Documente Academic
Documente Profesional
Documente Cultură
5
3
Service
Manual
8
5
3
H
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICSTM)
6724012 (495)
Printed in U.S.A.
MAINTENANCE SAFETY
WARNING
Safety Alert Symbol: This symbol with a warning statement, means: Warning, be alert! Your safety is
involved! Carefully read the message that follows.
CORRECT
CORRECT
CORRECT
B-10731a
B-12365
B-7469
WRONG
WRONG
WRONG
B-11799
B-15231
B-15280
WRONG
WRONG
WRONG
B-6590
B-6580
B-16102
B-6589
B-16102
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.
MSW01-0805
CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
SYSTEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
PREVENTIVE
MAINTENANCE
HYDRAULIC
SYSTEM
HYDROSTATIC
SYSTEM
DRIVE
SYSTEM
MAIN
FRAME
ELECTRICAL
SYSTEM
ENGINE
SERVICE
SYSTEM
ANALYSIS
SPECIFICATIONS
Revised June 97
FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS
(Including sidescreens) is in
good condition and is not
modified.
10. BobTach
wedges
and
linkages
must
function
correctly and be in good
condition.
must
ii
22. Check
for
any
field
modification not completed.
iii
iv
SAFETY INSTRUCTIONS
Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual,
Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure
to follow instructions can cause injury or death.
W20031289
The following publications provide information on the safe use and maintenance of the loader and attachments:
The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine
is in safe operating condition.
The Operation & Maintenance Manual delivered with the loader gives operating information as well as routine
maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement
Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.
The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are
shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.
The loader has a plastic Operators Handbook fastened to the operator cab. Its brief instructions are convenient to the
operator. The handbook is available from your dealer in English edition or French, German, Italian, Dutch, Spanish,
Portuguese, Finnish, Danish & Swedish editions.
The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.
The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and
repair work.
The SkidSteer Loader Operator Training Course is available through your local Bobcat dealer. This course is intended
to provide rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish
versions.
The Bobcat SkidSteer Loader Safety Video is available from your Bobcat Dealer.
I20190284
Safety Alert Symbol: This Safety Symbol is used for important safety messages. When you see this
symbol follow the safety message to avoid personal injury or death.
Revised June 97
Know where fire extinguishers and first aid kits are located and how to use them.
Do not use the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive
dust or gases.
The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent
fire hazard and overheating.
Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any
damaged part.
Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check
for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for
cleaning parts. Use commercial nonflammable solvents.
Follow any environmental safety regulations when disposing of used fluids such as engine oil, grease or antifreeze.
Do not use ether or starting fluids on this engine. It has glow plugs. These starting aids can cause explosion and injure
you or bystanders.
Always clean the loader and disconnect the battery before doing any welding. Cover rubber hoses, battery and all other
flammable parts. Keep a fire extinguisher near the loader 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.
Stop the engine and let it cool before adding fuel. No smoking!
Use the procedure in the Operation & Maintenance or Service Manuals for connecting the battery.
Use the procedure in the Operation & Maintenance or Service Manuals for cleaning the spark arrestor muffler.
A fire extinguisher is available from your local dealer. The fire extinguisher can be installed in the location shown [A].
P03705
Revised June 97
vi
P00369
XXXXX
Module 2. Production
Sequence (Series)
Module 1. Model/Engine
Version
The four digit Model/Engine Combination module number
identifies the model number and engine combination.
This number (in parenthesis beside the model number) is
used in the Service Manual to more easily identify the
standard, optional and field accessory equipment
included or available for each specific model.
The five digit Production Sequence Number identifies the
order which the loader is produced.
P00370
DELIVERY REPORT
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 [C].
vii
FRONT LIGHTS
GRAB HANDLES
OPERATOR SEAT
STEERING LEVER
REAR AUXILIARY
QUICK COUPLERS
SEAT BELT
TILT CYLINDER
FRONT AUXILIARY
QUICK COUPLERS
SAFETY TREAD
BUCKET
BUCKET STEPS
OPERATOR CAB
(ROPS & FOPS)
SEAT BAR
REAR WINDOW
LIFT ARM
LIFT ARM
SUPPORT DEVICE
REAR GRILL
LIFT CYLINDER
TAIL LIGHT
REAR LIGHT
REAR DOOR
REAR
TIE DOWN
TIRES*
B12555
B12556
* TIRES Flotation tires are shown. The Bobcat loader is basedequipped 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 I. Level ll FOPS is available for protection from heavy falling
objects. The Bobcat loader is baseequipped with a standard operator cab as shown. Extra insulated cab is
available as an option (Reduced noise level).
viii
Seat Belt
Seat Bar
Parking Brake
Gauges/Warning Lights
Bobcat Interlock Control System (BICSTM)
Below is a listing of the optional equipment which is available through your Bobcat Loader dealer.
853 & 853H
Tires
8.2515 6 PR . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.0016.5, Segmented . . . . . . . . . . . . . . . . . . . .
12.0016.5, 6 PR Flotation . . . . . . . . . . . . . . . . .
1216.5 8 PR Bobcat Heavy Duty Flotation . . .
8.0016 Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.0033 Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Std.
Opt.
Opt.
Opt.
Opt.
Opt.
Operator Cab
Sound Cab (85 dBa) . . . . . . . . . . . . . . . . . . . . . . .
Deluxe Cab (90 dBa) . . . . . . . . . . . . . . . . . . . . . .
Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Lights (Front & Rear) . . . . . . . . . . . . .
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Backup Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heated Enclosed Cab . . . . . . . . . . . . . . . . . . . . . .
Top Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Enclosure Panels . . . . . . . . . . . . . . . . . . . . .
Vinyl Cab Enclosure . . . . . . . . . . . . . . . . . . . . . . .
Hand Control Conversion . . . . . . . . . . . . . . . . . . .
Cover Kit (Pedals Area) . . . . . . . . . . . . . . . . . . . .
Cover Kit (Hydraulic Reservoir Area) . . . . . . . . .
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . .
Flasher Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strobe or Rotating Beacon Light . . . . . . . . . . . . .
3 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Applications Kit (Includes Front Door,
Top & Rear Windows) . . . . . . . . . . . . . . . . . . . . .
Hydraulics
Front Auxiliary Hydraulics . . . . . . . . . . . . . . . . . .
Rear Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . .
Hydraulic Bucket Positioning . . . . . . . . . . . . . . . .
Bucket Positioner On/Off . . . . . . . . . . . . . . . . . . .
High HP Hydraulics . . . . . . . . . . . . . . . . . . . . . . . .
Other
Catalytic Purifier . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . .
Single Point Lift . . . . . . . . . . . . . . . . . . . . . . . . . . .
Four Point Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locking Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator Screen Kit . . . . . . . . . . . . . . . . . . . . . . . .
Rear Door Bumpers . . . . . . . . . . . . . . . . . . . . . . .
Tailgate Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tool Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FA
FA
FA
FA
FA
FA
FA
FA (Std. in Europe)
FA (Std. in Europe)
Instrumentation
Bobcat Operation Sensing System (BOSS) . .
Opt.
FA
Specifications subject to
change without notice
ix
853,853HBICSServiceManual#6724012ContentsSection
PREVENTIVE MAINTENANCE
Page
Number
PREVENTIVE
MAINTENANCE
113
113
113
114
HYDRAULIC/HYDROSTATIC SYSTEM
Checking and Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Hydraulic/Hydrostatic Filters . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Reservoir Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
120
120
122
121
18
19
18
19
11
12
SERVICE SCHEDULE
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 Operation Maintenance Manual, Handbook and signs (decals)
on machine. Follow warnings and instructions in the manual when
making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Failure to follow instructions can
cause injury or death.
W20031289
ITEM
Engine Oil
Air Cleaner
Engine Cooling System
Lift Arms, Cyl., BobTach
Pivot Pins & Wedges
Engine Air System
Tires
Seat Belt, Seat Bar & Pedal
Interlocks
Bobcat Interlock Control
System (BICS)
Safety Signs & Safety
Tread
Operator Cab
Fuel Filter
Hydraulic Fluid, Hoses
& Tubelines
Final Drive Transmission
(Chaincase)
Battery
Control Pedals & Steering
Wheel Nuts
Parking Brake
Alternator Belt
Engine Oil & Filter
Spark Arrestor Muffler
Engine/Hydro. Drive Belt
Fuel Filter
Steering Shaft
Hyd./Hydro. Filter
Hydraulic Reservoir
Breather Cap
Fan Drive Gearbox
Final Drive Transmission
Hydraulic Reservoir
Hydraulic Motors
Bobcat Interlock Control
System (BICS)
SERVICE REQUIRED
810
50
100
250 1000
Check wheel nut torque every 8 hours for the first 24 hours.
Also replace hydraulic/hydrostatic filter element when the transmission warning light comes ON.
Or every 12 months.
* Inspect the new belt after first 50 hours.
Clean or replace case drain filters in the event of any major hydraulic or hydrostatic repair.
13
A
Instructions are necessary before operating or
servicing machine. Read Operation &
Maintenance Manuals, Handbook and signs
(decals) on machine. Follow warnings and
instructions in the manuals when making
repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Failure to follow instructions can
cause injury or death.
W20031289
W20170286
P04736
C
Put the floor jack under the front the loader [C].
Lift the front of the loader and put jackstands under the
axle tubes [C].
NOTE: Make sure the jackstands do not touch the
tires.
P04734
Revised June 97
14
Procedure
W20580494
MC01241
P05090
P05077
6707867
MC01242
15
MC01434
W20461290
B
The loader can be lifted with the four point lift which is
available as a kit from your Bobcat loader dealer.
Attach cables or chains to lift eyes as shown [A].
Single Point Lift
MC01664
W20071285
The loader can also be lifted with the single point lift which
is available as a kit from your Bobcat loader dealer.
Install the kit and lift as shown [B].
The single point lift, supplied by Melroe Company is
designed to lift and support the Bobcat loader without
affecting roll over and falling object protection features of
the operator cab.
16
Lower the lift arm support device on top of the lift cylinder.
Hook the free end of the spring (item 1) [B] to the lift arm
support device so there will be no interference with the
support device engagement.
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine.
P02118
Raise the lift arms, until the lift arm support device drops
onto the lift cylinder rod [C].
Lower the lift arms slowly until the support device is held
between the lift arm and the lift cylinder. Stop the engine.
Raise the seat and move pedals until both pedals lock.
Install pin (Item 1) [C] into the rear of the lift arm support
device below the cylinder rod.
Disengaging the Lift Arm Support Device
Remove the pin from the lift arm support device.
Connect the spring (Item 1) [D] from the lift arm support
device to the bracket below the lift arms.
P00095
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine.
Raise the lift arms a small amount and the spring will lift
the support device off the lift cylinder rod. Lower the lift
arms. Stop the engine.
Raise the seat bar and move pedals until both pedals
lock.
Revised June 97
17
OPERATOR CAB
Description
The Bobcat loader has an operator cab (ROPS and
FOPS) as standard equipment to protect the operator
from rollover and falling objects. Check with your dealer
if the operator cab has been damaged. The seat belt must
be worn for roll over protection.
ROPS/FOPS Roll Over Protective Structure per SAE
J104 and ISO 3471, and Falling Object Protective
Structure per SAE J1043 and ISO 3449, Level l. Level ll
is available.
CD15126
CD15125
W20691285
P00380
W20141285
Loosen the nut (Item 1) [A] (both sides) at the front corner
of the operator cab.
Remove the nut and plate (both sides) [B].
Lift on the grab handle and bottom of the operator cab
slowly until the cab latching mechanism engages and the
cab is all the way up [C].
18
CD15124
CD15126
Emergency Exit
P00660
Push the rear window out of the rear of the operator cab.
P00383
19
Description
The seat bar restraint system has a pivoting seat bar with
arm rests and has spring loaded interlocks for the lift and
tilt control pedals. The operator controls the use of the
seat bar. The seat bar in the down position helps to keep
the operator in the seat. The interlocks require the
operator to lower the seat bar in order to operate the foot
pedal controls. When the seat bar is up, the lift and tilt
pedals are locked when returned to the neutral position.
P03269
P03270
The seat bar system must lock the lift and tilt
control pedals in neutral when the seat bar is
up. Service the system if pedals do not lock
correctly.
W21051285
Clean
Pedal Lock
Shield
Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down. Start the
engine. Operate each foot pedal to check both the lift and
tilt functions. Raise the lift arms until the bucket is about
2 feet (600 mm) off the ground.
Raise the seat bar. Try to move each foot pedal. Pedals
must be firmly locked in neutral position. There must be
no motion of the lift arms or tilt (bucket) when the pedals
are pushed.
P01223
Pull the seat bar down, lower the lift arms. Operate the lift
pedals. While the lift arms are going up, raise the seat bar
and the lift arms should stop.
Lower the seat bar, lower the lift arms and place the
bucket flat on the ground. Stop the engine. Raise the seat
bar and operate the foot pedals to be sure that the pedals
are firmly locked in the neutral position. Unbuckle the seat
belt.
W21621194
1
2
CD15118
MC02042
CD15117
111
CD15119
CD15120
Remove the inner filter wing nut (Item 1) [C] to remove the
filter element.
CD15121
112
FUEL SYSTEM
Fuel Specifications
Use only clean, high quality diesel fuel, Grade No. 1 or
Grade No. 2 .
The following is one suggested blending guideline which
should prevent fuel gelling problems:
Temp. F (C)
No. 2
No.1
+15(9)
Down to 20 (29)
Below 20 (29)
100%
50%
0%
0%
50%
100%
P02124
WRONG
B13456
2
Always clean up spilled fuel or oil. Keep heat,
flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
combustibles can cause explosion or fire
which can result in injury or death.
CD15123
W21031285
2
Diesel fuel or hydraulic fluid under pressure
can penetrate skin or eyes causing serious
injury. Fluid leaks under pressure may not be
visible. Use a piece of cardboard or wood to
find leaks. Do not use your bare hand. Wear
safety goggles. If fluid enters skin or eyes, get
immediate medical attention.
CD15123
W20741285
Loosen the air vent plug (Item 1) [A] at the top of the fuel
filter.
Operate the priming bulb (Item 2) [A] until fuel flows from
the filter vent. Tighten the fuel filter vent plug (Item 1) [A].
Loosen the air vent plug at the top of the fuel injection
pump [B].
CD10847
Again operate the priming bulb (Item 2) [A] until fuel flows
from the air vent plug with no air bubbles showing.
Tighten the air vent plug at the fuel injection pump [B].
114
CD15112
1
TEMPERATURE RANGE ANTICIPATED BEFORE
NEXT OIL CHANGE
CD15113
Clean the filter housing surface. Put clean oil on the new
oil filter gasket. Install the filter and hand tighten only.
Install and tighten the drain plug.
CD15122
115
1
CD15114
116
P00378
W20191285
P00381
Open the rear door. Check the coolant level in the coolant
recovery tank on the right side of the engine [C].
The coolant recovery tank must be 1/3 full.
Propylene Glycol
Add premixed coolant, 47% water and 53% propylene
glycol to the recovery tank if the coolant level is low.
One gallon and one pint of propylene flycol mixed with one
gallon of water is the correct mixture of coolant to provide
a 34F (37C) freeze protection.
CD15011
Ethylene Glycol
Add premixed coolant, 50% water and 50% ethylene
glycol to the recovery tank if the coolant level is low.
117
P00379
B
Remove the drain plug (Item 1) [B] from the side of the
engine block. Drain the coolant into a container.
P02125
2
1
CD09339
118
Procedure
CD15009
W20660490
disconnected.
119
HYDRAULIC/HYDROSTATIC SYSTEM
CD15162
CD15135
CD15161
Add the fluid as needed to bring the level to the top mark
on the dipstick [A].
1
CD15127
1
CD15128
120
CD15135
CD15161
CD15163
C
Diesel fuel or hydraulic fluid under pressure
can penetrate skin or eyes causing serious
injury. Fluid leaks under pressure may not be
visible. Use a piece of cardboard or wood to
find leaks. Do not use your bare hand. Wear
safety goggles. If fluid enters skin or eyes, get
immediate medical attention.
W20741285
P05028
W21031285
Lower the operator cab. Start the engine and operate the
loader hydraulic controls. Stop the engine. Check for
leaks. Check the fluid level in the reservoir and add as
needed.
P05027
121
CD15134
CD15132
CD15133
122
Cleaning Procedure
See the Service Schedule Page 13 for service interval
for cleaning the spark arrestor muffler.
Do not operate the loader with a defective exhaust
system.
CD15172
I20221285
Stop the engine. Open the rear door and rear grill.
W20111285
W20681285
123
TIRE MAINTENANCE
Wheel Nuts
See the Service Schedule Page 13 for the service
interval to check the wheel nuts. The correct torque is
105115 ft.lbs. (142156 Nm) torque [A].
Tire Rotation
Check the tires regularly for wear, damage and pressure.
(See Specifications Page 91 for the correct tire
pressure.)
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 [B].
CD15165
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.
124
853,853HBICSServiceManual#6724012PreventiveMaintenanceSectionPart1of2
If oil can be reached with the tip of the your finger through
the hole the oil level is correct.
If the level is low, add oil through the check plug hole until
the oil flows from the hole. Install and tighten the plug.
Removing Oil From the Chaincase
To drain the oil from the chaincase, remove the cover
(Item 1) [B] which is installed over the drain plug at the
rear of the chaincase.
P01616
Remove the drain plug (Item 1) [C] and drain the oil into
a container.
NOTE: When installing the drain plug into the
chaincase, always use a NEW drain plug.
P01619
FAN GEARBOX
If the level is low, add SAE 90W gear lube through the
check plug hole until the lubricant flows from the hole.
Install and tighten the plug.
CD15164
125
Procedure
Lubricate the loader as specified in the Service Schedule
Page 13 for the best performance of the loader.
Record the operating hours each time you lubricate the
Bobcat loader.
Always use a good quality lithium based multipurpose
grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
CD15171
CD15170
CD15168
126
Procedure (Contd)
5. Rod End Tilt Cylinder [A].
5
CD15167
7
CD15166
C
8
CD15013
127
Procedure
The tool listed will be needed to do the following
procedure:
MEL1429 Remote Start Switch
The Remote Start Switch is required when the service
technician is adjusting the steering linkage, checking the
hydraulic/hydrostatic system.
Lift and block the loader. (See Page 14.)
Raise the lift arms and install an approved lift arm support
device. (See Page 17.)
P04732
B
Disconnect the operator cab wire harness from the
engine wire harness [A].
Connect the remote start switch to the engine harness
connectors (Item 1) [B].
1
Put jackstands under the front axles and rear
corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.
W20170286
W20590991
128
Procedure (Contd)
Put the traction lock override switch (Item 1) [A] in the
ON position so the traction function is locked. The
wheels are not able to turn.
Turn the key to the right and start the engine.
P04713
B
1
2
P04714
129
853,853HBICSServiceManual#6724012PreventiveMaintenanceSectionPart2of2
130
HYDRAULIC SYSTEM
Page
Number
BUCKET POSITION VALVE (OPTIONAL)
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
CONTROL PEDALS
Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
DUAL PRESSURE MAIN RELIEF VALVE 853H
Adjusting the Low Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the High Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Low Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the High Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
225
226
222
223
233
242
241
243
231
243
230
243
235
231
232
225
232
228
234
244
240
HYDRAULIC
SYSTEM
HYDRAULIC CYLINDERS
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Lift Cylinder Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Tilt Cylinder Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
HYDRAULIC FILTER HOUSING
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
HYDRAULIC FLUID RESERVOIR
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
HYDRAULIC PUMP
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Output of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
251
245
248
250
247
246
261
253
256
260
255
254
24
24
24
24
22
HYDRAULIC/HYDROSTATIC SCHEMATIC
TM
853 BICS
S/N 512816001 and Above
S/N 509718001 and Above
(Printed June 1997)
LEGEND
1
2
3
4
5
FLUID RESERVOIR:
Cap . . . . 15.5 Qts (14,7 L)
Screen Filter. . . . . 60 Mesh
HYDRAULIC FILTER:
#4 Synthetic Media
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
Standard Loader (Normally Open)
B.O.S.S. Loader (Normally Closed)
FILTER BYPASS
45-55 PSI (311-379 kPa)
CHECK VALVE . . LIFT CYLINDER
Printed in U.S.A.
MC 2142LE (5-30-97)
HYDRAULIC/HYDROSTATIC
SCHEMATIC
TM S/N 512816001 and Above
853 BICS
S/N 508418001 and Above
FRONT
AUXILIARY
FEMALE
D1
36
34
MALE
D2
P1
P2
31
33
FLOW
ADJUSTMENT
VALVE
REAR
AUXILIARY
HYDRAULIC
FILTER
FEMALE
F1
32
MALE
F2
6
5
CASE
DRAIN
FLOW
CONTROL
SPOOL
LIFT CYLINDER
CHECK VALVE
UNLOADING
SPOOL
ANTI-DRAIN
BACK
CHECK
DRIVE MOTOR
22
SHUTTLE
VALVE
CONTROL VALVE
OIL
COOLER
23
HYDROSTATIC
FILTER
21
SHUTTLE
RELIEF
VALVE
HYDROSTATIC
PUMPS
AUXILIARY
CONTROL
SOLENOID
TILT CYLINDER
WITH CUSHION
AUXILIARY PORT
RELIEF VALVE
(OPTIONAL)
AUXILIARY
CONTROL
SOLENOID
AUXILIARY SPOOL
NEUTRAL POSITION
20
30
20
MOTOR
CASE
DRAIN
FILTER
24
TILT CYLINDER
ANTI-CAVITATION
VALVE
25
DISPLACEMENT
CONTROL
VALVE
18
HYD. PUMP
OUTLET
DRIVE
MOTOR
HYDR.
MUFFLER
(OPTIONAL)
29
26
17
LIFT CYLINDERS
PORT
RELIEF
15
INLET
TILT CYLINDER
LOAD CHECK
19
INLET
OUTLET
CHARGE PUMP
27
LIFT CYLINDER
ANTI-CAVITATION
VALVE
17
LIFT CYLINDER SPOOL
NEUTRAL POSITION
28
23
15
MAIN RELIEF
VALVE
16
L1
SHUTTLE
RELIEF
VALVE
CONTROL SPOOL
12
DISPLACEMENT
CONTROL
VALVE
25
11
13
CONTROL SPOOL
14
24
P1
PT
ELECTRIC SOLENOID
SCREEN FILTER
PP
MOTOR
CASE
DRAIN
FILTER
10
MANUAL BYPASS
CONTROL
CHECK VALVE
B1
CHECK
VALVE
SHUTTLE VALVE
Printed in U.S.A.
11
22
PT
RESERVOIR
PILOT PRESSURE
INPUT
TILT CYLINDER
CHECK VALVE
P2
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
MC 2142 (5-30-97)
HYDRAULIC/HYDROSTATIC SCHEMATIC
853H BICS TM S/N 512816001 and Above
S/N 508418001 and Above
(Printed June 1997)
LEGEND
1 FLUID RESERVOIR:
Capacity . 16.0 Qts (15,1 L)
Screen Filter. . . . . 60 Mesh
2 HYDRAULIC FILTER:
#3 Synthetic Media
3 DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
Standard Loader (Normally Open)
B.O.S.S. Loader (Normally Closed)
4 FILTER BYPASS:
45-55 PSI (311-379 kPa)
5 CHECK VALVE . . LIFT CYLINDER
31 HYDROSTATIC FILTER
#3 Synthetic Media
32 TWO COIL SOLENOID VALVE
33 HIGH FLOW SOLENOID
34 HIGH FLOW MAIN RELIEF VALVE
35 PILOT TO OPEN CHECK VALVE
36 DIVERTER SOLENOID
HYDRAULIC/HYDROSTATIC SCHEMATIC
TM S/N 512816001 and Above
853H BICS
S/N 509718001 and Above
FEMALE
MALE
FEMALE
MALE
C1
REAR QUICK
COUPLERS
(Optional)
RIGHT SIDE
LIFT ARM
MALE
FEMALE
35
HYDRAULIC
FILTER
DRIVE MOTOR
FRONT AUXILIARY
FEMALE
C2
35
7
A
MALE
DRAIN
6
4
22
32
34
35
40
40
2
ANTI-DRAIN
BACK
CHECK
PB
36
CONTROL VALVE
21
PP
23
33
Press.
OIL
COOLER
20
AUXILIARY SPOOL
NEUTRAL POSITION
TILT CYLINDER
20
HYDROSTATIC PUMPS
HYDROSTATIC
FILTER
24
30
17
19
25
LIFT CYLINDERS
15
18
31
26
OUTLET
HYDRAULIC MUFFLER
(OPTIONAL)
17
27
OUTLET
INLET
15
OUTLET
INLET
28
DRIVE
MOTOR
16
L1
29
12
10
23
X
24
13
P1
PT
14
SCREEN
FILTER
ELECTRIC SOLENOID
PP
Printed in U.S.A.
B1
11
22
30
11
PT
P2
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
MC 2202 (5-30-97)
HYDRAULIC SYSTEM
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.
W20041285
PROBLEM
CAUSE
1, 2, 3, 5, 8
1, 3
1, 3, 4, 6, 8
1, 4, 5, 6, 7
1, 3, 4, 5, 6, 7, 8, 9
The lift arms or BobTach will move when the pedal is in neutral position.
The lift arms come down with the pedal in the neutral position.
4, 9, 10, 11
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
23
Tighten to Correct
Amount from Chart
I20030284
A01897
Flare Connections
Tube Size
Rotate No.
Wrench Size Outside Dia. Thread Size of Hex Flats
5/8
5/16
1/2 20
21/2
Tighten the nut until it makes contact with the seat. Make
a mark across the flats of both the male and female parts
of the connection [A].
Use the chart to find the correct tightness needed.[B]. If
the fitting leaks after tightening, disconnect it and inspect
the seat area for damage.
11/16
3/8
9/16 18
7/8
1/2
3/4 16
5/8
7/8 14
11/2 2
11/4
3/4
11/16 12
13/8
15/16 12
3/4 1
11/4
15/8 12
3/4 1
21/4
11/2
17/8 12
1/2 3/4
When the fitting is tightened, you can feel when the fitting
is tight to eliminate leakage caused by under or over
torqued fittings. Use Vaseline petroleum jelly to hold the
Oring in position until the fittings are assembled [C].
B07575
Nut
Nut
Washer
Washer
Oring
Oring
A01852
24
LIFT CYLINDER(S)
Lower the lift arms. Stop the engine. Raise the seat bar.
CD15067
W21450290
B
1
CD15068
Raise the lift arms so the rod end retaining pin will clear
the loader frame for removal.
Have a second person put jackstands under the
BobTach to support the lift arms [C]. Stop the engine.
Raise the operator cab. (See Page 11.)
CD15066
Remove the retaining bolt and nut (Item 1) [D] from the
retaining pin on the rod end of the cylinder.
CD15069
Revised June 97
25
CD15070
CD15072
CD15073
W21031285
26
TILT CYLINDER
CD15074
W21450290
Remove the retainer bolt and nut (Item 1) [C] from the rod
end pivot pin.
Installation: Tighten the retainer nut to 1820 ft.lbs.
(2427 Nm) torque.
CD15076
Remove the grease fitting from the rod end pivot pin.
P03904
27
1
CD15077
W21031285
CD15078
Remove the old seal (both sides) from the rod end of the
tilt cylinder.
Install the new seals with the lip facing out [C].
1
P03911
Using two pieces of shim stock, install the rod end of the
tilt cylinder into the BobTach [D].
Be careful not to damage the new seals during
installation.
P03910
Revised June 96
28
HYDRAULIC CYLINDER
Lift Cylinder Identification
1.
2.
3.
4.
5.
6.
7.
8.
Rod
Case
Oring
Nut
Piston
Ring
Oring
Spacer
9.
10.
11.
12.
13.
14.
15.
16.
Oring
Washer
Head
Seal
Seal
Plug
Oring
Tube
8
7
6
5
14
*4
15
3
13
16
12
14
15
11
2
10
9
TS01060
29
Case
Tube
Plug
Oring
Nut
Clamp
Nut
Piston
Seal
10.
11.
12.
13.
14.
15.
16.
17.
18.
Oring
Oring
Washer
Oring
Head
Seal
Seal
Rod
Bushing
MC01688
*5
6
7
14
15
16
10
11
17
12
MC1688
18
13
Revised June 97
TS01098
210
Disassembly
Tools necessary
procedures:
for
the
disassembly/assembly
B07000
Remove the nut from the piston end of the rod [C].
B07002
D
2
B07003
211
Disassembly (Contd)
If the head has a seal, remove the seal from the head [A].
B07004
B07199
B07005
B07006
212
Disassembly (Contd)
Remove the piston seal from the piston [A].
B03689
B03703
Assembly
B12812
Install the seal on the tool and stretch it until it fits the
piston [D].
Allow the Oring to stretch for 30 seconds before
removing it from the tool.
B12809
213
Assembly (Contd)
Install the seal on the piston [A].
B12813
B12811
B03702
B03671
214
Assembly (Contd)
Install the wiper seal with the lip toward the outside of the
head [A].
B03682
B07008
B07200
B07007
215
Assembly (Contd)
If a seal was removed from the head use the following
procedure to install a new one.
NOTE: Do not overstretch the seal.
Install the seal on the tool and stretch it until it fits the
piston [A].
Allow the Oring to stretch for 30 seconds before
removing it from the tool.
NOTE: Do not turn (roll) the seal as you install it.
Damage to the seal may result.
B12809
B14305
B07011
B07198
216
Assembly (Contd)
Install the nut (Item 1) [A] on the rod.
See Page 29 or 210 for the correct torque
specifications.
B07002
B07013
B07012
Revised June 97
217
Assembly (Contd)
Install the rod assembly in the cylinder case [A].
B07001
B07014
B07000
B07015
218
P05061
2
B13443
C
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.
Left
Steering
Lever
Control
(Optional)
W20170286
Start the engine and run at low engine idle RPM. Push the
mode switch (Item 1) [B] two times (on the instrument
panel) to engage the front auxiliary hydraulics, the light
(Item 2) [B] will come ON.
P02154
Right
Steering
Lever
Control
(Optional)
P02152
Push the button (Item 1) [C] for fluid 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.
There should be 18.0 GPM (68 L/min.) free flow. Turn the
restrictor control, on the tester, until the main relief valve
opens. The correct pressure for the main relief is
27002750 PSI (1861718961 kPa).
If the relief pressure is not correct, stop the engine.
Replace or adjust the main relief valve. (See Page 221.)
Revised June 96
219
P01187
220
CD15094
I20030284
1
The main relief valve (Item 1) [A] is located at the right
rear of the control valve.
Clean the area around the control valve.
P4777
CD15091
CD15093
221
P05195
3
1
The hydraulic tester must be in the fully open
position before you start the engine.
I20240284
P00998
C
When the engine is running during service, the
steering levers must be in neutral and the
parking brake engaged. Failure to do so can
cause injury or death.
1
Left
Steering
Lever
Control
W20060284
Start the engine and run at low idle RPM. Push the mode
switch (Item 1) [B] twice (on the instrument panel) to
engage the front auxiliary hydraulics detent, both lights
(Items 2 & 3) [B] will come ON.
P02130
Right
Steering
Lever
Control
P02129
W20170286
P05195
2
The hydraulic tester must be in the fully open
position before you start the engine.
I20240284
P04717
C
1
Put jackstands under the front axles and rear
corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.
W20170286
Obtain a 3/8 inch (9,5 mm) I.D. hose (Item 1) [B] with a
3000 PSI (20685 kPa) rating or greater.
The hose loop (Item 1) [B] should be a total of 28 inches
(711 mm) in length (including quick couplers).
P04757
223
1
P05196
W20060284
Start the engine and run at low idle RPM. Increase the
engine speed to full RPM. Push the mode switch (Item 1)
[B] twice (on the instrument panel) to engage the front
auxiliary hydraulics detent, the lights (Items 2 & 3) [B]
will come ON.
NOTE: The High Horsepower switch should be in the
OFF position.
3
1
2
P00998
Push and hold the button (Item 2) [C] for fluid flow through
the secondary auxiliary couplers and hose loop.
2
1
Left
Steering
Lever
Control
Release the button (Item 2) [C] and push the button (Item
1) [C] to disengage the detent position to the front
auxiliary quick couplers.
If the relief pressure is not correct, stop the engine.
Replace or adjust the main relief valve. (See Page 226.)
P02130
224
Right
Steering
Lever
Control
P02129
853,853HBICSServiceManual#6724012HydraulicSystemSectionPart1of3
Select Valve
(GEM Block)
Control Valve
E02232
B
1
MC01654
C
1
MC01654
225
Select Valve
(G.E.M Block)
Control Valve
E02232
Use a 1/4 allen wrench (Item 1) [B] to press the push pin
(Item 2) [B] in until it bottoms out.
MC01654
226
P04761
B
3
The hydraulic tester must be in the fully open
position before you start the engine.
I20240284
Left
Steering
Lever
Control
P02130
P00998
C
1
Start the engine and run at low idle RPM. Push the mode
switch (Item 1) [B] once (on the instrument panel) to
engage the front auxiliary hydraulics momentary, the light
(Item 2) [B] will come ON.
Push the rocker switch (Item 3) [B] for fluid pressure to
the secondary quick couplers.
Watch the flow meter on the hydraulic tester to make sure
the flow is correct. Increase the engine speed to full RPM.
P05201
1
P05200
227
P04779
I20030284
Raise the lift arms and install an approved lift arm support
device. (See Page 11.)
Stop the engine. Raise the seat bar.
Raise the operator cab. (See Page 11.)
P04784
Disconnect the linkage (Items 1 & 2) [C] from the lift and
tilt spools.
C
1
2
P04785
Remove the lift lock valve support bracket from the loader
frame [D].
P04787
228
P04780
P04786
3
4
Disconnect the outlet tubeline (Item 1) [D].
Remove the control valve mounting bolts (Item 2) [D].
P04788
W21031285
P04803
229
Identification Chart
Item
MR
F1
E1
853, 853H Loader
A1
A2
A3
Auxiliary Hydraulics
B1
B2
B3
Auxiliary Hydraulics
C1
C2
C3
C4
D1
Lift Spool
D2
Tilt Spool
D3
Auxiliary Spool
E1
AntiCavitation Valve
E2
Plug
F1
Port Relief
F2
AntiCavitation Valve
G1
G2
G3
Auxiliary Spool
H1
H2
H3
MR
G1
D1
F2
D2
D3
G2
G3
H1
H3
H2
MC02130
230
CD15087
I20030284
Mark each valve section and spool so that the parts will
be returned to its original bore during assembly.
Use bolts to fasten the control valve to a work bench for
easier disassembly and assembly.
Load Check Valve
Loosen the load check plug (Item 1) [A].
Assembly: Always use new Oring. Tighten the plug to
3540 ft.lbs. (4754 Nm) torque.
CD15088
CD15089
231
1
CD15090
CD15091
Remove the Oring, sleeve, and glide ring from the main
relief valve [C].
1
B06764
1. Relief Valve
2. Oring
3. Sleeve
4. Glide Ring
5. Oring
CD15092
1
CD15094
Revised June 96
232
CD15095
E01509
1.
2.
3.
4.
Relief Valve
Oring
Backup Washer
Oring
CD15096
AntiCavitation Valve
Loosen the anticavitation valve (Item 1) [C].
Assembly: Always use new Orings and backup
washers. Tighten to 3540 ft.lbs. (4754 Nm) torque.
CD15099
CD15098
233
1.
2.
3.
4.
AntiCavitation Valve
Oring
Backup Washer
Oring
CD15097
Rubber Boot
Loosen the two screws (Item 1) [B] on the rubber boot
retainer.
Assembly: Tighten the screws to 90100 in.lbs.
(10,211,3 Nm) torque.
CD15100
CD15101
CD15102
234
CD15103
2
1
CD15104
I20120284
1
CD15105
CD15041
235
CD15042
CD15043
CD15044
CD15045
236
CD15046
CD15047
b.
Drill a hole all the way through the plug using a 7/64
inch tap drill.
c.
Turn a 632 tap into the plug. Pull the tap and plug
out of the spool. Be careful, do not break the tap.
d.
CD15048
Plastic
Plug
0.60 inch
(15,2 mm)
B09973
237
CD15049
Install the detent balls and spring into the detent adapter.
Hold the detent balls in position with the tool (MEL1278)
and install the detent adapter into the end cap [B].
CD15050
Install the new spool seal (Item 1) [C] and backup washer
(Item 2) [C].
C
2
1
CD15047
CD15045
238
CD15051
Hold the detent balls and spring in position with the tool
(MEL1278) [B].
CD15052
Install the detent sleeve (Item 1) [C] over the balls and
into position.
CD15053
239
1
CD15054
CD15055
CD15056
240
Auxiliary Spool
Remove the end plate screws (Item 1) [A].
Assembly: Tighten the screws to 90100 in.lbs.
(10,211,3 Nm) torque.
CD15054
Remove the end plate, Oring and spring (both sides) [B].
CD15057
2
1
CD15058
241
1
CD15059
CD15060
CD15061
1
CD15062
242
1
CD15085
CD15063
Inspection
CD15064
1
CD15065
243
CD15080
CD15081
244
HYDRAULIC PUMP
P04869
P05032
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM.
Warm the fluid to 140F. (60C.) by turning the restrictor
control 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 mode switch (on the remote start switch) to
engage the front auxiliary hydraulics, the light will come
ON. Push the button (on the right steering lever) for fluid
pressure to the quick coupler (fluid pressure will go over
main relief). Record the highest pressure (PSI) and flow
(GPM). The high pressure flow must be at least 80% of
free flow.
%=
X 100
245
1
When making repairs on 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.
P04869
I20030284
P04865
C
1
P04857
1
Always clean up spilled fuel or oil. Keep heat,
flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
combustibles can cause explosion or fire
which can result in injury or death.
W21031285
P04866
246
3
4
5
8
9
4
10
8
6
5
13
11
14
12
TS01022
Ref.
Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
BOLT
WASHER
END HOUSING
ORING SEAL
SEAL
RING
BODY
BEARING HOUSING
DRIVE GEAR
IDLER GEAR
BOLT
WASHER
COVER
SEAL
247
Disassembly
Marks
CD15160
I20030284
1
1
CD15141
1
CD15142
1
CD15143
248
Disassembly (Contd)
Remove the gears/bearings assembly [A].
CD15144
1
CD15145
1
1
2
2
Remove the drive gear shaft seals (Item 1) [D].
CD15146
1
CD15150
249
853,853HBICSServiceManual#6724012HydraulicSystemSectionPart2of3
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 repaired.
Check the drive and idler gears [A].
If excessive wear is visible on the journals, side or face of
the gears they must be replaced. If the splines are worn,
replace the drive gear.
CD15148
CD15147
CD15149
250
Assembly
Always use new Orings and seals when assembling the
hydraulic pump.
1
CD15150
I20030284
Install the two seals (Item 1) [A] into the mounting flange
housing using the correct size driver tool.
Install the inside seal with the lip facing the drive gear and
the outside seal with the lip facing outward.
Install the bearing housing/gears assembly into the pump
housing [B].
CD15151
CD15152
CD15153
251
Assembly (Contd)
Install the backup seals/Oring seals (Item 1) [A].
Install the large Oring (Item 2) [A].
2
1
CD15154
CD15155
CD15156
252
P5198
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM.
Warm the fluid to 140F. (60C.) by turning the restrictor
control 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 mode switch (on the remote start switch) to
engage the front auxiliary hydraulics, the light will come
ON. Push the button (on the right steering lever) for fluid
pressure to the quick coupler (fluid pressure will go over
main relief). Record the highest pressure (PSI) and flow
(GPM). The high pressure flow must be at least 80% of
free flow.
%=
X 100
253
2
When making repairs on 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.
P05199
I20030284
254
3
4
5
10
9
6
4
12
11
13
14
16
15
17
18
20
15
19
14
13
21
23
22
24
26
25
Ref.
Description
Ref.
Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
BOLT
WASHER
COVER
ORING SEAL
SEAL
RING
BODY
DOWEL
BEARING
DRIVE GEAR
IDLER GEAR
COVER
ORING SEAL
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
SEAL
RING
BODY
BEARING
DRIVE GEAR
IDLER GEAR
BEARING
COVER
SEAL
BOLT
SEAL
WASHER
BOLT
255
TS01078
Disassembly
Mark
Mark
CD15159
I20030284
3
2
Remove the Oring (Item 1) [C] from the end housing.
CD15017
CD15018
2
1
256
CD15019
Disassembly (Contd)
Remove the bearing housing/gears assembly from the
housing [A].
CD15020
Remove the drive and idler gear from the bearing housing
[B].
CD15021
Remove the two hex head bolts (Item 1) [C] and two allen
head bolts (Item 2) [C] from the mounting flange housing.
Remove the mounting flange housing (Item 3) [C].
3
2
CD15022
1
2
CD15023
257
Disassembly (Contd)
Remove the center housing (Item 1) [A] from the large
gear pump housing.
1
CD15024
1
2
CD15025
CD15026
CD15027
258
Disassembly (Contd)
Remove the two seals (Item 1) [A] from the mounting
flange housing.
1
CD15032
1
CD15031
259
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.
Check the bushings in the large and small bearing
housings [A].
CD15028
Check the drive and idler gears for the large and small
pumps [B].
If excessive wear is visible on the journals, side or face of
the gears they must be replaced. If the splines are worn,
replace the drive gear(s).
CD15029
CD15030
260
Assembly
Always use new Orings and seals when assembling the
hydraulic pump.
1
CD15032
I20030284
Install the two seals (Item 1) [A] into the mounting flange
housing using the correct size driver tool.
Install the inside seal with the lip facing the drive gear and
the outside seal with the lip facing outward.
CD15026
Install the large drive and idler gears into the bearing
housing (Item 1) [B].
1
2
CD15033
2
1
CD15034
261
Assembly (Contd)
Install the center housing (Item 1) [A] on the large pump
housing.
CD15035
CD15036
Install the hex head bolts (Item 1) [C] and allen head bolts
(Item 2) [C]. Finger tighten only.
C
1
2
CD15037
Install the drive and idler gears into the bearing housing
(Item 1) [D].
CD15020
262
Assembly (Contd)
Install the bearing housing/gears assembly into the pump
housing [A].
Install the large Oring (Item 1) [A].
Install the backup seal/Oring seal (Item 2) [A].
CD15019
CD15017
CD15084
Tighten the large pump housing bolts (hex head & allen
head) to 3341 ft.lbs. (4556 Nm) torque [D].
CD15038
263
P04744
2
1
P04746
264
1
CD15130
P04856
Remove the bolt and plate from the mounting strap (Item
1) [C] & [D].
Installation: Tighten the bolt to 1620 ft.lbs. (2127
Nm) torque.
CD15132
P4858
265
I20030284
P04871
1
Always clean up spilled fuel or oil. Keep heat,
flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
combustibles can cause explosion or fire
which can result in injury or death.
P04853
W21031285
266
I20030284
P04872
P04861
267
CONTROL PEDALS
P04771
P04770
268
P01216
P01210
P01219
P01213
269
853,853HBICSServiceManual#6724012HydraulicSystemSectionPart3of3
P01215
B
1
P01212
If not, loosen the bolts and adjust the tab for correct
engagement.
Tighten the bolts to 2528 ft.lbs. (3438 Nm) torque.
P01214
The locking tab should fit into the slot of the interlock as
shown in figure [D], when adjusted correctly.
P04051
270
HYDROSTATIC SYSTEM
Page
Number
DRIVE BELT
Adjusting the Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Replacing the Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
DRIVE BELT SHIELD
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
DRIVE BELT TENSIONER PULLEY
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Pulley End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
368
372
366
365
HYDROSTATIC
SYSTEM
FRONT PANEL
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
HYDROSTATIC MOTOR
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing the Hydrostatic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
323
317
322
316
315
326
HYDROSTATIC PUMP
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrostatic Pump Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrostatic Pump Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrostatic Pump Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replenishing/High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . .
348
357
336
337
359
335
358
360
335
346
331
327
329
31
Revised June 96
32
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.
W20041285
PROBLEM
CAUSE
1, 2
2, 3, 4, 5
2, 3, 5, 6, 7
8, 9, 10, 11
Revised June 96
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
33
CHARGE OIL
FUNCTION 1
I20030284
FUNCTION 2
B02804
Revised June 96
34
FRONT PANEL
W20170286
P04731
Raise the lift arms and install an approved lift arm support
device. (See Page 11.)
P04735
Hold the lock nut and remove the knob (Item 1) [C] from
the lift lock valve.
P04733
P04737
Revised June 96
35
2
1
P04743
1
P04742
P04741
Revised June 96
36
STEERING LEVERS
P05033
3
2
P05034
P05035
1
1
P05039
Revised June 96
37
P05040
B
1
1
P05037
C
1
2
P05036
P05038
Revised June 96
38
PreAdjustment Checks
Read this adjustment completely to become familiar with
the procedure before beginning the adjustment.
The loader should not creep (slow wheel movement)
when the steering levers are at rest in the neutral position.
The following special tool will be needed to do the
following procedure:
MEL1429A Remote Start Switch
Lift and block the loader. (See Page 11.)
P02865
P02866
Socket
Detent
Bracket
MC01944
P07927
Revised June 96
39
2
P02867
P02868
Detent
Bracket
Pocket
Cam
MC01944
Revised June 96
310
P02875
FORWARD
3.66 inch
(93 mm)
MC01944
REVERSE
2.76 inch
(70 mm)
MC01943
Revised June 96
311
NEUTRAL
3.21 inch
(82 mm)
MC01943
CD11204
P02875
N00301
N00302
P07927
Revised June 96
312
P07721
b. Loosen the jam nut and turn the ball joint all the
way to the end of the threads (toward cable
housing).
c.
P07723
C
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.
W20170286
P02869
P07724
313
P02875
B
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.
W20170286
Revised June 96
P07959
314
HYDROSTATIC MOTOR
P04804
I20030284
Raise the lift arms and install an approved lift arm support
device. (See Page 11.)
Raise the operator cab. (See Page 11.)
Remove the front tire/wheel assembly.
Remove the four mounting bolts for the motor cover (Item
1) [A].
Remove the motor cover.
Mark the hoses for correct installation.
P04801
P04802
Revised June 96
P04799
315
20
21
27
27 24
21
16
23
19
22
13
17
12
15
14
10
11
4
9
7
8
4
6
2
3
18
26
D02124
Ref.
Description
Ref.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
FLANGE, mounting
ORING
DRIVE
ORING
GEROLER
PLATE, valve
DRIVE, valve
VALVE
PLATE, balance assy.
SEAL, outer
SEAL, inner
SPRING
ORING
ORING
15
16
17
18
19
20
21
22
23
24
25
26
27
HOUSING, valve
BOLT
BOLT
SEAL
PLUG
ORING
SPRING
POPPET
PISTON
PLUG
PLUG
BEARING, bronze
SHUTTLE
Revised June 96
316
Disassembly
B08695
I20030284
B08692
B08748
B08742
Revised June 96
317
Disassembly (Contd)
Remove the shuttle valve spool [A].
B08741
B08696
B08731
Revised June 96
318
Disassembly (Contd)
Remove the inner seal from the balance plate [A].
Balance
Plate
Outer
Seal
Outer
Seal
Pin
Inner Seal
Pin
B08733
B03046
Balance
Plate
Outer
Seal
Pin
Inner Seal
Pin
Outer
Seal
B08732
B03046
B08738
B09737
Revised June 96
319
Disassembly (Contd)
Remove the valve drive [A].
B08729
B08739
B08736
B08730
Revised June 96
320
Disassembly (Contd)
Remove the Orings inside the bore of the mounting
flange [A].
B04636
B09469
B09470
Revised June 96
321
Inspection
Clean all the parts in 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:
Check the geroler rollers and rotor for wear and scratches
[A].
B06392
B06390
B06391
Check the valve drive and the main drive for wear.
B06389
B06388
Revised June 96
322
Assembly
B04636
I20030284
B08730
B08736
Make sure to keep the rollers in the geroler and install the
geroler [D].
B08739
Revised June 96
323
Assembly (Contd)
Install the valve drive [A].
NOTE: See Page 326 for timing of the motor when
installing the valve, valve drive and geroler.
B08729
B08737
B08738
Outer
Seal
Pin
Revised June 96
324
Balance
Plate
Outer
Seal
Inner Seal
Pin
B08732
B03046
853,853HBICSServiceManual#6724012HydrostaticSystemSectionPart1of3
Assembly (Contd)
Put grease on the seals. Install the inner seal on the
balance plate as shown in Figure [A].
Outer
Seal
Pin
Balance
Plate
Outer
Seal
Inner Seal
Pin
B08733
B03046
Install the poppet, shuttle valve, spring and plug into the
end housing [B].
D02124
B08690
3
A02658
B08695
Revised June 96
325
Anyone of 6 Ports
Open to Outside of Valve
Largest Opening
Valve
Case Drain
Hole (2)
Find the largest opening between the geroler star and the
geroler ring and mark the outside of the geroler ring at that
point [A].
Valve Plate
Align the two drain holes and the three pressure holes in
the geroler ring with the same holes in the mounting
flange and install the geroler assembly.
2
3
Geroler
Ring
Valve Drive
Geroler
Star
C02384
Revised June 96
326
HYDROSTATIC PUMP
2
1
1
P04924
P04926
P04931
Install the nut on the end of the pump drive shaft (without
washer).
P04932
Revised June 96
327
P04933
P04935
P04946
Revised June 96
328
P04936
3
Ref.
Description
1.
2.
3.
4.
PLUG
ORING
SPRING
HIGH PRESSURE RELIEF
P04938
Revised June 96
329
21
30
13
12
11
1
10
2
3
4
22
14
15
16
20
23
17
19
18
24
34
5
8
31
32
33
35
25
36
26
27
28
37
29
36
35
7
46
41
40
47
48
49
38
34
10
11
50 52
51 53
54
55
43
56
12
30
45
58 57
59
19
51
61 62
42
32
31
44
64
60
TOP OF PUMP
39
66
67
68
63
72
73
65
70
72
69 67 68
71
76
74
75
74
77
76
78
E02012
Revised June 96
330
Revised June 96
Ref.
Description
Ref.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
ORING
ORING
ORING
COVER
ROTOR ASSY.
PIN
COUPLER
PIN
RELIEF VALVE
SPRING
ORING
PLUG
PLUG
ORING
SHIM
SPRING
CHARGE RELIEF VALVE
ORING
RING
BYPASS VALVE
BOLT
GUIDE
SPRING
STOP
GUIDE
SNAP RING
NUT
LOCKING NUT
BOLT
PLUG
BOLT
WASHER
SERVO COVER
GASKET
SEAL
RING
SERVO PISTON
ROTATING GROUP ASSY.
VALVE PLATE
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
BEARING
GASKET
PIN
SERVO COVER
NUT
COVER
HOUSING
ORING PLATE
ADAPTER
BOLT
ORIFICE
PLUG
SLEEVE
ORING
ORING
SPOOL
ORING
SPRING
BRACKET
BOLT
NUT
WASHER
HANDLE
SHAFT
KEY
PIN
SWASH PLATE
PIN
JOURNAL BEARING
PIN
SLEEVE
FRONT COVER
BOLT
PIN
SNAP RING
BEARING
SNAP RING
SEAL
NUT
331
22
21
23
24
25
26
1
2
5
27
7
8
26
25
28
10
11
29
15
30
16
11
36
17
13
12
14
19
38
32
33
34
18
51
50
53
55
37
31
54
39
35
40
20
41
56
44
60
59
57
49
42
58
52
51
24
48
61
42
39
38
43
44
37
21
45
47
46
62 63
36
22
TOP OF PUMP
E02011
Revised June 96
332
Revised June 96
Ref.
Description
Ref.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
ORING
SNAP RING
BEARING
SNAP RING
BOLT
BOLT
PIN
COVER
GASKET
JOURNAL BEARING
PIN
SLEEVE
PIN
PIN
SWASH PLATE
ROTATING GROUP ASSY.
VALVE PLATE
PIN
SHAFT
BEARING
BOLT
PLUG
SERVO COVER
GASKET
SEAL
RING
SERVO PISTON
BOLT
GUIDE
SPRING
STOP
GUIDE
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
LOCKING NUT
NUT
RING
PLUG
ORING
SPRING
RELIEF VALVE
PLUG
HOUSING
ORING
ORING
RING
BYPASS VALVE
COVER
NUT
COVER
STUD
NUT
PLUG
ORIFICE
SLEEVE
ORING
ORING
SPOOL
ORING
SPRING
BRACKET
BOLT
NUT
WASHER
HANDLE
333
Revised June 96
334
CD00048
I20030284
CD00049
CD00050
CD00051
Revised June 96
335
2
CD00052
CD00053
CD00054
2
CD00055
Revised June 96
336
CD00056
Disassembly
Front Pump
Rear Pump
Revised June 96
CD00060
337
Disassembly (Contd)
Remove the three bolts at the adapter housing [A].
CD00061
1
CD00062
CD00063
Front Pump
Rear Pump
Revised June 96
CD00064
338
Disassembly (Contd)
Mark the position of the neutral bracket for reference
during assembly [A].
NOTE: Removal of any part of the mechanical
control will result in the loss of the neutral
setting and will require neutral adjustment.
Refer to Page 39 for the correct neutral
adjustment
procedure.
The
neutral
adjustment procedure must be performed
with the pump installed and engine running.
CD00065
CD00066
CD00067
CD00111
Revised June 96
339
Disassembly (Contd)
1
If disassembly of the control lever and spool assembly is
necessary, locate the notch (Item 1) [A] in the end of the
spool. Mark the control lever and neutral bracket on the
same side as the spool notch.
CD00112
3
4
1
5
CD00113
CD00068
CD00070
Revised June 96
340
Disassembly (Contd)
Remove the end housing with the shaft assembly [A].
Remove the gasket [A].
CD00071
CD00090
CD00092
Front Pump
Rear Pump
Revised June 96
CD00093
341
Disassembly (Contd)
Install a seal puller and remove the seal [A].
CD00094
CD00088
CD00089
Front Pump
Rear Pump
Revised June 96
CD00072
342
Disassembly (Contd)
Remove the guide from the swashplate [A].
CD00099
CD00074
CD00073
Front Pump
Rear Pump
Revised June 96
CD00076
343
Disassembly (Contd)
Remove the end cap and gasket [A].
CD00077
CD00078
CD00079
CD00081
Revised June 96
344
Disassembly (Contd)
Turn the end cap off the centering screw. Remove the
gasket [A].
CD00083
Push the end of the piston into the housing and remove
the seal [B].
Remove the piston from the housing by pulling on the
centering screw [B].
CD00085
CD00109
Loosen the jam nut (Item 1) [D]. Tighten the nut at the
piston to release spring tension on the snap ring.
1
CD00107
Revised June 96
345
Disassembly (Contd)
Remove the snap ring and centering spring assembly
from the piston [A].
CD00106
Remove the lock nut (Item 1) [B], nut (Item 2) [B], short
spring guide (Item 3) [B], spring (Item 4) [B], stop (Item
5) [B] and long spring guide (Item 6) [B] from the
centering screw (Item 7) [B].
CD00105
Inspection
Clean all parts in 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.
Lubricate all internal pump parts with clean hydraulic oil
before assembly.
Check the two bearing locater pins (Item 1) [C] in the end
housing. The pins must measure 0.06250.080 inch
(1,652,03 mm) from the end housing surface to the end
of the pins.
CD00098
D
Check the shaft for wear or damage in the splined and
bearing areas [D].
Check the bearing for proper operation. Remove from the
shaft only if necessary to replace [D].
CD00110
Revised June 96
346
Inspection (Contd)
Check the needle bearing (Item 1) [A] in the housing for
proper operation.
If the bearing must be replaced, use the correct driver to
remove and install the bearing. The numbered end of the
bearing must be installed toward the inside of the pump
housing. When installed correctly, the end of the bearing
must measure 0.080.10 inch (2,02,5 mm) above the
machined housing surface.
1
4
CD00100
The spring pin must be installed with the split toward the
center of the swashplate. The spring pin must measure
0.330.5 inch (8,48,9 mm) from the swashplate to the
end of the pin.
CD00101
CD00102
Revised June 96
347
Inspection (Contd)
Check the spherical washer for wear or damage [A].
CD00103
The pins must not be bent. All pins must be the same
length.
NOTE: If there is any defect in the rotating group, the
complete rotating group must be replaced.
CD00104
Assembly
CD00105
Hold the centering screw from turning and tighten the nut
to compress the spring.
CD00106
Revised June 96
348
Assembly (Contd)
To seat the snap ring, loosen the nut until the centering
screw is loose [A].
Tighten the nut until all axial looseness is removed
between the centering screw and spring guides but stop
tightening the nut before the spring assembly becomes
loose in the piston [A].
NOTE: It will be impossible to set the pump neutral
position if there is any free play between the
piston and spring assembly or between the
spring assembly and centering screw.
CD00107
While holding the nut, tighten the jam nut to 1827 ft.lbs.
(2437 Nm) torque.
B
Install the rings, Orings and seals as shown in Figure
[B]:
Apply oil to two new bearing rings (Item 1) [B], two new
Orings (Item 2) [B] and two new seals (Item 3) [B].
CD00087
CD00086
Revised June 96
349
853,853HBICSServiceManual#6724012HydrostaticSystemSectionPart2of3
Assembly (Contd)
Install a new gasket. Install the end cap over the centering
screw. Turn the end cap up to the housing [A].
CD00084
CD00081
CD00080
CD00079
Revised June 96
350
Assembly (Contd)
Install a new gasket and the end cap [A].
CD00077
CD00076
The notch (Item 1) [C] in the valve plate must engage the
locating spring pin in the housing.
Apply oil to the needle bearing at the base of the housing.
CD00073
CD00074
351
Assembly (Contd)
Apply oil to the guide and swashplate. Install the guide
onto the swashplate with the guide offset positioned to
provide clearance for the journal bearing [A].
CD00099
CD00072
Apply oil to the bearing and shaft. Install the shaft and
bearing assembly into the end housing [C].
CD00089
CD00088
352
Assembly (Contd)
Apply a light coating of grease to the lips of a new
seal. Using a correct size driver tool, install the new
seal [A].
CD00095
CD00092
CD00090
When the shaft and end housing are properly installed the
rotating group spring will hold the end housing. A
maximum distance of 0.125 inch (3,2 mm) away from the
housing.
Front Pump
Rear Pump
Revised June 96
CD00071
353
Assembly (Contd)
Install the seven end housing bolts [A].
Evenly tighten the six 7/16 inch bolts to 6074 ft.lbs.
(81100 Nm) torque and 3/8 inch bolt to 3947 ft.lbs.
(5364 Nm) torque.
Rotate the shaft periodically while tightening the bolts to
assure the correct pump assembly. When fully
assembled a torque of 48 ft.lbs. (5,410,8 Nm) will be
required to turn the shaft.
CD00070
Apply oil to the control sleeve. Install the sleeve into the
housing [B].
CD00069
4
6
5
3
7
CD00113
D
Install the spring on the control lever and spool assembly
[D].
CD00111
Revised June 97
354
Assembly (Contd)
Apply oil to the spool. Install the control lever and spool
assembly into the housing [A].
CD00067
CD00066
CD00064
CD00063
Revised June 97
355
Assembly (Contd)
Apply oil to the three molded Orings on the plate
(Item 1) [A]. Install the plate onto the housing.
Install the adapter housing [A].
1
CD00062
CD00061
2
1
CD00060
Front Pump
Rear Pump
Revised June 96
CD00059
356
Assembly (Contd)
Apply petroleum jelly to a new Oring. Install the Oring
on the plug [A].
Apply oil to the high pressure relief valve cartridge. Install
the high pressure relief valve cartridge, spring, shims (if
equipped) and plug [A].
Tighten the plug to 70170 ft.lbs. (95230 Nm) torque.
CD00057
CD00056
Apply oil to the splined coupler (Item 1) [C] and drive pin
(Item 2) [C].
Install the splined coupler and drive pin into the gerotor
assembly [C].
2
CD00055
CD00054
Revised Mar. 03
357
CD00053
1
CD00052
CD00051
CD00050
358
CD0049
CD0048
359
Socket
Cam
1
P07927
D
1
1
2
P07928
360
P07929
P07930
P07931
P02866
361
P05041
Remove the belt shield (Item 1) [B] from the drive belt
housing.
B
1
P05096
362
DRIVE BELT
P04927
MEL1404 Bar
MEL1406 Spring Scale
1. Install the tool on the drive belt. The pin (Item 1) [A]
must be pulled tight against the engine drive pulley.
3
90o
B13459
363
1
P04926
B05095
364
1
P04924
1
P04926
2
P04929
365
Disassembly
NOTE: Be careful, the pulley hub is full of oil.
Remove the cap [A].
CD12634
CD12635
CD12636
Remove the idler pulley and bearing from the shaft using
a press [D].
CD12637
366
Disassembly (Contd)
Install a bearing puller behind the seal and wear sleeve
[A].
CD12638
CD12639
CD12640
367
Assembly
NOTE: The bearings, cups and spacers are a
matched set and must be replaced as a unit.
If the spacer is replaced, compress the new spacer and
install into the pulley [A].
CD12641
CD12642
Install the bearing cup using the driver tool (both sides)
[C].
NOTE: The seal side of the pulley hub has the larger
I.D. diameter.
CD12643
Install the taper roller bearing to the pulley (seal side) [D].
CD12644
368
Assembly (Contd)
Put sealant (P/N 6633538) around the diameter of the
shaft where the wear sleeve is installed on the shaft [A].
CD12645
MC01648
Press the seal into the pulley hub larger diameter using
a press [C].
CD12646
Use a spacer tube which goes over the shaft and pushes
on the inside diameter of the taper bearing, install the
pulley, seal and wear sleeve onto the shaft [D].
CD12647
369
Assembly (Contd)
Install the small bearing spacer [A].
CD12648
CD12649
CD12650
CD12651
370
Assembly (Contd)
Tighten the bolt to 2528 ft.lbs. (4338 Nm) torque [A].
CD12652
Measure Oil
Level in the
Center of the Cap
0.75 oz.
(20 C.C.)
Capacity
0.50 (12,7)
MC01648
Add the oil slowly, at one location of the bearing which will
allow the trapped air to escape from the other side [C].
OIL LEVEL
MC01648
Make sure the sealing edge on the hub bore and cap
sealing edge is clean and free of oil, put a bead of sealant
(P/N 6633538) on the cap [D].
Install the cap.
CD12653
371
CD12655
Move the pulley by hand, back and forth. The correct end
play is 0.0050.013 (0,130,33 mm) [B].
If the end play is not correct, there is no adjustment.
Replace the hub, pulley and/or bearings.
CD12656
372
OIL COOLER
P04884
Disconnect the outlet hose (Item 1) [B] from the oil cooler.
P04885
P04887
373
853,853HBICSServiceManual#6724012HydrostaticSystemSectionPart3of3
374
DRIVE SYSTEM
Page
Number
AXLE SEAL
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
AXLE, SPROCKET AND BEARINGS
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
CHAINCASE FLUID
Removing the Fluid From the Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . 426
DRIVE CHAIN
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
FRONT CHAINCASE COVER
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
DRIVE
SYSTEM
41
421
416
416
414
415
42
DRIVE SYSTEM
1
Remove the foot rest (both sides).
P04775
P04767
P04769
1
P04768
43
5
6
Loosen and remove the mounting bolt (Item 1) [A] and nut
from the spring mounting bracket (Item 2) [A].
Remove the brake pedal spring (Item 3) [A] from the
tension spring mounting bracket (Item 2) [A] and from the
brake pedal mounting bracket (Item 4) [A].
P04189
P04156
44
Raise the lift arms and install an approved lift arm support
device. (See Page 11.)
Raise the loader operator cab. (See Page 11.)
Disconnect the traction lock solenoid wiring harness
connector (Item 1) [A].
P04769
Remove the bolt and nut (Item 1) [B] to disconnect the lift
linkage from crossmember.
P04778
P04779
2
Remove the center cover mounting bolts (Item 2) [D].
1
2
2
P04772
45
1
P04783
Slide the brake disc (Item 1) [C] of the disc hub and
remove from chaincase.
C
1
P04782
1
Revised June 96
46
P04851
P04800
1
Remove the mounting bolts from the rear chaincase
cover (Item 1) [A].
Remove the cover.
P05028
47
AXLE SEAL
2
P04850
W21860395
P04849
P04848
D
Drill a hole into the axle seal [D].
P04815
48
Place the taper on the wear ring so it faces the outside [B].
Place the seal with the lip facing in [B].
Taper
B13493
Use a hammer, install the new axle seal until the tool is
flush with the edge of the axle tube [C].
P04814
49
Raise the lift arms and install an approved lift arm support
device. (See Page 11.)
P04810
P04850
1
P04849
W21860395
2
1
P04809
410
P04808
P04170
Press the splined end of the axle free from the bearing
[C].
P04171
Installation: Put the spline end of the axle shaft into the
bearing and press the bearing onto the axle.
P04175
411
P04812
P04818
Use the slide hammer and remove the bearing cup from
the axle tube [C].
P04816
412
2
P04807
Hold the inside nut (Item 3) [A] with a wrench and tighten
the outside nut [B].
Tighten the nut until the bearing cup is seated.
P04811
To install the outer bearing cup, install the bearing cup tool
on the driver handle.
Install the bearing cup into the axle tube, and put the tool
into the bearing cup.
Hit the driver handle with a hammer until the bearing cup
is seated inside the axle tube [C].
P04813
413
REDUCTION GEARCASE
P04795
Install a slide hammer with a screw tip end into the seal
[B].
P04798
P04806
414
Raise the lift arms and install an approved lift arm support
device (Page 11).
Raise the operator cab (Page 11).
Remove the front panel/steering levers assembly (Page
31).
Remove the hydraulic control valve if the right side
reduction gearcase is removed (Page 21).
P04805
P04819
2
P04797
415
B13458
Install the dial indicator on the output shaft [B]. The end
play must be between 0.000.010 inch (0,0254 mm). If
not, the following parts may need replacing: Bearing,
bearing cups, gear or gearcase housing.
Remove the seal (Page 414).
B13457
B08673
Disassembly
B08705
416
Disassembly (Contd)
Remove the end plate [A].
B08704
B08728
B08721
B08727
417
Disassembly (Contd)
Remove the bolt from the disc hub [A].
B08751
B08752
B08750
B08682
418
Disassembly (Contd)
Remove the bearing [A].
B08707
B08706
B08749
B08722
419
Disassembly (Contd)
Remove the bearing at the input shaft [A].
B08745
B08679
B08744
B08678
420
Assembly
Using a press and bearing cup tool, install the bearing cup
in the housing.
Install the input shaft [A].
B08744
B08745
B08722
Install the output shaft into the housing and large gear [D].
B08749
421
Assembly (Contd)
Install the spacer [A].
B08706
B08707
B08727
Put Boretite sealant on the edge of the dust cup and install
the dust cup into the housing.
B08721
422
Assembly (Contd)
Install the key and hub on the input shaft [A].
B08750
B08752
B08751
B08704
423
Assembly (Contd)
Install the end plate bolts and tighten to 1314 ft.lbs.
(Nm) torque [A].
B08705
B08675
Install the new seal using the seal installation tool [C].
B08734
424
DRIVE CHAIN
853,853HBICSServiceManual#6724012DriveSystemSectionPart1of2
Front Drive
Chain
Raise the lift arms and install an approved lift arm support
device (Page 11).
Rear Drive
Chain
425
CHAINCASE FLUID
853,853HBICSServiceManual#6724012DriveSystemSectionPart2of2
P1616
Remove the drain plug (Item 1) [B] and drain the oil into
a container.
Check the drain plug and replace if necessary.
P1619
426
MAIN FRAME
Page
Number
BOBTACH
BobTach Lever and Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
BobTach Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
FUEL TANK
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
Inlet Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
LIFT ARMS
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
OPERATOR CAB
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
OPERATOR CAB GAS CYLINDER
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
MAIN
FRAME
OPERATOR SEAT
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
REAR DOOR
Bumper Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door Latch and Catch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hood Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
519
519
519
519
518
REAR GRILL
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
SEAT BAR
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Compressing the Gas Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
51
52
MAIN FRAME
SEAT BAR
Removal and Installation
1
P03978
Install the curved end of the tool on the base end of the
gas cylinder.
Secure the tool to the gas cylinder with a hose clamp
(Item 2) [A].
Remove the cotter pin (Item 1) [B] from the clevis pin.
P03248
Remove the clevis pin (Item 1) [C] from the gas cylinder.
C
1
P03979
W21130288
53
P03981
2
P03246
P03247
Pull both ends of the seat bar which are mounted to the
operator cab, back from the mounting positions on the
operator cab [D].
P03982
54
P03983
P03984
The arm of the seat bar (Item 1) [B] should also be located
outside of the operator cab, just below the bottom edge
of the cab.
Grab both ends of the seat bar as shown and pull the left
side of the seat bar out of the operator cab until the seat
bar is free [B].
Remove the seat bar from the operator cab.
Reverse removal procedure to install the seat bar.
See the following assembly procedure when installing the
seat bar.
1
P04065
Assembly
Assemble the parts as shown for the left side of the seat
bar pivot assembly [C]:
Left Side
of Seat Bar
P03284
55
Assembly (Contd)
Assemble the parts as shown for the right side of the seat
bar pivot assembly [A]:
Mounting Bolt (Item 1).
Pivot Bushing (Item 2).
Keyed Plastic Bushing (Item 3).
Gas Spring Mounting Bracket (Item 4).
Mounting Bolt (Item 5).
Right Side
of Seat Bar
P03289
P03319
W21130288
Open the rear door of the loader and install the gas spring
(Item 1 ball stud end) [C] in the hole located in the loader
frame.
NOTE: Install the ball stud threads up through the
hole and install a nut (Item 2) [C] on the ball
stud.
2
1
Put the clevis end of the gas cylinder on the edge of the
rear door as shown [C] and install a vise grip (Item 3) [C]
on the bottom edge of the door to keep the gas cylinder
from sliding along the edge.
P03285
P03288
56
1
Cylinder contains high pressure gas. Do not
open. Opening cylinder can release rod and
cause injury or death.
W21130288
CD15014
1
CD15015
CD15016
Remove the cotter pin (Item 1) [D] from the top pivot pin.
Remove the pivot pin and bushing from the gas cylinder.
Remove the gas cylinder.
CD15173
57
P01008
P01006
58
OPERATOR CAB
1
CD15125
2
P04860
P05051
Revised June 97
59
1
P05048
1
P05049
P05050
510
OPERATOR SEAT
P03987
P03999
C
3
Remove the seat spring (Item 2) [C] from under the right
seat track when removing the operator seat.
P03996
Operator
Seat
Remove the mounting bolt from each end of the track and
replace the adjustment track if necessary.
Seat
Pan
MC02043
511
BOBTACH
1
CD15075
Remove the retainer bolt (Item 1) [B] from the pivot pin.
P04601
Remove the grease fitting from the pivot pin (Item 1) [C].
P03915
1
P03911
512
BOBTACH (Contd)
P03910
P03913
Use a punch to push the pivot pin all the way into the
BobTach frame.
P03909
513
BOBTACH (Contd)
P03912
1
P03930
3
1
Remove the BobTach lever (Item 1) [D].
P03928
1
P03924
514
BOBTACH (Contd)
P03925
1
P03926
2
1
4
3
P03929
BobTach Stops
P03914
515
LIFT ARMS
P05052
Remove the retainer bolt and nut (Item 1) [B] from the rod
end lift cylinder pivot pin (both sides).
Installation: Tighten the retainer bolt and nut to 1820
ft.lbs. (2427 Nm) torque.
Raise the lift arms with the chain hoist so there is enough
clearance to remove the rod end pivot pin.
Remove the lift cylinder rod end pivot pin (both sides).
CD15169
Remove the retainer bolt and nut (Item 2) [C] from the lift
arm pivot pin.
P05053
516
REAR GRILL
P04881
P04882
P04883
P04886
517
REAR DOOR
P05042
Connect a 1/4 inch chain to the rear door using two bolts
(Item 1) [B].
Inside the rear door, secure the chain with washers and
nuts.
Connect a chain hoist to the chain.
Remove the rear door pivot bolts.
Lift the rear door away from the loader frame and put the
door flat on the floor.
P05041
518
Remove the mounting bolts from the rear door hood (Item
1) [A].
Installation: Tighten the hood mounting bolts to 2528
ft.lbs. (3438 Nm) torque.
Remove the hood from the rear door.
P05043
2
1
P04281
1
P05044
AVOID INJURY
Never service or adjust the machine when the
engine is running unless instructed to do so in
the manual.
W20120290
519
FUEL TANK
P01616
P01619
P04855
P04959
520
P04960
Lift the fuel tank and remove it from the loader frame [B].
Fuel Level Sender
Loosen the fuel level sender (Item 1) [B].
P04961
Remove the fuel level sender from the fuel tank [C].
P04962
Inlet Screen
P05007
521
853,853HBICSServiceManual#6724012MainFrameSection
522
ELECTRICAL SYSTEM
Page
Number
ALTERNATOR
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
Disassembly and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Rectifier (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
BATTERY
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
ELECTRICAL SYSTEM INFORMATION
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
FRONT LIGHTS
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
RELAY SWITCHES
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
ELECTRICAL
SYSTEM
613
617
615
614
612
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
61
62
WIRE LEGEND
NO.'s COLOR
GAUGE
12 Orange
12A Orange
12B Orange
12B Orange(40 Power Harness)
12C Orange
12D Orange
12E Orange
19 Red/White
50 Black
50A Black
50B Black
50C Black
50D Black
50E Black
50W Black
56A Dk. Green/Yellow
56B Yellow
56BA Yellow
56BAA Yellow
56BB Dk. Blue
56BBA Dk. Blue
56BBB Dk. Blue
56R Dk. Green
56RA Dk. Green
56RAA Dk. Green
56RB White (*Orange/White)
56RBA Orange/White
56RBB Orange/White
56S Dk. Green
56SA Dk. Green
56SG Dk. Green
56W Lt. Green/White
57B Yellow/Red (*Lt. Blue)
57BA Lt. Blue
57BB Lt. Blue
57BBA Lt. Green
57BBB Lt. Green
57BBC Lt. Green
57BC Yellow/White
57C Orange/Dk. Blue
57CA Orange/Dk. Blue
57CB Orange/Dk. Blue
57RB Yellow/Red (*Red)
57RR Yellow/Lt. Green
(*Brown/White)
57RRA Yellow/Lt. Green (*Brown)
57RRB Brown
57RRC Brown
57RRD Red
57RRE White
57RRF Brown/Yellow
64 Orange/Blue
PARTS LEGEND
16
16
14
16
16
16
16
14
14
16
16
16
16
14
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
14
16
16
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Connector-Water Kit
Connector - Auxiliary/Hydraulic BASE
Connector - Fused and Switched
Connector - Power and Fused
(Angle Broom)
Connector-Stump Grinder
(High Flow Valve)
Power Relay - Stump Grinder
Power Relay - Angle Broom
Power Relay - Front/Rear
Auxiliary
Plug-In Connector - Lift Arm
Harness - Boom Electrical
Attachment Connector
Diode Module
Connector - Diode Module
Connector - Right Control Handle
Connector - Loader Control Harness
Connector - Left Control Handle
Adapter Connector - Optional
Attachment Harness
New to Old Adapter Harness
6706391
17
19
6706552 Rev. A
21
22
MC 2063LT (4-11-97)
Connects To
F Connects To
G Connects To
Connects To
Connects To
Connects To
Connects To
M Connects To M
N Connects To
P Connects To
14
K
14
13
C
B
A
CBA
12
ABC
A
B
C
B
A
BA
C
B
A
AB
A
B
56R
56W
12
BLUE
57RB
57RR
57RRE
2
N
BLACK
DK.GREEN/RED
BA
AB
B
A
20
DK. GREEN/YELLOW
10
11
56W
50W
BA
CENTER
YELLOW
57RRA
57B
56B
56BB
56RB
12A
BROWN
LT
RT
57RRB
56BA
56RA
57BC
56BBA
56RBA
E
D
C
B
A
57BA
57RRF
TM
LT
GD
GD
RED
TM
BLACK
17
16
19
56A
A
B
C
D
E
F
G
H
K
L
M
57RRD
50E
57BB
57RRC
56RBB
56BBB
56RAA
56BAA
12C
57CB
56S
A
B
C
D
E
F
G
H
K
L
M
56SA
BROWN
56SA
LT
56RC
56BC
56R
56B
BLACK
BLUE
RED
YELLOW
56RC
56BC
56R
56B
TM
CENTER
GD
RT
B
A
RT
A
B
BA
AB
A
B
15
12B
50
AB
9
BA
RED/WHITE
AB
ORANGE
BLACK
57RRC
19
D
N
56S
57BB
M
C
NO
NC
57RR
57CA
12C
NC
NO
B
J
57RRD
G
H
B
56RAA
56BAA
50E
BLACK E
F
BLUE
BROWN
E
F
P
C
G
H
RED G
H
YELLOW
LOADER
CONNECTOR
IS VIEWED
FROM THE
MATING SIDE
85
57RRF
57BBB
87A
50D
30
86
87
57RB
57C
57BC
85
87A
NC
NO
M
L
B
J
ADAPTER
CONNECTOR
IS VIEWED
FROM THE
MATING SIDE
15
ORANGE
ORANGE
L
K
G
F
M
N
Printed in U.S.A.
56RBB
56BBB
NC
7
Module 10-pin
Connector
30
57BBA
50C
86
87
57RRE
85
87A
50B
19
30
86
NO
57CB
85
87A
30
86
22
87
56SA
56SG
57BBC
57RRD
56SG
50A
87
56SB
BA
AB
E
F
21
18
BLUE
YELLOW
RED
BROWN
56SA
BROWN
56SA
LT
E
F
G
H
56RC
56BC
56R
56B
BLACK
BLUE
RED
YELLOW
56RC
56BC
56R
56B
TM
CENTER
GD
RT
G
H
56J
56J
ORANGE
BLUE
BLACK
YELLOW
BROWN
RT
LT
RT
BLACK
GD
TM
CONNECTOR IS VIEWED
FROM THE MATING SIDE
TM
LT
RED
E
P
17
CENTER
MC2063T (5-26-97)
GD
WIRE LEGEND
NO.'s COLOR
GAUGE
12 Orange
12A Orange
12B Orange
12C Orange
19 Red/White
50 Black
50A Black
50B Black
50C Black
50D Black
50E Black
50W Black
50Z Black
56A Dk. Green/Yellow
56B Yellow
56BA Yellow
56BAA Yellow
56BB Dk. Blue
56BBA Dk. Blue
56BBB Dk. Blue
56R Dk. Green
56RA Dk. Green
56RAA Dk. Green
56RB White
56RBA Orange/White
56RBB Orange/White
56S Dk. Green
56SA Dk. Green
56SG Dk. Green
56W Lt. Green/White
57B Yellow/Red
57BA Lt. Blue
57BB Lt. Blue
57BBA Lt. Green
57BBB Lt. Green
57BBC Lt. Green
57BC Yellow/White
57C Orange/Dk. Blue
57CA Orange/Dk. Blue
57CB Orange/Dk. Blue
57J Lt. Green
57N Pink
57P White
57RB Yellow/Red
57RR Yellow/Lt. Green
57RRA Yellow/Lt. Green
57RRB Brown
57RRC Brown
57RRD Red
57RRE White
57RRF Brown/Yellow
Printed in U.S.A.
PARTS LEGEND
16
16
14
16
14
14
16
16
16
16
14
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
14
16
16
1
2
3
4
Connector - Auxi
Connector-Water Kit
NOT USED
KL Attachments issue
Connector - Fused and Switched
Input to the C
Connector - Power and Fused
W/in PWM
(Angle Broom)
Connector-Stump Grinder
NOT USED
(High Flow Valve)
Power Relay - Stump Grinder
6670312
Power Relay - Angle Broom
6670312
Power Relay - Front/Rear
6670312
Auxiliary
Boom Connector
10
11
12
13
14
15
Diode Module
Assy. 6664388
Connector - Diode Module
Connector - Control Harness
Connector - Loader Control Harness
NOT USED
Connector - Left Control Handle
Main Frame Attachment Harness (Opt.)
5
6
7
8
6710300 Rev. A
MC 2211LJ (1-16-98)
K
14
13
21
12
CBA
C
B
A
ABC
A
B
C
C
B
A
C
B
A
CBA
50Z
57P
57N
57J
57RB
57RR
57RRA
57B
56BB
56RB
AB
A
B
57RRE
AB
2
N
56BA
56RA
57BC
56BBA
56RBA
E
D
C
B
A
57BA
57RRF
BA
BA
G
F
D
E
L
M
57CB
56S
A
B
C
D
E
F
G
H
J
K
L
M
N
P
A
B
C
D
E
F
G
H
J
K
L
M
N
P
57N
D
P
57RRC
57P
17
16
57RRD
50E
57BB
57RRC
56RBB
56BBB
56RAA
56BAA
57J
12C
57CB
56S
57N
57P
56RAA
56BBB
56RBB
57J
50E
12C
57BB
B
K
C
15
A
B
57RRD
57RRB
56A
10
11
56W
50W
56BAA
B
A
56R
56W
12
12A
BA
56B
14
57RRD
50E
57BB
57RRC
56RBB
56BBB
56RAA
56BAA
57J
12C
57CB
56S
57N
57P
57RRD
50E
57BB
57RRC
56RBB
56BBB
56RAA
56BAA
57J
12C
57CB
56S
57N
57P
A
B
C
D
E
F
G
H
J
K
L
M
N
P
12B
50
19
Connects To
Connects To
Connects To
Connects To
Connects To
K
N
P
Connects To
Connects To
Connects To
Printed in U.S.A.
K
N
P
NO
NC
57RR
57RRF
57BBB
50D
57CA
85
87A
30
87
86
57C
85
57BC
57RB
87A
50C
57BBA
NO
NC
NO
56RBB
57RRC
57BB
50E
57RRD
NC
A
F
56BBB
NC
57P
57N
H
M
56BAA
56S
57CB
18
ORANGE
ORANGE
L
K
G
F
M
N
12C
57J
57P
57N
56S
57CB
56RAA
56BBB
E
D
57J
56RBB
57RRC
57BB
H
B
56BAA
50E
57RRD
56RAA
30
87
86
57RRE
NO
85
87A
19
30
87
85
30
87A
86
56SG
56SA
50A
57BBC
50B
56SG
86
87
BA
57RRD
12C
YELLOW
RED
19
BLUE
A
56SA
BROWN
56SA
LT
E
F
G
H
56RC
56BC
56R
56B
BLACK
BLUE
RED
YELLOW
56RC
56BC
56R
56B
TM
CENTER
GD
RT
BLUE
BLACK
YELLOW
BROWN
RT
LT
RT
TM
LT
BROWN
RED
E
P
20
CENTER
BLACK
GD
GD
TM
MC2211P (10-15-97)
ELECTRICAL SYSTEM
TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for
assistance in locating and correcting problems. Many of
the recommended procedures must be done by
authorized Bobcat Service Personnel only.
W20031289
PROBLEM
CAUSE
2, 3, 4
1, 4
2, 3, 4, 6, 7, 8, 9
2.
3.
Battery is damaged.
4.
The cable & wire connection are not making a good contact.
5.
6.
7.
8.
9.
63
Description
CD15011
CD15007
The decal inside the rear door specifies the fuse sizes
used in various loader circuits [C].
AUX.
64
BATTERY
CD15008
W20651286
CD15136
W20660490
P00744
65
P00746
ALTERNATOR
W20170286
P4944
Output
Terminal
P1304
Connect the fuel stop solenoid, start the engine and run
at 2600 RPM.
If ammeter reading is between 4555 amps. @ 2600
RPM the alternator is good and no further testing is
needed.
If the reading is low, remove the screws and pull the
regulator cover away from the alternator and continue
testing (below).
Rectifier (Diode) Test
NOTE: The alternator is removed from the loader for
clarity purposes.
Disconnect the negative () cable from the battery.
Install the wire in their original location on the back of the
alternator.
Connect a jumper wire (Item 1) [B] to the alternator output
terminal and the regulator terminal.
Connect the battery negative () cable.
Start the engine and run at 2600 RPM.
If the reading is within 4555 amps. @ 2600 RPM replace
the rectifier (diode) assembly or replace the alternator.
If the reading is low, do the Alternator Regulator Test.
66
ALTERNATOR (Contd)
P05054
W20501285
Ground
Stud
Brush
Terminal
1
P01364
67
ALTERNATOR (Contd)
Raise the lift arms and install an approved lift arm support
device. (See Page 11.)
Raise the operator cab. (See Page 11.)
Open the rear door. Disconnect the negative () battery
cable.
2
P04945
68
ALTERNATOR (Contd)
1.
2.
3.
4.
5.
6.
7.
8.
Nut
Pulley
Fan
Bolt
Case Half (Front)
Bearing
Rotor
Stator
9. Rectifier (Diode)
10. Case Half (Rear)
11. Condenser Assy.
12. Strap
13. Regulator
14. Brush
15. Cover
7
12
13
11
9
14
10
15
C03312
P01369
Touch one probe to a bare stator lead and the other probe
to the bare metal surface of the stator [C].
There should be no continuity.
Replace the stator if there is continuity.
P01386
69
ALTERNATOR (Contd)
P01365
Touch one probe to one of the slip rings and the other
probe to the rotor shaft [B].
There should be no continuity.
Replace the rotor if there is continuity.
P01378
P01373
Touch one probe to the diode and the other probe to the
connected heatsink and read the meter [D].
P01370
610
ALTERNATOR (Contd)
Assembly
Reverse the order of disassembly.
Place the rotor in soft jaws when tightening the shaft nut.
Tighten to 50 ft.lbs. (68 Nm) torque [A].
Install the rear case half and the remaining parts.
P01808
611
STARTER
CD15138
CD15140
CD15139
612
STARTER (Contd)
Bat
S
M
Cranking
Motor
A01991
Bat
S
M
Cranking
Motor
A01992
613
STARTER (Contd)
Parts Identification
1
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
3
2
4
1
5
6
7
9
8
41
10
13
12
19
14
17
16
15
18 20
11
21
26
22
25 24
Screw
Solenoid
Bolt
Lever
Washer
Nut
Plug
Washer
Housing Drive
Washer
Bushing
Ring
Stop
Drive
Drive Support
Support
Drive Shaft
Washer
Washer
Washer
Screw
Brush
Frame Assy.
Gasket
Pin
Armature Support
Bolt
Spacer
Bearing
Armature
Bearing
Spring
Holder Assy.
Brush
Screw
Oring
Frame
Washer
Screw
Bolt
Ring
23
22
27
21
35
28 29
30
34
39
34
31
32
33
36
38
37
40
D02119
614
STARTER (Contd)
CD08924
CD08925
CD08926
CD08927
615
STARTER (Contd)
CD08928
CD08929
CD08930
616
STARTER (Contd)
A01995
Brush Holders
Broken springs
Broken insulation
Spring tension
Field Coils
Broken or burned insulation
Electrical continuity
Brush connections
Drive Gears
Worn teeth
Tooth engagement
A01994
617
P03995
Lower the light from the operator cab and locate the three
instrument panel mounting bolts (Item 1) [B] (both sides).
P03955
P03951
Repeat steps [A] and [B]. Pull the right instrument panel
down and disconnect the wire harness connectors from
the panel. Remove the panel [D].
P03953
618
FRONT LIGHTS
P03956
Pry the rubber light mount free from the operator cab [B].
P03995
Pull the light down and remove the three mounting bolts
(Item 1) [C] from the instrument panel.
P03955
619
RELAY SWITCHES
STANDARD
853,853HBICSServiceManual#6724012ElectricalSystemSection
Location
The loader engine harness has relay switches located at
the coolant recovery tank [A] and [B].
There are four switches (Item 1) [A] on the Standard
equipped loader.
The switches are for the starter, switch power, glow plug
and brake.
1
P04897
BOSS
1
P05190
620
ENGINE SERVICE
Page
Number
79
737
713
710
777
776
776
777
778
774
77
765
765
765
767
761
761
761
750
750
749
735
728
ENGINE
SERVICE
738
78
74
74
74
712
720
725
715
714
736
736
747
746
740
740
744
773
773
853, 853H BICS Loader
Service Manual
72
739
739
771
771
772
762
764
763
762
779
779
780
781
782
782
780
782
759
756
755
760
755
75
754
754
775
769
768
786
786
73
738
751
751
751
752
752
753
787
784
783
783
853, 853H BICS Loader
Service Manual
ENGINE SERVICE
TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most common.
Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM
Slow cranking speed.
Engine will not start.
Difficult to start.
No power for engine.
Engine is misfiring.
Too much fuel consumption.
Black exhaust.
Blue/white exhaust.
Low oil pressure.
Engine knocking.
Engine running rough.
Vibration.
High oil pressure warning.
Overheating.
Too much crankcase pressure.
Poor compression.
Start and stop.
CAUSE
1, 2, 3, 4
2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29
5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
4, 31, 32, 33, 34, 35, 37, 39, 52
13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
4, 33, 36
10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
22, 27, 29, 30, 40, 49
10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
9, 10, 11
KEY TO CORRECT THE CAUSE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
73
1
Remove the two mounting bolts (Item 1) [A] and nuts from
the speed control mounting bracket.
Installation: Tighten the bolts (Item 2) [A] evenly until the
speed control lever moves back and forth at a
comfortable tension.
2
P04731
Pull the speed control away from the loader frame and
disconnect the speed control rod (Item 1) [B] from the
control.
1
P04735
Disassembly
Loosen the two control lever mounting bolts and remove
the mounting nuts (Item 2) [C].
74
RADIATOR
Open the block drain (Item 1) [A] and drain coolant into
a container.
P04894
P04895
Propylene Glycol
P04893
75
RADIATOR (Contd)
P04904
BOSS
1
P05191
P04905
76
P04897
P04898
P04899
Revised June 97
77
ENGINE MUFFLER
P04892
P04888
Revised June 97
78
P04889
P04890
C
1
Remove the two mounting bolts (Item 2) [C] (at the top)
and one mounting bolt at the bottom of the housing.
Remove the air cleaner housing.
P04891
BOSS
P05194
79
CD15015
2
P04860
Remove the clamp and belt shield (Item 1) [C] for the fan
drive.
Remove the fan drive belt.
Installation: When checking the fan gearbox oil level,
make sure the level does not go above the top of the shaft
in the gearbox [C]. Use 90W gear lube oil if the level is low.
1
Oil Level
P04863
P04862
Revised June 97
710
P04877
P04859
P04864
P04876
711
1
P04954
Remove the spacers, bolt and washers from the arm [B].
P04956
P00581
P04955
3
2
5
N00303
Revised June 97
712
BLOWER FAN
CD09952
W21081186
P03006
CD09953
D
1
1
CD09954
713
FAN GEARBOX
Parts Identification
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
*16.
17.
18.
19.
20.
21.
22.
Seal
Snap Ring (Small)
Shims (1.0 inch O.D.)
Bearing
Shaft (Long)
Shims (2.0 inch O.D.)
Long Key
Shaft (Short)
Short Key
Long Housing
Nut
Gear
Washer
Screw
1
Square Shim
Short Housing
Bolt
Snap Ring (Large)
Cap
Long Housing Assy.
Short Housing Assy.
Fill Plug
18
7
5
22
2
12
17
13
12
14
10
*16
21
11
15
17
20
12
20
3
4
13
14
18
19
* Individual Part not available
TS01002
714
Disassembly
Complete Assembly
Long Housing Assembly
Long Housing
Short Housing Assembly (See Note
Below)
5. Internal Parts
1
2
P03005
Part Number
Tag
Loosen the set screws (Item 1) [A] and remove the pulley
(Item 2) [A].
Remove the long key (Item 3) [A].
Remove the four mounting bolts and the part number tag
[B].
P02983
Drill an 1/8 inch (13 mm) hole in the seal. Use a slide
hammer tool to remove the seal [C].
P02999
P02964
715
Disassembly (Contd)
Remove the small shims [A].
P02963
P02966
Support the lower flange and press the shaft from the
bearing [C].
P03004
Support the bearing and press the shaft from the bearing
[D].
P03298
716
Disassembly (Contd)
Short Housing
Remove the end cap [A].
Use care not to damage the housing.
P02997
W21081186
P02996
Remove the large snap ring from the flange end of the
housing [C].
P02970
P02969
717
Disassembly (Contd)
Remove the screw and washer (Item 1) [A] from the
shaft.
P02978
Remove the snap ring from the cap end of the housing
[B].
P02973
P02998
Press the bearing from the tapered end of the shaft [D].
P03088
718
Disassembly (Contd)
Press the bearing, shims and gear from the shaft [A].
P03001
P02972
719
Assembly
NOTE: See Note Page 715 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.
P02961
Long Housing
Press a bearing on the short keyed end of the long shaft
[A].
Install the long housing on the shaft [B].
Be sure the bearing is seated in the bore at the lower end
of the housing.
P02960
P02962
P02963
720
Assembly (Contd)
Install the small snap ring in the groove above the shims
[A].
P02964
Install the gear key in the flange end of the shaft [B].
P02965
P02967
P02966
721
Assembly (Contd)
Short Housing
Install a bearing in the flanged end of the housing [A].
P02968
P02969
Install the large snap ring in the groove above the shims
[C].
P02970
Align and press the gear on the shaft (teeth toward the
tapered end of the shaft) [D].
1
P02971
722
Assembly (Contd)
After the gear is seated, drive the key down inside the
gear key way [A].
NOTE: This will prevent damage to the shims when
the bearing is installed later.
P02975
P02976
Install on the shaft, the same number and size shims that
were removed during disassembly [C].
P02977
P02974
723
Assembly (Contd)
Install the snap ring in the groove above the bearing [A].
P02973
P02978
724
853,853HBICSServiceManual#6724012EngineServiceSectionPart1of4
Checking Backlash
NOTE: For procedures requiring the use of LOCTITE
adhesive, thoroughly clean and dry affected
parts before the application of LOCTITE.
The backlash tolerance between the gears should be
0.0050.008 inch (0,1270,203 mm).
To check the gear backlash use the following procedure:
Put the short housing in a vise, square flange facing up
as shown [A].
P02987
P02981
P02983
Install the long key (Item 1) [D] and the pulley (Item 2) [D].
1.000 inch
(25,4 mm)
P02984
725
P02982
Hold the locking pliers against the long housing and rotate
the pulley back and forth to read the dial gauge [B].
P02979
726
P03089
Install the seal(s) flush with the housing surface [B] & [C].
LONG HOUSING
P02985
SHORT HOUSING
P02986
727
ENGINE
Raise the lift arms and install an approved lift arm support
device. (See Page 11.)
Loosen both hose clamps and remove the fuel vent hose
(Item 1) [B].
Loosen both hose clamps and remove the fuel fill hose
(Item 2) [B].
P04855
P04863
P04861
728
ENGINE (Contd)
1
3
P04871
2
Disconnect the hose (Item 1) [C] from the oil cooler.
P04860
C
3
1
When making repairs on 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.
I20030284
P04867
729
ENGINE (Contd)
1
2
P04878
P04870
Disconnect the case drain filter hose (Item 1) [C] from the
pump.
Remove the bolt and nut (Item 2) [B] at the left front
engine mount.
P04879
P04934
1
730
P05008
ENGINE (Contd)
P04889
P04896
P04895
D
1
P04894
731
ENGINE (Contd)
P04897
P04900
Disconnect the fuel hose (Item 2) [C] from the fuel filter.
P04901
1
P04906
732
ENGINE (Contd)
P04903
P04902
13.0
(330)
0.50 (12,7)
2.5
(64)
INCHES
(MM)
0.75
(19,05)
21/2 x 21/2 x 6
1/4 Angle Iron
2.5 (64)
11/2 Square Tubing
1/4 (4)
Thick Gusset
1.0
(25)
2.0
(51)
16.0
(406)
4.0
(102)
4.0
(102)
3.1
(78,7)
1.0 (25)
0.5
(12,7)
0.3125 Dia. (2)
0.375
(9,5)
9.0
(229)
1.0
(25)
1.375
(35,0)
1.125
(28,6)
0.6875
(17,5)
0.66 (16,8)
4.5
(114)
8.525
(218)
1.125
(28,6)
1.75
(44,5)
(2) 2 x 2 x 1/4
Gusset
17.750
45
1.75
(44,5)
Revised June 97
0.60 (15,2)
2.0 (51)
4.25
(108)
0.5
(12,7)
0.60
(15,2)
0.775
(19,7)
9/16
Dia. Hole (2)
21/2 x 21/2 x 22
1/4 Thick
733
MC01801
MC01799
B13452
ENGINE (Contd)
The engine lift eye bracket (Item 1) [A] has been turned
down for clearance at the exhaust pipe. Turn the lift eye
bracket and install the bolt.
The valve cover (Item 2) [A] will have to be removed for
clearance for the engine lift brackets.
Install the engine lift brackets on the engine as shown in
Figure [A].
Connect a chain hoist to the ring (Item 3) [A] on the lift
bracket.
1
2
B13488
P04923
734
ENGINE (Contd)
7
MC01771
Washer
Engine
Mounting
Bracket
Loader
Frame
Engine
Mount
Snubbing
Washer
735
Spacer
MC01765
FLYWHEEL
P4928
P4939
736
BELT SHIELD
3
P04947
1
P04945
737
VALVE CLEARANCE
Adjustment
0.016 inch
(0,41 mm)
Cold
B04123
Put the correct size feeler gauge between the rocker arm
and the valve stem. Turn the adjustment bolt until the
clearance is correct [B].
Rear
Valve arrangement
3
I
4
E
B08934
ENGINE COMPRESSION
Checking
The tools listed will be needed to do the following
procedure:
OEM1074 Engine Compression Kit
MEL1268 Compression Gauge Test Adapter
The engine must be at operating temperature.
Remove the glow plugs (Page 739) [C].
Install the correct compression adapter into the cylinder
head.
B08922
B08920
738
GLOW PLUGS
B08957
B08919
B08923
B11571
739
Description
The injection pump contains parts which have a very
close tolerance and its operation has a direct effect on the
performance of the engine.
B08976
I20280289
B08935
740
12 oclock Position
12
14
TDC
1
16
3 oclock
Position
MC01665
2
P04949
P04952
Align the mark on the injection pump gear with the pointer
in the window [C].
B08939
741
B08975
B08917
Remove the high pressure fuel lines from the engine [C].
B08915
1
B08938
Revised Mar. 03
742
B08913
743
B08935
12 oclock Position
12
14
TDC
1
16
3 oclock
Position
MC01665
2
P04949
P04952
B08921
744
B08977
B08977
B08910
745
B08975
W20741285
B08917
I20290289
B08918
746
B08914
B08924
B08971
747
Checking (Contd)
If the pressure is not correct, do the following:
Disassemble the injector nozzle and clean.
4
3
7
2
W20721285
1.
2.
3.
4.
5.
6.
7.
Retaining Nut
Injection Nozzle
Spacer
Push Rod
Spring
Adjusting Shim
Nozzle Holder
CORRECT
B08959
INCORRECT
Does not come out the side of the nozzle. Does not have
drops coming from the nozzle. Does not have a solid
stream coming from nozzle.
Any of the above conditions show a defect or dirty injector
nozzle. Clean or replace any injector nozzle that does not
operate correctly.
B08895
748
CYLINDER HEAD
3
1
B08188
14
10
15
18
7
11
2
1
9
Step 2
New Bolts
Used Bolts
5967 ft.lbs.
(8091 Nm)
7280 ft.lbs.
(97108 Nm)
4
5
17
13
12
16
8
B08189
D
13
5
9
4
1
12
8
16
17
18
15
10
14
2
6
7
3
11
B08189
749
853,853HBICSServiceManual#6724012EngineServiceSectionPart2of4
B08198
B08197
Exhaust Manifold
If the exhaust manifold has been removed, use the
correct torque sequence and tighten the bolts to 1017
ft.lbs. (1423 Nm) torque [C].
B08187
750
Removal
1.
2.
3.
4.
5.
Spring Seat
Springs
Valve
Oil Seal
Spring Seat
B08193
45
B08202
751
Standard
Limit
Exhaust Standard
Limit
Contact
Width
Depression
Standard
Limit
Exhaust Standard
Limit
B08199
Welding
Bead
B08201
Valve Guide
0.40 inch
(10 mm)
Standard
Limit
Exhaust Standard
Limit
0.00150.0027 inch
(0,0390,068 mm)
0.008 inch (0,2 mm)
B08205
0.00250.0038 inch
(0,0640,96 mm)
0.010 inch (0,25 mm)
Intake
0.31280.3134 inch
Standard (7,9467,961 mm)
Exhaust 0.31190.3124 inch
Standard (7,9217,936 mm)
752
B08206
B08207
Valve Spring
Inclination
Std.
Limit
Inner
1.783 inch
(45,3 mm)
1.748 inch
(44,4 mm)
Outer
1.957 inch
(49,7 mm)
1.898 inch
(48,2 mm)
Inner
0.118 inch
(3,0 mm)
Outer
0.126 inch
(3,2 mm)
Free Length
Free Length
Inclination
Square
B08208
Std.
Limit
Inner
1.46 inch
(37 mm)
13 lbs.
(5,9 kg)
11 lbs.
(5,02 kg)
Outer
1.54 inch
(39,0 mm)
46 lbs.
(20,9 kg)
40 lbs.
(18,1 kg)
B08209
753
4
3
B08191
B08214
B08215
B08213
754
Removal
Remove the cylinder head. (See Page 749.)
Remove the oil pan. (See Page 779.)
Remove the ridge and carbon deposits at the top of the
cylinder bore with a ridge reamer.
B03248
A02344
B08909
Disassembly
B08194
755
Disassembly (Contd)
Remove the piston pin snap ring [A].
B08195
P08196
Checking
Clean all the parts in clean solvent.
Check the clearance of the new rings in the piston
grooves [C].
Standard
Limit
1st
Compression
0.00350.0049 inch
(0,09(0,125 mm)
0.006 inch
(0,15 mm)
2nd
Compression
0.0020.0033 inch
(0,050,085 mm)
0.006 inch
(0,15 mm)
Oil
0.0010.003 inch
(0,030,07 mm)
0.006 inch
(0,15 mm)
B08228
3.66083.6616 inch
(92,98593,004 mm)
Piston Grade C
3.66163.6624 inch
(93,00593,024 mm)
2.9 inch
(74 mm)
B08227
756
Checking (Contd)
Check the ring gap in the cylinder bore [A].
Standard
Limit
Compression
0.0080.016 inch
(0,20,4 mm)
0.059 inch
(1,5 mm)
Oil
0.0040.012 inch
(0,10,3 mm)
0.059 inch
(1,5 mm)
B08229
P08230
B08231
B08232
757
Checking (Contd)
Check the connecting rod small end bushing [A].
Standard 1.22081.2211 inch (31,00831,015 mm)
B08233
P08230
B08200
B08203
758
Assembly
Heat the piston to about 140F (60C) [A].
B08251
C02936
B08252
B08195
759
Assembly (Contd)
Marked Side Up
1st Comp.
2nd Comp.
Oil
B08253
Installation
Using a ring compressor tool, compress the rings on the
piston. Make sure the mark is to the front of the engine
and install the piston in the block [B].
B03337
B03208
5865 ft.lbs.
(7888 Nm)
B03325
760
CYLINDER LINERS
.75 inch
(20 mm)
Removal
Remove all the parts from the engine.
Using a cylinder liner tool, remove the cylinder liner from
the engine block [B].
There is only one size liner available.
Installation
The tools listed will be needed to do the following
procedure:
MEL1262 Cylinder Liner Installer
B08224
Clean the grease from the cylinder liner and dry it.
Use dry ice to cool the cylinder liner, so it will install easier
and smoothly into the engine block.
Using the correct tool, install the cylinder liner [C].
First apply a load of 1103 lbs. (500 kg) using a hydraulic
press.
NOTE: Do Not use a hammer to install the cylinder
liners.
Then, apply a final load of 5513 lbs. (2500 kg). Push the
liner in until 00.0039 inch (00,1 mm) of the liner is above
the block face [D].
B08225
3.66223.6630 inch
(93,02193,040 mm)
Piston Grade C
3.66303.6638 inch
(93,04193,060 mm)
761
MAIN BEARINGS
Description
The crankshaft has five main bearings. The end play is
controlled by a thrust washer on both sides of the center
main bearing.
FRONT
B08256
Removal
Remove the oil pan. (See Page 779.)
Remove the oil pump. (See Page 780.)
Remove the bolts from the main bearing caps.
Remove the main bearing cap and remove the bearing
from the cap half.
Remove the top half of the bearing by pushing on one side
of the bearing half and rotating the crankshaft [B].
B01865
B08255
762
Installation
Check the bearing spread as listed [A].
Limit 2.93 inch (74,5 mm)
B08241
B08242
Fit Correctly
No Oil Groove
and Hole
(Lower Side)
B08254
B08255
763
Installation (Contd)
Tighten the crankshaft bearing cap bolts in the correct
sequence [A].
10
4
8
B08257
End Play
Std.
Limit
B03347
B03291
764
CRANKSHAFT
Approximately
0.393 inch (10 mm)
B08243
B08244
765
CRANKSHAFT (Contd)
B08246
B08245
B08247
B08248
766
CRANKSHAFT GEAR
B08249
Use the correct size driver tool to install the gear [B].
Clean the crankshaft and check that all the oil passages
are clean and open.
Clean the engine block, lubricate and install the upper
halves of the main bearings.
Put the crankshaft carefully in position.
Install the main bearing caps and bolts. (See Page 763.)
Check the crankshaft so that it rotates freely. Check the
end play. (See Page 764.)
B08250
Install a new rear oil seal [C]. Using the correct size driver
tool.
Lubricate the connecting rod bearings. Install the
bearings and rod caps. (See Page 760.)
Install the oil pump. (See Page 780.)
Install the oil pan. (See Page 779.)
Install the timing gears, timing gearcase cover and new
front seal. (See Page 769.)
Install the flywheel. (See Page 736.)
B08261
767
B08945
B08983
B08943
Use a screwdriver and pry the front seal out of the timing
case cover [C].
B08946
Use the seal installation tool and install the new seal [D].
B08948
768
B08945
B08943
B08947
B08942
769
B08940
B08941
B08974
B08956
770
Removal
Remove the timing gearcase cover. (See Page 769.)
Remove the bolts at the tube for gear lubrication [A].
B08929
B08928
B08926
Checking
Check the idler gear hub.
Standard 1.76951.7707 inch (44,94544,975 mm)
Limit 1.7656 inch (44,845 mm)
Check the clearance between the idler gear and hub.
Limit 0.0079 inch (0,2 mm)
Check the end play at the gear and hub.
Standard 0.003 inch (0,07 mm)
Limit 0.008 inch (0,2 mm)
B08933
771
Installation
B08995
Revised Mar. 03
772
B08930
B08927
B08955
Bearing Installation
Projection
B08896
773
CAMSHAFT GEAR
B08931
B08932
B08980
B08979
774
TIMING GEARCASE
853,853HBICSServiceManual#6724012EngineServiceSectionPart3of4
B08925
B08937
B08952
775
CAMSHAFT
B08217
Checking
Check the camshaft journals [A].
B08218
B08221
B08222
776
CAMSHAFT (Contd)
Camshaft Bearings
The tools listed will be needed to do the following
procedure:
MEL1260 Camshaft Bearing Remover/Installer
Use the correct tool to remove the bearings [A].
B08219
B08220
Tappets
Remove the tappets from the engine block. Mark the
cylinder number on each tappet after removal [C].
B08190
D
Pitted
Crack
Normal Contact
Irregular Contact
777
B08210
CAMSHAFT (Contd)
Tappets (Contd)
Check the diameter of the tappets [A].
Standard 0.5110.5114 inch (12,9812,99 mm)
Limit 0.510 inch (12,95 mm)
B08211
B08212
Tappet Installation
Lubricate the tappets before installation.
Lubricate the camshaft bearings and journals. Install the
camshaft, carefully not to damage the bearings.
Install the camshaft gear. (See Page 774.)
Check the camshaft end play using a feeler gauge [C].
Standard 0.00020.0045 inch (0,050,114 mm)
Limit 0.0079 inch (0,2 mm)
After the rocker arm assembly is installed, make sure to
set the valve clearance. (See Page 738.)
B08216
778
OIL PAN
Removal
Remove the oil drain plug and remove the oil.
Remove the fastening bolts and nuts from the oil pan [A].
B08953
Installation
Clean the surface on the oil pan and engine block.
Put Three Bond (TB1207B) at the front and rear main
bearing caps (Item 1) [B] & [C].
Put liquid gasket on the oil pan surface area of the engine
block.
1
B08418
1
B08911
Install the oil pan. Install and tighten the bolts in the
sequence shown [D].
B12200
779
OIL PUMP
B08912
Remove the oil pump assembly from the engine block [B].
B08982
Checking
Oil Pipe
Strainer
Pump Cover
Vane
4
3
2
B08420
780
Checking (Contd)
Check the clearance between vane and body [A].
Standard 0.00080.0028 inch (0,020,07 mm)
Limit 0.0059 inch (0,15 mm)
B08421
B08422
B08423
Gear Replacement
File off one end of the roll pin at the gear. Use a punch and
hammer and remove the pin [C].
B08424
Installation: Install the gear and new pin. Peen the end
of the pin after installation.
B08425
781
Rotor Replacement
Remove the pin at the rotor using a punch and hammer
[A].
Installation: When installing the new pin in the rotor,
make sure to check the end of the pin that it does not
project from the end of the rotor [A].
After the oil pump is assembled, put oil into the pump and
turn the shaft to prime the pump.
B08426
B08427
B08949
2
2
1
Remove the two mounting bolts (Item 2) [D] at the oil filter
housing.
P04943
1
P04953
782
WATER PUMP
B08951
B08950
B08972
Disassembly
B08429
783
Disassembly (Contd)
Disassemble the water pump [A].
B08428
B08430
Assembly
Apply a thin coat of liquid gasket cement to the outer
surface of the seal unit before assembly [C].
B08432
B08431
784
Assembly (Contd)
After installation, check that the rear face of the impeller
has the correct height [A].
Height 0.98 inch (25 mm)
0.98 inch
(25 mm)
B08433
3.123.14 inch
(79,279,8 mm)
B08434
785
THERMOSTAT
B08954
B08435
B08419
786
B08981
Grip the edge of the water jacket tube with a vise grip. Use
a screwdriver to pry the jacket from the engine block [A].
Remove the water jacket tube from the engine block [B].
B08936
787
853,853HBICSServiceManual#6724012EngineServiceSectionPart4of4
788
SYSTEMS ANALYSIS
Page
Number
BICS SYSTEM CONTROLLER
Controller Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)
Inspecting the BICS System Controller
(Engine STOPPED Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting the Lift Arm ByPass Control . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting the Seat and Seat Bar Sensors (Engine RUNNING) . . . . . .
Inspecting the Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83
83
83
83
83
84
85
SYSTEMS
ANALYSIS
PWM MODULE
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 828
PWM TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 830
Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 829
RPM SENSOR
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 821
SEAT BAR SENSOR
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812
Seat Bar Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 813
SEAT SENSOR
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
Seat Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815
81
Revised June 97
82
1
2
3
4
5
P03760
P03763
Operator
Seat
Seat
Sensor
Seat
1 Spring
MC02043
Maintenance
Clean any debris, dirt or objects from under or behind the
operator seat [B] & [C]. The rear of the seat must move
up and down.
Clearance is necessary under the seat spring (Item 1) [C]
and the seat, to allow the seat to move up and down freely.
With adequate clearance, the seat sensor will be allowed
to function properly.
W21510394
Revised June 96
83
Indicator
Light
Light ON
Light OFF
Seat
Operator in Seat
No Operator in Seat
Seat Bar
Seat Bar Up
1
2
Valve
Traction
Loader can be
moved forward &
backward.
Loader cannot be
moved forward and
backward.
Loader cannot be
moved forward and
backward.
2
3
2
3
3
1
2
3
4
5
6
Power
BICS Controller
is operating
correctly.
BICS Controller is
not operating
correctly.
NOTES:
(1) If the seat and/or seat bar sensor circuits are open, the corresponding lights will be OFF. If one of the lights
stay OFF, check the circuit for continuity. See Inspection & Maintenance Instructions in Preventive
Maintenance section.
(2) If all five lights flash repeatedly, the voltage supply is greater than 16 volts or less than 9 volts.
(3) Flashing patterns will repeat every 3.25 seconds.
(4) If seat indicator light does not go ON, check for debris, dirt or objects under or behind the seat.
NOTE: If the Seat Bar is lowered before the seat sensor is activated, a 10 second delay will occur before the valve
and traction lights come on. (only loaders with BICS controller S/Ns above 200,000 will have this delay.)
* Normal BICS operating voltage is less than the electrical system voltage. If voltage is more, the circuit is shorted
to system voltage.
84
W20041285
PROBLEM
SOLUTION #
1, 2, 3, 6
6, 7, 8, 9
SOLUTION SUGGESTIONS
1.
2.
3.
Check wiring and connections. Make sure the connector is securely connected
to the controller. Remove controller and pull on connector to check.
4.
Look at indicator light windows, if they are milky white in appearance, it is most
likely caused by moisture in the controller. Allow to dry or replace the controller.
5.
6.
Check wire connections to make sure connectors are locked into place.
7.
8.
Move the system wiring back & forth to try to find area that may be causing the
intermittent connection.
9.
Use sensor tester MEL1428 to isolate problem between sensor and controller
and wiring.
85
W20041285
TRACTION LOCK
PROBLEM
SOLUTION #
1, 2, 3, 4, 5, 6, 7, 8
9, 10, 11
SOLUTION SUGGESTIONS
1.
2.
3.
Maneuver loader to allow brake discs to move and remove pressure on the brake
wedge so it can retract.
4.
If all lights indicate the brake should be released, but it doesnt, check the brake
25 amp. fuse.
5.
When checking fuse, also check other fuses. Check the fuse block for correct
orientation and location of fuses (See Electrical System, Page 61).
6.
To test the solenoid, the pull coil should be .4 to .5 ohms and the hold coil 10.5 to
11.0 ohms.
7.
Check brake solenoid and cover mounting hardware for the correct torque.
8.
Remove brake cover and check wedges for binding in the wedge guides.
9.
10.
11.
86
W20041285
SEAT SENSOR
PROBLEM
SOLUTION #
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11
SOLUTION SUGGESTIONS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
87
W20041285
PROBLEM
SOLUTION #
1, 2, 3, 4, 5, 6
SOLUTION SUGGESTIONS
1.
2.
3.
Use the BICS sensor tester MEL1428 to check sensor and controller.
4.
5.
Check keyed bushing to make sure magnet collar rotates with seat bar.
6.
88
W20041285
PROBLEM
SOLUTION #
SOLUTION SUGGESTIONS
1.
Rotate shaft.
2.
89
P03994
C
2
1
P04707
810
Controller Test
MEL1428 Sensor Tester is necessary for the following
procedure:
Turn the key to the ON position. DO NOT START THE
ENGINE.
P04703
P04706
P04704
2
P04699
811
P04702
P03246
I20881095
P03247
Left Side
of Seat Bar
P03284
812
1
Turn the key to the ON position. DO NOT START THE
ENGINE.
Disconnect the seat bar sensor connector (Item 1) [A].
P04702
1
P04701
P04700
P04698
Lower the seat bar. The sensor test light (Item 1) [D]
should illuminate.
Raise the seat bar. The sensor test light (Item 1) [D]
should go off.
If the above tests fails, there is a problem with the seat bar
sensor.
Refer to Page 83 for the correct procedure to inspect the
Seat Bar Sensor.
Refer to Page 51 for seat bar removal and installation
procedure.
P04699
813
SEAT SENSOR
P03987
1
3
4
DO NOT overtighten the magnet mounting
bolt to prevent damage to the magnet.
P03988
I20891095
5
3
2
1
I20881095
P04044
814
P03988
P04705
P04698
Sit on the operator seat. The sensor test light (Item 1) [C]
should illuminate.
Get off the operator seat. The sensor test light (Item 1) [C]
should go off.
815
TRACTION LOCK
2
P04769
W21650195
P04773
P04776
2
3
1
Failure to use LOCTITE may allow the traction
lock assembly to loosen up which can cause
damage to the traction lock system.
P04854
816
W20590991
P04747
I20030284
Raise the lift arms and install an approved lift arm support
device. (See Page 11.)
P04748
P04750
817
P04745
W21031285
1
Disassembly and Assembly
Remove the bypass valve (Item 1) [B] from the valve
block. Inspect the bypass valve for damage and replace
if necessary.
Remove the check valve (Item 2) [B] from the valve block.
Inspect the check valve for damage and replace if
necessary.
2
P04096
818
W20590991
P04752
P04754
819
1
2
P04115
Remove the check valve (Item 1) [B] from the lift lock
valve.
1
P04114
820
Procedure
P03871
Value
TEMPERATURE SENDER
70 degree F. (21 degree C.) . . . . . . . . . . . . . 970 ohms
80 degree F. (27 degree C.) . . . . . . . . . . . . 1013 ohms
ENGINE OIL PRESSURE SENDER
0 PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ohms Max.
6 PSI (41 kPa) . . . . . . . . . . . . . . . . . . . . . . . 7 ohms Min.
50 PSI (345 kPa) . . . . . . . . . . . . . . . . . . . . . . . . 49 ohms
70 PSI (483 kPa) . . . . . . . . . . . . . . . . . . . . . . . . 59 ohms
P05193
FUEL SENDER
Full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ohms
Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 ohms
RPM SENSOR
Adjustment
Continuity Resistance of 30003500 ohms.
Disconnect the connector [B] from the engine harness.
P05192
-8-22-
W20031289
SUBJECT
DISPLAY READS
CONDITION
ECL 1
SHUTDOWN, No Coolant
EC1.1
EC2.1
EC 3
EC 4
EC 5
EC 7
EP 1
EP 2
EP 3
SHUTDOWN, Pressure
WARNING, Pressure
Wiring Not Connected
Engine Speed
EP 4
EP 5
EP 7
ES 1
Wiring Shorted
High Sensor Voltage
Sensor Out Of Range
SHUTDOWN, Engine Speed Too High
Air Filter
ES2.1
ES6
ES7
AF 2
AF 6
b2.1
b2.2
FUEL2
Sensor No Signal
WARNING, Bad Battery
WARNING, Battery Voltage
WARNING, Low Level
FUEL3
FUEL4
FUEL5
FUEL7
Battery
Fuel Level
823
SUBJECT
DISPLAY READS
CONDITION
Hydrostatic Charge
Filter Condition
HF12
HF16
Hydrostatic Fluid
HP 1
HP 2
HP 3
HP 4
SHUTDOWN, Pressure
WARNING, Pressure
Wiring Not Connected
Wiring Shorted
HP 5
HP 7
HC 1
HC 2
HC 3
HC 4
HC 5
WARNING, Temperature
Wiring Not Connected
Wiring Shorted
High Sensor Voltage
HC 7
Hydrostatic Fluid
Temperature
824
SUBJECT
BOSS
SYMPTOM
INDICATES
Orange
Black
Purple/Red
Purple/White
LCD DISPLAY
CONNECTOR
A B C D E
Orange
LCD Display
TO CORRECT SYMPTOM
Ground
Negative Com. .5 to 1.5 Volts
Garbled
missing
etc.
825
Loosen the nuts (Item 1) [A] from the sensing system unit
(Item 2) [A].
Slide the unit forward in the mounting slots and remove
it from the operator cab.
P04043
1
1
P04042
826
P03995
Lower the light from the operator cab to locate the three
instrument panel mounting bolts (Item 1) [B] (both sides.)
B
1
P03955
Remove the three mounting bolts and pull the left panel
(Item 1) [C] down from the operator cab.
P03958
Remove the three mounting bolts and pull the right panel
(Item 1) [D] down from the operator cab.
P03959
827
PWM MODULE
Description
Volts
11.5
0
12.0
9.5
7.5
11.0
6.5
12.5
11.5
0
.51.5
0
2.0
12.0
12.0
11.0
11.0
10.0
06.0
06.0
MC2265
3
1
4
N00562
Item 1 [B]
Item 2 [B]
Item 3 [B]
Item 4 [B]
Item 5 [B]
Item 1 [C]
Item 2 [C]
Item 3 [C]
1
3
2
Right
Steering
Lever
Control
Left
Steering
Lever
Control
P02130
Revised Mar. 03
P03272
DELUXE HANDLES
828
P02129
Description (Contd)
Later S/N loaders have additional wires in the PWM
module as shown in Fig. [A]. Loaders with the module
mounted on the inside left fender are equipped with the
auxiliary hydraulic deactivation feature and are listed
below:
Loader S/Ns 514411603 & Above
514511003 & Above
514611002 & Above
TS01433
PWM TROUBLESHOOTING
Conditions
PWM fuse
Wires disconnected, shorted, or cut.
Auxiliary hydraulic switch failure.
Module failure.
Use the voltage tests in the wire identification
section to determine the cause.
Added Mar. 03
829
Chart
The PWM module sends a diagnostic code to the Mode
Switch lights when the conditions listed in the chart below
occur.
blinking.
blinking lights are off after the key switch is turned OFF
and then ON (during a proportional flow switch failure).
Momentary LED
(Item 1) [A]
Detent LED
(Item 2) [A]
P03272
PROBLEM AREA
PROBLEM CAUSE
Light Blinking
Light OFF
Light Off
Light Blinking
Light Blinking
Light Blinking
*Blinking/OFF
*OFF/Blinking
Wires Disconnected
Wires Shorted
Wires Cut
Solenoid failed. Perform solenoid
coil test.
PWM module failed.
Wires Disconnected
Wires Shorted
Wires Cut
Solenoid failed. Perform solenoid
coil test.
PWM module failed.
Wires Disconnected
Wires Shorted
Wires Cut
Solenoid failed. Perform solenoid
coil test.
PWM module failed.
Wires Disconnected
Wires Shorted
Wires Cut
Proportional flow switch failed.
Check voltage to switch.
Perform handle test.
PWM module failed.
Added Mar. 03
830
Handle Testing
The right side steering lever handle switch (Item 1) [A]
controls the proportional flow to front auxiliary. Test the
switch with a Ohm test meter.
Full Left
Center
Full Right
White/Black
& White
No
Test
4.85.2
Ohms
No
Test
White/Red
& White
1.31.5
Ohms
2.62.8
Ohms
3.84.0
Ohms
White/Red &
White/Black
3.84.0
Ohms
2.62.8
Ohms
1.31.5
Ohms
P02129
N00076
Added Mar. 03
831
Switch
Number
Left Side
Control Handle
Switches
RH
HFH
Attachment
Harness
Terminal
Activated
1,8
* 3
1,8
2,3 6,7
K, A, D
1,3 5,7
K, A, C
1,3 5,7
K, E
1,3 5,7
K, F
1,3 5,7
K, G
1,3 5,7
K, H
Attachment
Harness
Connector
Right Side
Control Handle
Switches
Solenoid
Number
8
5
3
2
3
1
Hydraulic
Coupler
Wiring
Color
Front
Female
Dk. Green/
Red
Front
Male
Dk. Green/
Lt. Green
Diverter
Yellow
Bleed Rear
Male & Female
Dk. Green/
Yellow
Rear
Female
Yellow/
Lt. Green
Rear
Male
Yellow/
Brown
7 (Bottom)
Diverter
Yellow
8 (Middle)
High
Flow
Lt. Blue/
Red
Bleed Rear
Male & Female
Dk. Green/
Yellow
3 (Top)
4 (Bottom)
8
7
6
5
8
5
3
H
1
9 (Top)
MC02314
NOTE: The Key Switch fully left position activates solenoids number 1, 4 and 9. The high flow rocker switch in
the left side instrument panel must be ON to activate solenoid number 8.
Added Mar. 03
832
SPECIFICATIONS
Page
Number
DECIMAL & MILLIMETER EQUIVALENTS
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 913
ENGINE SPECIFICATIONS
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rod & Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idler Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons, Pins & Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque for General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve, Valve Guide & Seat Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
96
96
97
95
96
97
97
97
96
95
96
98
95
95
94
94
94
93
94
93
93
94
94
91
92
LOADER SPECIFICATIONS
Dimensions are given for loader equipped with standard tires and dirt bucket.
Dimensions may vary with other types. All dimensions are shown in inches. Respective
metric dimensions are given in millimeters enclosed by parentheses.
Where applicable, specifications conform to SAE/ISO standards and are subject to
change without notice.
LOADER DIMENSIONS
153.3
(3894)
96o
119.6
(3038)
61.5
(1562)
76.2
(1935)
40o
48.3
(1227)
23.0
(584)
93.1
(2365)
45o
80.9
(2055)
61.5
(1562)
25.12
(638)
84.0
(2134)
26o
30o
38.6
(980)
8.0
(204)
*101.8
(2586)
6.2
(157)
51.8
(1316)
128.5
(3264)
60.9
(1547)
MC1113
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . .
Controls
Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loader Function . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Drive . . . . . . . . . . . . . . . . . . . . . . . . .
Service Brake . . . . . . . . . . . . . . . . . . . . . .
Secondary Brake . . . . . . . . . . . . . . . . . . . .
Parking Brake . . . . . . . . . . . . . . . . . . . . . .
ENGINE
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horsepower . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Governed RPM . . . . . . . . . . . .
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number of Cylinders . . . . . . . . . . . . . . . . .
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . .
Displacement . . . . . . . . . . . . . . . . . . . . . . .
Cooling System . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . .
Crankcase Ventilation . . . . . . . . . . . . . . . .
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . .
93
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . .
Bore Diameter:
Lift Cylinder (2)
Tilt Cylinder (1)
Rod Diameter:
Lift Cylinder (2)
Tilt Cylinder (1)
Stroke:
Lift Cylinder (2)
Tilt Cylinder (1)
Doubleacting
....................
....................
2.25 (57,2)
3.25 (82,6)
....................
....................
1.50 (38,1)
1.50 (38,1)
....................
....................
33.5 (851)
18.17 (462)
Control Valve . . . . . . . . . . . . . . . . . . . . . . .
Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SYSTEM
Transmission . . . . . . . . . . . . . . . . . . . . . . .
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . .
Total Engine to Wheel Reduction . . . . . .
3.9 Seconds
3.4 Seconds
2.2 Seconds
1.9 Seconds
Bobcat Fluid (P/N 6563328); If fluid is not available, use
10W30/10W40 Class SE Motor Oil for temperatures above 0oF (18oC)
& 5W30 Motor Oil for temperatures below 0oF (18oC).
Tandem hydro. pumps infinitely variable, driving 2 fully reversing hydrostatic motors
Gear Reduction & #100 HS roller chain &
sprockets in sealed chaincase with oil lubrication
47:27:1
CAPACITIES
Cooling System . . . . . . . . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil W/Filter . . . . . . . . . . . . . . . . . .
Hydraulic Reservoir . . . . . . . . . . . . . . . . . .
Hydraulic/Hydrostatic System . . . . . . . . .
Chaincase Reservoir . . . . . . . . . . . . . . . .
TIRES
Recommended Pressure . . . . . . . . . . . . .
22 qts. (20,8 L)
25 gals. (95 L)
8 qts. (7,6 L)
16.0 qts. (15.1 L)
8 gals. (30,3 L)
9 gals. (34,1 L)
Inflate tires to the MAXIMUM pressure shown on the side wall of the tire.
DO NOT mix brands of tires used on the same loader.
VIBRATION DATA
Hand Arm Vibration . . . . . . . . . . . . . . . . . .
Whole Body Vibration . . . . . . . . . . . . . . . .
Revised Mar. 03
94
ENGINE SPECIFICATIONS
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
Cylinder Head
Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.002 (0,05)
Limit 0.008 (0,20)
ReGrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limit 0.012 (0,30)
Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees
Valve, Valve Guide & Seat Insert
Valve Seat Width
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.067 (1,7)
Limit 0.087 (2,2)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.079 (2,0)
Limit 0.098 (2,5)
Valve Head Depth
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.029 (0,73)
Limit 0.05 (1,28)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.028 (0,70)
Limit 0.047 (1,2)
Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees
Valve Head Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.07 (1,8)
Limit 0.059 (1,5)
Valve Stem Diameter
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.31280.3134 (7,9457,960)
Limit 0.310 (7,87)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.31190.3124 (7,9227,935)
Limit 0.310 (7,87)
Valve & Valve Guide Clearance
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.00150.0027 (0,0380,069)
Limit 0.008 (0,2)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.00250.0038 (0,0640,097)
Limit 0.010 (0,25)
Valve Guide Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.51 (13)
Valve Springs
Free Length
Inner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 1.783 (45,3)
Limit 1.748 (44,4)
Outer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 1.957 (49,7)
Limit 1,898 (48,2)
Inclination
Inner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limit 0.118 (3,0)
Outer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limit 0.126 (3,2)
Tension
Inner Set Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.46 (37) Std. 13 lbs. (5,9 kg)
Limit 11 lbs. (5,02 kg)
Outer Set Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.54 (39) Std. 46 lbs. (20,9 kg)
Limit 40 lbs. (18,2 kg)
Rocker Arm
Shaft Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.74780.7486 (18,9919,01)
Limit 0.7427 (18,86)
Rocker Arm I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.74890.7497 (19,0219,04)
Limit 0.7505 (19,06)
Clearance Between Rocker Arm & Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.00030.0020 (0,0080,05)
Limit 0.0078 (0,2)
Push Rod RunOut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limit 0.012 (0,3)
Tappets
Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.5110.5114 (12,9812,99)
Limit 0.510 (12,95)
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.0012 (0,03)
Limit 0.0039 (0,10)
95
96
97
Head Mark 4
Head Mark 7
Head Mark 10
M 5 x 0.8
34 ft.lbs.
(45 Nm)
M 6 x 1.0
67 ft.lbs.
(89 Nm)
69 ft.lbs.
(812 Nm)
M 8 x 1.25
69 ft.lbs.
(812 Nm)
1116 ft.lbs.
(1522 Nm)
1825 ft.lbs.
(2434 Nm)
M 10 x 1.25
1318 ft.lbs.
(1824 Nm)
2230 ft.lbs.
(3041 Nm)
3650 ft.lbs.
(4968 Nm)
M 12 x 1.25
2230 ft.lbs.
(3041 Nm)
4054 ft.lbs.
(5473 Nm)
6987 ft.lbs.
(94118 Nm)
M 14 x 1.25
3650 ft.lbs.
(4968 Nm)
5880 ft.lbs.
(79108 Nm)
116137 ft.lbs.
(157186 Nm)
98
Ft.Lbs.
Nm
2528
50
175190
475525
3438
68
237258
644710
220245
2528
6570
6570
6570
198332
3438
8895
8895
8895
7287
1117
90100
5865
2125
1516
123152
New 5767
Used 7280
98118
1523
122136
7988
2834
2022
167206
7791
98108
1017
2035
1423
2747
Flywheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injector Holddown Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8390
1620
2332
113122
2227
3143
Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1518
2024
1429
25
1620
6570
6570
175200
1939
34
2227
8895
8895
237271
1012
3651
4358
4351
7287
1017
1017
1416
4669
5979
5869
98118
1423
1423
116130
3540
157176
4754
1017
1419
912
1017
4050
2535
157176
1926
1216
1423
5468
3447
78
25
1820
9,510,8
34
2427
1214
3643
1619
4958
4045
911
2528
5461
12,215
3438
99
Ft.Lbs.
Nm
1017
1117
1117
1423
1523
1523
613
818
1017
1118
105115
1423
1524
142156
910
W20741285
When temperatures below zero degree F (18C) are common, the loader must be
kept in a warm building. Extra warmup time must be used each time the loader is
started during cold temperature conditions. Cold fluid will not flow easily and it makes
action of the hydraulic function slower. Loss of fluid flow to the hydrostatic
transmission pump (indicated by TRANS light ON) can cause transmission
damage in less than 60 seconds.
W20271285
911
INCH.
LBS.
(Nm)
FOOT
LBS.
(Nm)
THREAD
SIZE
SAE GRADE 5
SAE GRADE 8
.250
8090
(9,010,2)
110120
(12,413,6)
.3125
180200
(20,322,6)
215240
(24,227,1)
.375
2528
(3438)
3540
(4754)
.4375
4045
(5461)
6065
(8188)
.500
6570
(8895)
90100
(122136)
.5625
90100
(122136)
125140
(170190)
.625
125140
(170190)
175190
(240260)
.750
220245
(300330)
300330
(410450)
.875
330360
(450490)
475525
(645710)
1.000
475525
(645710)
725800
(9851085)
1.125
650720
(880975)
10501175
(14251600)
1.250
9001000
(12001360)
14751625
(20002200)
1.375
12001350
(16301830)
20002200
(27202980)
1.500
15001650
(20402240)
26002850
(35303870)
1.625
20002800
(27202980)
34503800
(46805150)
1.750
25002750
(33903730)
43004800
(58306500)
1.875
31503500
(42704750)
55006100
(74508300)
2.000
38004200
(51505700)
65007200
(88009800)
912
DECIMALS
MM
0.015625
0.03125
0.046875
0.0625
0.078125
0.09375
0.109375
0.1250
0.140625
0.15625
0.171875
0.1876
0.203125
0.21875
0.234375
0.2500
0.265625
0.28125
0.296875
0.3125
0.328125
0.34375
0.359375
0.3750
0.390625
0.40625
0.421875
0.4375
0.453125
0.46875
0.484375
0.5000
0.397
0.794
1.191
1.588
1.984
2.381
2.778
3.175
3.572
3.969
4.366
4.762
5.159
5.556
5.953
6.350
6.747
7.144
7.541
7.938
8.334
8.731
9.128
9.525
9.922
10.319
10.716
11.112
11.509
11.906
12.303
12.700
FRACTIONS
DECIMALS
33/64
17/32
35/64
9/16
37/64
19/32
39/64
5/8
41/64
21/32
43/64
11/16
45/64
23/32
47/64
3/4
49/64
25/32
51/64
13/16
53/64
27/32
55/64
7/8
57/64
29/32
59/64
15/16
61/64
31/32
63/64
1
1 mm = 0.03937
0.515625
0.53125
0.546875
0.5625
0.578125
0.59375
0.609375
0.6250
0.640625
0.65625
0.671875
0.6875
0.703125
0.71875
0.734375
0.7500
0.765625
0.78125
0.796875
0.8125
0.828125
0.84375
0.859375
0.8750
0.890625
0.90625
0.921875
0.9375
0.953125
0.96875
0.984375
1.000
MM
13.097
13.494
13.891
14.288
14.684
15.081
15.478
15.875
16.272
16.669
17.066
17.462
17.859
18.256
18.653
19.050
19.447
19.844
20.241
20.638
21.034
21.431
21.828
22.225
22.622
23.019
23.416
23.812
24.209
24.606
25.003
25.400
0.001 = 0.0254 mm
INTO
MULTIPLY BY
LINEAR
MEASUREMENT
Miles
Yards
Feet
Feet
Inches
Inches
Inches
Kilometers
Meters
Meters
Centimeters
Meters
Centimeters
Millimeters
AREA
Square Miles
Square Feet
Square Inches
Acre
Square Kilometers
Square Meters
Square Centimeters
Hectare
VOLUME
Cubic Yards
Cubic Feet
Cubic Inches
Cubic Meters
Cubic Meters
Cubic Centimeters
0.7646
0.02832
16.39
WEIGHT
Tons (Short)
Pounds
Ounces (Avdp.)
Metric Tons
Kilograms
Grams
0.9078
0.4536
28.3495
PRESSURE
Pounds/Sq. In.
Kilopascal
6.895
WORK
FootPounds
NewtonMetre
1.356
LIQUID VOLUME
Quarts
Gallons
Liters
Liters
0.9463
3.785
LIQUID FLOW
Gallons/Minute
Liters/Minute
3.785
TEMPERATURE
Fahrenheit
Celsius
1.609
0.9144
0.3048
30.48
0.0254
2.54
25.4
2.59
0.0929
6.452
0.4047
1.Subtract 32
2. Multiply by 5/9
913
853,853HBICSServiceManual#6724012SpecificationsSection
914
850001
Revision Number
20 February 1996
SERVICE MANUAL
REVISION
Date
ROUTE TO
ATTENTION
AFFECTING:
Product BOBCAT LOADER
Model
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
850
NOTICE
Insert This Sheet With The Appropriate Manual For Future Reference.
The following pages are a revision to the 850 Service Manual P/N 6724012 (595).
Put in the added pages as follows:
TAKE OUT
PUT IN
Hydraulic/Hydrostatic Schmatic (P/N 6724476)
853H BICS
(Printed February 1996)
Printed in U.S.A.
850002
Revision Number
5 June 1996
SERVICE MANUAL
REVISION
Date
ROUTE TO
ATTENTION
AFFECTING:
Product BOBCAT LOADER
Model
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
853, 853H
NOTICE
Insert This Sheet With The Appropriate Manual For Future Reference.
The following pages are a revision to the 853, 853H Service Manual P/N 6724012 (495).
Take out the pages shown and put in the revised pages as follows:
TAKE OUT
PUT IN
27, 28
219, 220
231, 232
SECTION 3
45, 46
850003
Revision Number
12 July 1996
SERVICE MANUAL
REVISION
Date
ROUTE TO
ATTENTION
AFFECTING:
Product BOBCAT LOADER
Model
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
853, 853H
NOTICE
Insert This Sheet With The Appropriate Manual For Future Reference.
The following pages are a revision to the 853, 853H Service Manual P/N 6724012 (495).
Take out the pages shown and put in the revised pages as follows:
TAKE OUT
PUT IN
850004
Revision Number
1 June 1997
SERVICE MANUAL
REVISION
Date
ROUTE TO
ATTENTION
AFFECTING:
Product BOBCAT LOADER
Model
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
853, 853H
NOTICE
Insert This Sheet With The Appropriate Manual For Future Reference.
The following pages are a revision to the 853 & 853H Service Manual P/N 6724012 (495).
Take out the pages shown and put in the revised pages as follows:
TAKE OUT
PUT IN
853 Cover
i, ii
v, vi
13, 14
17, 18
HYDRAULIC/HYDROSTAIC SCHEMATIC
853 BICS
(Printed June 1997)
HYDRAULIC/HYDROSTATIC SCHEMATIC
853H BICS
(Printed June 1997)
25, 26
29, 210
217, 218
59, 510
TAKE OUT
PUT IN
853 BICS OPERATOR CONTROLS WIRING
DIAGRAM INDEX
OPERATOR CONTROLS WIRING DIAGRAM
SHEET 1 853 BICS
(Printed June 1997)
OPERATOR CONTROLS WIRING DIAGRAM
SHEET 2 853 BICS
(Printed June 1997)
OPERATOR CONTROLS WIRING DIAGRAM
SHEET 3 853 BICS
(Printed June 1997)
OPERATOR CONTROLS WIRING DIAGRAM
SHEET 4 853 BICS
(Printed June 1997)
853 BICS ATTACHMENT (OPTIONAL) WIRING
DIAGRAM INDEX
ATTACHMENT (OPTIONAL) WIRING DIAGRAM
SHEET 1 853 BICS
(Printed June 1997)
ATTACHMENT (OPTIONAL) WIRING DIAGRAM
SHEET 2 853 BICS
(Printed June 1997)
77, 78
79, 710
711, 712
733, 734
81, 82
850005
Revision Number
7 March 2003
SERVICE MANUAL
REVISION
AFFECTING:
Product BOBCAT LOADER
Model
Date
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
853, 853H
NOTICE
Insert This Sheet With The Appropriate Manual For Future Reference.
The following pages are a revision to the 853 & 853H Service Manual P/N 6724012 (495).
Take out the pages shown and put in the revised pages as follows:
TAKE OUT
PUT IN
REVISION DESCRIPTION
357, 358
357, 358
Text change
741, 742
771, 772
741, 742
771, 772
Text change
Text change
81, 82
827 thru 832
81, 82
827 thru 832
Text change
Added information
93, 94
93, 94
Text change