0,04-0,08)
Wear Limit 0.006 (0,15)
Valve Head O.D. (Intake) 1.594±0.004 (40,5±0,1)
Valve Head O.D. (Exhaust) 1.374±0.004 (34,9±0,1)
Valve Seat Width (Intake) 0.062±0.016 (1,58±0,4)
(Exhaust) 0.067±0.016 (1,7±0,4)
Seat Angle (Intake) 30°
(Exhaust) 45°
Marg Thickness (Intake) N/A
Wear Limit 0.0551 (1,4)
Marg Thickness (Exhaust) N/A
Wear Limit 0.047 (1,2)
Valve Recess 0.0512±0.0051 (1,3±0,13)
Wear Limit 0.0512 (1,3)
Valve Spring Free Length 0.132 (3,35) diameter 1.531 (38,9)
0.134 (3,40) diameter 1.547 (39,3)
Valve Spring Inclination 0.126 (3,2)
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parentheses.
Piston and Rings
Piston Diameter 3.578 (90,9)

I.D. for Piston Pin 1.0236+0.0004-0.0016 (26,0+0,01-0,04)
Piston Pin Diameter 1.118-0.0002 (30,0-0,005)
Piston Ring Groove 1st 0.0787+0.004 (2,0+0,10-0,08)
2nd 0.0787+0.004-0.003 (2,0+0,10-0,08)
3rd 0.118+0.002-0.0008 (3,0+0,04-0,02)
Piston Ring Clearance 1st 0.004-0.005 (0,09-0,12)
Wear Limit 0.0078 (0,2)
2nd 0.003-0.004 (0,07-0,10)
Wear Limit 0.006 (0,16)
3rd 0.015-0.003 (0,04-0,07)
Wear Limit 0.0005 (0,12)
Piston Ring Gap 1st 0.0118-0.019 (0,3-0,5)
2nd 0.0315-0.039 (0,8-1,0)
3rd 0.018-0.028 (0,45-0,7)
Wear Limit 1st 0.0315 (0,8)
2nd 0.071 (1,8)
3rd 0.035 (0,9)
Bore for Piston Pin Bushing N/A
Piston Pin Bushing O.D. N/A
Piston Pin Bushing I.D. (pressed in) N/A
Piston Pin Clearance 0.0009-0.0016 (0,025-0,04)
Wear Limit 0.0031 (0,08)
Connecting Rod
Small End Bushing I.D. (Pressed In) 1.181+0.0014 +0.00010 (30,0+0,035+0,025)

Wear Limit 0.003 (0,08)
Bore for Small End Bushing 1.299+0.0008 (33,0+0,02)
O.D. for Small End Bushing 1.299+0.0043 - +0.0028 (33,0+0,11 - +0,07)
Parallel Check Permissible 0.0039 over a distance of 3.937
(0,10 Over 100,0)
Alignment 0.002 (0,05)
Connecting Rod Width 1.063-0.0023 (27,0-0,06)
Connecting Rod End Play 0.0078-0.022 (0,2-0,56)
Wear Limit 0.0315 (0,8)
Center Distance from Small to Large Bore 6.811±0.0012 (173,0±0,03)
Bore for Large End Bearing 2.303+0.0008 (58,5+0,02)
Large End Bearing Shells I.D. 2.166-2.167 (55,004-55,04)
Limit for Undersize 2.146-2.147 (54,504-54,54)
Large End Bearing Radial Clearance 0.0009-0.003 (0,024-0,078)
Wear Limit 0.005 (0,12)
Large End Bearing Width 1.008-0.012 (25,6-0,3)
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parentheses.
Cylinder Head and Block
Cylinder Head Studs - Length 5.906±0.031 (150,0±0,8)

Cylinder Bore 3.583+0.0008 (91,0+0,02)
Wear Limit 3.587 (91,1)
Crankshaft and Main Bearings
Crankshaft Pin Width 1.220 (31,0)

Crankshaft Pin Diameter 2.165-0.0004-0.0012 (55,0-0,01-0,03)
Oval Wear Limit 0.0004 (0,01)
Crankshaft Journal Width 1.378+0.0016 (35,0+0,04)
Crankshaft Journal Diameter 2.756-0.0004-0.0012 (70,0-0,01-0,03)
Oval Wear Limit 0.0003 (0,008)
Eccentricity Max. Permitted 0.002 (0,05)
Thrust Bearing Journal Width 1.378+0.002 (35,0+0,04)
Main Bearing Shell I.D. 2.757-2.758 (70,02-70,055)
Radial Clearance 0.0011-0.0033 (0,03-0,084)
Wear Limit 0.0047 (0,12)
Bearing Bore in Crankcase 2.953+0.0007 (75,0+0,019)
Thrust Bearing Stop Rings O.D. 1.374-0.005 (34,9-0,133)
Oversize 0.0157 (0,4)
Limit for Oversize 1.406-0.0052 (35,7-0,133)
Crankshaft End Play 0.0039-0.0106 (0,1-0,27)
Wear Limit 0.016 (0,4)
Camshaft and Bearings
Camshaft End Play 0.0118-0.0236 (0,3-0,6)

Wear Limit 0.0315 (0,8)
Camshaft Bearing I.D. 2.126+0.0021 (54,0+0,054)
Wear Limit 2.129 (54,08)
Radial Clearance 0.0019-0.0048 (0,05-0,124)
Cam Lift (Intake) 0.260 (6,6)
Cam Lift (Exhaust) 0.268 (6,8)
Oil Pump
Oil Pump Pressure Setting 101.5 PSI (700 kPa) (7 bar)

Min. Eng. Oil Pressure, Oil Temp. 230° F (110° C) at 900 RPM 20.3 PSI (140 kPa) (1.4 bar)
1800 RPM 31.9 PSI (220 kPa) (2.2 bar)
2800 RPM 43.5 PSI (300 kPa) (3.0 bar)
Thermostat Rating 203°F (95°C)
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LOADER TORQUE
Specifications
Description ft.-lb. N•m

Air Intake Manifold Bolts (M8 Torx) 15 20
Adapter Housing Bolts (M12) 21 - 24 28 - 33
Camshaft Bolt (M14 x 1,5 x 110) Plus 210 degrees 22 30
Camshaft Thrust Washer Bolt (M8) 15 20
Connecting Rod Cap Nuts Plus 60 degrees,60 degrees=120 degrees 22 30
Crankcase Screw Plugs (M18) 37 50
(M24) 82 111
(M30) 12 - 15 16 - 20
Crankshaft Gear Mount Bolt 243 - 295 330 - 400
Cylinder Head Bolts Step 1 22 30
Step 2 59 80
Step 3 Plus 90 degrees 118 160
Exhaust Manifold Bolts (M10) 30 40
Exhaust Turbocharger Nuts (M8) 22 30
Flywheel Bolts Plus 60 degrees, 30 degrees=90 degrees 22 30
Front Cover Bolts 15 20
Front Mount Foot Bolts (M14x55) 38 52
Fuel Lift Pump Bolts (M8 Torx) 15 20
Glow Plug 15 - 18 20 - 24
Injector Cap Nut 35 47
Injector Pump Mounting Nuts 15 21
Main Bearing Bolts Plus 60 degrees,45 degrees=105 degrees 37 50
Oil Pan Bolts (M8) 15 20
Oil Pan Drain Plug 40 54
Oil Pump Bolts (M8 Torx) 16 22
Oil Press. Control Valve Screw Plug 82 111
Oil Return Line Cap Nut 13 - 14 18 - 19
Oil Suction Pipe 16 22
Oil Temp. Switch 21 28
Rocker Arm Bracket Bolts (M8 Torx) 15 20
Rear Cover Bolts 15 20
Rear Mounting Foot Bolts (M12) 23 31
Starter Carrier Bolts (M12) 15 - 18 20 - 24
Starter Fastening Bolts 25 - 28 34 - 38
Thermostat Housing Screw Plug (M38) 82 111
Timing Belt Tensioner Pulley Nut 33 45
V-Belt Pulley Bolts (M10) 30 - 36 41 - 49
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LOADER TORQUE (CONT’D)
Specifications (Cont’d)
Description ft.-lb. N•m

Air Intake 3-Hole Flange Bolts (M8 Torx) 54 - 65 6,1 - 7,3
Breather Vent Bolts 75 8,5
Crankcase Screw Plugs (M20) 85 - 104 9,6 - 11,7
(M10) 28 - 36 3,1 - 4,0
(M6) 13 - 16 1,4 - 1,8
(M16) 62 - 78 7,0 - 8,8
Cylinder Head Cover 75 8,5
Fuel Filter Bracket Bolt (M8) 54 6,1
Full Load Stop Screw Nut 40 4,5
Governor Lever Shaft Bolts 81 9,2
Injector Fastening Bolt (M8 Torx) 49 - 59 5,5 - 6,6
Injector Line 36 - 45 4,1 - 5,1
Minimum Speed Screw 40 4,5
Oil Filter Bracket Bolts (M6) 24 - 30 2,7 - 3,4
Oil Intake Housing Bolts (M8 Torx) 54 - 65 6,1 - 7,3
Oil Pressure Switch 115 13
Piston Cooling Nozzles 11 1,2
Rocker Arm Set Screw Nut 49 - 59 5,5 - 6,6
Shut Down Stop Screw 40 4,5
Shut Down Solenoid Bolts 79 9
Thermostat Housing Bolts (M6 Torx) 20 - 24 2,2 - 2,7
Thermostat Housing Bolts (M8 Torx) 24 - 32 2,7 - 3,6
Turbocharger Backing Plate Screws 88 10
Turbocharger Compressor Housing Bolts 62 7
Turbocharger Compressor Wheel Nut 44 5
Valve Plunger Housing Bolts (M8 Torx) 24 - 32 2,7 - 3,6
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LOADER TORQUE (CONT’D)
Specifications (Cont’d)
Item ft.-lb. N•m

Air Cleaner Mounting Bolts 25 - 28 24 - 38
Alternator Pulley Nut 50 68
Axle Hub Mounting Bolt 175 - 190 240 - 260
Axle Sprocket Bolt 475 - 525 645 - 710
BICS™ Control Valve Mounting Bolts 15 - 16 20 - 22

Bob-Tach Lever Pivot Bolt 25 - 28 34 - 38
Control Pedal Linkage Bolts 21 - 25 28 - 34

Control Valve Mounting Bolts & Nuts 15 - 16 20 - 22
Engine Mounting Bolts 65 - 70 88 - 95

Exhaust Pipe to Exhaust Manifold 20 - 35 27 - 47
Filter Housing Mounting Bolts 25 34

Front Panel Bolts 16 - 20 22 - 27
Hydraulic Pump Bolts 45 - 50 61 - 68

Hydraulic Pump Mounting Bolts 25 - 27 34 - 37
Hydraulic Reservoir Strap Bolts 16 - 20 22 - 27
Hydrostatic Motor Mounting Bolts 210 - 230 285 - 310
Hydrostatic Pump Mounting Bolts 65 - 70 88 - 95
Hydrostatic Pump Pulley Bolt 175 - 200 237 - 271
Lift Arm Bypass Control Valve Mounting Bolts 15 - 16 20 - 22
Main Frame to Chaincase Bolts 300 - 330 410 - 450

Main Relief Valve 35 - 40 47 - 54
Motor Carrier Bolts 220 - 245 300 - 330
Operator Cab Fastening Nuts 40 - 50 54 - 68

Operator Cab Pivot Bolts & Nuts 25 - 35 34 - 47
Pedal Lock Linkage to Main Frame Bolts 7-8 9,5 - 10,8

Pedal Lock Linkage Tab Bolt 25 34
Pivot Pins Lick Bolt & Nut 18 - 20 24 - 27
Seat Belt Fastening Bolts 40 - 45 54 - 61

Seat Mounting Bolts 9 - 11 12,2 - 15
Seat Bar Pivot Bolts 25 - 28 34 - 38
Wheel Nuts 105 - 115 142 - 156
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863 Bobcat Loader
936 of 968
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter H following the part number.
THREAD
SAE GRADE 5 SAE GRADE 8
SIZE
0.250 80 - 90 110 - 120
in.-lb. (9,0 - 10,2) (12,4 - 13,6)
(N•m) 0.3125 180 - 200 215 - 240
(20,3 - 22,6) (24,2 - 27,1)
0.375 25 - 28 35 - 40
(34 - 38) (47 - 54)
0.4375 40 - 45 60 - 65
(54 - 61) (81 - 88)
0.500 65 - 70 90 - 100
(88 - 95) (122 - 136)
0.5625 90 - 100 125 - 140
(122 - 136) (170 - 190)
0.625 125 - 140 175 - 190
(170 - 190) (240 - 260)
0.750 220 - 245 300 - 330
(300 - 330) (410 - 450)
0.875 330 - 360 475 - 525
(450 - 490) (645 - 710)
1.000 475 - 525 725 - 800
ft.-lb. (645 - 710) (985 - 1085)
(N•m) 1.125 650 - 720 1050 - 1175
(880 - 975) (1425 - 1600)
1.250 900 - 1000 1475 - 1625
(1200 - 1360) (2000 - 2200)
1.375 1200 - 1350 2000 - 2200
(1630 - 1830) (2720 - 2980)
1.500 1500 - 1650 2600 - 2850
(2040 - 2240) (3530 - 3870)
1.625 2000 - 2800 3450 - 3800
(2720 - 2980) (4680 - 5150)
1.750 2500 - 2750 4300 - 4800
(3390 - 3730) (5830 - 6500)
1.875 3150 - 3500 5500 - 6100
(4270 - 4750) (5830 - 6500)
2.000 3800 - 4200 6500 - 7200
(5150 - 5700) (8800 - 9800)
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TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)
Torque For General Metric Bolts
THREAD SIZE MATERIAL

(DIA. X PITCH) HEAD MARK 4 HEAD MARK 7 HEAD MARK 10
M 5 x 0.8 3 - 4 ft.-lb.
(4 - 5 N•m)
M 6 x 1.0 6 - 7 ft.-lb. 6 - 9 ft.-lb.
(8 - 9 N•m) (8 - 12 N•m)
M 8 x 1.25 6 - 9 ft.-lb. 11 - 16 ft.-lb. 18 - 25 ft.-lb.
(8 - 12 N•m) (15 - 22 N•m) (24 - 34 N•m)
M 10 x 1.25 13 - 18 ft.-lb. 22 - 30 ft.-lb. 36 - 50 ft.-lb.
(18 - 24 N•m) (30 - 41 N•m) (49 - 68 N•m)
M 12 x 1.25 22 - 30 ft.-lb. 40 - 54 ft.-lb. 69 - 87 ft.-lb.
(30 - 41 N•m) (54 - 73 N•m) (94 - 118 N•m)
M 14 x 1.25 36 - 50 ft.-lb. 58 - 80 ft.-lb. 116 - 137 ft.-lb.
(49 - 68 N•m) (79 - 108 N•m) (157 - 186 N•m)
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HYDRAULIC CONNECTION SPECIFICATIONS Straight Thread O-ring Fitting
O-ring Face Seal Connection Figure SPEC-50-2
IMPORTANT
Nut Nut
clean the work area before disassembly and keep all Washer
parts clean. Always use caps and plugs on hoses, Washer
tubelines and ports to keep dirt out. Dirt can quickly O-ring
damage the system. 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-50-
2].
Tubelines And Hoses
Replace any tubelines that are bent or flattened. They will

restrict flow, which will slow hydraulic action and cause
heat.
B-7575 Replace hoses which show signs of wear, damage or

weather cracked rubber.
When the fitting is tightened, you can feel when the fitting Always use two wrenches when loosening and tightening
is tight to eliminate leakage caused by under or over hose or tubeline fittings.
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-50-1].
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HYDRAULIC CONNECTION SPECIFICATIONS Use the following procedure to tighten the flare fitting:
(CONT'D)
Tighten the nut until it makes contact with the seat. Make
Flare Fitting a mark across the flats of both the male and female parts
of the connection (Item 1) [Figure SPEC-50-3].
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
TS-1619
Flare Fitting Tightening Torque

Tubeline TORQUE NEW RE-ASSEMBLY
Wrench Size Outside Thread Size ft.-lb. Rotate No. Rotate No.
Diameter (N•m) of Hex Flats of Hex Flats
5/8” 5/16” 1-2”-20 17 (23) 2-1/2 1
11/16” 3/8” 9/16”-18 22 (30) 2 1
7/8” 1/2” 3/4”-16 40 (54) 2 1
1” 5/8” 7/8”-14 60 (81) 1-1/2 1
1-1/4” 3/4” 1-1/16”-12 84 (114) 1 3/4
1-3/8” 1” 1-5/16”-12 118 (160) 3/4 3/4
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HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-50-5
(CONT'D)
Hex Flat Tightening Method
O-ring Flare Fitting
Figure SPEC-50-4
1
O-ring Flare
Primary
Seal
TS-1619
Secondary Use the following procedure to tighten the O-ring flare

Seal fitting.
P13009
Tighten the nut until it contacts with the seat. Make a
mark across the flats of both the male and female parts of
The flare is the primary seal, the O-ring is the secondary the connection (Item 1) [Figure SPEC-50-5].
seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-50-4]. Use the chart below to find the correct tightness needed
(Item 2) [Figure SPEC-50-5]. If the fitting leaks after
If necessary, the O-ring-flare fitting can be used without tightening, disconnect it and inspect the seat area for
an O-ring. damage.
O-Ring Flare Fitting Tightening Torque

* ** ***
Tubeline TORQUE NEW RE-ASSEMBLY
Wrench Size Outside Thread Size ft.-lb. Rotate No. Rotate No.
Diameter (N•m) of Hex Flats of Hex Flats
5/8” 5/16” 1-2”-20 17 (23) 2-1/2 1
11/16” 3/8” 9/16”-18 22 (30) 2 1
7/8” 1/2” 3/4”-16 40 (54) 2 1
1” 5/8” 7/8”-14 60 (81) 1-1/2 1
1-1/4” 3/4” 1-1/16”-12 84 (114) 1 3/4
1-3/8” 1” 1-5/16”-12 118 (160) 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.
863 Bobcat Loader

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HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-50-7
(CONT'D)
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-50-

7] 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.
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.
863 Bobcat Loader

942 of 968
HYDRAULIC CONNECTION SPECIFICATIONS
(CONT'D)
Port Seal and O-ring Boss
Port Seal Fitting
Tightening Torque
Figure SPEC-50-8 Fitting Nut Torque ft.-lb.
Thread Size
Wrench Size (N•m)
11/16” 9/16”-18 22 (30)
15/16” 3/4”-16 40 (54)
1-1/8” 7/8”-14 60 (81)
1-1/4” 1-1/16”-12 84 (114)
1-1/2” 1-5/16”-12 118 (160)
NOTE: If a torque wrench cannot be used, use the

hex flat tightening method as an approximate
guideline.
Nut Seals NOTE: Port seal fittings are not recommended in all
to Fitting
applications. Use O-ring boss fittings in these
applications.
Nut Seals
Figure SPEC-50-9
to Port
2
Secondary O-ring Seal
P13008
The nut is the primary seal, the O-ring is the secondary 1

seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-50-8].
The hex portion of the nut does not contact the surface of P13571
the component when the nut is tight.

Do not use port seal fittings when a thread in orifice (Item
Use the following procedure to tighten the port seal
1) [Figure SPEC-50-9] is used in the port. The orifice
fitting:
may interfere with the fitting and prevent it from sealing.
Port seal and nut, washer and O-ring (O-ring Boss)
Use an O-ring boss fitting (Item 2) [Figure SPEC-50-9]
fittings use the same tightening torque valve chart.
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.
863 Bobcat Loader

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863 Bobcat Loader
944 of 968
HYDRAULIC FLUID SPECIFICATIONS When temperatures below zero degree F (-18° C) are
common, the loader must be kept in a warm building.
Specifications Extra warm-up time must be used each time the loader is
started during cold temperature conditions. Cold fluid will
Use Bobcat hydraulic transmission fluid (P/N 6563328). If not flow easily and it makes action on the hydraulic
this fluid is not available, use 10W-30 or 10W-40 SAE function slower. Loss of fluid flow to the hydrostatic
Motor Oil (5W-30 for 0° F [-18° C] and Below). 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 During cold weather (32°F [0°C] and below), do not
operate machine until the engine has run for at least
AVOID INJURY OR DEATH five minutes at less than half throttle. This warm-up
Diesel fuel or hydraulic fluid under pressure can period is necessary for foot pedal operation and safe
penetrate skin or eyes, causing serious injury or stopping. Do not operate controls during warm-up
death. Fluid leaks under pressure may not be visible. period.
not use your bare hand. Wear safety goggles. If fluid When temperatures are below -20°F (-30°C), the
enters skin or eyes, get immediate medical attention hydrostatic oil must be heated or kept warm. The
from a physician familiar with this injury. hydrostatic system will not get enough oil at low
W-2072-0807
temperatures. Park the machine in an area where the
temperature will be above 0°F (-18°C) if possible.
W-2027-1285
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863 Bobcat Loader
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CONVERSIONS
Decimal And Millimeter Equivalents
863 Bobcat Loader

947 of 968
CONVERSIONS (CONT’D)
U.S. To Metric Conversion
863 Bobcat Loader

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ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: 863/863H-1

Date: 17 April 2000
Product: Bobcat Loader
Model: 863/863H
Manual No: 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 DESCRIPTION

Electrical Charts Electrical Charts
863 - WIRING SCHEMATIC 863 - WIRING SCHEMATIC
S/N 514440001 AND ABOVE SINGLE AND TWO-SPEED VALVE
S/N 514540001 AND ABOVE S/N 514440001 AND ABOVE
(PRINTED SEPTEMBER 1999) S/N 51460001 AND ABOVE
6719967 (PRINTED APRIL 2000)
V-003
863 - WIRING SCHEMATIC 863 - WIRING SCHEMATIC

ADVANCE HAND CONTROL OPTION ADVANCED HAND CONTROL OPTION
S/N 514440001 AND ABOVE SINGLE AND TWO-SPEED VALVE
(PRINTED SEPTEMBER 19999) S/N 514640001 AND ABOVE
6719968 (PRINTED APRIL 2000)
V-0004
Printed in U.S.A.
949 of 968
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ATTENTION
PARTS MANAGER

Date: 16 June 2000
Model: 863/863H
Manual No: 6900942 (9-99)

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 10-30-1 thru 10-30-2 Text change

20-01 thru 20-02 20-01 thru 20-02 Text change

HYD/HYDRO SCHEMATIC HYD/HYDRO SCHEMATIC Routing changed for implementation

863 (S/N 514440001 & Above) 863 (S/N 514440001 & Above) of Two Speed Valve
With High Flow Option (S/N 514540074 & Above)
(S/N 514640001 & Above) (Printed June 2000)
Mc2636TI V-0019ti
HYD/HYDRO SCHEMATIC Add Ending Serial Number

863 (S/N 514440001-41938)
(S/N 514640001-40147)
(Printed June 2000)
V-028ti
CONTINUED ON NEXT PAGE
Printed in U.S.A.
951 of 968
HYD/HYDRO SCHEMATIC Routing changed for implementation

WITH HIGH FLOW OPTION of Two Speed Valve
863 (S/N 514441939 & Above)
(S/N 51460148 & Above)
(Printed June 2000)
V-0023ti
HYD/HYDRO SCHEMATIC Two Speed Valve Added

863 (S/N 514441939 & Above)
(S/N 514540074 & Above)
(Printed June 2000)
V-0022ti
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 Removed Tilt Cylinders

20-21-1 thru 20-21-8 Added Tilt Cylinders
20-22-1 thru 20-22-6 Added Power Bob-Tach Cylinders
20-130-1 thru 20-130-4 Added Rear Auxiliary Diverter Valve (Single
Shuttle)
20-140-1 thru 20-140-8 Added Power Bob-Tach Block
30-01 thru 30-02 30-01 thru 30-02 Text Change

30-41-1 thru 30-41-20 Added Hydrostatic Motor (Two-Speed)

40-10-3 thru 40-10-4 40-10-3 thru 40-10-4 Test change
40-11-1 thru 40-11-8 Added Brake (Two-Speed)

DO NOT REMOVE CHARTS
Section 80 Section 80 Added HVAC
Section SPEC Change page number system
952 of 968
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ATTENTION
PARTS MANAGER

Date: 15 August 2000
Model: 863/863H
Manual No: 6900942 (9-99)

Alpha Index Alpha Index Text changes
i thru ii i thru ii Text changes

v thru vi v thru vi Updated
Section 10 Section 10 Added Breather Cap, Added Fan

Gearbox, Added Final Drive
Transmission (Chaincase), Added
Replacing Filter Elements
20-01 thru 20-02 20-01 thru 20-04 Text changes

20-31-1 thru 20-31-2 20-31-1 thru 20-31-4 Added Main Relief Valve (AHC)
20-41-1 thru 20-41-2 20-41-1 thru 20-41-26 Added Hydraulic Control Valve (AHC)
20-50-1 thru 20-50-2 20-50-1 thru 20-50-2 Added Inspecting
20-80-1 thru 20-80-2 20-80-1 thru 20-80-2 Added Draining The Fluid Reservoir
20-100-1 thru 20-100-1 20-100- thru 20-100-6 Added Bucket Positioning Valve
20-120-3 thru 20-120-4 20-120-3 thru 20-120-4 Text changes

30-32-1 thru 30-32-6 Added Steering AHC (W/Push Button Float)
Printed in U.S.A.
953 of 968

40-30-1 thru 40-30-4 40-30-1 thru 40-30-2 Removed Chaincase (Checking & Adding Oil)

50-31-1 thru 50-31-6 Added Operator Seat (Suspension)

60-90-1 thru 60-90-4 60-90-1 thru 60-90-4 Updated
60-120-1 thru 60-120-10 60-120-1 thru 60-120-4 Added PWM
60-130-1 thru 60-130-2 60-130-1 thru 60-130-10 Page Number change
60-131-1 thru 60-131-12 Added AHC System (W/Push Button Float)
60-140-1 thru 60-140-2 Page and text changes

70-40-7 thru 70-40-4 70-40-1 thru 70-40-2 Removed Gearbox Checking And Adding Oil
70-60-3 thru 70-60-20 70-60-3 thru 70-60-20 Remove Gearbox Checking And Adding Oil
954 of 968
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ATTENTION
PARTS MANAGER

Date: 14 August 2001
Model: 863/863H
Manual No: 6900942 (9-99)


10-120-1 thru 10-120-2 10-120-1 thru 10-120-4 Text changes and Added Breather Cap
Section 30 Section 30 Text changes

50-41-1 thru 50-41-4 Added Power Bob-Tach
50-90-1 thru 50-90-4 Added Control Panels
50-91-1 thru 50-91-2 Added Control Pedals (ACS)
50-100-1 thru 50-100-2 Added Control Panel
Printed in U.S.A.
955 of 968
50-110-1 thru 50-110-10 Added Control Handle
50-112-1 thru 50-112-12 Added Control Handle (Advanced Hand Control)
(AHC) (W/Push Button Float)
50-113-1 thru 50-113-8 Added Control Handle (Advanced Control System)
(ACS) Advanced Hand Control
50-114-1 thru 50-114-8 Added Control Handle (Advanced Control System)
(ACS) Selectable Hand/Foot Control
Section 60 Section 60 Text changes, added Alternator (90 AMP), Starter

(Including SCHEMATICS) (Including SCHEMATICS) (Checking), Advanced Control System

70-91-1 thru 70-91-2 Added RPM Sensor
Section 80 Section 80 Text changes
956 of 968
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ATTENTION
PARTS MANAGER
Revision No: 863-5

Date: 10 September 2001
Model: 863 (Includes High Flow)
Manual No: 6900942 (9-99)

10-50-1 thru 10-50-2 10-50-1 thru 10-50-2 Photo change

Section 20 Section 20 Revised Text & photos
SPEC Section SPEC Section Revised Text
Printed in U.S.A.
957 of 968
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ATTENTION
PARTS MANAGER
Revision No: 863-6

Date: 4 April 2002
Model: 863 (Includes High Flow)
Manual No: 6900942 (9-99)
All Hyd/Hydro Schematics All Hyd/Hydro Schematics Added Serial Number Information And
(Printed June 2000) (Printed April 2002) New Components
Printed in U.S.A.
959 of 968
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ATTENTION
PARTS MANAGER
Revision No: 863-7

Date: 25 November 2002
Model: 863
Manual No: 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.
961 of 968
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ATTENTION
PARTS MANAGER
Revision No: 863-8

Date: 1 December 2003
Model: 863
Manual No: 6900942 (11-02)
MSW08-0500 MSW08-0903 Revised text
i thru x i thru x Revised text
10-10-1 thru 10-10-2 10-10-1 thru 10-10-2 Revised text

Hydraulic/Hydrostatic Schematic Hydraulic/Hydrostatic Schematic Revised chart

With High Flow Option With High Flow Option
863 (S/N 514450946-514451083) 863 (S/N 514450946-514451083)
(S/N 514641255-514641266) (S/N 514641255-514641266)
(Printed November 2002) (Printed December 2003)

With Two Speed Valve and High With Two Speed Valve and High
Flow Option Flow Option
863 (S/N 514450946-514451083) 863 (S/N 514450946-514451083)
(S/N 514641255-514641266) (S/N 514641255-514641266)

863 (S/N 5144551084 & Above) 863 (S/N 514451084 & Above)
(S/N 514541114 & Above) (S/N 514541114 & Above)
Printed in U.S.A.
963 of 968
With Two Speed Valve Option With Two Speed Valve Option
863 (S/N 514451084 & Above) 863 (S/N 514451084 & Above)
(S/N 514541114 & Above) (S/N 514541114 & Above)

With High Flow Option With High Flow Option
863 (S/N 514451084 & Above) 863 (S/N 514451084 & Above)
(S/N 514641267 & Above) (S/N 514641267 & Above)

With Two Speed Valve and High With Two Speed Valve and High
Flow Option Flow Option
863 (S/N 514451084 & Above) 863 (S/N 514451084 & Above)
(S/N 514641267 & Above) (S/N 514641267 & Above)
Wiring Schematic Wiring Schematic Revised chart

(Without ACS Option) (Without ACS Option)
863 (S/N 514450764 & Above) 863 (S/N 514450764 & Above)
(S/N 514541104 & Above) (S/N 514541104 & Above)
(S/N 514641255 & Above) (S/N 514641255 & Above)
Wiring Schematic Wiring Schematic Revised chart

(With ACS Option) (With ACS Option)
863 (S/N 514450764 & Above) 863 (S/N 514450764 & Above)
(S/N 514541104 & Above) (S/N 514541104 & Above)
(S/N 514641255 & Above) (S/N 514641255 & Above)
964 of 968
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ATTENTION
PARTS MANAGER
Revision No: 863-9

Date: 23 March 2006
Model: 863
Manual No: 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.
965 of 968
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ATTENTION
PARTS MANAGER
Revision No: 863-10

Date: 20 July 2010
Model: 863
Manual No: 6900942 (7-10)
The following Sections are a revision to the above Service Manual.
COVER
MAINTENANCE SAFETY
FOREWORD
70-80
Printed in U.S.A.
967 of 968
968 of 968

Bobcat 963 Service Manual

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CORRECT CORRECT CORRECT

P-90216 B-15590 B-15591

WRONG WRONG WRONG

B-15592 B-15593 B-15599

B-15600 B-15601 B-6589

ADVANCED CONTROL SYSTEM ENGINE LUBRICATION SYSTEM .........................10-01

BASIC TROUBLESHOOTING ................................ 80-01 GENERAL AIR CONDITIONING SERVICE

ELECTRICAL / HYD. CONTROLS REFERENCE .. 60-01

863 Bobcat Loader

POWER BOB-TACH (OPTION)....................10-01, 50-01

863 Bobcat Loader

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . XI HYDROSTATIC

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

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

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

863 Bobcat Loader

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

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

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

6. Machine signs (decals) must 14. Check hydraulic fluid level,

7. Steering levers, hand controls 15. Inspect for fuel, oil or

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

22. Check for any field

863 Bobcat Loader

• The Skid-Steer Loader Operator Training Course is

DANGER available through your local dealer or at

WARNING • The Skid-Steer Loader Safety Video is available from

863 Bobcat Loader

The dealer and owner / operator review the

Cutting or drilling concrete containing sand or rock

Call Before You Dig

863 Bobcat Loader

Check hydraulic tubes, hoses and fittings for damage

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

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

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

Check the spark arrestor exhaust system regularly to

Battery gas can explode and cause serious injury. Use

863 Bobcat Loader

Welding And Grinding

Always clean the machine and attachment, disconnect

Have good ventilation when grinding or welding painted

Dust generated from repairing nonmetallic parts such as

Know where fire extinguishers and first aid kits are

Always use the serial number of the loader when Figure 2

Loader Serial Number

The loader serial number plate is located on the inside of

Explanation of loader Serial Number:

XXXX XXXXX N-19359

Model 1.-Model / Engine Model 2.-Production

2. The five digit Production Sequence Number identifies

863 Bobcat Loader

The Delivery Report must be filled out by the dealer and

863 Bobcat Loader

BUCKET STEPS SAFETY TREAD B-15565

◆REAR LIGHT LIFT CYLINDER

◆TAIL LIGHT TIRES*

◆ OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment)

863 Bobcat Loader

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1