863 6900942 Bobcat PDF

TURBO
Service
Manual
TURBO
Dealer Copy -- Not for Resale

S/N 514440001 & Above
S/N 514540001 & Above
S/N 514640001 & Above
Doosan purchased Bobcat Company from Ingersoll-Rand Company in

2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Bobcat Company or the products of
either.
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6900942 (10 ) Printed in U.S.A. © Bobcat Company 2010

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

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

B-15592 B-15593 B-15599
Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
B-15600 B-15601 B-6589

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

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

BATTERY ............................................................... 60-01 GUIDELINES ........................................................80-01
BICS™ SYSTEM .................................................... 60-01
BOBCAT CONTROLLER ....................................... 60-01 HEATER COIL .........................................................80-01
BOBCAT INTERLOCK HEATER / AC FAN .................................................80-01
CONTROL SYSTEM (BICS™) ............................ 60-01 HEATER VALVE ......................................................80-01
BOB-TACH................................................... 10-01, 50-01 HYDRAULIC CONNECTION SPECS ............... SPEC-01
BRAKE .................................................................... 40-01 HYDRAULIC CONTROL VALVE

BRAKE (TWO-SPEED)........................................... 40-01 (ADVANCED CONTROL SYSTEM) (ACS) ..........20-01
BUCKET POSITITON VALVE 20-01 HYDRAULIC CONTROL VALVE
(FOOT CONTROL)...............................................20-01
CHAINCASE ........................................................... 40-01 HYDRAULIC FLUID RESERVOIR ..........................20-01
CHARGE PRESSURE ........................................... 30-01 HYDRAULIC / HYDROSTATIC FILTER ..................20-01
COOLING FAN ...................................................... 70-01 HYDRAULIC FLUID SPECIFICATIONS............ SPEC-01
COMPONENTS ..................................................... 80-01 HYDRAULIC / HYDROSTATIC SYSTEM ............10-01
COMPRESSOR ..................................................... 80-01 HYDRAULIC PUMP ................................................20-01
CONDENSER ......................................................... 80-01 HYDRAULIC SYSTEM INFORMATION ..................20-01
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) HYDROSTATIC MOTOR .........................................30-01
(ACS) ADVANCED HAND CONTROL................. 20-01 HYDROSTATIC MOTOR (TWO-SPEED) ................30-01
CONTROL HANDLE (ADVANCED HAND CONTROL) HYDROSTATIC PUMP ............................................30-01
(AHC) .................................................................. 20-01 HYDROSTATIC SYSTEM INFORMATION..............30-01
CONTROL HANDLE (ADVANCED HAND CONTROL)
(AHC) (W/ PUSH BUTTON FLOAT) .................... 20-01 INSTRUMENT PANEL ............................................60-01
CONTROL HANDLE (ADVANCED CONTROL SYSTEM)
(ACS) SELECTABLE HAND / FOOT CONTROL. 20-01 LIFT ARMS ..............................................................50-01
CONTROL PANEL ..................................................50-01 LIFT ARM BYPASS VALVE .....................................20-01
CONTROL PEDALS ............................................... 50-01 LIFT ARM SUPPORT DEVICE................................10-01
CONTROL PEDALS (ACS) .................................... 50-01 LIFTING AND BLOCKING THE LOADER...............10-01
CONVERSIONS ............................................... SPEC-01 LIGHTS....................................................................60-01
CYLINDER (LIFT) ................................................... 20-01 LOADER SPECIFICATIONS ............................. SPEC-01
CYLINDER (POWER BOB-TACH).......................... 20-01 LOADER TORQUE............................................ SPEC-01
CYLINDER (TILT) ................................................... 20-01 LUBRICATING THE LOADER.................................10-01
DELUXE INSTRUMENTATION SERVICE CODES 60-01 MAIN RELIEF VALVE (FOOT CONTROL) ..............20-01
DRIVE BELT ........................................................... 30-01 MUFFLER................................................................70-01
DRIVE COMPONENTS .......................................... 40-01
ELECTRICAL / HYD. CONTROLS REFERENCE .. 60-01

ELECTRICAL SYSTEM INFORMATION ................ 60-01
ENGINE & ENGINE MOUNTS ............................... 70-01
ENGINE COMPONENTS AND TESTS .................. 70-01
ENGINE COOLING SYSTEM ................................. 10-01
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ALPHABETICAL INDEX (CONT’D)
OIL COOLER...........................................................30-01
OPERATOR CAB..........................................10-01, 50-01
OPERATOR SEAT...................................................50-01
OPERATOR SEAT (SUSPENSION)........................50-01
POWER BOB-TACH (OPTION)....................10-01, 50-01

POWER BOB-TACH BLOCK...................................20-01
PRESSURE RELIEF VALVE ...................................80-01
PRESSURE SWITCH..............................................80-01
RADIATOR...............................................................70-01
REAR AUXILIARY DIVERTER VALVE ....................20-01
REAR DOOR ..........................................................50-01
REAR GRILL ..........................................................50-01
RECEIVER / DRIER..................................................80-
01
RECOMMENDED SERVICE TOOLS ......................80-01
RECONDITIONING THE ENGINE ..........................70-01
REMOTE START .....................................................10-01
RPM SENSOR.........................................................70-01
SAFETY...................................................................80-01
SEAT BAR ...............................................................50-01

SEAT BAR SENSOR ...............................................60-01
SELECT VALVE.......................................................20-01
SERVICE SCHEDULE.............................................10-01
STARTER ................................................................60-01
SYSTEM CHARGING AND RECLAMATION ..........80-01
SYSTEM TROOUBLESHOOTING CHART.............80-01
01
TEMPERATURE / PRESSURE.................................80-
THERMOSTAT ........................................................80-01
TIRE MAINTENANCE..............................................10-01
TORQUE SPECIFICATIONS FOR BOLTS........ SPEC-01
TOWING THE LOADER ..........................................10-01
TRACTION LOCK....................................................60-01
TRANSPORTING THE LOADER ............................10-01
TROUBLESHOOTING.............................................70-01
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CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY AND
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V MAINTENANCE
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

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

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

SYSTEM
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
s
MAINFRAME
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01 A
MAINFRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

ELECTRICAL
SYSTEM &
ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01 ANALYSIS
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 ENGINE

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

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

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

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

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

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

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

the work lights.
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17. Check the condition of the 23. Operate the machine and
battery and cables. check all functions.
18. Inspect the air cleaner for 24. Check for correct function of
damage or leaks. Check the the Bobcat Interlock Control
condition of the element. System (BICS™) before the
machine is returned to the
customer.
19. Check the electrical charging 25. Check for proper function of
system. front horn and back-up alarm
(if equipped).
20. Check tires for wear and 26. Check function or condition of
pressure. Check tracks for all equipped options and
wear and tension. Use only accessories (examples: fire

approved tires or tracks. extinguisher, rotating beacon,
lift kits, etc.).
21. Inspect for loose or broken 27. Recommend to the owner
parts or connections. that all necessary corrections
be made before the machine
is returned to service.
22. Check for any field

modification not completed.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the state of California
to cause cancer, birth defects and other
reproductive harm.
FW SSL-1008 SM
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SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions • An Operator’s Handbook fastened to the operator
can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903

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

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

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

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

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

Dial 811 (USA Only)

1-888-258-0808 (USA & Canada)
When you call, you will be directed to a location in your
state / province, or city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.).
SI SSL-1008 SM
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FIRE PREVENTION Hydraulic System
Check hydraulic tubes, hoses and fittings for damage

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

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

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

cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Starting
All fuels, most lubricants and some coolants mixtures are Do not use ether or starting fluids on any engine that has
flammable. Flammable fluids that are leaking or spilled glow plugs or air intake heater. These starting aids can
onto hot surfaces or onto electrical components can cause explosion and injure you or bystanders.
cause a fire.
Use the procedure in the Operation & Maintenance
Operation Manual for connecting the battery and for jump starting.
Do not use the machine where exhaust, arcs, sparks or

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

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

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

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

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

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

Know where fire extinguishers and first aid kits are
located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.
SI SSL-1008 SM
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SERIAL NUMBER LOCATIONS Engine Serial Number
Always use the serial number of the loader when Figure 2

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Loader Serial Number
Figure 1
P-10443
Figure 3

N-19358
The loader serial number plate is located on the inside of

the operator cab on the right fender and in front of the
seat [Figure 1].
Explanation of loader Serial Number:
XXXX XXXXX N-19359
Model 1.-Model / Engine Model 2.-Production

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

the order which the loader is produced.
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DELIVERY REPORT
Figure 4
B-16315
The Delivery Report must be filled out by the dealer and

signed by the owner or operator when the Bobcat loader
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [Figure

4].
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BOBCAT LOADER IDENTIFICATION
OPERATOR
SEAT With
◆FRONT LIGHTS
SEAT BELT
GRAB
HANDLES
◆REAR
AUXILIARY
QUICK
TILT CYLINDER COUPLERS

◆ FRONT AUXILLIARY
†BUCKET QUICK COUPLERS
BUCKET STEPS SAFETY TREAD B-15565
LIFT ARM
SUPPORT DEVICE •OPERATOR CAB
(ROPS/FOPS)
REAR GRILL
SEAT BAR
LIFT ARM
◆REAR LIGHT LIFT CYLINDER
REAR
DOOR
◆TAIL LIGHT TIRES*

B-15566
◆ OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment)

* TIRES - Flotation tires◆ are shown. The Bobcat loader is factory equipped with standard tires.
† BUCKET - Several different buckets and other attachments are available for the Bobcat loader.
• ROPS, FOPS - Roll-Over Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective Structure per
SAE J1043 and ISO 3449, Level 1. Level II is available. The Bobcat loader is base-equipped with a standard operator cab
as shown. Extra insulated cab is available as an option (Reduced noise level).
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SAFETY AND MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
SAFETY &
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1 MAINTENANCE
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . 10-90-1
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . 10-110-1

Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1 DRIVE
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1 SYSTEM
FAN GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . 10-130-1

Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Replacing The Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

ELECTRICAL
SYSTEM &
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 ANALYSIS
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Fuel Lift Pump Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3 ENGINE
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 SERVICE
Removing Air From The Fuel System . . . . . . . . . . . . . . . 10-100-3
HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . 10-120-1

Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-4 SPECIFICATIONS
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Replacing The Hydraulic / Hydrostatic Fluid . . . . . . . . . . 10-120-2
Replacing Hydraulic Fluid And Case Drain Filters . . . . . . 10-120-2
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Disengaging The Lift Arm Support Device. . . . . . . . . . . . . 10-20-2
Engaging The Lift Arm Support Device . . . . . . . . . . . . . . . 10-20-1
LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
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SAFETY AND MAINTENANCE (CONT’D)
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
POWER BOB-TACH (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151-1
REMOTE START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-4
Procedure For Loader With, Attachments Control Harness. . . . . . . . . . . 10-60-2
Procedure For Loader Without, Attachments Control Harness . . . . . . . . 10-60-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Tire Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Procedure For Non-Two-Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
Procedure (S/N 51451171, 514540173, 514449390 and Above) . . . . . . 10-50-3
Procedure For Two-Speeds (S/N 51464170, 514540172, 514449389 And
Below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-2
TRANSPORTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Adjusting The Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
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LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Procedure
WARNING
AVOID INJURY OR DEATH
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
N-19374
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions
can cause injury or death. Put a floor jack under the rear of the loader [Figure 10-
W-2003-0807
10-2].
Figure 10-10-1 Lift the rear of the loader and install jackstands [Figure
10-10-2].

Figure 10-10-3
B-7023A
Read the removal and installation, disassembly and P-7704

assembly, etc., completely to become familiar with the
procedure before beginning [Figure 10-10-1].
Put the floor jack under the front of the loader [Figure 10-
Always park the loader on a level surface. 10-3].
Lift the front of the loader and put jackstands under the
axle tubes [Figure 10-10-3].
WARNING NOTE: Make sure the jackstands do not touch the
tires.
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
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LIFT ARM SUPPORT DEVICE Figure 10-20-2
Engaging The Lift Arm Support Device
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
N-19369
WARNING Lower the lift arm support device on top of the lift cylinder.
Hook the free end of the spring (Item 1) [Figure 10-20-2]
to the lift arm support device so there will be no
Repair the support device if damaged or if parts are interference with the support device engagement.
missing. Using a damaged support device or with
missing parts can cause lift arms or boom to fall With the operator in the seat, seat belt fastened and seat

causing serious injury or death. bar lowered, start the engine.
W-2271-1007
Figure 10-20-1
DANGER
1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
N-19368 can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
Maintenance and service work can be done with the loft support. Replace if damaged.
arms lowered. If the lift arms are raised, use the following
D-1009-0409
procedures to engage and disengage an approved lift
arm support device:
Install jackstands under the rear of the loader frame.

Disconnect the spring from the lift arm support device
retaining pin (Item 1) [Figure 10-20-1]. Support the lift
arm support device (Item 2) [Figure 10-20-1] with your
hand and remove the retaining pin.
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LIFT ARM SUPPORT DEVICE (CONT’D) Figure 10-20-5
Engaging The Lift Arm Support Device (Cont’d)
Figure 10-20-3
P-10707
1 N-19372
Raise the lift arms a small amount and the spring will lift
N-19370 the support device off the lift cylinder rod [Figure 10-20-
5]. Lower the lift arms. Stop the engine.
Raise the lift arms, until the lift arm support device drops Raise the seat bar and move pedals until both pedals
onto the lift cylinder rod (Inset) [Figure 10-20-3]. lock.

Lower the lift arms slowly until the support device is held
Disconnect the spring from the bracket.
between the lift arm and the lift cylinder. Stop the engine.
Raise the seat bar and move pedals until both pedals
lock. Raise the support device into storage position and insert
pin through lift arm support device and bracket. (See
Install the pin (Item 1) [Figure 10-20-3] into the rear of Engaging The Lift Arm Support Device on Page 10-20-1.)
the lift arm support device below the cylinder rod. (Item 1) [Figure 10-20-1 on Page 1].]
Disengaging The Lift Arm Support Device Connect spring to pin. (See Engaging The Lift Arm
Support Device on Page 10-20-1, [Figure 10-20-1 on
Figure 10-20-4 Page 1].)
N-19371
Remove the pin from the lift arm support device.
Connect the spring (Item 1) [Figure 10-20-4] from the lift

arm support device to the bracket below the lift arms.
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine.
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OPERATOR CAB Figure 10-30-1
Raising The Operator Cab
WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to
the cab can cause loss of operator protection from
rollover and falling objects, and result in injury or
death.
W-2069-0200 N-19374
Install jackstands under the rear of the loader frame

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

MOVEMENT CAUSED BY CAB CONTACT WITH
CONTROLS CAN CAUSE SERIOUS
INJURY OR DEATH
• STOP ENGINE before raising or lowering cab.
W-2758-0908
The Bobcat loader has an operator cab (ROPS and

FOPS) as standard equipment to protect the operator
from rollover and falling objects. Check with your dealer if
the operator cab has been damaged. The seat belt must
be worn for roll over protection.
N-19364 N-19365
ROPS / FOPS Roll Over Protective Structure per SAE
J1040 and ISO 3471, and Falling Object Protective
Structure per SAE J1043 and ISO 3449, Level 1. Level II Loosen the nut (both sides) at the front corners of the
is available. operator cab [Figure 10-30-2].
Level 1 - Protection from falling bricks, small concrete Remove the nuts and plates (both sides) [Figure 10-30-
blocks and hand tools encountered in operations such as 2]
highway maintenance, landscaping, and other
construction site services.
Level II - Protection from falling trees, rocks; for

machines involved in site clearing, overhead demolition
or forestry.
Always stop the engine before raising or lowering the

cab.
Stop the loader in a level surface. Lower the lift arms. If

the lift arms must be up while raising the operator cab,
install the lift arm support device. (See Engaging The Lift
Arm Support Device on Page 10-20-1.) (See Engaging
The Lift Arm Support Device on Page 10-20-1.)
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OPERATOR CAB (CONT’D) Lowering The Operator Cab
Raising The Operator Cab (Cont’d) Figure 10-30-4
Figure 10-30-3
N-20120
N-19517
Lift on the grab handles and bottom of the operator cab

slowly until the cab is all the way up and the latching

mechanism engages [Figure 10-30-3].
Advanced Control System (ACS) And Advanced Hand

Control (AHC)
N-19518
Always stop the engine before raising or lowering the

cab.
NOTE: Make sure the seat bar is fully raised or

lowered when lowering the cab. Always use
the grab handles to lower the cab.
Pull down on the bottom of the operator cab until it stops

at the latching mechanism [Figure 10-30-4].
Release the latching mechanism (Inset) [Figure 10-30-4]

and pull the cab all the way down.
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OPERATOR CAB (CONT’D) Emergency Exit
Lowering The Operator Cab (Cont’d) The front opening on the operator cab and rear window
provide exits.
Figure 10-30-5
Rear Window (If Equipped)
Figure 10-30-6
N-19365 N-19364
Install the plates and nuts [Figure 10-30-5] (both sides).

N-19385

Tighten the nuts to 40 - 50 ft.-lb. (54 - 68 N•m) torque.
Pull on the tag on the top of the rear window to remove
the rubber cord [Figure 10-30-5].
Push the rear window out of the rear of the operator cab.
Figure 10-30-7
N-19520
Exit through the rear of the operator cab [Figure 10-30-

7].
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OPERATOR CAB (CONT’D) Figure 10-30-9
Emergency Exit (Cont’d)
Front Door (If Equipped)
Figure 10-30-8
X
N-20170
Push the window out with your foot [Figure 10-30-9] at

any corner of the window.
N-20171 Exit through the front door.

NOTE: When an Operator Cab Enclosure Kit is
installed, the window of the front door can be
used as an emergency exit [Figure 10-30-8].
NOTE: When the special applications kit is installed,

the front door cannot be used for an
emergency exit.
Pull the plastic loop at the top of the window in the front
door to remove the rubber cord [Figure 10-30-8].
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TRANSPORTING THE LOADER Adjusting The Bumper
Procedure Figure 10-40-2
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0807 N-19048 N-19523
Figure 10-40-1

1
N-19521
P-39472
6707867
A loader with an empty bucket or no attachment must be
loaded backward onto the transport vehicle [Figure 10-
40-1]. Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving
Be sure the transport and towing vehicles are of during sudden stops or when going up or down slopes
adequate size and capacity (See Performance on Page [Figure 10-40-2].
SPEC-10-2.) for weight of loader.
• Lower the bucket or attachment to the floor.
The rear of the trailer must be blocked or supported (Item • Stop the engine.
1) [Figure 10-40-1] when loading or unloading the loader • Engage the parking brake.
to prevent the front end of the trailer from raising up. • Install chains at the front and rear loader tie down
positions (Inset) [Figure 10-40-2].
• Fasten each end of the chain to the transport vehicle.
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TOWING THE LOADER Figure 10-50-2
Procedure For Non-Two-Speeds
IMPORTANT
Do not push or pull the machine at more than 2 MPH
(3,2 km/h) or for a distance of more than 25 feet (7,6
meters) with the towing tool in place. 1
I-2017-0389
Figure 10-50-1
N-18409
• Press the TRACTION LOCK OVERRIDE Button

(Item 1) [Figure 10-50-2].
• Tow the Bobcat at 2 MPH (3,2) km/hr.) or less for not
1 more than 25 feet (7,6 meters).
If the electrical system is not functioning, contact your

local Bobcat dealer.
P-28360A
To prevent damage to the loaders hydrostatic system, the

loader must be towed only a short distance at slow
speed. (Example: Moving the loader onto a transport
vehicle.)
The towing chain (or cable) must be rated at 1 & 1/2

times the weight of the loader. (See Performance on
Page SPEC-10-2.)
• Turn the key switch to RUN (Item 1) [Figure 10-50-1]

(Standard Panel) OR press the RUN / ENTER Button
(Deluxe).
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TOWING THE LOADER (CONT’D) Figure 10-50-3
Procedure For Two-Speeds (S/N 51464170,

514540172, 514449389 And Below)
DANGER
1
P-16466
P-90328
Raise the operator cab. (See Raising The Operator Cab
AVOID DEATH on Page 10-30-1.)
tubeline, hose, fitting, component or a part failure Disengage the parking brake solenoid valve by pushing
can cause lift arms to drop. IN on the red Traction Lock Bypass Knob (Item 1)
• Keep out of this area when lift arms are raised [Figure 10-50-3] and turning it 1/4 TURN

counterclockwise. The knob will come out to release
support. Replace if damaged. the solenoid valve.
D-1009-0409
Figure 10-50-4
WARNING
1
W-2059-0598
P-16465
Connect a Port-a-Power to the coupler (Item 1) [Figure

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

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

4
Lower the operator cab and tow the loader.
Before operating the loader again, disconnect the Port-a- P-34159

Power.
Engage the parking brake solenoid valve, by pushing Raise the operator cab. (See Raising The Operator Cab
IN the red Traction Lock Bypass Knob (Item 1) [Figure on Page 10-30-1.)
10-50-3] and turning it 1/4 TURN clockwise.
The parts from the list below are required to complete the
Procedure (S/N 51451171, 514540173, 514449390 and towing tool needed in this procedure [Figure 10-50-6]:
Above)
1 - 2 ft. common drain hose (Item 1)
1 - 6678026 - Check relief valve (500 PSI) (Item 2)
DANGER 1 - 10K5 - Tee fitting (Item 3)

1 - 13K5 - Swivel fitting (Item 4)
1 - 6661753 - Coupler, male (Item 5)
1 - MEL1218 - Coupler, female (Item 6)
2 - 36K5 - Caps (Item 7)
Connect the drain hose (Item 1) [Figure 10-50-6] to the

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

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

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

kPa) to release the brakes [Figure 10-50-9].
P-34088
Lower the cab and tow the loader.
Disconnect the two hoses (Item 1) [Figure 10-50-7] from Release the port-a-power pressure to apply the brakes.

the parking brake solenoid valve that go to the right and
left brake housings on the hydrostatic motors. Remove the towing tool from the brake hoses.
Figure 10-50-8 Install the two hydraulic hoses to the parking brake
solenoid valve.
1
2
1
3
P-34089
Connect the two hoses (Item 1) [Figure 10-50-8] to the

tee fitting of the towing tool.
Connect the Port-a-Power (Item 2) [Figure 10-50-8] (with

an attached pressure gauge 600 PSI (4137 kPa) or
larger) to the quick coupler on the towing tool.
Route the drain hose (Item 3) [Figure 10-50-8] into a

bucket.
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REMOTE START Figure 10-60-2
Procedure For Loader Without, Attachments Control

Harness
Figure 10-60-1
1
1
N-19983
Figure 10-60-3
P-13841
The tool listed will be needed to do the following

procedure:
MEL1563: Remote Start Tool Kit 1
The remote start (Item 1) [Figure 10-60-1] is required

when the operator cab is in the raised position for service
and the service technician needs to turn the key switch 2
on or start the engine. Example: adjusting the steering
linkage.
N-19984
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Remove the cap (Item 1) [Figure 10-60-2] from the
Raise the lift arms (if required by the procedure) and loader harness (Item 1) [Figure 10-60-3].
install an approved lift arm support device. (See
Engaging The Lift Arm Support Device on Page 10-20-1.) When the remote start procedure is completed, replace
the loader connected cap (Item 2) [Figure 10-60-3].
Raise the operator cab (if required by the procedure).
(See Raising The Operator Cab on Page 10-30-1.)
Open the rear door of the loader.
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REMOTE START (CONT’D) Procedure For Loader With, Attachments Control
Harness
Procedure For Loader Without, Attachments Control
Harness (Cont’d) The tool listed will be needed to do the following
procedure:
MEL 1563: Remote Start Tool Kit

With the 7-pin connector plugged into the loader and
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel 1
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
service technician will be working the engine area it
is important to remove the operator panel keys.
W-2357-0899
Figure 10-60-4
P-13841

The remote start (Item 1) [Figure 10-60-5] is required
when the operator cab is in the raised position for service
and the service technician needs to turn the key switch
on or start the engine. Example: adjusting the steering
1 linkage.
2 Lift and block the loader. (See LIFTING AND BLOCKING

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

install an approved lift arm support device. (See
N-19985 Engaging The Lift Arm Support Device on Page 10-20-1.)
Connect the remote start tool to the engine harness Raise the operator cab (See Raising The Operator Cab
connector (Item 1) [Figure 10-60-4]. on Page 10-30-1.)
The connector (Item 2) [Figure 10-60-4] from the remote Open the rear door of the loader.
start harness is not used in the remote start procedure
and should remain capped.
NOTE: The key switch on the right-hand side operator

panel must be in the off position or the
Remote Start Kit will not operate.
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REMOTE START (CONT’D) Figure 10-60-7
Procedure For Loader With, Attachments Control

Harness (Cont’d)
WARNING
2
With the 7-pin connector plugged into the loader and
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the N-20079
operator panel key switch from the start circuit. If the
service technician will be working the engine area it
is important to remove the operator panel keys. Disconnect the attachment control harness (Item 1)
W-2357-0899 [Figure 10-60-6] & [Figure 10-60-7] from the loader
harness (Item 2) [Figure 10-60-7].
Figure 10-60-6 Figure 10-60-8

1
1
2
N-19987
N-20080
Connect the remote start tool (Item 1) [Figure 10-60-8] to

the loader harness connector (Item 2) [Figure 10-60-7].
The connector (Item 2) [Figure 10-60-8] on the remote

start harness is not used in the remote start procedure
and should remain capped.
NOTE: The key switch on the right-hand side operator

panel must be in the off position or the
Remote Start Kit will not operate.
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REMOTE START (CONT’D) Figure 10-60-10
Procedure
Figure 10-60-9
2
3 1
N-19541
The traction lock switch (Item 1) [Figure 10-60-10] is

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

The maximum flow / variable flow switch (Item 2) [Figure
10-60-10] is used to activate the auxiliary hydraulics.
Pressing the switch once will activate variable flow.
Pressing the switch again will activate maximum flow.
The switch will illuminate to indicate which flow rate is
active. Pressing the switch a third time will turn the flow
OFF. The switch is used when checking pressures and
flow rate.
The auxiliary pressure release (Item 3) [Figure 10-60-10]

is used to release hydraulic pressure to the front and / or
rear auxiliary couplers. To release pressure; push and
hold the switch for three seconds.
NOTE: With the engine running; pushing and holding

the pressure release switch this will cause the
engine to stop in three seconds. To relieve the
pressure; continue to press the switch after
the engine has stopped.
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SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat loader.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
SERVICE SCHEDULE HOURS

■ ■ ■ ▼
ITEM SERVICE REQUIRED 8-10 50 100 250 500 1000 3000
Engine Oil Check the oil level and add as needed.
Engine Air Filter and Air System Check display panel. Service only when required. Check for leaks and
damaged components.
Engine Cooling System Clean debris from oil cooler, radiator & grill.
Lift Arms, Cylinders, Bob-Tach Lubricate with multi-purpose lithium based grease (14 places).
Pivot Pins and Wedges
Tires Check for damaged tires and correct air pressure.
Seat Bar, Control Interlocks, Seat Check the condition of seat belt. Clean or replace seat belt retractors as
Belt, Seat Belt Retractors needed. Check the sear bar and control interlocks for correct operation. Clean
dirt and debris from moving parts.
Bobcat Interlock Control Systems Check that four (4) BICS™ indicator lights and functions are activated. See
(BICS™) details in this Manual.

Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or
safety treads that are damaged or worn.
Operator Cab Check the fastening bolts, washers and nuts. Check the condition of the cab.
Indicators and Lights Check for correct operation of all indicators and lights.
Fuel Filter Remove the trapped water.
Heater and A/C Filters Clean or replace filters as needed during heating / cooling season.
Hydraulic Fluid, Hoses and Check fluid level and add as needed. Check for damage and leaks. Repair or
Tubelines replace as needed.
Final Drive Trans. (Chaincase), Check oil level. Check for correct operation. Repair or adjust as needed.
Foot Pedals or Hand Controls,
and Steering Levers
Wheel Nuts ❏Check for loose wheel nuts and tighten to 105 - 115 ft.-lb. (142 - 156 N•m)
torque
Parking Brake Check operation.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Engine / Hydro. Drive Belt *Check for wear or damage. Check idler arm stop.
Alternator Belt Check tension and adjust as needed.
Air Conditioner Belt Check belt for wear. Adjust or replace as needed.
Bobcat Interlock Control System Check the function of the lift arm bypass control.
(BICS™)
Fuel Filter Replace filter element.
Steering Shaft Grease three fittings.
Fan Drive Gearbox Check gear lube level.
Hydraulic Reservoir Breather Cap Replace the reservoir breather cap.
Hyd. / Hydro. Filter ●Replace the filter element.
Engine Oil and Filter ^Replace oil and filter. Use CD or better grade oil and Bobcat filter. ^ ❍
Final Drive Trans. (Chaincase) Replace the fluid.
Hydraulic Reservoir Replace the fluid.
Case Drain Filters Replace the filters.
Engine Valves #Adjust the engine valves.
Engine Timing Belt ▼Replace the timing belt and belt tensioner assy.
❏ Check wheel nut torque every 8 hours for the first 24 hours.
* Inspect the new belt after first 50 hours.
● Also replace hydraulic / hydrostatic filter element when the transmission warning light comes ON.
^ First oil and filter change must occur at 50 hours; 500 hours thereafter.
❍ When operating under severe conditions, change oil and filter every 250 hours.
# After the first 500 hours on new engine, adjust engine valves; 1000 hours thereafter.
■ Or every 12 months.
▼ Or every 5 years.
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AIR CLEANER SERVICE OUTER FILTER
Replacing Filter Element Figure 10-80-3
Figure 10-80-1
1 2
B-15553
B-15552
P-24843
It is important to change the air filter element only when

the Air Cleaner Icon in the right panel is ON (Item 1)
Disengage the clamps (Item 1) [Figure 10-80-3] and

[Figure 10-80-1] and you hear three beeps from the
remove the dust cover (Item 2) [Figure 10-80-3].
alarm.
Figure 10-80-4
Replace the inner filter every third time the outer filter is
replaced or as indicated. (See Replacing Filter Element
on Page 10-80-1.)
Figure 10-80-2
1 1
P-24844
B-15551
Remove the outer filter element (Item 1) [Figure 10-80-

Press and hold the LIGHT Button (Item 1) [Figure 10-80- 4].
2] for two seconds.
NOTE: Make sure all sealing surfaces are free of dirt
If the filter element needs replacement, the CODE [01- and debris.
17] (Air Filter Plugged) will show in the HOURMETER /
CODE DISPLAY (Item 2) [Figure 10-80-2]. Install a new outer element.
Install the dust cover and fasten the clamps.
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AIR CLEANER SERVICE (CONT’D) Figure 10-80-6
Replacing Filter Element (Cont’d)
Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight.
INNER FILTER
Only replace the inner filter element under the following

conditions:
• Replace the inner filter element every third time the

outer filter is replaced.
• After the outer element has been replaced, start the
engine and run at full RPM. If the HOURMETER / 1
CODE DISPLAY shows [01-17] (Air Filter Plugged),
replace the inner filter element.
P-24843
Figure 10-80-5
Install the dust cover and fasten the clamps (Item 1)

[Figure 10-80-6].

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

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

and debris.
Install the new inner element.
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ENGINE COOLING SYSTEM Figure 10-90-2
Cleaning The Cooling System
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist: 1
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907 P-28467
Figure 10-90-1 Remove the fasteners (Item 1) [Figure 10-90-2] (both

sides) and raise the oil cooler.
Check the cooling system for leaks.
Figure 10-90-3

1
1
N-19411
Check the cooling system every day to prevent

overheating, loss of performance or engine damage.
N-19416
Lift the grill [Figure 10-90-1].
Use air pressure or water pressure to clean the top of the Use air pressure or water pressure to clean the top of the
oil cooler (Item 1) [Figure 10-90-1]. engine oil cooler (Item 1) [Figure 10-90-3].
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ENGINE COOLING SYSTEM (CONT’D)
Cleaning The Cooling System (Cont’d)
Figure 10-90-4
Access
Cover
N-19361
NOTE: The access cover (both sides) must be in place

to ensure correct air flow through the oil

cooler which will ensure cooling for the
engine and hydraulic system [Figure 10-90-4].
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FUEL SYSTEM Figure 10-100-2
Fuel Specifications WRONG

Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1.
The following is a suggested blending guideline which

should prevent fuel gelling during cold temperatures:
Temp. F° (C°) No. 2 No.1

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

Use a clean, approved safety container to add fuel of the
Filling The Fuel Tank correct specifications. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING! [Figure 10-100-2].
WARNING Install and tighten the fuel cap (Item 1) [Figure 10-100-1]

Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
Open the rear door.
Figure 10-100-1
N-19408
Remove the fuel fill cap (Item 1) [Figure 10-100-1].
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FUEL SYSTEM (CONT’D)
Fuel Filter
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
Figure 10-100-3

2
1
N-19327
(See SERVICE SCHEDULE on Page 10-70-1.) for the

service interval for removing water from, or replacing the
fuel filter.
Loosen the drain (Item 1) [Figure 10-100-3] at the

bottom of the filter element to remove water from the
filter.
Remove the filter element (Item 2) [Figure 10-100-3].
Clean the area around the filter housing. Put clean oil on
the seal of the new filter element. Install the fuel filter, and
hand tighten.
Remove the air from the fuel system. (See Removing Air
From The Fuel System on Page 10-100-3.)
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FUEL SYSTEM (CONT’D) Removing Air From The Fuel System
Fuel Lift Pump Strainer
Figure 10-100-4
WARNING
2
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
1
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
After replacing the filter element or when the fuel tank

has run out of fuel, the air must be removed from the fuel
system before starting the engine.
Open the vent (Item 2) [Figure 10-100-4] on the fuel filter

housing.

Squeeze the hand pump (priming bulb) (Item 3) [Figure
P-24722
10-100-4] until fuel flows from the vent with no air
bubbles.
Close the vent (Item 2) [Figure 10-100-4].
N-19325
Loosen the bolt and remove the cover and strainer (Item
1) [Figure 10-100-4].
Clean the strainer with clean diesel fuel.
Install the strainer and cover and tighten bolt.
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ENGINE LUBRICATION SYSTEM Replacing Oil And Filter
Checking Engine Oil
Figure 10-110-1
WARNING
2
explosion or fire.
W-2103-0508
1 Figure 10-110-2
N-19327
Check the engine oil every day.

Before restarting the engine for the work shift, open the 1
rear door. Remove the dipstick (Item 1) [Figure 10-110-
1]
Keep the oil level between the marks on the dipstick.

N-19328
Use a good quality motor oil that meets API Service
Classification of CD or better. (See oil chart below.)
RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)
service interval for replacing the engine oil filter.
C°
Run the engine until it its at operating temperature. Stop
the engine.
Open the rear door. Remove the drain plug [Figure 10-
110-2]. Drain the oil into container. Recycle or dispose of
the used oil in an environmentally safe manner.
F° TEMPERATURE RANGE ANTICIPATED

BEFORE NEXT OIL CHANGE (DIESEL ENGINES
MUST USE API CLASSIFICATION CD, CF4, CG4)
*Can be used ONLY when available with appropriate
diesel rating.
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ENGINE LUBRICATION SYSTEM (CONT’D)
Replacing Oil And Filter (Cont’d)
Figure 10-110-3
N-19325
Remove the oil filter (Item 1) [Figure 10-110-3].

Clean the filter housing surface. Use genuine Bobcat
filter only. Put clean oil on the new oil filter gasket. Install
the filter and hand tighten only.
Install and tighten the drain plug.
Remove the filler cap (Item 2) [Figure 10-110-1].
Put 10 qt. (9,5 L) of oil in the engine.
Start the engine and let it run for several minutes. Stop
the engine. Check for leaks and check the oil level. Add
oil as needed if it is not at the top mark on the dipstick.
Install dipstick and close the rear door.
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HYDRAULIC / HYDROSTATIC SYSTEM Figure 10-120-2
Checking And Adding Fluid
Use only recommended fluid in the hydraulic system.

(See HYDRAULIC FLUID SPECIFICATIONS on Page
SPEC-60-1.) for the correct fluid.
1
Put the loader on a level surface.
Lower the lift arms and tilt the Bob-Tach fully back.
Stop the engine.
Figure 10-120-1
CD-12250 N-19360
Sight Gauge
Remove the fill cap (Item 1) [Figure 10-120-2].
Add fluid as needed to bring the level to the center of the

sight gauge.
P-4613 NOTE: Before installing the fill breather cap, make

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

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

whenever the hydraulic fluid is replaced.
Figure 10-120-3
Remove the fill cap and raise the operator cab. (See
Raising The Operator Cab on Page 10-30-1.)
Hydraulic Fill Screen
Figure 10-120-4
1
N-19516
Remove the filter (Item 1) [Figure 10-120-3].
Clean the surface of the filter housing where the filter

seal contacts the housing. Put clean oil on the seal of the N-19362
new filter element.
Install and hand tighten the filter element. Remove two hose clamps and remove the hose (Item 1)
[Figure 10-120-4]
Lower the operator cab.
Start the engine and operate the loader hydraulic

controls.
Stop and check for leaks at the filter.
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HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-6
Replacing The Hydraulic Fluid And Case Drain Filters

(Cont’d)
Hydraulic Fill Screen (Cont’d)
WARNING
N-19496
explosion or fire.
W-2103-0508
Drain the reservoir [Figure 10-120-6]. Remove Left

Figure 10-120-5 Motor Cover.
Case Drain Filters
Remove the hydrostatic motor covers. (Both Sides.) Pull

the reservoir drain hose [Figure 10-120-6] out the left
motor cover hole. Remove the plug and drain the fluid
into a container.
1
Recycle or dispose of used fluid on an environmentally
safe manner.
N-19363
Remove the hydraulic fill screen (Item 1) [Figure 10-120-

5] and use clean solvent to remove contamination from
the screen.
Use air pressure to dry the screen.
Install screen, hose and hose clamps.
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HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Breather Cap
Replacing Hydraulic Fluid And Case Drain Filters The fill cap is also a breather for the hydraulic /
(Cont’d) hydrostatic reservoir. (See SERVICE SCHEDULE on
Page 10-70-1.) for correct service interval.
Case Drain Filters (Cont’d)
Figure 10-120-9
Figure 10-120-7
RIGHT CASE DRAIN
FILTER
N-19360
N-19495

Remove the cap (Item 1) [Figure 10-120-9] and use
Figure 10-120-8 clean solvent to remove debris. Dry the cap thoroughly.
LEFT CASE DRAIN Install the fill / breather cap.
FILTER
N-19497
Disconnect the hoses from the hydrostatic motor case

drain filter (Item 1) [Figure 10-120-7] and [Figure 10-
120-8].
Remove the case drain filters (Item 1) [Figure 10-120-7]

and [Figure 10-120-8] and clean thoroughly with clean
solvent.
Install the case drain filters and tighten hoses.
Install the plug in the reservoir drain hose and tighten.

Install motor covers. (Both Sides.)
Add the correct fluid to the reservoir until the fluid levels
at the center of the sight gauge.
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FINAL DRIVE TRANSMISSION (CHAINCASE) Replacing The Oil
Checking And Adding Oil Figure 10-130-2
Figure 10-130-1
P-1616
P-10153
To drain the oil from the chaincase, remove the cover
(Item 1) [Figure 10-130-2] which is installed over the
The chaincase contains the final drive sprockets and the drain plug at the rear of the chaincase.
chains and uses the same type of fluid as is used in the

hydraulic / hydrostatic system. (See HYDRAULIC FLUID Figure 10-130-3
SPECIFICATIONS on Page SPEC-60-1.)
To check the chaincase oil level, use the following

procedure:
Drive the loader on a level surface. Stop the engine.
Remove the plug (Item 1) [Figure 10-130-1] from the

front of the chaincase housing.
1
If oil can be reached with the tip of your finger through the
hole the oil level is correct.
If the level is low, add oil through the check plug hole until
the oil flows from the hole. Install and tighten the plug. P-1619
Remove the drain plug (Item 1) [Figure 10-130-3] and

drain the oil into a container. Recycle or dispose of the
used oil in an environmentally safe manner.
Check the drain plug and replace if necessary.
Install and tighten the plug.
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FAN GEAR BOX
Checking And Adding Oil
Figure 10-140-1
Gear Lube 1
Level
P-7616

correct service interval.

on Page 10-30-1.)
Remove the plug (Item 1) [Figure 10-140-1] to check the

lubricant level.
If the level is low, add SAE 90W gear lubricant through

the check plug hole until lubricant flows from the hole.
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BOB-TACH Figure 10-150-3
Inspection And Maintenance
Bob-Tach
Wedge
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0497
Wedge Must Contact
Lower Edge Of Hole
Figure 10-150-1 In The Attachment B-15177
If the wedge does not contact the lower edge of the hole
[Figure 10-150-2] and [Figure 10-150-3], the
attachment will be loose and can come off the Bob-Tach.
Figure 10-150-4

1
N-17022
N-17027
Move the Bob-Tach levers to engage the wedges (Item 1)

[Figure 10-150-1]. The levers and wedges must move
freely.
The wedges must extend through the holes in the

attachment mounting frame (Item 1) [Figure 10-150-1].
TS-1062
Figure 10-150-2
Inspect the mounting frame on the attachment and the
Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-150-4]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
Look for cracked welds. Contact your Bobcat dealer for

repair or replacement parts.
Lubricate the wedges. (See LUBRICATING THE

LOADER on Page 10-160-1.)
1
N-17023
The spring loaded wedge (Item 1) [Figure 10-150-1]

must contact the lower edge if the hole in the attachment
(Item 1) [Figure 10-150-2] and [Figure 10-150-3].
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POWER BOB-TACH (OPTION) Figure 10-151-3
Inspection And Maintenance
Figure 10-151-1
B-15177
Wedge Must Contact

Lower Edge Of Hole
In The Attachment N-17043
B-15554B If the wedge does not contact the lower edge of the hole
B-15554A [Figure 10-151-3], the attachment will be loose and can
B-15993C
come off the Bob-Tach.
Push and hold the BOB-TACH “WEDGES UP” switch Figure 10-151-4
[Figure 10-151-1] until wedges are fully raised. Push and

hold the BOB-TACH “WEDGES DOWN” switch [Figure
10-151-1] until the wedges are fully down. The wedges
must move freely.
Figure 10-151-2
TS-1062
Inspect the mounting frame on the attachment and the

1
Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-151-4]. Replace any parts including
N-17043 decals and lever that are damaged, bent, or missing.
Keep all fasteners tight. Inspect the hoses and fittings for
leaks.
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [Figure 10-151-2] Look for cracked welds. Contact your Bobcat dealer for
and must contact the lower edge of the hole in the repair or replacement parts.
attachment [Figure 10-151-2] and (Item 1) [Figure 10-
151-3]. Lubricate the wedges. (See LUBRICATING THE
LOADER on Page 10-160-1.)
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LUBRICATING THE LOADER Figure 10-160-3
Procedure
Figure 10-160-1
3
N-19358
3. Lift Arm Pivot Pin (Both sides) [Figure 10-160-3].

N-19367
Figure 10-160-4
Lubricate the loader for the best performance of the

loader. (See LUBRICATING THE LOADER on Page 10-

160-1.)
Record the operating hours each time you lubricate the

Bobcat loader. 4
Always use a good quality lithium based multi-purpose
grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Lubricate the following locations on the loader:
1. Rod End Lift Cylinder (Both Sides) [Figure 10-160-1]. P-7641
Figure 10-160-2
4. Base End Tilt Cylinder (Both Sides) [Figure 10-160-
4].
P-10815
2. Base End Lift Cylinder (Both Sides) [Figure 10-160-

2].
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LUBRICATING THE LOADER (CONT’D) Figure 10-160-7
Procedure (Cont’d)
Figure 10-160-5
1
N-19502
8. Steering Lever Shaft (Both Sides) [Figure 10-160-7].

N-19501
5. Rod End Tilt Cylinder (Both Sides) [Figure 10-160-5].

Figure 10-160-6
N-19500
6. Bob-Tach Pivot Pin (Both Sides) [Figure 10-160-6].
7. Bob-Tach Wedge (Both Sides) [Figure 10-160-6].
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TIRE MAINTENANCE Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
Wheel Nuts capability. Check for the correct pressure before
operating the loader.
Figure 10-170-1
Tire Mounting
WARNING
Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1007
P-10142
(See SERVICE SCHEDULE on Page 10-70-1.) for the IMPORTANT

service interval to check the wheel nuts. The correct

torque is 105 - 115 ft.-lb. (142 - 156 N•m) torque [Figure Inflate tires to the MAXIMUM pressure shown on the
10-170-1]. sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
Tire Rotation I-2057-0794
Check the tires regularly for wear, damage and pressure. Tires are to be repaired only by an authorized person
(See Tires on Page SPEC-10-4.) for the correct tire using the proper procedures and safety equipment. Tires
pressure.) and rims must always be checked for correct size before
mounting. Check rim and tire bead for damage.
Figure 10-170-2
The rim flange must be cleaned and free of rust. The tire
bead and rim flange must be lubricated with a rubber
lubricant before mounting the tire, avoid excessive
pressure which can rupture the tire and cause serious
injury or death. During inflation of the tire, check the tire
pressure frequently to avoid over inflation
B-9976
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires
to the front [Figure 10-170-2].
It is important to keep the same size tires on each side of

the loader. If different sizes are used, each tire will be
turning at a different rate and cause excessive wear. The
tread bars of all the tires must face the same direction.
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HYDRAULIC SYSTEM
BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

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

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-7 SYSTEM
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4 DRIVE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2 SYSTEM
CYLINDER (POWER BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-5
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-3

ELECTRICAL
SYSTEM &
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 ANALYSIS
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-7
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5 ENGINE
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-4 SERVICE
Rod End Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-3
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK. . . . . . . . . . . . . 20-130-1 SPECIFICATIONS

Disassembly And Assembly (518916011 & Above). . . . . . . . . . . . . 20-130-1
Removal And Installation (514449564 & Above) . . . . . . . . . . . . . . . 20-130-1
Continued On Next Page
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HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS). 20-41-1

Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . 20-41-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . 20-41-1
Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-25
Anti-Cavitation Valve / Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24
Auxiliary Electric Solenoid Disassembly And Assembly . . . . . . . . . . . . . 20-41-30
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
BICS™ Valve Check Valve Removal And Installation . . . . . . . . . . . . . . . 20-41-16
BICS™ Valve Lift Arm Bypass Orifice Removal And Installation . . . . . . . 20-41-15
BICS™ Valve Lock Valve Removal And Installation . . . . . . . . . . . . . . . . 20-41-17
BICS™ Valve Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-13
BICS™ Valve Removal Solenoid And Installation . . . . . . . . . . . . . . . . . . 20-41-18
BICS™ Valve Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-19
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-32
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-19
Lift And Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . 20-41-28
Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-20
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-26

Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-20
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-22
Port-Auxiliary Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-31
Port Relief Valve(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-23
Removal & Installation (S/N 514447863 & Below). . . . . . . . . . . . . . . . . . . 20-41-3
Removal And Installation (S/N 514447864 & Above) . . . . . . . . . . . . . . . . 20-41-7
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-27
863 Bobcat Loader

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HYDRAULIC CONTROL VALVE (FOOT CONTROL) . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-1

Anti-Cavitation Valve / Port Relief Valve, Tilt Spool . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-20
Anti-Cavitation Valve, Lift Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-20
Auxiliary Electric Solenoid Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-36
Auxiliary Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-35
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-33
BICS™ Valve, Check Valve Disassembly And Assembly (S/N 514450007 & Below)20-40-12
BICS™ Valve, Lift arm Bypass Orifice Disassembly And Assembly . . . . . . . . . . . . . 20-40-11
BICS™ Valve, Lock Valve Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . .20-40-14
BICS™ Valve, Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-10
BICS™ Valve, Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . .20-40-15
BICS™ Valve, Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-16
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-38
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-16
Lift And Tilt Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-21
Lift Spool And Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-22
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-17
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-18
Port Relief-Auxiliary Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-37

Port Relief Valve, Tilt Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-19
Port Relief Valve, Lift Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-19
Removal And Installation (S/N 514447863 & Below). . . . . . . . . . . . . . . . . . . . . . . . . .20-40-1
Removal And Installation (S/N 514447864 & Above) . . . . . . . . . . . . . . . . . . . . . . . . .20-40-4
Rubber Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-21
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-31
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-1

Draining The Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-1
Hydraulic Fluid Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-1
HYDRAULIC / HYDROSTATIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-70-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-70-1
863 Bobcat Loader

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HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 & BELOW) . . . . . . . . . . . . . . 20-60-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-7
Checking The Output Of The Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-6
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N 514449483 & BELOW) . . . . . . 20-61-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-10
Checking The Output Of The High Flow Pump . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-5
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-9
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-4
HYDRAULIC PUMP (CAST IRON) (S/N 514449260 & ABOVE) . . . . . . . . . . . . . . 20-62-1

Check The Output Of The Hydraulic Pump With Power Bob-Tach . . . . . . . . . . 20-62-3
Check The Output Of The Hydraulic Pump Without Power Bob-Tach . . . . . . . . 20-62-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-7
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-6
HYDRAULIC PUMP (CAST IRON HIGH FLOW) (S/N 514449484-514450945) . . 20-63-1

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

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

Additional Inspection For Loaders With ACS. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
863 Bobcat Loader

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MAIN RELIEF VALVE (FOOT CONTROL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-5
Checking The Main Relief Valve At Front Auxiliary Hydraulics . . . . . . . . . 20-30-1
Checking The Main Relief Valve Without Front Auxiliaries . . . . . . . . . . . . 20-30-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
POWER BOB-TACH BLOCK (6676547-ALUMINUM) . . . . . . . . . . . . . . . . . 20-120-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
POWER BOB-TACH BLOCK (6678554-CAST IRON) . . . . . . . . . . . . . . . . . 20-121-1

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

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2

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

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863 Bobcat Loader

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HYDRAULIC/HYDROSTATIC SCHEMATIC
863 (S/N 514440001-41938)
(S/N 514540001-40073)
(PRINTED NOVEMBER 2002)
V-0027legend Printable Version Click Here
LEGEND
1 RESERVOIR: 14 SOLENOID ACTIVATED DIRECTIONAL 29 CHARGE PUMP 41 CHECK VALVE - BICS CONTROL VALVE
Capacity . . . . . . 18.8 Qts. (17.8 L) CONTROL VALVE - BICS CONTROL 11.0 GPM (41,6 L/min.) at 2615 Engine RPM
2 FILTER - CASE DRAIN (90 Micron) 42 LIFT ARM BY-PASS RESTRICTOR
15 PULL BUTTON ACTIVATED 30 HYDRAULIC PUMP . . . . . . . Gear Type
DIRECTIONAL CONTROL VALVE - LIFT 18.0 GPM (68,1 L/min.) at 2615 Engine RPM
3 FILTER - HYDRAULIC (CANISTER) ARM BY-PASS 43 CHECK VALVE - AUXILIARY
31 DRIVE MOTOR SHUTTLE VALVE
16 FILTER - BICS CONTROL VALVE
4 SPRING LOADED FILTER BY-PASS 44 MUFFLER (If Equipped)
VALVE: 45-55 PSI (311-379 kPa) (SCREEN) 32 SHUTTLE RELIEF VALVE:
200 PSI (1378 kPa)
* 45 VARIABLE CAPACITY DISPLACEMENT
5 PILOT ACTIVATED DIRECTIONAL 17 BOOM DOWN RESTRICTOR
BIDIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - HYDRAULIC 33 SOLENOID ACTIVATED DIRECTIONAL
POWERED BOB-TACH 18 LIFT AND TILT LOAD CHECK VALVE CONTROL VALVE - BLEED OFF REAR 46 RESTRICTOR - 0.020 inch (0,5 mm)
AUXILIARY ("SV2")
6 DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa) 19 RELIEF VALVE - MAIN: 47 SOLENOID ACTIVATED DIRECTIONAL
2950-3050 PSI (20340-21030 kPa) 34 LOAD SHUTTLE VALVE - BLEED OFF CONTROL VALVE (TWO COIL)
7 FLOW DIVIDER ADJUSTMENT VALVE at Front Quick Couplers
48 RELIEF VALVE - 1200 PSI (8268 kPa)
Dealer Copy --35NotPILOT ACTIVATED DIRECTIONAL
for Resale
20 RELIEF VALVE - PORT: CONTROL VALVE - FOR REAR
8 CHECK VALVE - BUCKET POSITION
3500 PSI (24132 kPa) AUXILIARY - NORMALLY CLOSED 49 RESTRICTOR - 0.090 inch (2,3 mm)
VALVE
("P2" and "F2")
21 ANTICAVITATION VALVE
9 FIXED CAPACITY DISPLACEMENT 50 RELIEF VALVE - 2000 PSI (13780 kPa)
BIDIRECTIONAL HYDROSTATIC 36 PILOT ACTIVATED DIRECTIONAL
MOTOR 22 RELIEF/ANTICAVITATION VALVE - CONTROL VALVE - FOR REAR
PORT (TILT BASE END) AUXILIARY - NORMALLY OPEN 51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa) ("D1" and "P1") 3500 PSI (24132 kPa)
10 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL 52 SOLENOID ACTIVATED DIRECTIONAL
23 ONE WAY RESTRICTOR VALVE 37 PILOT ACTIVATED DIRECTIONAL
SPOOL CONTROL VALVE - BUCKET POSITION
CONTROL VALVE - FOR REAR VALVE (ON/OFF)
11 PILOTED ACTIVATED DIRECTIONAL 24 SOLENOID ACTIVATED DIRECTIONAL AUXILIARY - NORMALLY OPEN
CONTROL VALVE - AUXILIARY ("D2" and "P2") 53 SCREEN
CONTROL VALVE - UNLOADING
SPOOL
25 RELIEF VALVE - PORT: . . . . . (Optional) 38 FILTER - DIVERTER VALVE (SCREEN)
12 PILOTED ACTIVATED DIRECTIONAL 3500 PSI (24132 kPa) INTEGRATED IN SOLENOID
CONTROL VALVE - TILT CONTROL
26 RELIEF/REPLENISHING VALVE - HIGH 39 SOLENOID ACTIVATED DIRECTIONAL
13 PILOTED ACTIVATED DIRECTIONAL PRESSURE: 4712 PSI (32489 kPa) CONTROL VALVE - TO ACTIVATE NOTE: Unless otherwise specified
CONTROL VALVE - LIFT CONTROL REAR AUXILIARY ("SV1") springs have NO significant
27 CHARGE PRESSURE SWITCH pressure value.
40 PILOT ACTIVATED DIRECTIONAL
28 RELIEF VALVE - CHARGE: CONTROL VALVE - FOR REAR
120 degrees F. (53 degrees C.)Fluid AUXILIARY - NORMALLY CLOSED
at 1775 Pump RPM ("P1" and "F1")
390 - 430 PSI (2689 - 2965 kPa)
Printed in U.S.A. V-0027legend (11-5-02)
73 of 970
DIVERTER VALVE (OPTIONAL)
863 (S/N 514440001-41938) 38
(S/N 514540001-40073)
39
(PRINTED NOVEMBER 2002) PILOT
V-0027
Printable Version Click Here

DRIVE MOTOR
40 36
MALE MALE F1 D1 MALE
31 2
32
34 (FRONT AUXILIARY
(REAR QUICK
COUPLERS) LEFT SIDE LIFT ARM)
33 35 37
F2 D2
FEMALE
FEMALE FEMALE
9
DRAIN P1 P2
HYDRAULIC FILTER
3
BUCKET POSITION VALVE (OPTIONAL)
HYDROSTATIC PUMPS OIL
4 D
COOLER
45 8
28
26
26 7
6
A
CHARGE INLET OUTLET
52 C
HYDRAULIC CONTROL VAVLE 10
29
43
11
26 27
26
BOB-TACH
CYLINDER
Dealer Copy -- Not for24 Resale 24
45 25 B
(OPTIONAL)
A B
HYDRAULIC
POWERED 53 AUXILIARY
BOB-TACH SPOOL
DR (OPTIONAL)
INLET OUTLET
23 TILT CYLINDER
22
BICS CONTROL VALVE
30 46 47
48
49
50 A B 12
51 TILT
CYLINDER
SPOOL
DRIVE MOTOR
21
18
9
20 LIFT CYLINDERS
P1 17
P2
5 13
A B
LIFT
CYLINDER
SPOOL
31 32
18 42
* (If Equipped)
19 14 WORKING CIRCUITS
44 16 41 16 PILOT CIRCUITS
2
* DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY- PASS VALVE
15
Printed in U.S.A. V-0027 (11-5-02)
74 of 970
WITH HIGH FLOW OPTION
863 (S/N 514440001-41938)
(S/N 514640001-40147)
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 32 SHUTTLE RELIEF VALVE: 50 RELIEF VALVE - 2000 PSI (13780 kPa)
Capacity . . . . . . 18.8 Qts. (17.8 L) (SCREEN) 200 PSI (1378 kPa)
17 BOOM DOWN RESTRICTOR 51 RELIEF VALVE - PORT:
2 FILTER - CASE DRAIN (90 Micron) 33 REAR AUXILIARY BLEED SHUTTLE VALVE
3500 PSI (24132 kPa)
3 FILTER - HYDRAULIC (CANISTER) 18 LIFT AND TILT LOAD CHECK VALVE 34 LOAD CHECK VALVE - SELECT VALVE 52 SOLENOID ACTIVATED DIRECTIONAL
(HIGH FLOW)
19 RELIEF VALVE - MAIN: CONTROL VALVE - BUCKET POSITION
4 SPRING LOADED FILTER BY-PASS
35 SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF)
VALVE: 45-55 PSI (311-379 kPa) 2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers CONTROL VALVE - HIGH FLOW
5 PILOT ACTIVATED DIRECTIONAL 53 HYDRAULIC HIGH FLOW PUMP
20 RELIEF VALVE - PORT: 36 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - HYDRAULIC 10.0 GPM (37,8 L/min.) at 2615 Engine RPM
POWERED BOB-TACH 3500 PSI (24132 kPa) CONTROL VALVE - DIVERTER
21 ANTICAVITATION VALVE 54 SELECT VALVE RESTRICTOR
6 DIFFERENTIAL PRESSURE SWITCH: 37 RELIEF VALVE - MAIN (HIGH FLOW)
36-44 PSI (248-303 kPa) 3000 PSI (20685 kPa)
22 RELIEF/ANTICAVITATION VALVE - 55 SCREEN
PORT (TILT BASE END) 38 SOLENOID ACTIVATED DIRECTIONAL
7 FLOW DIVIDER ADJUSTMENT VALVE
3500 PSI (24132 kPa) CONTROL VALVE (TWO COIL)
8 CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE 39 PILOT TO OPEN CHECK VALVE
VALVE Dealer Copy -- Not for Resale
24 SOLENOID ACTIVATED DIRECTIONAL 40
9 FIXED CAPACITY DISPLACEMENT SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - BLEED OFF
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional)
3500 PSI (24132 kPa) 41 CHECK VALVE - BICS CONTROL VALVE
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH 42 LIFT ARM BY-PASS RESTRICTOR
SPOOL PRESSURE: 4712 PSI (32489 kPa)
43 CHECK VALVE - AUXILIARY
11 PILOTED ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH
CONTROL VALVE - UNLOADING 44 MUFFLER (If Equipped)
SPOOL
28 RELIEF VALVE - CHARGE:
120 degrees F. (53 degrees C.)Fluid * 45 VARIABLE CAPACITY DISPLACEMENT
12 PILOTED ACTIVATED DIRECTIONAL at 1775 Pump RPM
CONTROL VALVE - TILT CONTROL 390 - 430 PSI (2689 - 2965 kPa)
46 RESTRICTOR - 0.020 inch (0,5 mm)
13 PILOTED ACTIVATED DIRECTIONAL 29 CHARGE PUMP
CONTROL VALVE - LIFT CONTROL 11.0 GPM (41,6 L/min.) at 2615 Engine RPM 47 SOLENOID ACTIVATED DIRECTIONAL
14 SOLENOID ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . Gear Type CONTROL VALVE (TWO COIL)
CONTROL VALVE - BICS CONTROL 18.0 GPM (68,1 L/min.) at 2615 48 RELIEF VALVE - 1200 PSI (8268 kPa)
Engine RPM
15 PULL BUTTON ACTIVATED 53
HIGH FLOW CAPACITY: (Includes ) 49 RESTRICTOR - 0.090 inch (2,3 mm)
DIRECTIONAL CONTROL VALVE - LIFT 28.0 GPM (106 L/min.) at 2615
ARM BY-PASS Engine RPM
31 DRIVE MOTOR SHUTTLE VALVE NOTE: Unless otherwise specified
springs have NO significant
pressure value.
75 of 970
FEMALE
MALE
SELECT VALVE C2 C1
863 (S/N 514440001-41938) (RIGHT SIDE LIFT ARM
(S/N 514640001-40147) QUICK COUPLERS)
40
MALE
MALE
FEMALE
FEMALE
V-0028
33
Printable Version Click Here 39 39
DRIVE MOTOR
(REAR QUICK COUPLERS)
54 54
31 32
2 * 44
38 34
FEMALE
PRESS PB
(FRONT AUXILIARY
36
LEFT SIDE LIFT ARM)
MALE
37 35
9
T
DRAIN
HYDRAULIC FILTER (MALE)
3
4 D
COOLER
45 8
28
26
26 7
6
A
CHARGE INLET OUTLET 52
C
29
43
11
26 27
26
BOB-TACH Dealer Copy -- Not
24 for Resale 24
CYLINDER 25
45 B
(OPTIONAL)
A B
HYDRAULIC
POWERED AUXILIARY
55
BOB-TACH SPOOL
DR (OPTIONAL)
INLET
23
TILT CYLINDER
22
OUTLET BICS CONTROL VALVE
30 46 47
53 48
49
50 A B 12
51 TILT
CYLINDER
SPOOL
DRIVE MOTOR
21
18
9
20 LIFT CYLINDERS
P1 17
P2
5 13
A B
LIFT
CYLINDER
SPOOL
31 32
18 42
* (If Equipped)
2
* 44
16 41 16 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0028 (11-5-02)
76 of 970
863 (S/N 514441939 - 514449259)
(S/N 514540074 - 514541068)
LEGEND
1 RESERVOIR: 15 PULL BUTTON ACTIVATED 29 CHARGE PUMP 41 CHECK VALVE - BICS CONTROL VALVE
Capacity . . . . . . . 18.8 Qts. (17.8 L) DIRECTIONAL CONTROL VALVE - LIFT (S/N 514441939-46864)
ARM BY-PASS (S/N 514540074-41034)
2 FILTER - CASE DRAIN (90 Micron) 42 LIFT ARM BY-PASS RESTRICTOR
11.0 GPM (41,6 L/min.) at 2615 Engine RPM
16 FILTER - BICS CONTROL VALVE (S/N 514446865 AND ABOVE)
3 FILTER - HYDRAULIC (CANISTER) (SCREEN) (S/N 514541035 AND ABOVE) 43 CHECK VALVE - AUXILIARY
17 BOOM DOWN RESTRICTOR 30 HYDRAULIC PUMP . . . . . . . Gear Type 44
SPRING LOADED FILTER BY-PASS MUFFLER (If Equipped)
4
VALVE: 45-55 PSI (311-379 kPa)
18 LIFT AND TILT LOAD CHECK VALVE
(S/N 514441939-46864)
(S/N 514540074-41034)
* 45 VARIABLE CAPACITY DISPLACEMENT
5 PILOT ACTIVATED DIRECTIONAL 18.0 GPM (68,1 L/min.) at 2615 EngineRPM
(S/N 514446865 AND ABOVE) BIDIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - HYDRAULIC
19 RELIEF VALVE - MAIN: (S/N 514541035 AND ABOVE)
POWERED BOB-TACH 46
2950-3050 PSI (20340-21030 kPa) 20.0 GPM (75,7 L/min.) at 2615 Engine RPM RESTRICTOR - 0.020 inch (0,5 mm)
6 DIFFERENTIAL PRESSURE SWITCH: at Front Quick Couplers
36-44 PSI (248-303 kPa) 31 DRIVE MOTOR SHUTTLE VALVE 47 SOLENOID ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: CONTROL VALVE (TWO COIL)
FLOW DIVIDER ADJUSTMENT VALVE 3500 PSI (24132 kPa) 32 SHUTTLE RELIEF VALVE:
7
200 PSI (1378 kPa) 48 RELIEF VALVE - 1200 PSI (8268 kPa)
21 ANTICAVITATION VALVE Dealer Copy -- Not for Resale
33 SOLENOID ACTIVATED DIRECTIONAL
8 CHECK VALVE - BUCKET POSITION CONTROL VALVE - BLEED OFF REAR 49 RESTRICTOR - 0.090 inch (2,3 mm)
VALVE 22 RELIEF/ANTICAVITATION VALVE - AUXILIARY ("SV2")
PORT (TILT BASE END)
34 LOAD SHUTTLE VALVE - BLEED OFF 50 RELIEF VALVE - 2000 PSI (13780 kPa)
9 FIXED CAPACITY DISPLACEMENT 3500 PSI (24132 kPa)
BIDIRECTIONAL HYDROSTATIC 35 PILOT ACTIVATED DIRECTIONAL
MOTOR 23 ONE WAY RESTRICTOR VALVE CONTROL VALVE - FOR REAR 51 RELIEF VALVE - PORT:
AUXILIARY - NORMALLY CLOSED 3500 PSI (24132 kPa)
10 PILOTED ACTIVATED DIRECTIONAL 24 SOLENOID ACTIVATED DIRECTIONAL ("P2" and "F2")
CONTROL VALVE - FLOW CONTROL 52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY 36 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION
SPOOL
CONTROL VALVE - FOR REAR VALVE (ON/OFF)
25 RELIEF VALVE - PORT: . . . . . . . . (Optional) AUXILIARY - NORMALLY OPEN
11 PILOTED ACTIVATED DIRECTIONAL 53 SCREEN
3500 PSI (24132 kPa) ("D1" and "P1")
SPOOL 37 PILOT ACTIVATED DIRECTIONAL
26 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - FOR REAR 54 ACCUMULATOR - FOUND ONLY ON
PRESSURE: (S/N 514441939-46864) AUXILIARY - NORMALLY OPEN MACHINES WITH
(S/N 514540074-41034) ("D2" and "P2") S/N 514444558 AND ABOVE
CONTROL VALVE - TILT CONTROL
4712 PSI (32489 kPa) S/N 514540126 AND ABOVE
38 FILTER - DIVERTER VALVE (SCREEN)
(S/N 514446865 AND ABOVE)
13 PILOTED ACTIVATED DIRECTIONAL INTEGRATED IN SOLENOID
CONTROL VALVE - LIFT CONTROL
5000 PSI (34475 kPa) 39 SOLENOID ACTIVATED DIRECTIONAL
27 CHARGE PRESSURE SWITCH CONTROL VALVE - TO ACTIVATE NOTE: Unless otherwise specified
14 SOLENOID ACTIVATED DIRECTIONAL REAR AUXILIARY ("SV1") springs have NO significant
CONTROL VALVE - BICS CONTROL pressure value.
28 RELIEF VALVE - CHARGE: 40 PILOT ACTIVATED DIRECTIONAL
120 degrees F. (53 degrees C.) Fluid CONTROL VALVE - FOR REAR
at 1775 Pump RPM AUXILIARY - NORMALLY CLOSED
390 - 430 PSI (2689 - 2965 kPa) ("P1" and "F1")
77 of 970
863 (S/N 514441939 - 514449259) 38
(S/N 514540074 - 514541068) 39
V-0019

DRIVE MOTOR
40 36
31 32
34 (FRONT AUXILIARY
(REAR QUICK
33 35 37
F2 D2
FEMALE
FEMALE FEMALE
9
DRAIN P1 P2
HYDRAULIC FILTER
3
4 D
COOLER
45 8
28
26
26 7
6
54
A
CHARGE INLET OUTLET
52 C
29
43
11
26 27
26
24 for Resale 24
CYLINDER 25
45 (OPTIONAL) B
A B
HYDRAULIC
BOB-TACH SPOOL
DR (OPTIONAL)
INLET OUTLET
23
22 TILT CYLINDER
BICS CONTROL VALVE
30 46 47
48
49
50 A B 12
51 TILT
CYLINDER
SPOOL
DRIVE MOTOR
21
18
9
20 LIFT CYLINDERS
P1 17
P2
5 13
A B
LIFT
CYLINDER
SPOOL
31 32
18 42
19 14
* (If Equipped)
WORKING CIRCUITS
2
* DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0019 (11-4-02)
78 of 970
WITH TWO SPEED VALVE OPTION
863 (S/N 514441939 - 514449259)
(S/N 514540074 - 514541068)
LEGEND
1 RESERVOIR: 19 RELIEF VALVE - MAIN: 34 LOAD SHUTTLE VALVE - BLEED OFF 50 RELIEF VALVE - 2000 PSI (13780 kPa)
Capacity . . . . . . . . 18.8 Qts. (17.8 L) 2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers 35 PILOT ACTIVATED DIRECTIONAL 51 RELIEF VALVE - PORT:
2 FILTER - CASE DRAIN (90 Micron) 3500 PSI (24132 kPa)
AUXILIARY - NORMALLY CLOSED 52 SOLENOID ACTIVATED DIRECTIONAL
3 FILTER - HYDRAULIC (CANISTER) 3500 PSI (24132 kPa)
("P2" and "F2") CONTROL VALVE - BUCKET POSITION
21 ANTICAVITATION VALVE VALVE (ON/OFF)
4 SPRING LOADED FILTER BY-PASS 36 PILOT ACTIVATED DIRECTIONAL
VALVE: 45-55 PSI (311-379 kPa) 22 RELIEF/ANTICAVITATION VALVE - CONTROL VALVE - FOR REAR 53 FIXED CAPACITY DISPLACEMENT
AUXILIARY - NORMALLY OPEN BIDIRECTIONAL HYDROSTATIC
5 PILOT ACTIVATED DIRECTIONAL PORT (TILT BASE END)
("D1" and "P1") MOTOR
CONTROL VALVE - HYDRAULIC 3500 PSI (24132 kPa)
POWERED BOB-TACH 54 HYDRAULIC BRAKE - SPRING APPLIED -
23 ONE WAY RESTRICTOR VALVE 37 PILOT ACTIVATED DIRECTIONAL PRESSURE TO RELEASE
6 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE - FOR REAR
36-44 PSI (248-303 kPa) 24 SOLENOID ACTIVATED DIRECTIONAL AUXILIARY - NORMALLY OPEN 55 PULL BUTTON ACTIVATED
CONTROL VALVE - AUXILIARY ("D2" and "P2") DIRECTIONAL CONTROL VALVE -
7 FLOW DIVIDER ADJUSTMENT VALVE BRAKE
25 RELIEF VALVE - PORT: . . . . . . . (Optional) 38 FILTER - DIVERTER VALVE (SCREEN)
8 CHECK VALVE - BUCKET POSITION 3500 PSI (24132 kPa) 56 SOLENOID ACTIVATED DIRECTIONAL
INTEGRATED IN SOLENOID
VALVE CONTROL VALVE - MAKE-UP
26 RELIEF/REPLENISHING VALVE - HIGH Dealer Copy -- Not for Resale
39 SOLENOID ACTIVATED DIRECTIONAL 57 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT PRESSURE: 5000 PSI (34475 kPa)
CONTROL VALVE - TO ACTIVATE CONTROL VALVE - TWO SPEED
BIDIRECTIONAL HYDROSTATIC REAR AUXILIARY ("SV1")
MOTOR 27 CHARGE PRESSURE SWITCH 58 BRAKE DIAGNOSTIC PLUG
10 PILOTED ACTIVATED DIRECTIONAL 28 RELIEF VALVE - CHARGE:
CONTROL VALVE - FOR REAR 59 SCREEN
CONTROL VALVE - FLOW CONTROL 120 degrees F. (53 degrees C.)Fluid
AUXILIARY - NORMALLY CLOSED
SPOOL at 1775 Pump RPM
("P1" and "F1")
390 - 430 PSI (2689 - 2965 kPa)
11 PILOTED ACTIVATED DIRECTIONAL 41 CHECK VALVE - BICS CONTROL VALVE 60 ACCUMULATOR - FOUND ONLY ON
CONTROL VALVE - UNLOADING 29 CHARGE PUMP MACHINES WITH
SPOOL 14.0 GPM (53,0 L/min.) at 2615 Engine RPM 42 LIFT ARM BY-PASS RESTRICTOR S/N 514444558 AND ABOVE
S/N 514540126 AND ABOVE
12 PILOTED ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . . Gear Type
CONTROL VALVE - TILT CONTROL 20.0 GPM (75,7 L/min.) at 2615 Engine RPM 43 CHECK VALVE - AUXILIARY
13 PILOTED ACTIVATED DIRECTIONAL 31 DRIVE MOTOR SHUTTLE VALVE 44 PILOT ACTIVATED DIRECTIONAL

CONTROL VALVE - LIFT CONTROL CONTROL VALVE - TWO SPEED
14 SOLENOID ACTIVATED DIRECTIONAL 32 SHUTTLE RELIEF VALVE: DRIVE MOTOR
CONTROL VALVE - BICS CONTROL 200 PSI (1378 kPa)
15 PULL BUTTON ACTIVATED 33 45 VARIABLE CAPACITY DISPLACEMENT
SOLENOID ACTIVATED DIRECTIONAL
DIRECTIONAL CONTROL VALVE - LIFT CONTROL VALVE - BLEED OFF REAR BIDIRECTIONAL HYDROSTATIC PUMP
ARM BY-PASS AUXILIARY ("SV2") 46 RESTRICTION - 0.020 inch (0,5 mm)
(SCREEN) 47 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL) NOTE: Unless otherwise specified
17 BOOM DOWN RESTRICTOR
48 springs have NO significant
RELIEF VALVE - 1200 PSI (8268 kPa)
18 LIFT AND TILT LOAD CHECK VALVE pressure value.
49 RESTRICTOR - 0.090 inch (2,3 mm)
79 of 970
863 (S/N 514441939 - 514449259) 38
(S/N 514540074 - 514541068) 39
PILOT
(PRINTED NOVEMBER 2002) Printable Version Click Here
V-0022
TWO SPEED DRIVE MOTOR
40 36
31 32 MALE MALE F1 D1 MALE
34 (FRONT AUXILIARY
(REAR QUICK
LEFT SIDE LIFT ARM)
COUPLERS)
33 35 37
F2 D2
54 44 FEMALE
FEMALE FEMALE
53
DRAIN P1 P2
9 HYDRAULIC FILTER
3
4 D
COOLER
45 8
26 26
28
7
6
60
A
52 C
CHARGE OUTLET HYDRAULIC CONTROL VAVLE 10
INLET 29
43
11
27
BOB-TACH
CYLINDER
Dealer Copy -- Not
24 for Resale 24
45 25 B
(OPTIONAL)
A B
26 30 26 HYDRAULIC
INLET POWERED 59 AUXILIARY
OUTLET
BOB-TACH SPOOL
58 DR (OPTIONAL)
23
TWO SPEED VALVE B1 22 TILT CYLINDER
BICS CONTROL VALVE
46 47
55 48
B 49
54 50 A B 12
51 TILT
56 9
CYLINDER
SPOOL
53 21
C
18
P D 44 20 LIFT CYLINDERS
P1 17
P2
5 13
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
T DRAIN CIRCUITS
COMPONENTS
2 LIFT ARM BY- PASS VALVE
15
Printed in U.S.A. V-0022 (11-5-02)
80 of 970
863 (S/N 514441939 - 514449483)
(S/N 514640148 - 514641170)
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 30 HYDRAULIC PUMP . . . . . . . . Gear Type 42 LIFT ARM BY-PASS RESTRICTOR
Capacity . . . . . . . . . 18.8 Qts. (17.8 L) (SCREEN) (S/N 514441939-46822)
(S/N 514640148-41074) 43 CHECK VALVE - AUXILIARY
2 FILTER - CASE DRAIN (90 Micron) 17 BOOM DOWN RESTRICTOR
18.0 GPM (68,1 L/min.) at 2615
18 LIFT AND TILT LOAD CHECK VALVE Engine RPM 44 MUFFLER (If Equipped)
3 FILTER - HYDRAULIC (CANISTER)
SPRING LOADED FILTER BY- PASS 19 RELIEF VALVE - MAIN: HIGH FLOW CAPACITY: (Includes )

53 45 VARIABLE CAPACITY DISPLACEMENT
4
VALVE: . . . 45-55 PSI (311-379 kPa) 2950-3050 PSI (20340-21030 kPa) 28.0 GPM (106,0 L/min.) at 2615 BIDIRECTIONAL HYDROSTATIC PUMP
at Front Quick Couplers
20 RELIEF VALVE - PORT:
Engine RPM
* 46 RESTRICTOR - 0.020 inch (0,5 mm)
(S/N 514446823 AND ABOVE) 47
POWERED BOB-TACH 3500 PSI (24132 kPa) (S/N 514641075 AND ABOVE)
CONTROL VALVE (TWO COIL)
6 DIFFERENTIAL PRESSURE SWITCH: 21 ANTICAVITATION VALVE 20.0 GPM (75,7 L/min.) at 2615
Engine RPM 48 RELIEF VALVE - 1200 PSI (8268 kPa)
36-44 PSI (248-303 kPa)
22 RELIEF/ANTICAVITATION VALVE -
7 FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END) 53
HIGH FLOW CAPACITY: (Includes ) 49 RESTRICTOR - 0.090 inch (2,3 mm)
3500 PSI (24132 kPa) 30.0 GPM (113,6 L/min.) at 2615
8 CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE Engine RPM
VALVE 51 RELIEF VALVE - PORT:
Dealer Copy --31Not for Resale
24 SOLENOID ACTIVATED DIRECTIONAL DRIVE MOTOR SHUTTLE VALVE 3500 PSI (24132 kPa)
9 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - AUXILIARY 52 SOLENOID ACTIVATED DIRECTIONAL
32 SHUTTLE RELIEF VALVE:
MOTOR 25 RELIEF VALVE - PORT: . . . . . . (Optional) CONTROL VALVE - BUCKET POSITION
200 PSI (1378 kPa)
3500 PSI (24132 kPa) VALVE (ON/OFF)
10 PILOTED ACTIVATED DIRECTIONAL 33 REAR AUXILIARY BLEED SHUTTLE VALVE
CONTROL VALVE - FLOW CONTROL 53 HYDRAULIC HIGH FLOW PUMP
26 RELIEF/REPLENISHING VALVE - HIGH
SPOOL 10.0 GPM (37,8 L/min.) at 2615 Engine RPM
PRESSURE: (S/N 514441939-46822) 34 LOAD CHECK VALVE - SELECT VALVE
(S/N 514640148-41074) (HIGH FLOW) 54 FILTER - CASE DRAIN (ATTACHMENT)
CONTROL VALVE - UNLOADING 4712 PSI (32489 kPa) 35 SOLENOID ACTIVATED DIRECTIONAL
SPOOL (S/N 514446823 AND ABOVE) CONTROL VALVE - HIGH FLOW 55 RESTRICTION - SELECT VALVE
12 PILOTED ACTIVATED DIRECTIONAL 5000 PSI (34475 kPa) 36 SOLENOID ACTIVATED DIRECTIONAL 56 SCREEN
CONTROL VALVE - TILT CONTROL 27 CONTROL VALVE - DIVERTER
CHARGE PRESSURE SWITCH
13 PILOTED ACTIVATED DIRECTIONAL 37 RELIEF VALVE - MAIN (HIGH FLOW) 57 ACCUMULATOR - FOUND ONLY ON
CONTROL VALVE - LIFT CONTROL 28 RELIEF VALVE - CHARGE: 3000 PSI (20685 kPa) MACHINES WITH
120 degrees F. (53 degrees C.)Fluid
14 SOLENOID ACTIVATED DIRECTIONAL at 1775 Pump RPM 38 SOLENOID ACTIVATED DIRECTIONAL S/N 514444558 AND ABOVE
CONTROL VALVE - BICS CONTROL 390 - 430 PSI (2689 - 2965 kPa) CONTROL VALVE (TWO COIL) S/N 514640276 AND ABOVE
15 PULL BUTTON ACTIVATED 29 CHARGE PUMP: (S/N 514441939-46822) 39 PILOT TO OPEN CHECK VALVE

DIRECTIONAL CONTROL VALVE - LIFT (S/N 514640148-41074)
ARM BY- PASS 11.0 GPM (41,6 L/min.) at 2615 Engine RPM 40 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF
(S/N 514641075 AND ABOVE) NOTE: Unless otherwise specified
14.0 GPM (53,0 L/min.) at 2615 Engine RPM 41 CHECK VALVE - BICS CONTROL VALVE springs have NO significant
pressure value.
81 of 970
FEMALE
MALE
WITH HIGH FLOW OPTION SELECT VALVE C2 C1
863 (S/N 514441939 - 514449483) (RIGHT SIDE LIFT ARM
(S/N 514640148 - 514641170) QUICK COUPLERS)
40
MALE
MALE
FEMALE
FEMALE
V-0023
33
39 39
DRIVE MOTOR
55 55
31 32 * 44
38 34
FEMALE
PRESS PB
(FRONT AUXILIARY
36
LEFT SIDE LIFT ARM)
MALE
37 35
9
T
DRAIN
3 54
4 D
COOLER
45 8
28
26 26
7
6
57
A
CHARGE INLET OUTLET
52 C
29
43
11
26 27
26
BOB-TACH Dealer Copy -- Not for Resale
24 24
CYLINDER 25
45 B
(OPTIONAL)
A B
HYDRAULIC
BOB-TACH SPOOL
DR (OPTIONAL)
INLET
23
22 TILT CYLINDER
30 46 47
53 48
49
50 A B 12
51 TILT
CYLINDER
SPOOL
DRIVE MOTOR 21
18
9
20 LIFT CYLINDERS
P1 17
P2
5 13
A B
LIFT
CYLINDER
SPOOL
32
31
18 42
* (If Equipped)
2 * 44 16 41 16 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0023 (11-5-02)
82 of 970
WITH HIGH FLOW AND TWO SPEED VALVE OPTION
863 (S/N 514441939 - 514449483)
(S/N 514640148 - 514641170)
LEGEND
1 RESERVOIR: 19 RELIEF VALVE - MAIN: 31 DRIVE MOTOR SHUTTLE VALVE 50 RELIEF VALVE - 2000 PSI (13780 kPa)
Capacity . . . . . . . . . . 18.8 Qts. (17.8 L) 2950-3050 PSI (20340-21030 kPa)
at Front Quick Couplers 32 SHUTTLE RELIEF VALVE: 200 PSI (1378 kPa) 51 RELIEF VALVE - PORT:
2 FILTER - CASE DRAIN (90 Micron) 3500 PSI (24132 kPa)
3500 PSI (24132 kPa) 33 REAR AUXILIARY BLEED SHUTTLE VALVE 52 SOLENOID ACTIVATED DIRECTIONAL
3 FILTER - HYDRAULIC (CANISTER)
CONTROL VALVE - BUCKET POSITION
4 SPRING LOADED FILTER BY-PASS 34 LOAD CHECK VALVE - SELECT VALVE VALVE (ON/OFF)
VALVE: 45-55 PSI (311-379 kPa) 22 RELIEF/ANTICAVITATION VALVE - (HIGH FLOW) 53 FIXED CAPACITY DISPLACEMENT
PORT (TILT BASE END) BIDIRECTIONAL HYDROSTATIC
5 PILOT ACTIVATED DIRECTIONAL 35 SOLENOID ACTIVATED DIRECTIONAL
3500 PSI (24132 kPa) MOTOR
CONTROL VALVE - HYDRAULIC CONTROL VALVE - HIGH FLOW
54 HYDRAULIC BRAKE - SPRING APPLIED -
POWERED BOB-TACH 23 ONE WAY RESTRICTOR VALVE
36 SOLENOID ACTIVATED DIRECTIONAL PRESSURE TO RELEASE
6 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE - DIVERTER
24 SOLENOID ACTIVATED DIRECTIONAL 55 PUSH BUTTON SOLENOID ACTIVATED
36-44 PSI (248-303 kPa)
CONTROL VALVE - AUXILIARY DIRECTIONAL CONTROL VALVE -
37 RELIEF VALVE - MAIN (HIGH FLOW) BRAKE
7 FLOW DIVIDER ADJUSTMENT VALVE 25 RELIEF VALVE - PORT: . . . . . (Optional) 3000 PSI (20685 kPa)
8 CHECK VALVE - BUCKET POSITION 38
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - MAKE-UP
VALVE 26 RELIEF/REPLENISHING VALVE - HIGH Dealer Copy -- Not for Resale
CONTROL VALVE (TWO COIL)
PRESSURE: 5000 PSI (34475 kPa) 57 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT CONTROL VALVE - TWO SPEED
39 PILOT TO OPEN CHECK VALVE
BIDIRECTIONAL HYDROSTATIC 27 CHARGE PRESSURE SWITCH
MOTOR 58 BRAKE DIAGNOSTIC PLUG
28 RELIEF VALVE - CHARGE: 40 SOLENOID ACTIVATED DIRECTIONAL
10 PILOTED ACTIVATED DIRECTIONAL 120 degrees F. (53 degrees C.)Fluid CONTROL VALVE - BLEED OFF 59 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL at 1775 Pump RPM
SPOOL 41 CHECK VALVE - BICS CONTROL VALVE CONTROL VALVE - TWO SPEED
390 - 430 PSI (2689 - 2965 kPa) DRIVE MOTOR
11 PILOTED ACTIVATED DIRECTIONAL 29 CHARGE PUMP 42 LIFT ARM BY-PASS RESTRICTOR
CONTROL VALVE - UNLOADING 60 HYDRAULIC HIGH FLOW PUMP
SPOOL 43 CHECK VALVE - AUXILIARY 10.0 GPM (37,8 L/min.) at 2615 Engine RPM
30 HYDRAULIC PUMP . . . . . . . . Gear Type
12 PILOTED ACTIVATED DIRECTIONAL (S/N 514441939-46822) 44 FILTER - CASE DRAIN (Attachment) 61 RESTRICTION - SELECT VALVE
CONTROL VALVE - TILT CONTROL (S/N 514640148-41074)
13 PILOTED ACTIVATED DIRECTIONAL 18.0 GPM (68,1 L/min.) at 2615 45 VARIABLE CAPACITY DISPLACEMENT 62 SCREEN
CONTROL VALVE - LIFT CONTROL Engine RPM BIDIRECTIONAL HYDROSTATIC PUMP
46 RESTRICTOR - 0.020 inch (0,5 mm) 63 ACCUMULATOR - FOUND ONLY ON
14 SOLENOID ACTIVATED DIRECTIONAL HIGH FLOW CAPACITY: (Includes )
60
CONTROL VALVE - BICS CONTROL MACHINES WITH
28.0 GPM (106,0 L/min.) at 2615 47 SOLENOID ACTIVATED DIRECTIONAL S/N 514444558 AND ABOVE
15 PULL BUTTON ACTIVATED Engine RPM
CONTROL VALVE (TWO COIL) S/N 514640276 AND ABOVE
DIRECTIONAL CONTROL VALVE - LIFT
ARM BY-PASS (S/N 514446823 AND ABOVE) 48 RELIEF VALVE - 1200 PSI (8268 kPa)
16 FILTER - BICS CONTROL VALVE 49
20.0 GPM (75,7 L/min.) at 2615 RESTRICTOR - 0.090 inch (2,3 mm)
(SCREEN) NOTE: Unless otherwise specified
Engine RPM
17 BOOM DOWN RESTRICTOR springs have NO significant
pressure value.
60
HIGH FLOW CAPACITY: (Includes )
30.0 GPM (113,6 L/min.) at 2615
Engine RPM
83 of 970
863 (S/N 514441939 - 514449483) SELECT VALVE C2 C1
(S/N 514640148 - 514641170) (RIGHT SIDE LIFT ARM
QUICK COUPLERS)
(PRINTED NOVEMBER 2002) Printable Version Click Here 40
V-0024
MALE
MALE
FEMALE
FEMALE
TWO SPEED DRIVE MOTOR 33
39 39
31 32
61 61
38 34
FEMALE
PRESS PB
(FRONT AUXILIARY
36
LEFT SIDE LIFT ARM)
MALE
59
54 37 35
53
T
DRAIN
9 HYDRAULIC FILTER (MALE)
3 44
4 D
COOLER
45 8
26 26
28
7
6
63
A
52 C
INLET 29
43
11
27
BOB-TACH
CYLINDER
Dealer Copy -- Not
24 for Resale 24
45 25 B
(OPTIONAL)
A B
26 30 26 HYDRAULIC
INLET POWERED 62 AUXILIARY
OUTLET
BOB-TACH SPOOL
58 DR (OPTIONAL)
23
TWO SPEED VALVE 22 TILT CYLINDER
B1 BICS CONTROL VALVE
46 47
60
55 48
B 49
54 50 A B 12
51 TILT
56 9
CYLINDER
SPOOL
53 21
C
18
P1 17
P2
5 13
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
T DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A.
V-0024 (11-5-02)
84 of 970
863 (S/N 514449260 - 514449563)
(S/N 514541069 - 514541072)
LEGEND
Capacity . . . . . . . 18.8 Qts. (17.8 L) DIRECTIONAL CONTROL VALVE - LIFT 14.0 GPM (53,0 L/min.) at 2450 Engine RPM
ARM BY-PASS
2 FILTER - CASE DRAIN (90 Micron) 30 HYDRAULIC PUMP . . . . . . . Gear Type 42 LIFT ARM BY-PASS RESTRICTOR
16 FILTER - BICS CONTROL VALVE 20.7 GPM (78,4 L/min.) at 2450 Engine RPM
3 FILTER - HYDRAULIC (CANISTER) (SCREEN) 31 DRIVE MOTOR SHUTTLE VALVE 43 CHECK VALVE - AUXILIARY
17 BOOM DOWN RESTRICTOR 32 SHUTTLE RELIEF VALVE:
SPRING LOADED FILTER BY-PASS 44 MUFFLER (If Equipped)
4
VALVE: 45-55 PSI (311-379 kPa)
18 LIFT AND TILT LOAD CHECK VALVE 33
200 PSI (1378 kPa)
SOLENOID ACTIVATED DIRECTIONAL * 45 VARIABLE CAPACITY DISPLACEMENT
5 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - BLEED OFF REAR
AUXILIARY ("SV2") BIDIRECTIONAL HYDROSTATIC PUMP
19 RELIEF VALVE - MAIN:
POWERED BOB-TACH 34 LOAD SHUTTLE VALVE - BLEED OFF 46
2950-3050 PSI (20340-21030 kPa) TWO STAGE RELIEF VALVE 1000 PSI/
6 DIFFERENTIAL PRESSURE SWITCH: at Front Quick Couplers 2000 PSI (6894 kPA/ 13788 kPA)
36-44 PSI (248-303 kPa) CONTROL VALVE - FOR REAR 47 SOLENOID ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: CONTROL VALVE (TWO COIL)
3500 PSI (24132 kPa)
7 FLOW DIVIDER ADJUSTMENT VALVE ("P2" and "F2")
21 ANTICAVITATION VALVE Dealer Copy --36NotPILOT ACTIVATED DIRECTIONAL
for Resale
8 CHECK VALVE - BUCKET POSITION CONTROL VALVE - FOR REAR 49 PRESSURE COMPENSATED FLOW
VALVE 22 RELIEF/ANTICAVITATION VALVE - AUXILIARY - NORMALLY OPEN
CONTROL
("D1" and "P1")
9 FIXED CAPACITY DISPLACEMENT 3500 PSI (24132 kPa) 37 PILOT ACTIVATED DIRECTIONAL 50 CHECK VALVE WITH .015 (0,38mm)
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - FOR REAR ORIFICE
MOTOR 23 ONE WAY RESTRICTOR VALVE AUXILIARY - NORMALLY OPEN
("D2" and "P2") 51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
10 PILOTED ACTIVATED DIRECTIONAL 38 FILTER - DIVERTER VALVE (SCREEN)
CONTROL VALVE - FLOW CONTROL INTEGRATED IN SOLENOID 52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY CONTROL VALVE - BUCKET POSITION
SPOOL 39 SOLENOID ACTIVATED DIRECTIONAL
VALVE (ON/OFF)
25 RELIEF VALVE - PORT: . . . . . . . . (Optional) CONTROL VALVE - TO ACTIVATE
11 PILOTED ACTIVATED DIRECTIONAL REAR AUXILIARY ("SV1") 53 ACCUMULATOR
3500 PSI (24132 kPa)
SPOOL 40 PILOT ACTIVATED DIRECTIONAL
26 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - FOR REAR
PRESSURE: 5000 PSI (34475 kPa) AUXILIARY - NORMALLY CLOSED
CONTROL VALVE - TILT CONTROL ("P1" and "F1")
27 CHARGE PRESSURE SWITCH
120 degrees F. (53 degrees C.) Fluid
at 1775 Pump RPM NOTE: Unless otherwise specified
14 SOLENOID ACTIVATED DIRECTIONAL springs have NO significant
390 - 430 PSI (2689 - 2965 kPa)
85 of 970
863 (S/N 514449260 - 514449563) 38
(S/N 514541069 - 514541072) 39
V-0161

DRIVE MOTOR
40 36
31 32
34 (FRONT AUXILIARY
(REAR QUICK
33 35 37
F2 D2
FEMALE
FEMALE FEMALE
9
DRAIN P1 P2
HYDRAULIC FILTER
3
4 D
COOLER
45 8
28
26
26 7
6
53
A
CHARGE INLET OUTLET
52 C
29
43
11
27
26
26
45
Dealer Copy -- Not
24 for Resale 24
BOB-TACH 25 B
CYLINDER A B
HYDRAULIC (OPTIONAL)
POWERED
BOB-TACH
(OPTIONAL) AUXILIARY
DR SPOOL
INLET OUTLET
23
22 TILT CYLINDER
BICS CONTROL VALVE
30
A B 12
46 47 TILT
48 51
49 CYLINDER
SPOOL
DRIVE MOTOR
50 21
9 18
20 LIFT CYLINDERS
17
13
P1 P2
5
A B
PP LIFT
CYLINDER
SPOOL
31 32
18 42
19 14
* (If Equipped)
WORKING CIRCUITS
2 * DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0161 (11-5-02)
86 of 970
863 (S/N 514449260 - 514449563)
(S/N 514541069 - 514541072)
LEGEND
1 RESERVOIR: 19 RELIEF VALVE - MAIN: 34 LOAD SHUTTLE VALVE - BLEED OFF 47 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . . . 18.8 Qts. (17.8 L) 2950-3050 PSI (20340-21030 kPa) CONTROL VALVE (TWO COIL)
at Front Quick Couplers 35 PILOT ACTIVATED DIRECTIONAL
2 FILTER - CASE DRAIN (90 Micron) 48 RELIEF VALVE - 1200 PSI (8268 kPa)
3 FILTER - HYDRAULIC (CANISTER) 3500 PSI (24132 kPa) 49 PRESSURE COMPENSATED FLOW
("P2" and "F2") CONTROL
4 SPRING LOADED FILTER BY-PASS 36 PILOT ACTIVATED DIRECTIONAL 50 CHECK VALVE WITH .015 (0,38mm)
VALVE: 45-55 PSI (311-379 kPa) 22 RELIEF/ANTICAVITATION VALVE - CONTROL VALVE - FOR REAR ORIFICE
5 PILOT ACTIVATED DIRECTIONAL PORT (TILT BASE END) AUXILIARY - NORMALLY OPEN
3500 PSI (24132 kPa)
POWERED BOB-TACH 23 ONE WAY RESTRICTOR VALVE 37 PILOT ACTIVATED DIRECTIONAL 52 SOLENOID ACTIVATED DIRECTIONAL
6 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE - FOR REAR CONTROL VALVE - BUCKET POSITION
36-44 PSI (248-303 kPa) 24 SOLENOID ACTIVATED DIRECTIONAL AUXILIARY - NORMALLY OPEN VALVE (ON/OFF)
CONTROL VALVE - AUXILIARY ("D2" and "P2")
7 FLOW DIVIDER ADJUSTMENT VALVE 53 FIXED CAPACITY DISPLACEMENT
25 RELIEF VALVE - PORT: . . . . . . . (Optional) BIDIRECTIONAL HYDROSTATIC
8 CHECK VALVE - BUCKET POSITION 3500 PSI (24132 kPa) MOTOR
VALVE 26 RELIEF/REPLENISHING VALVE - HIGH Dealer Copy -- Not for Resale 54 HYDRAULIC BRAKE - SPRING APPLIED -
PRESSURE: 5000 PSI (34475 kPa)
9 FIXED CAPACITY DISPLACEMENT CONTROL VALVE - TO ACTIVATE
BIDIRECTIONAL HYDROSTATIC REAR AUXILIARY ("SV1") 55 PULL BUTTON ACTIVATED
MOTOR 27 CHARGE PRESSURE SWITCH DIRECTIONAL CONTROL VALVE -
40 PILOT ACTIVATED DIRECTIONAL BRAKE
CONTROL VALVE - FOR REAR
CONTROL VALVE - FLOW CONTROL 120 degrees F. (53 degrees C.)Fluid 56 SOLENOID ACTIVATED DIRECTIONAL
SPOOL at 1775 Pump RPM CONTROL VALVE - MAKE-UP
("P1" and "F1")
390 - 430 PSI (2689 - 2965 kPa)
11 PILOTED ACTIVATED DIRECTIONAL 41 CHECK VALVE - BICS CONTROL VALVE 57 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING 29 CHARGE PUMP CONTROL VALVE - TWO SPEED
SPOOL 14.0 GPM (53,0 L/min.) at 2450 Engine RPM 42 LIFT ARM BY-PASS RESTRICTOR 58 BRAKE DIAGNOSTIC PLUG
12 PILOTED ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . Gear Type
CONTROL VALVE - TILT CONTROL 20.7 GPM (78,4 L/min.) at 2450 43 CHECK VALVE - AUXILIARY
59 ACCUMULATOR
13 PILOTED ACTIVATED DIRECTIONAL Engine RPM
31 DRIVE MOTOR SHUTTLE VALVE
14 SOLENOID ACTIVATED DIRECTIONAL DRIVE MOTOR
CONTROL VALVE - BICS CONTROL 32 SHUTTLE RELIEF VALVE:
15 PULL BUTTON ACTIVATED 200 PSI (1378 kPa) 45 VARIABLE CAPACITY DISPLACEMENT
DIRECTIONAL CONTROL VALVE - LIFT BIDIRECTIONAL HYDROSTATIC PUMP
ARM BY-PASS CONTROL VALVE - BLEED OFF REAR 46 TWO STAGE RELIEF VALVE 1000 PSI/
16 FILTER - BICS CONTROL VALVE AUXILIARY ("SV2") 2000 PSI (6894 kPa/ 13788 kPa)
(SCREEN)
NOTE: Unless otherwise specified
87 of 970
863 (S/N 514449260 - 514449563) 38
(S/N 514541069 - 514541072) 39
PILOT
V-0162
40 36
34 (FRONT AUXILIARY
(REAR QUICK
LEFT SIDE LIFT ARM)
COUPLERS)
33 35 37
F2 D2
54 44 FEMALE
FEMALE FEMALE
53
DRAIN P1 P2
9 HYDRAULIC FILTER
3
4 D
COOLER
45 8
26 26
28
7
6
60
A
52 C
INLET 29
43
11
27

24 for Resale 24
45 CYLINDER 25 B
HYDRAULIC (OPTIONAL) A B
POWERED
BOB-TACH
26 30 26 (OPTIONAL)
INLET OUTLET DR AUXILIARY
SPOOL
58
23
BICS CONTROL VALVE
55
46 47
54 48 A B 12
49 51 TILT
56 9
CYLINDER
50 SPOOL
53 21
C
18
17
P1 P2
5 13
PP
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
T DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0162 (11-5-02)
88 of 970
863 (S/N 514449484 - 514449563)
(S/N 514641171 - 514641175)
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 30 HYDRAULIC PUMP . . . . . . . Gear Type 45 VARIABLE CAPACITY DISPLACEMENT
Capacity . . . . . . . . . 18.8 Qts. (17.8 L) (SCREEN) 20.7 GPM (78,4 L/min.) at 2450 BIDIRECTIONAL HYDROSTATIC PUMP
Engine RPM
2
3
FILTER - CASE DRAIN (90 Micron)
FILTER - HYDRAULIC (CANISTER)
53
30.7 GPM (116,2 L/min.) at 2450
* 46 TWO STAGE RELIEF VALVE 1000 PSI/
2000 PSI (6894 kPa/ 13788 kPa)
Engine RPM 47 SOLENOID ACTIVATED DIRECTIONAL
4 SPRING LOADED FILTER BY- PASS 19 RELIEF VALVE - MAIN: CONTROL VALVE (TWO COIL)
VALVE: . . . 45-55 PSI (311-379 kPa) 2950-3050 PSI (20340-21030 kPa) 31 DRIVE MOTOR SHUTTLE VALVE 48 RELIEF VALVE - 1200 PSI (8268 kPa)
32 SHUTTLE RELIEF VALVE: 49 PRESSURE COMPENSATED FLOW
CONTROL VALVE - HYDRAULIC 20 RELIEF VALVE - PORT:
POWERED BOB-TACH 3500 PSI (24132 kPa) 200 PSI (1378 kPa) CONTROL
21 ANTICAVITATION VALVE 33 REAR AUXILIARY BLEED SHUTTLE VALVE
6 DIFFERENTIAL PRESSURE SWITCH: 50 CHECK VALVE WITH .015 (0,38mm)
36-44 PSI (248-303 kPa) 34 LOAD CHECK VALVE - SELECT VALVE
ORIFICE)
22 RELIEF/ANTICAVITATION VALVE -
PORT (TILT BASE END) (HIGH FLOW) 51 RELIEF VALVE - PORT:
7 FLOW DIVIDER ADJUSTMENT VALVE
3500 PSI (24132 kPa) 35 SOLENOID ACTIVATED DIRECTIONAL 3500 PSI (24132 kPa)
8 CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE CONTROL VALVE - HIGH FLOW 52 SOLENOID ACTIVATED DIRECTIONAL
VALVE CONTROL VALVE - BUCKET POSITION
Dealer Copy --36NotSOLENOID ACTIVATED DIRECTIONAL
for Resale VALVE (ON/OFF)
9 FIXED CAPACITY DISPLACEMENT 24 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - DIVERTER
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - AUXILIARY
37 RELIEF VALVE - MAIN (HIGH FLOW) 53 HYDRAULIC HIGH FLOW PUMP:
MOTOR 25 10.0 GPM (37,8 L/min.) at 2450 Engine RPM
RELIEF VALVE - PORT: . . . . . . (Optional) 3000 PSI (20685 kPa)
3500 PSI (24132 kPa)
10 PILOTED ACTIVATED DIRECTIONAL 38 SOLENOID ACTIVATED DIRECTIONAL 54 FILTER - CASE DRAIN (ATTACHMENT)
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE (TWO COIL)
SPOOL PRESSURE: 5000 PSI (34475 kPa)
39 PILOT TO OPEN CHECK VALVE 55 RESTRICTION - SELECT VALVE
27 CHARGE PRESSURE SWITCH
CONTROL VALVE - UNLOADING 56 ACCUMULATOR
SPOOL 28 RELIEF VALVE - CHARGE:
CONTROL VALVE - BLEED OFF
12 PILOTED ACTIVATED DIRECTIONAL 120 degrees F. (53 degrees C.)Fluid
CONTROL VALVE - TILT CONTROL at 1775 Pump RPM 41 CHECK VALVE - BICS CONTROL VALVE
390 - 430 PSI (2689 - 2965 kPa)
13 PILOTED ACTIVATED DIRECTIONAL 42 LIFT ARM BY-PASS RESTRICTOR
29 CHARGE PUMP:
43 CHECK VALVE - AUXILIARY
CONTROL VALVE - BICS CONTROL 44 MUFFLER (If Equipped)
15 PULL BUTTON ACTIVATED
ARM BY- PASS
pressure value.
89 of 970
FEMALE
MALE
863 (S/N 514449484 - 514449563) (RIGHT SIDE LIFT ARM
(S/N 514641171 - 514641175) QUICK COUPLERS)
40
MALE
MALE
FEMALE
FEMALE
V-0159
Printable Version Click Here 33
39 39
DRIVE MOTOR
55 55
31 32 * 44
38 34
FEMALE
PRESS PB
(FRONT AUXILIARY
36 LEFT SIDE LIFT ARM)
MALE
37 35
9
T
DRAIN
3 54
4 D
COOLER
45 8
28
26 26
7
6
56
A
CHARGE INLET OUTLET
52 C
29
43
11
26 27
26
BOB-TACH
24 24
45 CYLINDER 25 B
POWERED
BOB-TACH
(OPTIONAL)
DR AUXILIARY
SPOOL
INLET
23
22 TILT CYLINDER
30
53
46 47
48 A B 12
49 51 TILT
CYLINDER
SPOOL
50
DRIVE MOTOR 21
18
9
20 LIFT CYLINDERS
17
P1 P2
5 13
A B
LIFT
CYLINDER
SPOOL
32
31
18 42
* (If Equipped)
2 * 44 16 41 16 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0159 (11-5-02)
90 of 970
863 (S/N 514449484 - 514449563)
(S/N 514641171 - 514641175)
LEGEND
1 RESERVOIR: 19 RELIEF VALVE - MAIN: 34 LOAD CHECK VALVE - SELECT VALVE 50 CHECK VALVE WITH .015 (0,38mm)
Capacity . . . . . . . . . . 18.8 Qts. (17.8 L) 2950-3050 PSI (20340-21030 kPa) (HIGH FLOW) ORIFICE
2 FILTER - CASE DRAIN (90 Micron) 35 SOLENOID ACTIVATED DIRECTIONAL 51 RELIEF VALVE - PORT:
20 RELIEF VALVE - PORT: CONTROL VALVE - HIGH FLOW 3500 PSI (24132 kPa)
3 FILTER - HYDRAULIC (CANISTER) 3500 PSI (24132 kPa) 52 SOLENOID ACTIVATED DIRECTIONAL
21 ANTICAVITATION VALVE CONTROL VALVE - BUCKET POSITION
4 SPRING LOADED FILTER BY-PASS CONTROL VALVE - DIVERTER VALVE (ON/OFF)
VALVE: 45-55 PSI (311-379 kPa) 22 RELIEF/ANTICAVITATION VALVE -
PORT (TILT BASE END) 37 RELIEF VALVE - MAIN (HIGH FLOW)
5 PILOT ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC
3500 PSI (24132 kPa) 3000 PSI (20685 kPa)
CONTROL VALVE - HYDRAULIC MOTOR
POWERED BOB-TACH 23 ONE WAY RESTRICTOR VALVE 38 SOLENOID ACTIVATED DIRECTIONAL 54 HYDRAULIC BRAKE - SPRING APPLIED -
6 CONTROL VALVE (TWO COIL) PRESSURE TO RELEASE
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa) PILOT TO OPEN CHECK VALVE 55 PUSH BUTTON SOLENOID ACTIVATED
CONTROL VALVE - AUXILIARY 39
DIRECTIONAL CONTROL VALVE -
7 FLOW DIVIDER ADJUSTMENT VALVE 25 RELIEF VALVE - PORT: . . . . . (Optional) BRAKE
8 CHECK VALVE - BUCKET POSITION CONTROL VALVE - BLEED OFF 56 SOLENOID ACTIVATED DIRECTIONAL
VALVE 26 RELIEF/REPLENISHING VALVE - HIGH Dealer Copy -- Not for Resale CONTROL VALVE - MAKE-UP
PRESSURE: 5000 PSI (34475 kPa) 41 CHECK VALVE - BICS CONTROL VALVE
9 FIXED CAPACITY DISPLACEMENT 57 SOLENOID ACTIVATED DIRECTIONAL
BIDIRECTIONAL HYDROSTATIC 27 42 LIFT ARM BY-PASS RESTRICTOR CONTROL VALVE - TWO SPEED
28 RELIEF VALVE - CHARGE: 43 CHECK VALVE - AUXILIARY
CONTROL VALVE - FLOW CONTROL at 1775 Pump RPM 44 FILTER - CASE DRAIN (Attachment) 59 PILOT ACTIVATED DIRECTIONAL
SPOOL 390 - 430 PSI (2689 - 2965 kPa) CONTROL VALVE - TWO SPEED
45 VARIABLE CAPACITY DISPLACEMENT DRIVE MOTOR
11 PILOTED ACTIVATED DIRECTIONAL 29 CHARGE PUMP BIDIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - UNLOADING 14.0 GPM (53,0 L/min.) at 2450 Engine RPM 60 HYDRAULIC HIGH FLOW PUMP
SPOOL 46 TWO STAGE RELIEF VALVE 1000 PSI/
30 HYDRAULIC PUMP . . . . . . . Gear Type 10 GPM (37.85 L/min.) at 2450 RPM
2000 PSI (6894 kPa/13788 kPa)
12 PILOTED ACTIVATED DIRECTIONAL 20.7 GPM (78,4 L/min.) at 2450
CONTROL VALVE - TILT CONTROL Engine RPM 47 SOLENOID ACTIVATED DIRECTIONAL
61 RESTRICTION - SELECT VALVE
60
HIGH FLOW CAPACITY: (Includes ) CONTROL VALVE (TWO COIL)
CONTROL VALVE - LIFT CONTROL 30.7 GPM (116,2 L/min.) at 2450 48 RELIEF VALVE - 1200 PSI (8268 kPa) 62 ACCUMULATOR
Engine RPM
14 SOLENOID ACTIVATED DIRECTIONAL 49 PRESSURE COMPENSATED FLOW
CONTROL VALVE - BICS CONTROL 31 DRIVE MOTOR SHUTTLE VALVE
CONTROL
32 SHUTTLE RELIEF VALVE: 200 PSI (1378 kPa)
ARM BY-PASS
33 REAR AUXILIARY BLEED SHUTTLE VALVE
pressure value.
91 of 970
(S/N 514641171 - 514641175) (RIGHT SIDE LIFT ARM
QUICK COUPLERS)
V-0160
MALE
MALE
FEMALE
FEMALE
39 39
31 32
61 61
38 34
FEMALE
PRESS PB
(FRONT AUXILIARY
36
LEFT SIDE LIFT ARM)
MALE
59
54 37 35
53
T
DRAIN
9 HYDRAULIC FILTER (MALE)
3 44
4 D
COOLER
45 8
26 26
28
7
6
62
A
52 C
INLET 29
43
11
27
Dealer Copy -- Not
24 for Resale 24
45 25 B
A B
BOB-TACH
CYLINDER
26 30 26 HYDRAULIC (OPTIONAL)
POWERED AUXILIARY
INLET OUTLET BOB-TACH SPOOL
58 (OPTIONAL)
DR
23
60
55
54 A B 12
51 TILT
56 9
46 CYLINDER
48 47 SPOOL
49
53 21
C
50 18
17
13
57 P1 A B
P2
5 LIFT
CYLINDER
SPOOL
A
18 42
31 32
T DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A.
V-0160 (11-5-02)
92 of 970
863 (S/N 514449564 - 514451083)
(S/N 514541073 - 514541113)
LEGEND
ARM BY-PASS 30
2 FILTER - CASE DRAIN (90 Micron) HYDRAULIC PUMP . . . . . . . Gear Type 42 LIFT ARM BY-PASS RESTRICTOR
17 BOOM DOWN RESTRICTOR 44 FRONT AUXILIARY MANUAL
4 SPRING LOADED FILTER BY-PASS 200 PSI (1378 kPa)
VALVE: 45-55 PSI (311-379 kPa) PRESSURE BLEED-OFF VALVE
CONTROL VALVE - BLEED OFF REAR 45 VARIABLE CAPACITY DISPLACEMENT
5 PILOT ACTIVATED DIRECTIONAL AUXILIARY ("SV2") BIDIRECTIONAL HYDROSTATIC PUMP
6 DIFFERENTIAL PRESSURE SWITCH: at Front Quick Couplers 35 PILOT ACTIVATED DIRECTIONAL 2000 PSI (6894 kPA/ 13788 kPA)
20 RELIEF VALVE - PORT: AUXILIARY - NORMALLY CLOSED CONTROL VALVE (TWO COIL)
FLOW DIVIDER ADJUSTMENT VALVE 3500 PSI (24132 kPa) ("P2" and "F2")
7
for Resale
8 CONTROL VALVE - FOR REAR
CHECK VALVE - BUCKET POSITION 49 PRESSURE COMPENSATED FLOW
AUXILIARY - NORMALLY OPEN
VALVE 22 RELIEF/ANTICAVITATION VALVE - CONTROL
("D1" and "P1")
37 PILOT ACTIVATED DIRECTIONAL 50 CHECK VALVE WITH .015 (0,38mm)
MOTOR AUXILIARY - NORMALLY OPEN
23 ONE WAY RESTRICTOR VALVE ("D2" and "P2") 51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
10 PILOTED ACTIVATED DIRECTIONAL 24 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TO ACTIVATE VALVE (ON/OFF)
25 RELIEF VALVE - PORT: . . . . . . . . (Optional)
3500 PSI (24132 kPa) REAR AUXILIARY ("SV1")
CONTROL VALVE - UNLOADING 40 PILOT ACTIVATED DIRECTIONAL
SPOOL
12 PILOTED ACTIVATED DIRECTIONAL ("P1" and "F1")
CONTROL VALVE - TILT CONTROL 27 CHARGE PRESSURE SWITCH
390 - 430 PSI (2689 - 2965 kPa)
93 of 970
863 (S/N 514449564 - 514451083) 38
(S/N 514541073 - 514541113) 39
V-0165

DRIVE MOTOR FRONT AUXILIARY
LEFT SIDE LIFT ARM
40 36 44
MALE MALE F1 D1
MALE
31 32
34 DRAIN
REAR QUICK
(MALE)
COUPLERS
(OPTIONAL)
37 FEMALE
33 35
F2 D2 44
FEMALE FEMALE
9
DRAIN P1 P2
HYDRAULIC FILTER
3 2 BUCKET POSITION VALVE (OPTIONAL)
4 D
COOLER
45 8
28
26
26 7
6
A
CHARGE INLET OUTLET
52 C
29
43
11
27
26
26
45
Dealer Copy -- Not
24 for Resale 24
BOB-TACH 25 B
CYLINDER A B
POWERED
BOB-TACH
DR SPOOL
INLET OUTLET
23
22 TILT CYLINDER
BICS CONTROL VALVE
30
A B 12
46 47 TILT
48 51
CYLINDER
SPOOL
49
DRIVE MOTOR
50 21
9 18
20 LIFT CYLINDERS
17
P2
13
P1
5 PP
A B
LIFT
CYLINDER
SPOOL
31 32
18 42
19 14
* (If Equipped)
WORKING CIRCUITS
2 DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0165 (11-4-02)
94 of 970
863 (S/N 514449564 - 514451083)
(S/N 514541073 - 514541113)
LEGEND
3500 PSI (24132 kPa)
("P1" and "F1")
390 - 430 PSI (2689 - 2965 kPa)
59 FRONT AUXILIARY MANUAL PRESSURE
13 PILOTED ACTIVATED DIRECTIONAL 31 DRIVE MOTOR SHUTTLE VALVE 44 PILOT ACTIVATED DIRECTIONAL BLEED-OFF VALVE
ARM BY-PASS AUXILIARY ("SV2") 46 TWO STAGE RELIEF VALVE 1000 PSI/
16 FILTER - BICS CONTROL VALVE 2000 PSI (6894 kPa/ 13788 kPa)
(SCREEN)
95 of 970
863 (S/N 514449564 - 514451083) 38
(S/N 514541073 - 514541113) 39
PILOT
(PRINTED NOVEMBER 2002) Printable Version Click Here
V-0166
FRONT AUXILIARY
LEFT SIDE LIFT ARM
40 36 59
34 DRAIN
(REAR QUICK (MALE)
COUPLERS)
37 FEMALE
33 35
F2 D2 59
54 44
FEMALE FEMALE
53
33
DRAIN P1 P2
9 HYDRAULIC FILTER
3
2 BUCKET POSITION VALVE (OPTIONAL)
4 D
COOLER
45 8
26 26
28
7
6
52 C
INLET 29
43
11
27

24 for Resale 24
45 CYLINDER 25 B
POWERED
BOB-TACH
26 30 26 (OPTIONAL)
SPOOL
58
23
BICS CONTROL VALVE
55
46 47
54 48 A B 12
49 51 TILT
56 9
CYLINDER
50 SPOOL
53 21
C
18
17
P1 P2
5 13
PP
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
T DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0166 (11-4-02)
96 of 970
863 (S/N 514449564 - 514450945)
(S/N 514641176 - 514641254)
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 30 HYDRAULIC PUMP . . . . . . . Gear Type 47 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . . . . 18.8 Qts. (17.8 L) (SCREEN) 20.7 GPM (78,4 L/min.) at 2450 CONTROL VALVE (TWO COIL)
2 FILTER - CASE DRAIN (90 Micron) 17 BOOM DOWN RESTRICTOR Engine RPM
53
HIGH FLOW CAPACITY: (Includes ) 48 RELIEF VALVE - 1200 PSI (8268 kPa)
3 FILTER - HYDRAULIC (CANISTER) 18 LIFT AND TILT LOAD CHECK VALVE 30.7 GPM (116,2 L/min.) at 2450
49 PRESSURE COMPENSATED FLOW
Engine RPM
SPRING LOADED FILTER BY- PASS 19 RELIEF VALVE - MAIN: CONTROL
4 31 DRIVE MOTOR SHUTTLE VALVE
VALVE: . . . 45-55 PSI (311-379 kPa) 2950-3050 PSI (20340-21030 kPa) 50 CHECK VALVE WITH .015 (0,38mm)
at Front Quick Couplers 32 SHUTTLE RELIEF VALVE: ORIFICE)
CONTROL VALVE - HYDRAULIC 20 RELIEF VALVE - PORT: 200 PSI (1378 kPa)
POWERED BOB-TACH 3500 PSI (24132 kPa) 33 REAR AUXILIARY BLEED SHUTTLE VALVE 3500 PSI (24132 kPa)
6 DIFFERENTIAL PRESSURE SWITCH: 21 ANTICAVITATION VALVE
34 LOAD CHECK VALVE - SELECT VALVE 52 SOLENOID ACTIVATED DIRECTIONAL
36-44 PSI (248-303 kPa) CONTROL VALVE - BUCKET POSITION
22 RELIEF/ANTICAVITATION VALVE - (HIGH FLOW)
VALVE (ON/OFF)
7 FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END) 35 SOLENOID ACTIVATED DIRECTIONAL
3500 PSI (24132 kPa) 53 HYDRAULIC HIGH FLOW PUMP:
CONTROL VALVE - HIGH FLOW
8 CHECK VALVE - BUCKET POSITION 10.0 GPM (37,8 L/min.) at 2450 Engine RPM
23 ONE WAY RESTRICTOR VALVE 36 SOLENOID ACTIVATED DIRECTIONAL
VALVE
Dealer Copy -- Not CONTROL VALVE - DIVERTER
for Resale 54 FILTER - CASE DRAIN (ATTACHMENT)
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - AUXILIARY 37 RELIEF VALVE - MAIN (HIGH FLOW)
3000 PSI (20685 kPa) 55 RESTRICTION - SELECT VALVE
MOTOR 25 RELIEF VALVE - PORT: . . . . . . (Optional)
CONTROL VALVE - FLOW CONTROL CONTROL VALVE (TWO COIL)
26 RELIEF/REPLENISHING VALVE - HIGH
SPOOL PRESSURE: 5000 PSI (34475 kPa) 39 PILOT TO OPEN CHECK VALVE
CONTROL VALVE - UNLOADING 27 CHARGE PRESSURE SWITCH 40 SOLENOID ACTIVATED DIRECTIONAL
SPOOL CONTROL VALVE - BLEED OFF
28 RELIEF VALVE - CHARGE:
12 PILOTED ACTIVATED DIRECTIONAL 120 degrees F. (53 degrees C.)Fluid 41 CHECK VALVE - BICS CONTROL VALVE
CONTROL VALVE - TILT CONTROL at 1775 Pump RPM
390 - 430 PSI (2689 - 2965 kPa) 42 LIFT ARM BY-PASS RESTRICTOR
CONTROL VALVE - LIFT CONTROL 29 CHARGE PUMP: 43 CHECK VALVE - AUXILIARY
CONTROL VALVE - BICS CONTROL
BLEED-OFF VALVE
15 PULL BUTTON ACTIVATED 45 VARIABLE CAPACITY DISPLACEMENT
ARM BY- PASS
46 TWO STAGE RELIEF VALVE 1000 PSI/
* 2000 PSI (6894 kPa/ 13788 kPa) NOTE: Unless otherwise specified
pressure value.
97 of 970
FEMALE
MALE
863 (S/N 514449564 - 514450945)
RIGHT SIDE LIFT ARM
(S/N 514641176 - 514641254) QUICK COUPLERS
40
(PRINTED NOVEMBER 2002) (OPTIONAL)
MALE
MALE
FEMALE
FEMALE
V-0163
39 39
DRIVE MOTOR
REAR QUICK COUPLERS
(OPTIONAL)
FRONT AUXILIARY
55 55 (LEFT SIDE LIFT ARM)
44
31 38 34
32 FEMALE
PRESS PB
36 DRAIN
(MALE)
37 35
MALE
9
T 44
HYDRAULIC FILTER
3 54
4 D
COOLER
45 8
28
26 26
7
6
A
CHARGE INLET OUTLET
52 C
29
43
11
26 27
26
BOB-TACH
24 24
45 CYLINDER 25 B
POWERED
BOB-TACH
(OPTIONAL)
DR AUXILIARY
SPOOL
INLET
23
22 TILT CYLINDER
30
53
46 47
48 A B 12
49 51 TILT
CYLINDER
SPOOL
50
DRIVE MOTOR 21
18
9
20 LIFT CYLINDERS
17
P1 P2
5 13
A B
LIFT
CYLINDER
SPOOL
32
31
18 42
* (If Equipped)
2 DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A. V-0163 (11-4-02)
98 of 970
863 (S/N 514449564 - 514450945)
(S/N 514641176 - 514641254)
LEGEND
1 RESERVOIR: 19 RELIEF VALVE - MAIN: 34 LOAD CHECK VALVE - SELECT VALVE 50 CHECK VALVE WITH .015 (0,38mm)
Capacity . . . . . . . . . . 18.8 Qts. (17.8 L) 2950-3050 PSI (20340-21030 kPa) (HIGH FLOW) ORIFICE
2 FILTER - CASE DRAIN (90 Micron) 35 SOLENOID ACTIVATED DIRECTIONAL 51 RELIEF VALVE - PORT:
20 RELIEF VALVE - PORT: CONTROL VALVE - HIGH FLOW 3500 PSI (24132 kPa)
3 FILTER - HYDRAULIC (CANISTER) 3500 PSI (24132 kPa) 52 SOLENOID ACTIVATED DIRECTIONAL
21 ANTICAVITATION VALVE CONTROL VALVE - BUCKET POSITION
4 SPRING LOADED FILTER BY-PASS CONTROL VALVE - DIVERTER VALVE (ON/OFF)
VALVE: 45-55 PSI (311-379 kPa) 22 RELIEF/ANTICAVITATION VALVE -
PORT (TILT BASE END) 37 RELIEF VALVE - MAIN (HIGH FLOW)
5 PILOT ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC
3500 PSI (24132 kPa) 3000 PSI (20685 kPa)
CONTROL VALVE - HYDRAULIC MOTOR
POWERED BOB-TACH 23 ONE WAY RESTRICTOR VALVE 38 SOLENOID ACTIVATED DIRECTIONAL 54 HYDRAULIC BRAKE - SPRING APPLIED -
6 CONTROL VALVE (TWO COIL) PRESSURE TO RELEASE
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa) PILOT TO OPEN CHECK VALVE 55 PUSH BUTTON SOLENOID ACTIVATED
CONTROL VALVE - AUXILIARY 39
DIRECTIONAL CONTROL VALVE -
7 FLOW DIVIDER ADJUSTMENT VALVE 25 RELIEF VALVE - PORT: . . . . . (Optional) BRAKE
8 CHECK VALVE - BUCKET POSITION CONTROL VALVE - BLEED OFF 56 SOLENOID ACTIVATED DIRECTIONAL
VALVE 26 RELIEF/REPLENISHING VALVE - HIGH Dealer Copy -- Not for Resale CONTROL VALVE - MAKE-UP
PRESSURE: 5000 PSI (34475 kPa) 41 CHECK VALVE - BICS CONTROL VALVE
BIDIRECTIONAL HYDROSTATIC 27 42 LIFT ARM BY-PASS RESTRICTOR CONTROL VALVE - TWO SPEED
28 RELIEF VALVE - CHARGE: 43 CHECK VALVE - AUXILIARY
CONTROL VALVE - FLOW CONTROL at 1775 Pump RPM 44 FILTER - CASE DRAIN (Attachment) 59 PILOT ACTIVATED DIRECTIONAL
SPOOL 390 - 430 PSI (2689 - 2965 kPa) CONTROL VALVE - TWO SPEED
45 VARIABLE CAPACITY DISPLACEMENT DRIVE MOTOR
11 PILOTED ACTIVATED DIRECTIONAL 29 CHARGE PUMP BIDIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - UNLOADING 14.0 GPM (53,0 L/min.) at 2450 Engine RPM 60 HYDRAULIC HIGH FLOW PUMP:
SPOOL 46 TWO STAGE RELIEF VALVE 1000 PSI/
30 HYDRAULIC PUMP . . . . . . . Gear Type 10.0 GPM (38,7 L/min.) at 2450 Engine RPM
2000 PSI (6894 kPa/13788 kPa)
12 PILOTED ACTIVATED DIRECTIONAL 20.7 GPM (78,4 L/min.) at 2450
CONTROL VALVE - TILT CONTROL Engine RPM
47 SOLENOID ACTIVATED DIRECTIONAL 61 RESTRICTION - SELECT VALVE
60
HIGH FLOW CAPACITY: (Includes ) CONTROL VALVE (TWO COIL)
CONTROL VALVE - LIFT CONTROL 30.7 GPM (116,2 L/min.) at 2450 48 RELIEF VALVE - 1200 PSI (8268 kPa) 62 FRONT AUXILIARY MANUAL
Engine RPM PRESSURE BLEED-OFF VALVE
14 SOLENOID ACTIVATED DIRECTIONAL 49 PRESSURE COMPENSATED FLOW
CONTROL VALVE - BICS CONTROL 31 DRIVE MOTOR SHUTTLE VALVE
CONTROL
32 SHUTTLE RELIEF VALVE: 200 PSI (1378 kPa)
ARM BY-PASS
33 REAR AUXILIARY BLEED SHUTTLE VALVE
pressure value.
99 of 970
(S/N 514641176 - 514641254) RIGHT SIDE LIFT ARM
QUICK COUPLERS
(PRINTED NOVEMBER 2002) Printable Version Click Here 40 (OPTIONAL)
V-0164
MALE
MALE
FEMALE
FEMALE
39 39
REAR QUICK COUPLERS
31 (OPTIONAL)
32
61 61
FRONT AUXILIARY
LEFT SIDE LIFT ARM
38 34
62
FEMALE
PRESS PB
36
DRAIN
59 (MALE)
54 37 35
53
T
MALE
9 HYDRAULIC FILTER 62
3 44
4 D
COOLER
45 8
26 26
28
7
6
52 C
INLET 29
43
11
27
Dealer Copy -- Not
24 for Resale 24
45 25 B
A B
BOB-TACH
CYLINDER
26 30 26 HYDRAULIC (OPTIONAL)
POWERED AUXILIARY
INLET OUTLET BOB-TACH SPOOL
58 (OPTIONAL)
DR
23
60
55
54 A B 12
51 TILT
56 9
46 CYLINDER
48 47 SPOOL
49
53 21
C
50 18
17
13
57 P1 A B
P2
5 LIFT
CYLINDER
SPOOL
A
18 42
31 32
T DRAIN CIRCUITS
COMPONENTS
15
Printed in U.S.A.
V-0164 (11-5-02)
100 of 970
863 (S/N 514450946 - 514451083)
(S/N 514641255 - 514641266)
(PRINTED DECEMBER 2003)
V-0236legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 31 DRIVE MOTOR SHUTTLE VALVE 44 FRONT AUXILIARY MANUAL
Capacity . . . . . . . . . 18.8 Qts. (17.8 (SCREEN) PRESSURE BLEED-OFF VALVE
L) 32 SHUTTLE RELIEF VALVE:
2 FILTER - CASE DRAIN (90 Micron) 17 ONE WAY RESTRICTOR 200 PSI (1378 kPa) 45 VARIABLE CAPACITY DISPLACEMENT
3 FILTER - HYDRAULIC (CANISTER) 18 LOAD CHECK VALVE 33 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR 46 TWO STAGE RELIEF 1000 PSI/2000 PSI
4 SPRING LOADED FILTER BYPASS 19 RELIEF VALVE - MAIN: AUXILIARY ("SV2") (6894kPa/13788 kPa)
at Front Quick Couplers 34 LOAD SHUTTLE VALVE - BLEED OFF 47 SOLENOID ACTIVATED DIRECTIONAL
5 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)
CONTROL VALVE - HYDRAULIC 20 RELIEF VALVE - PORT: 35 PILOT ACTIVATED DIRECTIONAL
POWERED BOB-TACH 48 RELIEF VALVE - 1200 PSI (8268 kPa)
3500 PSI (24132 kPa) CONTROL VALVE - FOR REAR
6 DIFFERENTIAL PRESSURE SWITCH: AUXILIARY - NORMALLY CLOSED 49
21 ANTICAVITATION VALVE PRESSURE COMPENSATED FLOW
36-44 PSI (248-303 kPa) ("P2" and "F2")
CONTROL
22 RELIEF/ANTICAVITATION VALVE - 36 PILOT ACTIVATED DIRECTIONAL
7 FLOW DIVIDER ADJUSTMENT VALVE Dealer Copy -- Not for Resale 50 CHECK VALVE WITH 0.015 (0,38 mm)
PORT (TILT BASE END) CONTROL VALVE - FOR REAR
RESTRICTION
3500 PSI (24132 kPa) AUXILIARY - NORMALLY OPEN
8 CHECK VALVE - BUCKET POSITION ("D1" and "P1")
23 ONE WAY RESTRICTOR VALVE
37 PILOT ACTIVATED DIRECTIONAL 3500 PSI (24132 kPa)
FIXED CAPACITY DISPLACEMENT 24 SOLENOID ACTIVATED DIRECTIONAL
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - AUXILIARY AUXILIARY - NORMALLY OPEN 52 SOLENOID ACTIVATED DIRECTIONAL
MOTOR 25 ("D2" and "P2") CONTROL VALVE - BUCKET POSITION
RELIEF VALVE - PORT: . . . . . (Optional)
VALVE (ON/OFF)
3500 PSI (24132 kPa)
10 PILOTED ACTIVATED DIRECTIONAL 38 FILTER - DIVERTER VALVE (SCREEN) 53 AUXILIARY HYDRAULIC PUMP
CONTROL VALVE - FLOW CONTROL 26 INTEGRATED IN SOLENOID
RELIEF/REPLENISHING VALVE - HIGH 10 GPM (37.85 L/min.)at 2450 RPM
SPOOL PRESSURE: 5000 PSI (34474 kPa) 39 SOLENOID ACTIVATED DIRECTIONAL 54 FILTER - CASE DRAIN (ATTACHMENT)
11 PILOTED ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH CONTROL VALVE - TO ACTIVATE
CONTROL VALVE - UNLOADING REAR AUXILIARY ("SV1") 55 RELIEF VALVE - 3300 PSI (22754 kPa)
12 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FOR REAR 56 DUMP VALVE (ON/OFF)
at 1775 Pump RPM
CONTROL VALVE - TILT CONTROL AUXILIARY - NORMALLY CLOSED
390 - 430 PSI (2689 - 2965 kPa)
("P1" and "F1")
13 PILOTED ACTIVATED DIRECTIONAL 29 57 CHECK VALVE
CHARGE PUMP
CONTROL VALVE - LIFT CONTROL 41 CHECK VALVE - BICS CONTROL VALVE
14.0 GPM (53.0 L/min.) at 2450 RPM
14 SOLENOID ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . Gear Type 42 LIFT ARM BY-PASS RESTRICTOR
CONTROL VALVE - BICS CONTROL 20.7 GPM (78,4 L/min.) at 2450
Engine RPM 43 CHECK VALVE - AUXILIARY
15 PULL BUTTON ACTIVATED NOTE: Unless otherwise specified
53
DIRECTIONAL CONTROL VALVE - LIFT springs have NO significant
30.7 GPM (116,2 L/min.) at 2450 pressure value.
ARM BY PASS
Engine RPM
101 of 970
HYDRAULIC/HYDROSTATIC SCHEMATIC 38
39
863 (S/N 514450946 - 514451083 ) PILOT
(S/N 514641255 - 514641266) Printable Version Click Here
V-0236 DRIVE MOTOR
INTEGRATED QUICK COUPLER BLOCK
40 36
31 32
34 44
(REAR QUICK
COUPLERS) MALE (FRONT AUXILIARY
33 35 37
F2 D2
FEMALE
9 FEMALE FEMALE
DRAIN P1 P2
HYDRAULIC FILTER
3
4 D
COOLER
45 8
28
26 26
7
6
A
CHARGE INLET OUTLET
52 C
29
43
11
BOB-TACH 27
26
CYLINDER
26 45 24 24
(OPTIONAL)
Dealer Copy 25-- Not for Resale B
A B
HYDRAULIC
POWERED
BOB-TACH AUXILIARY
(OPTIONAL) SPOOL
INLET OUTLET
23 TILT CYLINDERS
22
BICS CONTROL VALVE
30
53
57 47
48 46
55
56 A B 12
49 51 TILT
CYLINDER
SPOOL
DRIVE MOTOR DR 50 21
9 18
P1 P2
5 20 LIFT CYLINDERS
17
PP 13
A B
LIFT
CYLINDER
SPOOL
32
31
18 42
* (If Equipped)
2 DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY PASS VALVE
15
Printed in U.S.A. V-0236 (11-26-03)
102 of 970
WITH TWO SPEED VALVE AND HIGH FLOW OPTION
863 (S/N 514450946 - 514451083)
(S/N 514641255 - 514641266)
V-0237legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 32 SHUTTLE RELIEF VALVE: 47 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . 18.8 Qts. (17,8 L) (SCREEN) 200 PSI (1378 kPa) CONTROL VALVE (TWO COIL)
17 ONE WAY RESTRICTOR 33 SOLENOID ACTIVATED DIRECTIONAL 48 RELIEF VALVE - 1200 PSI (8268 kPa)
2 FILTER - CASE DRAIN (90 Micron)
CONTROL VALVE - BLEED OFF REAR
18 LOAD CHECK VALVE AUXILIARY ("SV2") 49 PRESSURE COMPENSATED FLOW
3 FILTER - HYDRAULIC (CANISTER) CONTROL
19 RELIEF VALVE - MAIN: 34 LOAD SHUTTLE VALVE - BLEED OFF 50 CHECK VALVE WITH 0.015 (0,38 mm)
4 SPRING LOADED FILTER BYPASS 2950-3050 PSI (20340-21030 kPa) 35 PILOT ACTIVATED DIRECTIONAL RESTRICTION
VALVE: 45-55 PSI (311-379 kPa) at Front Quick Couplers CONTROL VALVE - FOR REAR 51 RELIEF VALVE - PORT:
5 PILOT ACTIVATED DIRECTIONAL 20 RELIEF VALVE - PORT: AUXILIARY - NORMALLY CLOSED 3500 PSI (24132 kPa)
CONTROL VALVE - HYDRAULIC 3500 PSI (24132 kPa) ("P2" and "F2") 52 SOLENOID ACTIVATED DIRECTIONAL
POWERED BOB-TACH
21 ANTICAVITATION VALVE 36
PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION
6 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE - FOR REAR VALVE (ON/OFF)
36-44 PSI (248-303 kPa) 22 RELIEF/ANTICAVITATION VALVE -
Dealer Copy -- Not AUXILIARY - NORMALLY OPEN
for Resale 53 FIXED CAPACITY DISPLACEMENT
("D1" and "P1") BIDIRECTIONAL HYDROSTATIC
7 FLOW DIVIDER ADJUSTMENT VALVE 3500 PSI (24132 kPa)
37 MOTOR
23 ONE WAY RESTRICTOR VALVE PILOT ACTIVATED DIRECTIONAL
8 CHECK VALVE - BUCKET POSITION CONTROL VALVE - FOR REAR 54 HYDRAULIC BRAKE - SPRING APPLIED -
VALVE AUXILIARY - NORMALLY OPEN PRESSURE TO RELEASE
CONTROL VALVE - AUXILIARY ("D2" and "P2") 55 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT CONTROL VALVE - BRAKE
BIDIRECTIONAL HYDROSTATIC 25 RELIEF VALVE - PORT: . . . . . (Optional) 38 FILTER - DIVERTER VALVE (SCREEN)
MOTOR 3500 PSI (24132 kPa) INTEGRATED IN SOLENOID 56 SOLENOID ACTIVATED DIRECTIONAL
39 CONTROL VALVE - MAKE-UP
26 RELIEF/REPLENISHING VALVE - HIGH SOLENOID ACTIVATED DIRECTIONAL
10 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TO ACTIVATE 57 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL PRESSURE: 5000 PSI (34475 kPa)
REAR AUXILIARY ("SV1") CONTROL VALVE - TWO SPEED
SPOOL 27 CHARGE PRESSURE SWITCH 40 PILOT ACTIVATED DIRECTIONAL 58 FRONT AUXILIARY MANUAL
11 PILOTED ACTIVATED DIRECTIONAL 28 CONTROL VALVE - FOR REAR PRESSURE BLEED-OFF VALVE
RELIEF VALVE - CHARGE:
CONTROL VALVE - UNLOADING AUXILIARY - NORMALLY CLOSED
120 degrees F. (53 degrees C.)Fluid 59 FILTER - CASE DRAIN (ATTACHMENT)
SPOOL ("P1" and "F1")
at 1775 Pump RPM
12 PILOTED ACTIVATED DIRECTIONAL 390 - 430 PSI (2689 - 2965 kPa) 41 CHECK VALVE - BICS CONTROL VALVE 60 RELIEF VALVE - 3300 PSI (22754 kPa)
CONTROL VALVE - TILT CONTROL 29 CHARGE PUMP 61 DUMP VALVE (ON/OFF)
42 LIFT ARM BY-PASS RESTICTOR
13 PILOTED ACTIVATED DIRECTIONAL 14.0 GPM (53,0 L/min.) at 2450 RPM
30 HYDRAULIC PUMP . . . . . . . Gear Type 43 CHECK VALVE - AUXILIARY 62 CHECK VALVE
20.7 GPM (78,4 L/min.) at 2450 44 PILOT ACTIVATED DIRECTIONAL 63 FILTER (BRAKE)
14 SOLENOID ACTIVATED DIRECTIONAL Engine RPM
CONTROL VALVE - BICS CONTROL CONTROL VALVE - TWO SPEED 64 AUXILIARY HYDRAULIC PUMP
64
HIGH FLOW CAPACITY: (Includes ) DRIVE MOTOR 10 GPM (37.85 L/min.) at 2450 RPM
15 PULL BUTTON ACTIVATED 30.7 GPM (116,2 L/min.) at 2450 45 VARIABLE CAPACITY DISPLACEMENT
DIRECTIONAL CONTROL VALVE - LIFT Engine RPM NOTE: Unless otherwise specified
ARM BY PASS 31 DRIVE MOTOR SHUTTLE VALVE springs have NO significant
46 TWO STAGE RELIEF 1000 PSI/2000 PSI pressure value.
(6894 kPa/13788 kPa)
103 of 970
38
863 (S/N 514450946 - 514451083) PILOT
39
(S/N 514641255 - 514641266) Printable Version Click Here

(PRINTED DECEMBER 2002) TWO SPEED DRIVE MOTOR
V-0237
40 36
34 (FRONT AUXILIARY
58
(REAR QUICK LEFT SIDE LIFT ARM)
MALE
COUPLERS)
58
33 35 37
F2 D2
54 44 FEMALE
FEMALE FEMALE
53
DRAIN P1 P2
9 HYDRAULIC FILTER
3
4 D
COOLER
45 8
26 26
28
7
6
52 C
INLET 29
26 43
11
27

24 for Resale 24
45 CYLINDER 25 B
(OPTIONAL) A B
26 30 26
HYDRAULIC
INLET OUTLET POWERED AUXILIARY
BOB-TACH SPOOL
(OPTIONAL)
23 TILT CYLINDERS
TWO SPEED VALVE 22
64 61 BICS CONTROL VALVE
55 B 62
63 60
47
63 TWO SPEED DRIVE MOTOR 48 46
A B 12
51 TILT
56 9
49 CYLINDER
SPOOL
54 53 21
C DR 50 18
P1 P2 17
5 13
PP
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
T DRAIN CIRCUITS
COMPONENTS
2 LIFT ARM BY PASS VALVE
15
Printed in U.S.A. V-0237 (11-26-03)
104 of 970
863 (S/N 514451084 AND ABOVE)
LEGEND
ARM BY-PASS 30
2 FILTER - CASE DRAIN (90 Micron) HYDRAULIC PUMP . . . . . . . Gear Type 42 LIFT ARM BY-PASS RESTRICTOR
17 BOOM DOWN RESTRICTOR 44 FRONT AUXILIARY MANUAL
4 SPRING LOADED FILTER BY-PASS 200 PSI (1378 kPa)
VALVE: 45-55 PSI (311-379 kPa) PRESSURE BLEED-OFF VALVE
CONTROL VALVE - BLEED OFF REAR 45 VARIABLE CAPACITY DISPLACEMENT
5 PILOT ACTIVATED DIRECTIONAL AUXILIARY ("SV2") BIDIRECTIONAL HYDROSTATIC PUMP
6 DIFFERENTIAL PRESSURE SWITCH: at Front Quick Couplers 35 PILOT ACTIVATED DIRECTIONAL 2000 PSI (6894 kPA/ 13788 kPA)
20 RELIEF VALVE - PORT: AUXILIARY - NORMALLY CLOSED CONTROL VALVE (TWO COIL)
FLOW DIVIDER ADJUSTMENT VALVE 3500 PSI (24132 kPa) ("P2" and "F2")
7
for Resale
CHECK VALVE - BUCKET POSITION 49 PRESSURE COMPENSATED FLOW
AUXILIARY - NORMALLY OPEN
VALVE 22 RELIEF/ANTICAVITATION VALVE - CONTROL
("D1" and "P1")
37 PILOT ACTIVATED DIRECTIONAL 50 CHECK VALVE WITH .015 (0,38mm)
MOTOR AUXILIARY - NORMALLY OPEN
23 ONE WAY RESTRICTOR VALVE ("D2" and "P2") 51 RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
10 PILOTED ACTIVATED DIRECTIONAL 24 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TO ACTIVATE VALVE (ON/OFF)
25 RELIEF VALVE - PORT: . . . . . . . . (Optional)
3500 PSI (24132 kPa) REAR AUXILIARY ("SV1")
CONTROL VALVE - UNLOADING 40 PILOT ACTIVATED DIRECTIONAL
SPOOL
12 PILOTED ACTIVATED DIRECTIONAL ("P1" and "F1")
CONTROL VALVE - TILT CONTROL 27 CHARGE PRESSURE SWITCH
390 - 430 PSI (2689 - 2965 kPa)
105 of 970
863 (S/N 514451084 AND ABOVE) 38
(S/N 514541114 AND ABOVE) 39
V-0238

DRIVE MOTOR FRONT AUXILIARY
LEFT SIDE LIFT ARM
40 36 44
MALE MALE F1 D1
MALE
31 32
34 DRAIN
REAR QUICK
(MALE)
COUPLERS
(OPTIONAL)
37 FEMALE
33 35
F2 D2 44
FEMALE FEMALE
9
DRAIN P1 P2
HYDRAULIC FILTER
3 2 BUCKET POSITION VALVE (OPTIONAL)
4 D
COOLER
45 8
28
26
26 7
6
A
CHARGE INLET OUTLET
52 C
29
43
11
27
26
26
45
Dealer Copy -- Not
24 for Resale 24
BOB-TACH 25 B
CYLINDER A B
POWERED
BOB-TACH
DR SPOOL
INLET OUTLET
23
22 TILT CYLINDER
BICS CONTROL VALVE
30
A B 12
46 47 TILT
48 51
CYLINDER
SPOOL
49
DRIVE MOTOR
50 21
9 18
20 LIFT CYLINDERS
17
P2
13
P1
5 PP
A B
LIFT
CYLINDER
SPOOL
31 32
18 42
19 14
* (If Equipped)
WORKING CIRCUITS
16 PILOT CIRCUITS
2 DRAIN CIRCUITS
COMPONENTS
16
41
15
Printed in U.S.A. V-0238 (11-6-02)
106 of 970
863 (S/N 514451084 AND ABOVE)
LEGEND
3500 PSI (24132 kPa)
("P1" and "F1")
390 - 430 PSI (2689 - 2965 kPa)
13 PILOTED ACTIVATED DIRECTIONAL 31 DRIVE MOTOR SHUTTLE VALVE 44 PILOT ACTIVATED DIRECTIONAL BLEED-OFF VALVE
ARM BY-PASS AUXILIARY ("SV2") 46 TWO STAGE RELIEF VALVE 1000 PSI/
16 FILTER - BICS CONTROL VALVE 2000 PSI (6894 kPa/ 13788 kPa)
(SCREEN)
107 of 970
863 (S/N 514451084 AND ABOVE) 38
(S/N 514541114 AND ABOVE) 39
PILOT
(PRINTED DECEMBER 2003) Printable Version Click Here
V-0239
FRONT AUXILIARY
LEFT SIDE LIFT ARM
40 36 59
34 DRAIN
(REAR QUICK (MALE)
COUPLERS)
37 FEMALE
33 35
F2 D2 59
54 44
FEMALE FEMALE
53
33
DRAIN P1 P2
9 HYDRAULIC FILTER
3
4 D
COOLER
45 8
26 26
28
7
6
52 C
INLET 29
43
11
27

24 for Resale 24
45 CYLINDER 25 B
POWERED
BOB-TACH
26 30 26 (OPTIONAL)
SPOOL
58
23
BICS CONTROL VALVE
55
46 47
54 48 A B 12
49 51 TILT
56 9
CYLINDER
50 SPOOL
53 21
C
18
17
P1 P2
5 13
PP
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
16 PILOT CIRCUITS
T DRAIN CIRCUITS
COMPONENTS
16 41
15
Printed in U.S.A. V-0239 (11-26-03)
108 of 970
863 (S/N 514451084 AND ABOVE)
V-0240legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 31 DRIVE MOTOR SHUTTLE VALVE 44 FRONT AUXILIARY MANUAL
Capacity . . . . . . . . . 18.8 Qts. (17.8 (SCREEN) PRESSURE BLEED-OFF VALVE
L) 32 SHUTTLE RELIEF VALVE:
2 FILTER - CASE DRAIN (90 Micron) 17 ONE WAY RESTRICTOR 200 PSI (1378 kPa) 45 VARIABLE CAPACITY DISPLACEMENT
3 FILTER - HYDRAULIC (CANISTER) 18 LOAD CHECK VALVE 33 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR 46 TWO STAGE RELIEF 1000 PSI/2000 PSI
4 SPRING LOADED FILTER BYPASS 19 RELIEF VALVE - MAIN: AUXILIARY ("SV2") (6894kPa/13788 kPa)
at Front Quick Couplers 34 LOAD SHUTTLE VALVE - BLEED OFF 47 SOLENOID ACTIVATED DIRECTIONAL
5 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)
CONTROL VALVE - HYDRAULIC 20 RELIEF VALVE - PORT: 35 PILOT ACTIVATED DIRECTIONAL
POWERED BOB-TACH 48 RELIEF VALVE - 1200 PSI (8268 kPa)
3500 PSI (24132 kPa) CONTROL VALVE - FOR REAR
6 DIFFERENTIAL PRESSURE SWITCH: AUXILIARY - NORMALLY CLOSED 49
21 ANTICAVITATION VALVE PRESSURE COMPENSATED FLOW
36-44 PSI (248-303 kPa) ("P2" and "F2")
CONTROL
22 RELIEF/ANTICAVITATION VALVE - 36 PILOT ACTIVATED DIRECTIONAL
7 FLOW DIVIDER ADJUSTMENT VALVE Dealer Copy -- Not for Resale 50 CHECK VALVE WITH 0.015 (0,38 mm)
PORT (TILT BASE END) CONTROL VALVE - FOR REAR
RESTRICTION
3500 PSI (24132 kPa) AUXILIARY - NORMALLY OPEN
8 CHECK VALVE - BUCKET POSITION ("D1" and "P1")
23 ONE WAY RESTRICTOR VALVE
37 PILOT ACTIVATED DIRECTIONAL 3500 PSI (24132 kPa)
FIXED CAPACITY DISPLACEMENT 24 SOLENOID ACTIVATED DIRECTIONAL
BIDIRECTIONAL HYDROSTATIC CONTROL VALVE - AUXILIARY AUXILIARY - NORMALLY OPEN 52 SOLENOID ACTIVATED DIRECTIONAL
MOTOR 25 ("D2" and "P2") CONTROL VALVE - BUCKET POSITION
RELIEF VALVE - PORT: . . . . . (Optional)
VALVE (ON/OFF)
3500 PSI (24132 kPa)
10 PILOTED ACTIVATED DIRECTIONAL 38 FILTER - DIVERTER VALVE (SCREEN) 53 AUXILIARY HYDRAULIC PUMP
CONTROL VALVE - FLOW CONTROL 26 INTEGRATED IN SOLENOID
RELIEF/REPLENISHING VALVE - HIGH 10 GPM (37.85 L/min.) at 2450 RPM
SPOOL PRESSURE: 5000 PSI (34474 kPa) 39 SOLENOID ACTIVATED DIRECTIONAL 54 FILTER - CASE DRAIN (ATTACHMENT)
11 PILOTED ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH CONTROL VALVE - TO ACTIVATE
CONTROL VALVE - UNLOADING REAR AUXILIARY ("SV1") 55 RELIEF VALVE - 3300 PSI (22754 kPa)
12 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FOR REAR 56 DUMP VALVE (ON/OFF)
at 1775 Pump RPM
CONTROL VALVE - TILT CONTROL AUXILIARY - NORMALLY CLOSED
390 - 430 PSI (2689 - 2965 kPa)
("P1" and "F1")
13 PILOTED ACTIVATED DIRECTIONAL 29 57 CHECK VALVE
CHARGE PUMP
CONTROL VALVE - LIFT CONTROL 41 CHECK VALVE - BICS CONTROL VALVE
14.0 GPM (53.0 L/min.) at 2450 RPM
14 SOLENOID ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . Gear Type 42 LIFT ARM BY-PASS RESTRICTOR
CONTROL VALVE - BICS CONTROL 20.7 GPM (78,4 L/min.) at 2450
Engine RPM 43 CHECK VALVE - AUXILIARY
15 PULL BUTTON ACTIVATED NOTE: Unless otherwise specified
53
DIRECTIONAL CONTROL VALVE - LIFT springs have NO significant
30.7 GPM (116,2 L/min.) at 2450 pressure value.
ARM BY PASS
Engine RPM
109 of 970
HYDRAULIC/HYDROSTATIC SCHEMATIC 38
39
863 (S/N 514451084 AND ABOVE ) PILOT
(S/N 514641267 AND ABOVE) Printable Version Click Here
V-0240 DRIVE MOTOR
40 36
31 32
34 44
(REAR QUICK
COUPLERS) MALE (FRONT AUXILIARY
33 35 37
F2 D2
FEMALE
9 FEMALE FEMALE
DRAIN P1 P2
HYDRAULIC FILTER
3
4 D
COOLER
45 8
28
26 26
7
6
A
CHARGE INLET OUTLET
52 C
29
43
11
27
26
26 45 24 24
BOB-TACH
Dealer Copy 25-- Not for Resale B
CYLINDER A B
POWERED
BOB-TACH AUXILIARY
(OPTIONAL) SPOOL
INLET OUTLET
23 TILT CYLINDERS
22
BICS CONTROL VALVE
30
53
57 47
48 46
55
56 A B 12
49 51 TILT
CYLINDER
SPOOL
DRIVE MOTOR DR 50 21
9 18
P1 P2
5 20 LIFT CYLINDERS
17
PP 13
A B
LIFT
CYLINDER
SPOOL
32
31
18 42
* (If Equipped)
16 PILOT CIRCUITS
2 DRAIN CIRCUITS
COMPONENTS
16 41
LIFT ARM BY PASS VALVE
15
Printed in U.S.A. V-0240 (11-26-03)
110 of 970
863 (S/N 514451084 AND ABOVE)
V-0241legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 32 SHUTTLE RELIEF VALVE: 47 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . 18.8 Qts. (17,8 L) (SCREEN) 200 PSI (1378 kPa) CONTROL VALVE (TWO COIL)
17 ONE WAY RESTRICTOR 33 SOLENOID ACTIVATED DIRECTIONAL 48 RELIEF VALVE - 1200 PSI (8268 kPa)
2 FILTER - CASE DRAIN (90 Micron)
CONTROL VALVE - BLEED OFF REAR
18 LOAD CHECK VALVE AUXILIARY ("SV2") 49 PRESSURE COMPENSATED FLOW
3 FILTER - HYDRAULIC (CANISTER) CONTROL
19 RELIEF VALVE - MAIN: 34 LOAD SHUTTLE VALVE - BLEED OFF 50 CHECK VALVE WITH 0.015 (0,38 mm)
4 SPRING LOADED FILTER BYPASS 2950-3050 PSI (20340-21030 kPa) 35 PILOT ACTIVATED DIRECTIONAL RESTRICTION
VALVE: 45-55 PSI (311-379 kPa) at Front Quick Couplers CONTROL VALVE - FOR REAR 51 RELIEF VALVE - PORT:
5 PILOT ACTIVATED DIRECTIONAL 20 RELIEF VALVE - PORT: AUXILIARY - NORMALLY CLOSED 3500 PSI (24132 kPa)
CONTROL VALVE - HYDRAULIC 3500 PSI (24132 kPa) ("P2" and "F2") 52 SOLENOID ACTIVATED DIRECTIONAL
POWERED BOB-TACH
21 ANTICAVITATION VALVE 36
PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION
6 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE - FOR REAR VALVE (ON/OFF)
36-44 PSI (248-303 kPa) 22 RELIEF/ANTICAVITATION VALVE -
Dealer Copy -- Not AUXILIARY - NORMALLY OPEN
for Resale 53 FIXED CAPACITY DISPLACEMENT
("D1" and "P1") BIDIRECTIONAL HYDROSTATIC
7 FLOW DIVIDER ADJUSTMENT VALVE 3500 PSI (24132 kPa)
37 MOTOR
23 ONE WAY RESTRICTOR VALVE PILOT ACTIVATED DIRECTIONAL
8 CHECK VALVE - BUCKET POSITION CONTROL VALVE - FOR REAR 54 HYDRAULIC BRAKE - SPRING APPLIED -
VALVE AUXILIARY - NORMALLY OPEN PRESSURE TO RELEASE
CONTROL VALVE - AUXILIARY ("D2" and "P2") 55 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT CONTROL VALVE - BRAKE
BIDIRECTIONAL HYDROSTATIC 25 RELIEF VALVE - PORT: . . . . . (Optional) 38 FILTER - DIVERTER VALVE (SCREEN)
MOTOR 3500 PSI (24132 kPa) INTEGRATED IN SOLENOID 56 SOLENOID ACTIVATED DIRECTIONAL
39 CONTROL VALVE - MAKE-UP
26 RELIEF/REPLENISHING VALVE - HIGH SOLENOID ACTIVATED DIRECTIONAL
10 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TO ACTIVATE 57 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL PRESSURE: 5000 PSI (34475 kPa)
REAR AUXILIARY ("SV1") CONTROL VALVE - TWO SPEED
SPOOL 27 CHARGE PRESSURE SWITCH 40 PILOT ACTIVATED DIRECTIONAL 58 FRONT AUXILIARY MANUAL
11 PILOTED ACTIVATED DIRECTIONAL 28 CONTROL VALVE - FOR REAR PRESSURE BLEED-OFF VALVE
RELIEF VALVE - CHARGE:
CONTROL VALVE - UNLOADING AUXILIARY - NORMALLY CLOSED
120 degrees F. (53 degrees C.)Fluid 59 FILTER - CASE DRAIN (ATTACHMENT)
SPOOL ("P1" and "F1")
at 1775 Pump RPM
12 PILOTED ACTIVATED DIRECTIONAL 390 - 430 PSI (2689 - 2965 kPa) 41 CHECK VALVE - BICS CONTROL VALVE 60 RELIEF VALVE - 3300 PSI (22754 kPa)
CONTROL VALVE - TILT CONTROL 29 CHARGE PUMP 61 DUMP VALVE (ON/OFF)
42 LIFT ARM BY-PASS RESTICTOR
13 PILOTED ACTIVATED DIRECTIONAL 14.0 GPM (53,0 L/min.) at 2450 RPM
30 HYDRAULIC PUMP . . . . . . . Gear Type 43 CHECK VALVE - AUXILIARY 62 CHECK VALVE
20.7 GPM (78,4 L/min.) at 2450 44 PILOT ACTIVATED DIRECTIONAL 63 FILTER (BRAKE)
14 SOLENOID ACTIVATED DIRECTIONAL Engine RPM
CONTROL VALVE - BICS CONTROL CONTROL VALVE - TWO SPEED 64 AUXILIARY HYDRAULIC PUMP
64
HIGH FLOW CAPACITY: (Includes ) DRIVE MOTOR 10 GPM (37.85 L/min.) at 2450 RPM
15 PULL BUTTON ACTIVATED 30.7 GPM (116,2 L/min.) at 2450 45 VARIABLE CAPACITY DISPLACEMENT
DIRECTIONAL CONTROL VALVE - LIFT Engine RPM NOTE: Unless otherwise specified
ARM BY PASS 31 DRIVE MOTOR SHUTTLE VALVE springs have NO significant
46 TWO STAGE RELIEF 1000 PSI/2000 PSI pressure value.
(6894 kPa/13788 kPa)
111 of 970
38
863 (S/N 514451084 AND ABOVE) PILOT
39
(S/N 514641267 AND ABOVE) Printable Version Click Here

(PRINTED DECEMBER 2003) TWO SPEED DRIVE MOTOR
V-0241
40 36
34 (FRONT AUXILIARY
58
(REAR QUICK LEFT SIDE LIFT ARM)
MALE
COUPLERS)
58
33 35 37
F2 D2
54 44 FEMALE
FEMALE FEMALE
53
DRAIN P1 P2
9 HYDRAULIC FILTER
3
4 D
COOLER
45 8
26 26
28
7
6
52 C
INLET 29
26 43
11
27
Dealer Copy -- Not
24 for Resale 24
45 25 B
A B
BOB-TACH
26 26 CYLINDER
30 HYDRAULIC (OPTIONAL)
INLET OUTLET POWERED AUXILIARY
BOB-TACH SPOOL
(OPTIONAL)
23 TILT CYLINDERS
TWO SPEED VALVE 22
64 61 BICS CONTROL VALVE
55 B 62
63 60
47
63 TWO SPEED DRIVE MOTOR 48 46
A B 12
51 TILT
56 9
49 CYLINDER
SPOOL
54 53 21
C DR 50 18
P1 P2 17
5 13
PP
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
16 PILOT CIRCUITS
T DRAIN CIRCUITS
41 COMPONENTS
16
2 LIFT ARM BY PASS VALVE
15
Printed in U.S.A. V-0241 (11-26-03)
112 of 970
HYDRAULIC SYSTEM INFORMATION
MC 2340 (6-2-98)
863 Bobcat Loader

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

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

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HYDRAULIC SYSTEM INFORMATION (CONT’D) Troubleshooting Chart
The following troubleshooting chart is provided for

assistance in locating and correcting problems which are
IMPORTANT most common. Many of the recommended procedures
must be done by authorized Bobcat Service Personnel
only.
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. WARNING
I-2003-0888
Check for correct function after adjustments, repairs
Tighten Procedures or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
For tightening torques for hydraulic fittings, tubelines etc.,
(See HYDRAULIC FLUID SPECIFICATIONS on Page
SPEC-60-1.).
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
The transmission warning light comes ON when hydraulics are operating. 1, 3,

Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine RPM. 1, 3, 4, 5, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position. 4, 9, 10, 11
Bypass valve stuck. 12
Bypass valve stem bent or broke. 13
KEY TO CORRECT THE CAUSE

1. The fluid level is not correct.
2. The pedal linkage is disconnected.
3. The hydraulic pump has damage.
4. The pedal linkage is not adjusted correctly.
5. Relief valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold. Wrong viscosity fluid. (See Hydraulic System on Page SPEC-10-3.)
8. Using the loader for more than its rated capacity.
9. Internal leak in the lift cylinder(s).
10. External leak from the lift cylinder(s).
11. Damaged lift spool.
12. Rotate shaft.
13. Replace manual spool cartridge.
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CYLINDER (LIFT) Figure 20-20-2
Checking
WARNING
enters skin or eyes, get immediate medical attention CD-15068
W-2072-0807
Install a plug (Item 1) [Figure 20-20-2] in the hose and
tighten.
Figure 20-20-1
Engage the parking brake. Lower the seat bar. Start the
engine and push the top (toe) of the lift pedal.

1 If there is any leakage from the open port, remove the lift
cylinder for repair. Repeat the procedure to check the
other lift cylinder.
CD-15067
Lower the lift arms. Stop the engine. Raise the seat bar.
Check only one cylinder at a time. Disconnect the hose

(Item 1) [Figure 20-20-1] which goes to the base end of
the lift cylinder.
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CYLINDER (LIFT) (CONT’D) Figure 20-20-5
Removal And Installation
Figure 20-20-3
CD-15070
Remove the retaining bolt and nut (Item 1) [Figure 20-

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

Raise the lift arms so the rod end retaining pin will clear ft.-lb. (24 - 27 N•m) torque.
the loader frame for removal.

Figure 20-20-6
Have a second person put jackstands under the Bob-
Tach to support the lift arms [Figure 20-20-3]. Stop the
engine.

on Page 10-30-1.)
Figure 20-20-4
CD-15072
1 Remove the pivot pin from the base end of the cylinder
[Figure 20-20-6].
Slide the cylinder forward for clearance to disconnect the

hoses.
CD-15069
Mark the hoses for correct installation.
Remove the retaining bolt and nut (Item 1) [Figure 20-

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

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

CD-15073
Disconnect the two hoses (Item 1) [Figure 20-20-7] from

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

2. O-Ring 11. O-ring
3. Plug 12. Washer
4. Case 13. Head
5. O-Ring 14. Seal
6. Nut 15. Seal
7. Piston 16. Rod
8. Ring
9. O-ring

10
9
B-14213A B-14213B
8
3 6 16
2
5
15
1
14
3
2 13
4
12
11
B-13593B
TS-1060
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Disassembly 4
Figure 20-20-8 3
1 2
P-7428
Lift Cylinder: Remove the head and the rod assembly

P-7429 from the cylinder [Figure 20-20-10]. Put the rod end in a
vise.
Figure 20-20-9 Lift Cylinder: Remove the nut (Item 1) [Figure 20-20-10],
piston (Item 2) [Figure 20-20-10], spacer (Item 3)

[Figure 20-20-10]. and head (Item 4) [Figure 20-20-10].
Figure 20-20-11
3
2
1
P-7435
Use the following tools to disassemble the cylinder:

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

the rod in and out slowly to remove the fluid from the
cylinder.
Put the base end of the cylinder in a vise.
Use a spanner wrench to loosen the head [Figure 20-20-

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

P-7430 the back-up washer (Item 2) [Figure 20-20-14] from the
groove in the head. Remove the thin O-ring (Item 3)
[Figure 20-20-14].
Standard Piston: Remove the seal (Item 1) [Figure 20-
20-12], and O-ring (Item 2) [Figure 20-20-12] from the Figure 20-20-15

piston (Item 3) [Figure 20-20-12].
Figure 20-20-13
2
2 1
1 3
P-7426
P-7439 Remove the wiper seal (Item 1) [Figure 20-20-15], and

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

P-7424 17] and O-ring (Item 2) [Figure 20-20-17] on the piston
(Item 3) [Figure 20-20-17].
Use the following tools to assemble the cylinder: Figure 20-20-18

MEL 1396 - Seal Installation Tool
MEL 1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
1
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts.
Always install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic oil during

installtion. P-7438
Install a new seal on the tool and slowly stretch it until it

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

P-7427
Install the back-up washer (Item 2) [Figure 20-20-21]
and thick O-ring (Item 3) [Figure 20-20-21] into the
Install the rod seal on the rod seal tool [Figure 20-20-19]. groove in the head.

NOTE: During Installation the O-ring side of the seal NOTE: Clean and dry the threads before installing the
must be toward the inside of the cylinder. nut. Install the new nut from the kit.
Rotate the handles to collapse the rod seal [Figure 20- Figure 20-20-22
20-19].
Figure 20-20-20
1
2
3
P-7434
P-7425 Tilt Cylinder: Install the head (Item 1) [Figure 20-20-22],

and piston (Item 2) [Figure 20-20-22]. The small
diameter of the piston goes into the cylinder tube first.
Install the rod seal in the head [Figure 20-20-20].
Tilt Cylinder: Grease the piston where the nut contacts
Install the wiper seal with the wiper toward the outside of the piston. Do not get grease on the threads.
the head.
Tilt Cylinder: Install the nut (Item 3) [Figure 20-20-22].
Tilt Cylinder: Tighten the nut to 100 ft.-lb. (136 N•m)

torque.
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Assembly (Cont’d)
Figure 20-20-23
P-7429
Figure 20-20-26
P-10450 P-10456
Tilt Cylinder: Mark the end of the shaft and nut [Figure
20-20-23]. Tighten the nut an additional 135 degrees or

2-1/4 flats [Figure 20-20-23].
NOTE: Clean and dry the threads before installing the

nut. Install the new nut from the kit.
Figure 20-20-24
1
2
3
P-7435
4
Tighten the head using a spanner wrench [Figure 20-20-

25] & [Figure 20-20-26].
P-7428
Lift Cylinder: Install the head (Item 1) [Figure 20-20-24],

and spacer (Item 2) [Figure 20-20-24].
Lift Cylinder: Install the piston (Item 3) [Figure 20-20-24],

and the nut (Item 4) [Figure 20-20-24].
Lift Cylinder: Tighten the nut (Item 4) [Figure 20-20-24]

to 400 ft.-lb. (542 N•m) torque.
Put the base end of the hydraulic cylinder in a vise.
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863 Bobcat Loader

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CYLINDER (TILT) Removal And Installation
Checking Figure 20-21-2
WARNING
W-2072-0807 P-7694
Figure 20-21-1
Remove the attachment. Roll the Bob-Tach fully forward
[Figure 20-21-2].
Stop the engine. Raise the seat bar.

2 Figure 20-21-3
1
P-1187
Remove the attachment. Roll the Bob-Tach fully back.

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

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

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

ft.-lb. (24 - 27 N•m) torque.

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

Remove the old seal (both sides) from the rod end of the installation.
tilt cylinder.

Hold the rod end in position and remove the shim stock.
Install the new seals (Item 1) [Figure 20-21-7] with the lip
facing out.
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CYLINDER (TILT) (CONT’D)
1. Case
2. Plug
3. O-Ring
4. Tube
5. Nut
6. Clamp
7. Bolt
8. Nut
9. Piston MC-1688B
10. Seal
11. O-Ring 3
12. O-Ring 2
MC-1688A
13. Washer
14. O-Ring 4
15. Head
6 5 1
16. Seal
17. Seal
18. Rod
19. Seal

20. Bushing
15
9
10 16
11 17
12
13
19 20 19 18
14
MC-1688C
MC-1688D
TS-1233
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Disassembly
MEL 1074 - O-ring Seal Hook

Spanner Wrench
The lift and tilt cylinders internal components are similar,

the differences are listed below.
Tilt rod is larger in diameter.

Piston relief area is slightly different.
No spacer in the tilt cylinder.
P-7435
Hold the hydraulic cylinder over a drain pan and move
cylinder. Use a spanner wrench to loosen the head [Figure 20-21-
9] & [Figure 20-21-10].
Figure 20-21-9

P-7429
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Disassembly (Cont’d) 3
Figure 20-21-11
2
4
3 1
1 2
P-7430
Standard piston: Remove the seal (Item 1) [Figure 20-

P-7428 21-13], and O-ring (Item 2) [Figure 20-21-13] from the
Lift Cylinder: Remove the head and the rod assembly Figure 20-21-14
from the cylinder [Figure 20-21-11]. Put the rod end in a

vise. 3
Lift Cylinder: Remover the nut (Item 1) [Figure 20-21-
11], piston (Item 2) [Figure 20-21-11], spacer (Item 3)
[Figure 20-21-17] and head (Item 4) [Figure 20-21-11]. 2
1
Figure 20-21-12
3
2
1
P-7439
Cushion Piston: Remove the seal (Item 1) [Figure 20-21-

14], and O-ring (Item 2) [Figure 20-21-14] from the
P-7434
Tilt Cylinder: Remove the head and rod assembly from

the cylinder [Figure 20-21-12]. Put the rod end in a vise.
Tilt Cylinder: Remove the nut (Item 1) [Figure 20-21-12],

piston (Item 2) [Figure 20-21-12] and head (Item 3)
[Figure 20-21-12].
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CYLINDER (TILT) (CONT’D) Assembly
Disassembly (Cont’d) Use the following tools to assemble the cylinder:
Figure 20-21-15 MEL1396 - Seal Installation Tool

MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
2 Inspect the cylinder parts for nicks, scratches or other

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

installation.
P-7426 Figure 20-21-17
Remove the thick O-ring (Item 1) [Figure 20-21-15], and

the back-up washer (Item 2) [Figure 20-21-15] from the

groove in the head. Remove the thin O-ring (Item 3)
[Figure 20-21-15].
Figure 20-21-16
2 P-7424
1
3 Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-21-17].
Allow the seal to stretch for 30 seconds before installing it

on the piston.
P-7426
Remove the wiper seat (Item 1) [Figure 20-21-16], and

rod seal (Item 2) [Figure 20-21-16].
Remove the O-ring (Item 3) [Figure 20-21-16] from the

rod seal.
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Assembly (Cont’d)
Figure 20-21-18
P-7427
Install the rod seal on the rod seal tool [Figure 20-21-20].
P-7430
NOTE: During installation the O-ring side of the seal
must be toward the inside of the cylinder.
Standard Piston: Install the seal (Item 1) [Figure 20-21-
18] and O-ring (Item 2) [Figure 20-21-18] on the piston Rotate the handles to collapse the rod seal [Figure 20-

(Item 3) [Figure 20-21-18]. 21-20].
Figure 20-21-19 Figure 20-21-21
P-7438 P-7425
Cushion Piston: Install the seal and O-ring on the piston Install the rod seal in the head [Figure 20-21-21].
(Item 1) [Figure 20-21-19].
Install the wiper seal with the wiper toward the outside of
Use a ring compressor to compress the seal to the the head.
correct size. Leave the piston in the compressor for about
three minutes.
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CYLINDER (TILT) (CONT’D) Tilt Cylinder: Tighten the nut to 100 ft.-lb. (136 N•m)
torque.
Assembly (Cont’d)
Figure 20-21-24
Figure 20-21-22
1
2
3
P-10450 P-10456
P-7422
Tilt Cylinder: Mark the end of the shaft and nut [Figure
Install the thin O-ring (Item 1) [Figure 20-21-22]. 20-21-24]. Tighten the nut an additional 135 degrees or
2-1/4 flats [Figure 20-21-24].

Install the back-up washer (Item 2) [Figure 20-21-22]
and thick O-ring (Item 3) [Figure 20-21-22]into the NOTE: Clean and dry the threads before installing the
groove on the head. nut. Install the new nut from the kit.
NOTE: Clean and dry the threads before installing the Figure 20-21-25
nut. Install the new nut from the kit.
1
Figure 20-21-23 2
3
4
1
2
3
P-7428
Lift Cylinder: Install the head (Item 1) [Figure 20-21-25],

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

P-7435

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

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


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

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

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

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

N-23031
Installation: Tighten the bolts to 25 - 28 ft.-lb. (34 - 38
N•m) torque.
Disconnect the hoses (Item 1 & 2) [Figure 20-22-4] from
the cylinder fittings. Remove the washers and cylinder from the lever pivots.

Install plugs and cap in fittings.
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CYLINDER (POWER BOB-TACH) (CONT’D)
1. Cylinder
2. Nut
3. Piston
4. O-Ring
5. Ring
6. Spacer
7. O-Ring
8. Ring
9. O-Ring
10. Head
11. Seal
12. Seal
13. Rod 1
2 3
4

5
6
7
8 9
10
11
12
13
TS-1233
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Disassembly
2
3 1
Figure 20-22-6
P-16294
Remove the head and rod assembly from the cylinder

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

Remove the nut (Item 1) [Figure 20-22-7], piston (Item 2)

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

6].
P-16295
Piston: Remove the O-ring (Item 1) [Figure 20-22-8],

and seal (Item 2) [Figure 20-22-8] from the piston (Item
3) [Figure 20-22-8].
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CYLINDER (POWER BOB-TACH) (CONT’D) Assembly
Disassembly (Cont’d) Figure 20-22-10
Figure 20-22-9
5
3
4
2
1
P-7424
N-20611
Use the following tools to assemble the cylinder:
Remove the wiper seal (Item 1) [Figure 20-22-9], and MEL1396 - Seal Installation Tool
rod seal (Item 2) [Figure 20-22-9], the back-up washer MEL1033 - Rod Seal Installation Tool

(Item 3) [Figure 20-22-9] the thin O-ring (Item 4) [Figure Piston Ring Compressor
20-22-9] and the thick O-ring (Item 5) [Figure 20-22-9] Spanner Wrench
from the head.
Inspect the cylinder parts for nicks, scratches or other

Always install new O-rings and seals during assembly.

installation.
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-22-10].
Allow the seal to stretch for 30 seconds before installing it

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

P-16295 22-13].
Figure 20-22-14
Piston: Install the O-ring (Item 1) [Figure 20-22-11]and
seal (Item 2) [Figure 20-22-11] on the piston (Item 3)

[Figure 20-22-11].
NOTE: The piston center hole (Item 4) [Figure 20-22-

11] has a bevel on one end. The bevel goes
toward the rod.
Figure 20-22-12
P-7425
Install the rod seal in the head [Figure 20-22-14].
Install the wiper seal with the wiper toward the outside of
the head.
N-20612
Install the rod seal on the rod seal tool[Figure 20-22-12].
NOTE: During installation the O-ring side of the seal

must be toward the inside of the cylinder.
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Assembly (Cont’d)
1 3
2 4
Figure 20-22-15
2
3
P-16294
Install the head (Item 1) [Figure 20-22-16], and spacer

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

Install the thin O-ring (Item 1) [Figure 20-22-15].
Lift Cylinder: Grease the piston where the nut contacts

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

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

Hydraulics IMPORTANT
NOTE: This procedure is the same for 863 and 863 H
The hydraulic tester must be in the fully open
in the standard flow mode.
position before you start the engine.
I-2024-0284
The 863H is a single pressure (3000 PSI) system with 2
flow modes. There are 2 pumps with a relief valve for
each pump. Only the standard flow (main relief valve) is
adjustable.

WARNING
procedure: Put jackstands under the front axles and rear corners
MEL 10003 - Hydraulic Tester Failure to use jackstands can allow the machine to
MEL 10006 - Hydraulic Test Kit fall or move and cause injury or death.
W-2017-0286
Turn the key switch to the OFF position, as the engine
stops running, turn the key switch all the way to the left to
release the hydraulic pressure at the front auxiliary quick Figure 20-30-2
couplers.

Figure 20-30-1
B-15551
Start the engine and run at low engine idle RPM. Push
the mode switch (Item 1) [Figure 20-30-2] (on the
instrument panel) two times to engage the front auxiliary
hydraulics, the light (Item 2) [Figure 20-30-2]will come
P-5061
ON.
Connect the IN port of the hydraulic tester to the female

quick coupler on the loader [Figure 20-30-1].
Connect the OUT port of the hydraulic tester to the male

quick coupler on the loader [Figure 20-30-1].
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MAIN RELIEF VALVE (FOOT CONTROL) (CONT’D) Checking The Main Relief Valve Without Front
Auxiliaries
Checking The Main Relief Valve At Front Auxiliary
Hydraulics (Cont’d) The tools listed will be needed to do the following
procedure:
Figure 20-30-3
MEL 10003 - Hydraulic Tester
MEL - 10006 - Hydraulic Test Kit
Stop the engine.

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

1

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

sure the flow is correct. Increase the engine speed to full
RPM.
CD-15074
There should be 18.0 GPM (68,1 L/min.) free flow (S/N
51444001-514441938) & 20.7 GPM (78,4 L/min.) free
flow (S/N 514441939 & Above). Turn the restrictor Disconnect the hydraulic hoses (Item 1) [Figure 20-30-4]
control, on the tester, until the main relief valve opens. from the tilt cylinder.
The correct pressure for the main relief is 3000 PSI
(20685 kPa).
Stop the engine. Replace or adjust the main relief valve.

(See Removal And Installation on Page 20-30-4.)
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MAIN RELIEF VALVE (FOOT CONTROL) (CONT’D) Replace or adjust the main relief valve. (See Removal
And Installation on Page 20-30-4.)
Checking The Main Relief Valve Without Front
Auxiliaries (Cont’d)
Figure 20-30-5
WARNING
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-0807
P-1193
Connect the hydraulic tester to the tilt cylinder hoses

[Figure 20-30-5].
Have a second person in the operator seat, with seat bar

in down position.
IMPORTANT
I-2024-0284
Start the engine and run at idle RPM.
Push the tilt pedal at the top (toe) or bottom (heel) until
the hydraulic tester shows the correct fluid flow through
the flow meter.
Increase the engine RPM to maximum.
There should be 18.0 GPM (68,1 L/min.) free flow (S/N

51444001-514441938) & 20 GPM (75,7 L/min.) free flow
(S/N 514441939 & Above).
Turn the restrictor control, on the tester, to increase the

pressure until the main relief valve opens.
The correct pressure is 3000 PSI (20685 kPa).
Stop the engine.
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MAIN RELIEF VALVE (FOOT CONTROL) (CONT’D) Figure 20-30-7

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

(47 - 54 N•m) torque.

Figure 20-30-8
N-20039
The main relief valve (Item 1) [Figure 20-30-6] is located

at the lower front of the control valve.
CD-15092
Remove the right side motor cover. (See Disassembly on
Page 30-20-4.)
Remove the O-rings and back-up washers from the main
Clean the area around the control valve. relief valve [Figure 20-30-8].
Clean the main relief valve in clean solvent. Use air

pressure to dry the valve.
Install new O-rings and backup washers. Install the main

relief valve and tighten [Figure 20-30-6]. Check the
pressure again. (See Checking The Main Relief Valve
Without Front Auxiliaries on Page 20-30-2.)
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MAIN RELIEF VALVE (FOOT CONTROL) (CONT’D)
Adjustment
If the pressure is not correct, adjust the main relief valve.

Remove the end cap (Item 2) [Figure 20-30-7 on Page
4].
Figure 20-30-9
N-19743

Turn the adjusting screw (Item 1) [Figure 20-30-9] in or
out until the pressure is correct. Turning screw in will
increase pressure.
NOTE: If the correct pressure can not be reached,

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

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

support device can allow the lift arms or attachment Remove the three hydraulic hoses (Item 1) [Figure 20-
to fall and cause injury or death. 40-2] from the lift arm bypass valve.
W-2059-0598
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-5
(CONT’D)

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

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

connected to the control valve.
Disconnect the wire harness connectors (Item 1) [Figure

Connect a chain to the control valve and support the
20-40-3] from the auxiliary solenoids and the lift and tilt valve with an arm hoist.
lock solenoids.
Figure 20-40-6
Remove the Never Modify tie strap, and disconnect the
wire harness connector (Item 2) [Figure 20-40-3] from
the BICS valve solenoid connector.
Figure 20-40-4
1
1
2
N-19759
At the right side motor cover hole, remove the two control
valve mounting bolts (Item 1) [Figure 20-40-6] from the
N-19755 back side of the control valve.
Remove the case drain hose (Item 1) [Figure 20-40-4]

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

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

(Cont’d)
1
Figure 20-40-7
2
2
N-19760
1
Remove tubeline (Item 1) [Figure 20-40-9] from control
valve to hydraulic oil cooler.
N-19757 Remove the two auxiliary tubelines (Item 2) [Figure 20-

Disconnect the hydraulic tubeline (Item 1) [Figure 20-40-

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

Remove the tubeline mount clamp and bolt (Item 1)

[Figure 20-40-8].
Remove the tubeline from the loader.
Remove the two control valve mount plate mounting bolts

(Item 2) [Figure 20-40-8].
Remove the control valve from the loader.
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Removal And Installation (S/N 514447864 & Above)
(CONT’D)
(Cont’d)
Figure 20-40-11
DANGER
1
P-90328
1 AVOID DEATH
N-19762 can cause lift arms to drop.
Remove the three lift tubelines (Item 1) [Figure 20-40-

11] from the control valve. D-1009-0409
WARNING
W-2059-0598
device.

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

Reservoir on Page 20-80-1.)

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

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

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

nuts (Item 1) [Figure 20-40-14] from the lift arm bypass
valve.
P-28544
Figure 20-40-15
The fixed end main valve hose assembly (Item 1) [Figure

20-40-12] is connected to a fixed end fitting on the
control valve. The hose is routed to the upright where the
1
hose is connected to a tee fitting that feeds the base end
of both lift cylinders. The hose can only be removed by
first removing it from the tee fitting located at the
rear of the loader.
Cap and plug the hose and fitting.
Figure 20-40-13
P-28561
Disconnect the wire harness connector (Item 1) [Figure

20-40-15] from the charge pressure sender.
P-28560
Disconnect the three hoses (Item 1) [Figure 20-40-13]

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

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

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

20-40-16] from auxiliary valve solenoids.
Figure 20-40-17
1
P-28547
Loosen the fixed end main valve hose assembly (Item 1)

[Figure 20-40-19] from the control valve.
1
P-28563 The hose can be removed from the control valve by
rotating the hose assembly.
Disconnect the harness connector (Item 1) [Figure 20- Cap the hose and plug the fitting.
40-17] from the BICS™ valve solenoid connector.
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(CONT’D)

(Cont’d)
Figure 20-40-20
2 1
P-26833
At the right side motor cover access hose, remove the

inlet tubeline fitting (Item 1) [Figure 20-40-22] from the
bottom of the control valve.
P-28545
Figure 20-40-23
Remove the auxiliary hose (Item 1) [Figure 20-40-20]

from the control valve to the auxiliary pressure release
accumulator.
Remove the case drain filter hose (Item 2) [Figure 20-40- 1 2
20] from the control valve to the case drain filter.
Figure 20-40-21
2
3
P-26832
1
At the top of the control valve, remove the tubeline clamp
mount bolt (Item 1) [Figure 20-40-23] and remove the
inlet tubeline (Item 2) [Figure 20-40-23] from the control
valve mount plate.
P-28549
and nuts (Item 3) [Figure 20-40-23] from the loader
Install a chain hoist (Item 1) [Figure 20-40-21] to the fender.
control valve.
that goes from the control valve to the auxiliary pump.
Cap the hose and plug the fitting.
Remove the right side motor cover.
Remove the right rear wheel / tire assembly from the
loader.
Remove the right side pump access cover.
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(CONT’D)

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

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

the side to allow clearance for the control valve removal.
At the right side pump access hole, remove the two

Figure 20-40-27
control valve mounting bolts (Item 1) [Figure 20-40-24]
from the mounting plate.
Figure 20-40-25
1
P-28553
Mark all tubelines for correct installation.

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

(Cont’d)
Figure 20-40-28
3
1
P-28557
Lower the chain hoist and valve to allow clearance

between valve spool and tubelines.
2
P-28554 Rotate the valve upward until the valve spools are above
the tubelines [Figure 20-40-30].
Disconnect the three auxiliary tubelines that are

connected to the fitting (Item 1) [Figure 20-40-28].
Remove the fitting from the loader.
Disconnect the tilt tubeline (Item 2) [Figure 20-40-28]

from the fitting on the control valve.
Loosen the bolt on tubeline clamp (Item 3) [Figure 20-

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

29] from the control valve.
Cap and plug the tubeline and fitting.
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(CONT’D)
BICS™ Valve, Removal And Installation
Remove the control valve (See Removal And Installation

(S/N 514447863 & Below) on Page 20-40-1.)
1
Figure 20-40-31 1
2
1
1
1 1 N-20035
1
1 Remove the four large O-rings (Item 1) [Figure 20-40-
33] and the small O-ring (Item 2) [Figure 20-40-33] from
the top of the control valve.
Install the four large O-rings (Item 1) [Figure 20-40-33]

N-20033 and the small O-ring (Item 2) [Figure 20-40-33] on top of

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

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

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

1
N-18685
N-20040
Using a flat blade screw driver, remove the lift arm

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

bypass orifice.
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(CONT’D)
BICS™ Valve, Check Valve Disassembly And

Assembly (S/N 514450007 & Below)
1
Figure 20-40-38
P-8956
Clean and inspect the screen (Item 1) [Figure 20-40-40]

1 on the end of the valve.
N-20037
Remove the check valve (Item 1) [Figure 20-40-38].

Installation: Tighten the valve to 20 ft.-lb. (27 N•m)
torque.
Figure 20-40-39
N-18684
Remove the O-rings (Item 1) [Figure 20-40-39] and

back-up ring (Item 2) [Figure 20-40-39] from the check
valve.
Install new O-rings and back-up ring on the check valve.
The check valve has a rating of 5-10 PSI.
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(CONT’D)
BICS™ Valve, Check Valve Disassembly And

Assembly (514450007 & Above)
Figure 20-40-41 1
P-37710
Remove the 90° fitting (Item 1) [Figure 20-40-43] out of

the control valve.
2 1 P-37712 Figure 20-40-44
Remove the tubeline (Item 1) and the check valve (Item

2) [Figure 20-40-41].
2
Installation: Tighten the valve to 20 ft.-lb. (27 N•m) 1
torque.
Figure 20-40-42
1 P-37721
2
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-40-44] from the fitting.
Install new O-rings and back-up ring on the check valve.
P-37706
Clean and inspect the screen (Item 1) and replace the o-

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

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

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

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

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

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

N•m) torque.
Remove the mounting nut (Item 1) [Figure 20-40-49] Figure 20-40-52
from the solenoid cartridge.

Installation: Tighten the mounting nut to 53 in.-lb. (6
N•m) torque.
3
Remove the solenoid (Item 2) [Figure 20-40-49]. 2
NOTE: The solenoid resistance is (8 - 10 ohm).
Figure 20-40-50
1 1
1 N-18694

back-up washers (Item 2) [Figure 20-40-52] on the stem.
Clean all parts in solvent and dry with compressed air.
Inspect all parts for wear and replace any part showing
excessive wear.
N-18693
NOTE: The screen (Item 3) [Figure 20-40-52] may be
cleaned with solvent. If it is torn or worn
Remove the O-rings (Item 1) [Figure 20-40-50] form replace the solenoid stem.
both ends of the solenoid.
Use only new O-rings and apply oil to all O-rings and
back-up washers before installation.
Install new O-rings and new back-up washers on the

solenoid stem.
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Identification Chart
(CONT’D)
Item 863 Loader
BICS™ Valve, Solenoid Testing A1 Lift Cylinder Base End / Restrictor
A2 Tilt Cylinder Base End
Figure 20-40-53 A3 Auxiliary Hydraulics
B1 Lift Cylinder Rod End
B2 Tilt Cylinder Rod End
B3 Auxiliary Hydraulics
C1 Load Check Valve / Lift Function
C2 Load Check Valve / Tilt Function
C3 Orifice Load Check Valve / Auxiliary Function
C4 Outlet Fluid Flow
D1 Lift Spool Detent
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool / Centering Springs
E1 Port Relief Valve - 3500 PSI
E2 Anti-Cavitation / Port Relief Valve - 2500 PSI
F1 Anti-Cavitation Valve
F2 Port Relief Valve - 3500 PSI
G1 Lift Spool End
P-9175
G2 Tilt Spool End
G3 Auxiliary Electric Solenoid
Use a test meter to measure the coil resistance [Figure H1 Auxiliary Electric Solenoid
20-40-53]. Coil wires do not have polarity. Correct H2 Plug / Port Relief (Optional) - 3500 PSI

resistance for the auxiliary pressure relief (small) coil is 7- H3 Auxiliary Electric Solenoid
10 ohm and the other coils 5-8 ohms. H4 Lift Lock Solenoid
H5 Tilt Lock Solenoid
Replace the test meter with 12 volt power. You can see MR Main Relief Valve - 3000 PSI
and hear the spool shift.
H2 H1
H3
C4
G3 B3 A3
D3
H5 C3
G2 B2 A2 E2 D2
F2 C2
G1 H4 B1 A1 E1
F1 C1
MR D1 TS-1971
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(CONT’D)
Load Check Valve
Remove the BICS valve assembly from the control valve.

(See Removal And Installation (S/N 514447864 & Above) 2
on Page 20-40-4.)
Figure 20-40-54
1
1
1 N-18698
1
1 Loosen the load check plugs (Item 1) [Figure 20-40-55]
from the lift and tilt sections of the control valve.
2
Installation: Always use new O-ring. Tighten the plug to
35 - 40 ft.-lb. (47 - 54 N•m) torque.

N-20035 Figure 20-40-56
Remove the four large O-rings (Item 1) [Figure 20-40-

54] and small O-ring (Item 2) [Figure 20-40-54]. Always
replace these O-rings before installing the BICS valve
assembly.
3
IMPORTANT 1
2
N-20077
damage the system.
I-2003-0888
Remove the load check plugs (Item 1) [Figure 20-40-56].
Mark each valve section, spool and related parts so that Remove the spring (Item 2) [Figure 20-40-56] and
they will be returned to its original valve section during poppet (Item 3) [Figure 20-40-56].
assembly.
NOTE: Both load checks poppets, plugs and springs
Use bolts to fasten the control valve to a work bench for are the same for the lift and tilt.
easier disassembly and assembly procedures.
Loosen the load check plug (Item 2) [Figure 20-40-55]
from the auxiliary section of the control valve.
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Main Relief Valve
(CONT’D)
Figure 20-40-58
Load Check Valve (Cont’d)
Figure 20-40-57
N-20039
1
N-20078 Loosen and remove the main relief valve (Item 1) [Figure
20-40-58].
The auxiliary section uses a load check poppet with an Figure 20-40-59
orifice (Item 1) [Figure 20-40-57].

2
NOTE: For correct port locations and valve 3 4 5
component See Identification Chart on Page
20-40-16.
1
B-6764
1. Relief Valve
2. O-Ring
3. Sleeve
4. Glide Ring
5. O-Ring
CD-15092
Remove the O-rings, sleeve, and glide ring from the main
relief valve [Figure 20-40-59].
Installation: Always use new O-rings, sleeve and glide

ring. Tighten to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Port Relief Valve, Lift Spool
(CONT’D)
Figure 20-40-62
Port Relief Valve, Tilt Spool
Figure 20-40-60
1
1
N-20040
N-20043 Remove the port relief valve (Item 1) [Figure 20-40-62]

from the control valve lift section.
Remove the port relief valve (Item 1) [Figure 20-40-60] Figure 20-40-63
from the control valve tilt section.

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

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

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

Figure 20-40-67
Figure 20-40-65
1 2 3 4
1
E-1509
1. Anti-Cavitation Valve
2. O-Ring
3. Back-Up Washer
4. O-Ring
N-18839
N-18843
Remove the O-rings and back-up washer from the anti-

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

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

the rubber boot retainer. 1

Installation: Tighten the screws to 90 - 100 in.-lb. (10,2-
11,3 N•m) torque.
Figure 20-40-69 1
2 2
2
N-20021
1 2
Remove the lock solenoid (Item 1) [Figure 20-40-70] &

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

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

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

MEL1285 - Detent Spring Tool
Figure 20-40-73
N-20022
Remove the lift and tilt block [Figure 20-40-72].

N-20022

The lock must be clean and oil free. (Oil can cause the
solenoids not to function properly.) Remove the lift and tilt lock block (Item 1) [Figure 20-40-
73] from the control valve. (See Lift And Tilt Block on
Page 20-40-21.)
Figure 20-40-74
1 2
N-20023
Remove the bushing (Item 1) [Figure 20-40-74] and O-

ring (Item 2) [Figure 20-40-74] from the lift spool.
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(CONT’D)
Lift Spool And Detent (Cont’d)
Figure 20-40-75
N-18972
1
Remove the screws (Item 1) [Figure 20-40-77] from the
detent bonnet.
N-20040
Remove the detent bonnet (Item 2) [Figure 20-40-77].
Remove the end cap (Item 1) [Figure 20-40-75].

Figure 20-40-76
IMPORTANT
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
1
Figure 20-40-78
N-18971
Use a screwdriver to remove the snap ring (Item 1)

[Figure 20-40-76].
Remove the washer (Item 2) [Figure 20-40-76].
N-18973
Put a rag around the detent assembly [Figure 20-40-78].

This will prevent the detent balls and spring from being
lost when the detent sleeve is removed.
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(CONT’D)
Figure 20-40-79
3 2 1
1
N-18930
2 Remove the spool seal (Item 1) [Figure 20-40-81] from

the linkage end of the valve.
N-18974
Figure 20-40-82
Remove the detent sleeve (Item 1) [Figure 20-40-79],
detent balls (Item 2) [Figure 20-40-79] and spring (Item

3) [Figure 20-40-79].
Figure 20-40-80
P-8988
1 Clamp the linkage end of the spool in a vise [Figure 20-

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

20-40-80] from the control valve.
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(CONT’D)
Lift Spool And Detent (Cont’d) 1
Figure 20-40-83
1
3
N-19004
Remove the detent adapter (Item 1) [Figure 20-40-85]

from the spring assembly.
N-18915
Figure 20-40-86
Install the spring tool (Item 1) [Figure 20-40-83] over the
centering spring. 1

NOTE: Be careful when removing the detent adapter
(Item 2) [Figure 20-40-83] from the centering
spring, as it is under spring pressure.
NOTE: The centering spring (Item 3) [Figure 20-40-83]

is orange on all 800 series loaders.
Figure 20-40-84
N-19009
Remove the spring tool (Item 1) [Figure 20-40-86] from

the spring assembly.
2 1
N-18916
Put a rag around to detent assembly [Figure 20-40-84].

This will prevent the detent balls and spring from being
lost when the detent adapter is removed.
Remove the detent adapter with and allen wrench.
Remove the back-up washer (Item 1) [Figure 20-40-84]

and spool seal (Item 2) [Figure 20-40-84].
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(CONT’D)
Figure 20-40-87
1
2
3
4
1
N-18920
Turn a 6-32 tap (Item 1) [Figure 20-40-89] into the plug.

Pull the tap and plug out of the spool. Be careful, do not
N-18919 break the tap.
Clean all the debris from inside the spool bore.

Inspect the adapter (Item 1) [Figure 20-40-87], collar
(Item 2) [Figure 20-40-87], spring (Item 3) [Figure 20-

NOTE: DO NOT USE Loctite® ON THE STUD
40-87] and washer (Item 4) [Figure 20-40-87]. THREADS
Figure 20-40-88 Figure 20-40-90
N-18918
N-18961
Remove the stud from the end of the spool [Figure 20- Install the O-ring (Item 1) [Figure 20-40-90] over the
40-88]. nipple on the plastic plug (Item 2) [Figure 20-40-90].
Removal of the plastic plug:
Make a center point in the plug using a 1/16 in. drill.
Drill a hole all the way through the plug using a 7/64 in.
tap drill.
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(CONT’D)
Figure 20-40-91
N-18967
Clamp the collar (Item 1) [Figure 20-40-93] in a vise.
N-18963 Figure 20-40-94
Install the plastic plug and O-ring in the spool [Figure 20-
40-91].

2
Figure 20-40-92
O-ring
1
3
2
N-18958
Plastic
Plug Apply grease on all the detent component surfaces
0.60 in. before assembly [Figure 20-40-94].
(15,2 mm)
B-14712 Install the spring (Item 1) [Figure 20-40-94] and detent
balls (Item 2) [Figure 20-40-94] into the adapter (Item 3)
[Figure 20-40-94] and compress with the detent pliers
Install the stud and tighten until the other end of the stud (Item 1) [Figure 20-40-95 on Page 28].
is out about 0.600 in. (15,2 mm) from the spool [Figure
20-40-92].
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(CONT’D)
Figure 20-40-95
N-18917
1
Install the spool seal (Item 1) [Figure 20-40-97] and
back-up washer (Item 2) [Figure 20-40-97].
N-18968
Figure 20-40-98
Install the detent adapter to the collar [Figure 20-40-95].

NOTE: The collar and the detent adapter are held
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out. 1
Figure 20-40-96
N-19005
1
Install the spring assembly to the lift spool hand tight

[Figure 20-40-98].
Remove the spring tool.
Check the alignment of the detent adapter and the

washer.
N-19004
Tighten the adapter to 90 - 100 in.-lb. (10,2 - 11,3 N•m).
Install the spring tool (Item 1) [Figure 20-40-96] over the NOTE: The adapter must fit in the center of the washer
washer, spring, collar and detent adapter. (Item 1) [Figure 20-40-98].
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(CONT’D)
Figure 20-40-99
N-19008
Install the detent sleeve (Item 1) [Figure 20-40-101] to

the detent adapter.
CD-15051
Figure 20-40-102
Install the detent balls and spring [Figure 20-40-99].

Figure 20-40-100
2 N-18972
Install the lift spool assembly in the spool bore [Figure

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

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

11,3 N•m) torque.
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(CONT’D)
Figure 20-40-103
1
2
N-18930
1
Install the spool seal (Item 1) [Figure 20-40-105] on the
linkage end of the valve.
N-18971
Figure 20-40-106
Install the washer (Item 1) [Figure 20-40-103] and snap
ring (Item 2) [Figure 20-40-103].

Figure 20-40-104
1 2
N-18927
1
Install the bushing (Item 1) [Figure 20-40-106] and O-
ring (Item 2) [Figure 20-40-106] on the linkage end of the
N-20040 lift spool.
Install the end cap (Item 1) [Figure 20-40-104].
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Tilt Spool Removal And Installation
(CONT’D)
Figure 20-40-108
Figure 20-40-107
1
N-20022
1
N-20022 Remove the lift and tilt block (Item 1) [Figure 20-40-108]
from the control valve. (See Lift And Tilt Block on Page
20-40-21.)
Install the lift and tilt block (Item 1) [Figure 20-40-107].
(See Lift And Tilt Block on Page 20-40-21.)

Figure 20-40-109
1 2
N-20024
Remove the bushing (Item 1) [Figure 20-40-109] and O-

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

1
Figure 20-40-110
N-18942
Put the linkage end of the spool in the vise [Figure 20-
40-112].
N-20042
Install the spool tool (Item 1) [Figure 20-40-112] over the
centering spring.
end cap.

Figure 20-40-113
Installation: Tighten the bolt to 90 - 100 in.-lb. (10,2 -
11,3 N•m) torque.
1
Figure 20-40-111
N-19014
Remove the bolt (Item 1) [Figure 20-40-113] holding the

centering spring to the spool.
N-18816
11,3 N•m) torque.
Remove the spool, centering spring, back-up washer and
spool seal [Figure 20-40-111]. Remove spring tool from the spring assembly.
Assembly: Always use a new spool seal.
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Auxiliary Spool Removal And Installation
(CONT’D)
Figure 20-40-116
Tilt Spool Removal And Installation (Cont’d)
Figure 20-40-114
2 1
3
N-20042
N-18944 Remove the screws (Item 1) [Figure 20-40-116] from the

end cap.
Inspect the adapter (Item 1) [Figure 20-40-114], collar Installation: Tighten the bolt to 90 - 100 in.-lb. (10,2 -

11,3 N•m) torque.
40-114] and washer (Item 4) [Figure 20-40-114].
Figure 20-40-117
Figure 20-40-115
1 2
N-18990
N-19098 N-18943
Remove the end cap, O-ring, springs and spring guide

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

auxiliary bleed block (Item 2) [Figure 20-40-120].
N-18989
11,3 N•m) torque.
Remove the spool (Item 1) [Figure 20-40-118].

Figure 20-40-121
Assembly: Put grease on all the centering spring
component parts.
Figure 20-40-119 1
N-20074
Remove the auxiliary bleed block (Item 1) [Figure 20-40-

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

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

Assembly: Put grease on all the centering spring

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

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

torque.
Installation: Tighten the nut to 8 - 12 ft.-lb. (11 - 16 N•m) Figure 20-40-128
torque.
Figure 20-40-126
1 N-18795
N-20026 Remove the O-rings (Item 1) [Figure 20-40-128] from

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

housing (Item 2) [Figure 20-40-126].
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HYDRAULIC VALVE CONTROL (FOOT CONTROL) Figure 20-40-130
(CONT’D)
Port Relief-Auxiliary Section Disassembly Plug
Figure 20-40-129
2
1 1
N-18800
Figure 20-40-131
N-20031
Port Relief (Optional)
Remove the plug (Item 1) [Figure 20-40-129] or optional

port relief valve from the control valve. 2

1
NOTE: Optional port relief (Item 1) [Figure 20-40-129]
is 3500 PSI (24129 kPa).
1
N-18843
Remove the O-rings (Item 1) [Figure 20-40-130] &

[Figure 20-40-131] and back-up ring (Item 2) [Figure 20-
40-130] & [Figure 20-40-131] from the plug.
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HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Cleaning And Inspection
Clean all components with clean solvent and dry with

compressed air.
Check the spools for wear or scratches.
Check that the spools are not loose in their bore.
Check that the centering springs are not broken.
Check that the load check valve seats are not worn.
Check the load check poppets for damage.
Check the rubber boots and retainers.
Replace the parts as needed.
Use New O-rings and back-up rings.

Apply oil to all new O-rings and back-up rings before
installation.
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HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-2
CONTROL SYSTEM) (ACS)
Description
the Advanced Control System (ACS) includes the

Advanced Hand Control (AHC) and / or the Selectable
Hand / Foot Control Systems.
Actuator Removal And Installation (In Loader) 2

1
Raise the lift arms and install and approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
P-26842
WARNING Remove the screws (Item 1) [Figure 20-41-2] from the

actuator retainer.
Installation: Tighten the bolts to 90 - 100 in.-lb. (10,2 -
11,3 N•m) torque.

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

(Cont’d)
Figure 20-41-4
P-28621A
Check and replace the O-ring (Item 1) [Figure 20-41-6]

on the control valve housing.
P-26820
Remove the spacer (Item 1) [Figure 20-41-4].

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

on the spacer.
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Removal & Installation (S/N 514447863 & Below)
DANGER
1
N-19865
P-90328
Loosen the tubeline clamps (Item 1) [Figure 20-41-7] at
AVOID DEATH
the engine compartment.
Clean the area around the control valve.
Figure 20-41-8

D-1009-0409
WARNING
the lift arms are secured by an approved lift arm 1
W-2059-0598
N-23630
device. (See Engaging The Lift Arm Support Device on Disconnect the three hoses (Item 1) [Figure 20-41-8]
Page 10-20-1.) from the lift arm bypass control valve.

on Page 10-30-1.)


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

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

41-11] from the BICS™ valve solenoid connector.
At the right fender, remove the two mounting bolts (Item

Figure 20-41-12
1) [Figure 20-41-9].
Remove the lift arm bypass valve and mount from the
loader.
Figure 20-41-10
2
1
1
N-23636
Disconnect both harness connectors (Item 1) [Figure 20-

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

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

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

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

Disconnect the case drain hose (Item 1) [Figure 20-41-

Remove the charge pressure hose and sending unit
13]. (Item 3) [Figure 20-41-15].
Figure 20-41-14 Figure 20-41-16
1 1
2
N-23634
N-23639
Remove the two tubelines clamps (Item 1) [Figure 20- Remove the rod end tilt cylinder tubeline (Item 1) [Figure
41-14]. 20-41-16] and (Item 2) [Figure 20-41-16] if equipped.
Remove the rod end lift cylinder tubeline (Item 3) [Figure

20-41-16].
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(Cont’d)
Figure 20-41-17
N-23642
1
Install a chain hoist to the control valve for support
[Figure 20-41-19].
2
4 Figure 20-41-20
N-23640
Remove the base end tilt cylinder tubeline (Item 1)

[Figure 20-41-17] and (Item 2) [Figure 20-41-17] if
equipped.
Remove the base end lift cylinder tubeline (Item 3)

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

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

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

21].
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HYDRAULIC CONTROL VALVE (ADVANCED Remove the loader alternator. (See Removal And
CONTROL SYSTEM (ACS) (CONT’D) Installation on Page 60-30-3.)
Removal And Installation (S/N 514447864 & Above) Figure 20-41-22
DANGER
P-90328
1
AVOID DEATH P-28544
The fixed end main valve hose assembly (Item 1) [Figure
20-41-22] is connected to a fixed end fitting on the
control valve. The hose is routed to the back upright

where the hose is connected to a tee fitting that feeds the
base end of both lift cylinders. The hose can only be
D-1009-0409
removed from the tee fitting located and the rear of
the loader first.
Cap and plug the hose and fitting.


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

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

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

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

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

from the control valve to the auxiliary pressure release
accumulator.
P-26826
Remove the case drain hose (Item 2) [Figure 20-41-30]
from the control valve to the case drain filter.
Disconnect both harness connectors (Item 1) [Figure 20-

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

loader.
Remove the right side pump access cover.
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(Cont’d)
Figure 20-41-32
1 P-26831
At the right side pump access cover hole, remove the two
control valve mount bolts (Item 1) [Figure 20-41-34] from
the mounting plate.
P-26833
Figure 20-41-35
At the right side motor cover access hole, remove the

inlet tubeline fitting (Item 1) [Figure 20-41-32] from the
bottom of the control valve.
Figure 20-41-33
1 2
1 P-26834
3
Disconnect the lift tubeline (Item 1) [Figure 20-41-35]
P-26832 Cap and plug the tubeline and fitting.

At the top of the control valve, remove the tubeline clamp
mount bolt (Item 1) [Figure 20-41-33] and remove the
inlet tubeline (Item 2) [Figure 20-41-33] from the control
valve mount plate.

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

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

Disconnect the hydraulic fitting (Item 1) [Figure 20-41-

from the fitting on the control valve.
36] from the charge pressure sender.
Figure 20-41-39
Move the charge pressure sender and hose assembly to
the side, to allow clearance for the control valve removal.
Mark all tubelines for correct installation.
Figure 20-41-37
1
1 P-26838
Remove the lift tubeline (Item 1) [Figure 20-41-39] that

goes from the control valve to the bucket position valve.
(If so equipped.)
P-26836
Remove the two bucket position tubelines (Item 1)

[Figure 20-41-37]. (If so equipped.)
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HYDRAULIC CONTROL VALVE (ADVANCED Actuator Removal And Installation (Out Of Loader)
Figure 20-41-42
(Cont’d)
Figure 20-41-40 2
P-28319
1
Remove the two screws (Item 1) [Figure 20-41-42] on

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

Disconnect the auxiliary tubeline (Item 1) [Figure 20-41-

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

Remove the actuator (Item 1) [Figure 20-41-44].

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

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

every bolt or repeat step 3.
P-28324
Replace the four large O-rings (Item 1) [Figure 20-41-47]

and small O-ring (Item 2) [Figure 20-41-47] from the top

of the control valve.
Figure 20-41-48
3 6
1 2
5
4
P-28322
Install the six mounting bolts (Item 1) [Figure 20-41-48].
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BICS™ Valve Lift Arm Bypass Orifice Removal And

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

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

Remove the fitting (Item 1) [Figure 20-41-49] from the

BICS valve. Reverse the removal procedure to install the lift arm
bypass orifice.
Figure 20-41-50
P-28333
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BICS™ Valve Check Valve Removal And Installation
Figure 20-41-52 1
P-8956
Clean and inspect the screen (Item 1) [Figure 20-41-54]

on the end of the valve.
P-28334
Reverse the removal procedure to install the BICS™
check valve.
Remove the check valve (Item 1) [Figure 20-41-52].

Installation: Tighten the check valve to 20 ft.-lb. (27
N•m) torque.
Figure 20-41-53
N-18684

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

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

10 PSI.
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BICS™ Valve Lock Valve Removal And Installation
Figure 20-41-55
1
2
1
P-28337
Loosen and remove the lock valve(s) (Item 1) [Figure 20-

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

Figure 20-41-58
2) [Figure 20-41-55].
Figure 20-41-56 1
1 2
2
2 N-18690
P-28336 Remove the O-rings (Item 1) [Figure 20-41-58] and

back-up rings (Item 2) [Figure 20-41-58] from both the tilt
and lift lock valves.

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

torque.
Remove the nut (Item 1) [Figure 20-41-59] from the Figure 20-41-62
solenoid cartridge.

Installation: Tighten the mounting nut to 53 in.-lb. (6
N•m) torque.
2 3
Remove the coil (Item 2) [Figure 20-41-59].
Figure 20-41-60
1 1
N-18694

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

Remove the O-rings (Item 1) [Figure 20-41-60] from cleaned with solvent. If it is torn or worn it
both ends of the coil. needs to be replaced.
Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-41-60] & [Figure

20-41-62] and new back-up rings (Item 2) [Figure 20-41-
62] on the stem.
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HYDRAULIC CONTROL VALVE (ADVANCED Identification Chart
Item 863 Loader
BICS™ Valve Solenoid Testing A1 Lift Cylinder Base End / Restrictor
A2 Tilt Cylinder Base End
Figure 20-41-63 A3 Auxiliary Hydraulics
B1 Lift Cylinder Rod End
B2 Tilt Cylinder Rod End
B3 Auxiliary Hydraulics
C1 Load Check Valve / Lift Function
C2 Load Check Valve / Tilt Function
C3 Orifice Load Check Valve / Auxiliary Function
C4 Outlet Fluid Flow
D1 Lift Spool Detent
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool / Centering Springs
E1 Port Relief Valve - (863) - 3500 PSI
E2 Anti-Cavitation / Port Relief Valve - 3500 PSI
F1 Anti-Cavitation Valve
F2 Port Relief Valve - 3500 PSI
G1 Lift Spool End
P-9175
G2 Tilt Spool End
G3 Auxiliary Spool / Centering Springs
Use an Ohm meter to measure coil resistance [Figure H1 Auxiliary Electric Solenoid
20-41-63]. H2 Plug / Port Relief (Optional) - 3500 PSI

H3 Auxiliary Electric Solenoid
Coil wires do not have polarity. MR Main Relief Valve - (863)-2950-3050 PSI
Correct resistance for the auxiliary, lift and tilt lock coils
are 7-10 ohms. H2 H1
H3
The other coils (BICS, diverter, select valve) are 5-8
ohms.) C4
G3 B3 A3
D3
C3
G2 B2 A2 E2 D2
F2 C2
G1 B1 A1 E1 D1
F1 C1
MR TS-2136
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HYDRAULIC CONTROL VALVE (ADVANCED Load Check Valve
Lift Base End Restrictor
Remove the BICS™ valve assembly from the control IMPORTANT

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

N-21159
Remove the restrictor (Item 1) [Figure 20-41-64] from

2
the lift section base end port.
P-28324
Remove the BICS™ valve assembly from the control

valve. (See BICS™ Valve Removal And Installation on
page 20-41-13.)
Remove the four large O-rings (Item 1) [Figure 20-41-

65] and small O-ring (Item 2) [Figure 20-41-65]. Always
replace these O-rings before installing the BICS valve
assembly.
Mark each valve section, spool and related parts so that

they will be returned to their original valve section during
assembly.
Use bolts to fasten the control valve to a work bench for

easier disassembly and assembly procedures.
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Load Check Valve (Cont’d)
Figure 20-41-66 1
N-20078 P-28324
The auxiliary section (Item 1) [Figure 20-41-68] may

have a load check with an orifice located in the center of
P-28324 the poppet (Item 2) [Figure 20-41-68].
Loosen and remove the load check valve plugs (Item 1)

[Figure 20-41-66].

Installation: Always use new O-rings. Tighten the plugs
to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
Figure 20-41-67
1 2
3
P-28325
Remove the spring (Item 1) [Figure 20-41-67] and

poppet (Item 2) [Figure 20-41-67] from the load check
plug (Item 3) [Figure 20-41-67].
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2
3 5
Main Relief Valve 4
Figure 20-41-69
1
B-6764
1. Relief Valve
2. O-Ring
3. Sleeve
4. O-Ring
5. Glide Ring
P-28328
1
Remove the O-rings, sleeve and glide ring from the main
P-28326
Installation: Always use new O-rings, sleeve and glide
ring. Tighten to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
Loosen the main relief valve (Item 1) [Figure 20-41-69].

Figure 20-41-70
P-28327
Remove the main relief valve (Item 1) [Figure 20-41-70].
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Port Relief Valve(s)
Figure 20-41-72
N-18981
Remove the port relief valve (Item 1) [Figure 20-41-74].
N-19000 Figure 20-41-75
Figure 20-41-73 4
3

2
1
1
1. O-Ring
2. Backup Washer
3. O-Ring
4. Relief Valve
N-18844
N-19034 Remove the O-rings and back-up washer from the port
Loosen the port relief valve (Item 1) [Figure 20-41-72] &

[Figure 20-41-73].

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Anti-Cavitation Valve / Port Relief Valve
Figure 20-41-76
1
N-18843
Remove the O-rings (Item 1) [Figure 20-41-78] from the

anti-cavitation / port relief valve.
N-19003
Loosen the anti-cavitation valve (Item 1) [Figure 20-41-

76].

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

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

cavitation valve [Figure 20-41-81].
P-28329
Figure 20-41-80

1
N-19036
Remove the anti-cavitation valve (Item 1) [Figure 20-41-

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

1 cap.
N-19112
Figure 20-41-85
Remove the actuator (Item 1) [Figure 20-41-82] from the
control valve. (See Actuator Removal And Installation (In

Loader) on page 20-41-1.)
Figure 20-41-83
N-18983
2
1 Remove the spool assembly (Item 1) [Figure 20-41-85]

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

ring (Item 2) [Figure 20-41-83] from the lift spool.
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Tilt Spool Removal And Installation
Figure 20-41-86
1
1
N-19003
2 1
end cap.
P-28320
11,3 N•m) torque.
Remove the bolts (Item1) [Figure 20-41-86] to pull the
actuator (Item 2) [Figure 20-41-86] from the spacer.

Figure 20-41-89
Figure 20-41-87
2 N-18985
2 1 P-28321
Remove the spool assembly (Item 1) [Figure 20-41-89]
and seal from the control valve.
Remove the spacer (Item 1) [Figure 20-41-87] and the
O-rings (Item 2) [Figure 20-41-87] from the tilt spool. Assembly: Always use a new spool seal.
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1
Lift And Tilt Spool Disassembly And Assembly 2
3
Figure 20-41-90
4
N-18944
NOTE: The centering spring (Item 3) [Figure 20-41-92]

is orange on all 800 Series loaders.
N-18942
Inspect the adapter (Item 1) [Figure 20-41-92], collar
Put the linkage end of the spool in the vise [Figure 20- 41-92] and washer (Item 4) [Figure 20-41-92].
41-90].

Figure 20-41-93
Install the spool tool (Item 1) [Figure 20-41-90] over the
centering spring.
Figure 20-41-91 1
2
N-18930 N-18943
Remove the spool seal(s) (Item 1) [Figure 20-41-93] and

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

centering spring to the spool.

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

component parts.
end cap (both sides).

Installation: Tighten the screws to 90 - 100 in.-lb. (10,2 -
11,3 N•m) torque.
Figure 20-41-95
N-18987
Remove the end cap, O-ring, springs and washer (both

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

Assembly
1
Figure 20-41-97
N-18795

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

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

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

remove the screws (Item 2) [Figure 20-41-100] from the
end cap.
Installation: Tighten the screws to 90 - 100 in.-lb. (10,2 -

11,3 N•m) torque.
P-28342
Remove the coil (Item 1) [Figure 20-41-98] and the stem

(Item 2) [Figure 20-41-98].
Installation: Tighten the stem to 20 ft.-lb. (27 N•m)

torque.
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Auxiliary Electric Solenoid Disassembly And Plug

Assembly (Cont’d)
2
Figure 20-41-101
1
1
1
N-18800
Figure 20-41-104
Port Relief (Optional)

P-28345
Remove the end cap and solenoid assembly (Item 1) 2

[Figure 20-41-101]. Remove the O-ring, springs and 1
washer [Figure 20-41-101].
Port-Auxiliary Section Disassembly
Figure 20-41-102
1
N-18843
Remove the O-rings (Item 1) [Figure 20-40-103] &

[Figure 20-41-104] and back-up ring (Item 2) [Figure 20-
40-103] & [Figure 20-41-104] from the plug.
P-28343
Remove the plug (Item 1) [Figure 20-41-102] or optional

port relief valve from the control valve.
NOTE: The optional port relief (Item 1) [Figure 20-41-

102] is 3500 PSI (24129 kPa).
863 Bobcat Loader

221 of 970
HYDRAULIC CONTROL VALVE (ADVANCED
Cleaning And Inspection
Clean all components with clean solvent and dry with

compressed air.
Check the spools for wear or scratches.
Check that the spools are not loose in their bore.
Check that the centering springs are not broken.
Check that the load check valve seats are not worn.
Check the load check poppets for damage.
Check the rubber boots and retainers.
Use new O-rings and back-up rings.

Apply oil to all new O-rings and back-up rings before
installation.
863 Bobcat Loader

222 of 970
LIFT ARM BYPASS CONTROL VALVE Removal And Installation
Inspecting
Raise the lift arms 6 feet (2 m) off the ground. Stop the
engine. Turn the Lift Arm Bypass Control Knob clockwise
DANGER
1/4 turn. Then pull up and hold the Lift Arm Bypass
Control Knob until the lift arms slowly lower.
Additional Inspection For Loaders With ACS
Sit in the operator’s seat and fasten the Seat Belt. Lower
the Seat Bar, start the engine and press the green
PRESS TO OPERATE Button.
P-90328
Raise the lift arms about 6 feet (2 meters) off the ground.
AVOID DEATH
Turn the key OFF and wait for the engine to come to a • Disconnecting or loosening any hydraulic
complete stop. tubeline, hose, fitting, component or a part failure
Turn the key ON. Press the green PRESS TO OPERATE • Keep out of this area when lift arms are raised
Button, move the let hand control toward the operator. unless supported by an approved lift arm
The lift arms should not lower. support. Replace if damaged.
D-1009-0409

Move the right hand control away from the operator. The
bucket (or attachment) should not tilt forward.
WARNING
W-2059-0598
WARNING
explosion or fire.
W-2103-0508
Raise the lift arms and install the lift arm support device.
(See Engaging The Lift Arm Support Device on Page 10-
20-1.)

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

Removal And Installation on Page 50-100-1.)
863 Bobcat Loader

223 of 970
LIFT ARM BYPASS CONTROL VALVE (CONT’D) Disassembly And Assembly
Removal And Installation (Cont’d) Figure 20-50-3
Figure 20-50-1
2
1 2
1
1
P7939
P-28558
Remove the bypass valve (Item 1) [Figure 20-50-3] from
the valve block. Inspect the bypass valve for damage and
Disconnect the hydraulic hoses (Item 1) [Figure 20-50-1] replace if necessary.
and cap the plug lines.

Installation: Tighten the valve to 33 - 37 ft.-lb. (45 - 50
Remove the two mounting bolts (Item 2) [Figure 20-50- N•m) torque.
1].
Inspect the hydraulic fittings (Item 2) [Figure 20-50-3] on
Installation: Tighten the mounting bolts to 180 - 200 in.- the valve block for damage and replace if necessary.
Remove the bypass valve.
Figure 20-50-2
N-19734
Remove the two bolts (Item 1) [Figure 20-50-2] to

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

bypass valve in the loader.
863 Bobcat Loader

224 of 970
HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 & Disconnect the OUTLET hose (Item 1) [Figure 20-60-1]
BELOW) from the pump.
Checking The Output Of The Pump Figure 20-60-2
WARNING
2
of the frame before running the engine for service. 1
W-2017-0286
NOTE: This procedure is the same for 863 and 863H in

the standard flow mode.
The tools listed will be needed to do the following
procedure:
MEL 10003 - Hydraulic Tester
MEL 10006 - Hydraulic Test Kit
NOTE: Make sure all the air is removed from the

P-7753
hydraulic system before beginning the test.
Air in the system can give an inaccurate test.
*Relief pressure must be per specification Connect the INLET hose from the tester to the OUTLET
before the test is done. hose (Item 1) [Figure 20-60-1] of the pump. Connect the
OUTLET hose (Item 2) [Figure 20-60-2] from the tester
Lift and block the loader. (See LIFTING AND BLOCKING to the tubeline (Control Valve Inlet) which was previously
THE LOADER on Page 10-10-1.) disconnected from the pump outlet hose (Item 1) [Figure
20-60-2].
Raise the lift arms and install the lift arm support device.
(See Engaging The Lift Arm Support Device on Page 10- Start the engine and ran at low idle RPM. Make sure the
20-1.) tester is connected correctly. If no flow is indicated on the
Raise the operator cab. (See Raising The Operator Cab tester, the hoses are connected wrong. With the hoses
on Page 10-30-1.) connected correctly, increase the engine speed to full
RPM.
Connect the remote start switch. (See REMOTE START
on Page 10-60-1.) Warm the fluid to 140° F (60° C) by turning the restrictor
control on the tester about 1000 PSI (6895 kPa). DO
Figure 20-60-1 NOT exceed the system relief pressure. Open the
restrictor control and record the free flow (GPM) at full
RPM.
1
Turn the restrictor down to system operating pressure.
DO NOT EXCEED SYSTEM RELIEF PRESSURE. The
highest pressure flow must be at least 80% of free flow.
HIGH PRESSURE FLOW (GPM)

%= x100
FREE FLOW (GPM)
A low percentage may indicate a pump problem.
N-19740
863 Bobcat Loader

225 of 970
HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 & Figure 20-60-3
BELOW) (CONT’D)
DANGER 1
N-19741
P-90328
Loosen the hose clamps and disconnect the inlet hoses
AVOID DEATH
(Item 1) [Figure 20-60-3] from the pump inlet fitting.
Figure 20-60-4

D-1009-0409
WARNING
Never work on a machine with the lift arms up unless 1
N-17600
W-2059-0598
Disconnect the hose (Item 1) [Figure 20-60-4] from the
pump outlet to the control valve.
device. (See Engaging The Lift Arm Support Device on Remove the pump mounting bolts (Item 2) [Figure 20-
Page 10-20-1.) 60-4] (both sides).
Installation: Tighten the mounting bolts to 25 - 27 ft.-lb.
Raise the operator cab. (See Raising The Operator Cab (34 - 37 N•m) torque.
on Page 10-30-1.)
Remove the hydraulic pump.
WARNING
explosion or fire.
W-2103-0508
863 Bobcat Loader

226 of 970
HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 &
BELOW) (CONT’D)
1 2 3
4
5
6 7

9
10
8 6
5
13 14
11
12
TS-1022A
Ref. Description
1. Bolt
2. Washer
3. End Housing
4. O-Ring Seal
5. Seal
6. Ring
7. Body
8. Bearing Housing
9. Drive Gear
10. Idler Gear
11. Bolt
12. Washer
13. Cover
14. Seal
863 Bobcat Loader

227 of 970
BELOW) (CONT’D)
Disassembly
IMPORTANT
1
damage the system.
I-2003-0888
CD-15142
Figure 20-60-5
Remove the end housing (Item 1) [Figure 20-60-7].
Marks Figure 20-60-8

CD-15160
1
Mark the pump for correct assembly (Item 1) [Figure 20- CD-15143
60-5].
Figure 20-60-6 Remove the mounting flange end housing (Item 1)

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

6]
863 Bobcat Loader

228 of 970
BELOW) (CONT’D)
1
Figure 20-60-9
1
2
2
CD-15146
Remove the bearing housing (Item 1) [Figure 20-60-11]

from the gears.
CD-15144
Remove the back-up seals / O-ring seals (Item 2) [Figure
20-60-11] from the bearing housing.
Remove the gear / bearing housing assembly [Figure
20-60-9].

Figure 20-60-12
Figure 20-60-10
1
CD-15150
1
CD-15145
Remove the drive gear shaft seals (Item 1) [Figure 20-
60-12].
pump housing.
863 Bobcat Loader

229 of 970
BELOW) (CONT’D)
Inspection
Wash all parts in clean solvent.
Use air pressure to dry them.
Make a visual inspection of all the parts.
After visual inspection, those parts which show wear or

damage must be replaced.
Figure 20-60-13
CD-15149
Check the pump housing (Item 1) [Figure 20-60-15].
Check the surface in the gear area for scratches, wear,

etc.

CD-15148
Check the drive and idler gears [Figure 20-60-13].
If excessive wear is visible on the journals or side or face

of the gears, they must be replaced. If the splines are
worn, replace the drive gear.
Figure 20-60-14
CD-15147
Check the bushings in the housing [Figure 20-60-14].
If the bushings are worn, scratched, and etc. replace

them as needed.
863 Bobcat Loader

230 of 970
BELOW) (CONT’D)
Assembly
IMPORTANT
damage the system.
I-2003-0888
CD-15151
Figure 20-60-16
Install the bearing housing / gears assembly into the
pump housing [Figure 20-60-17].
Figure 20-60-18

2
1 CD-15150
Always use new O-rings and seals when assembling the

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

mounting flange housing using the correct size driver Install the back-up seals / O-ring seals (Item 1) [Figure
tool. 20-60-18].
Install the inside seal with the lip facing the drive gear Install the large O-ring (Item 2) [Figure 20-60-18]
and the outside seal with the lip facing outward.
863 Bobcat Loader

231 of 970
BELOW) (CONT’D)
Assembly (Cont’d)
Figure 20-60-19
CD-15155
Install the end housing (Item 1) [Figure 20-60-21].
CD-15153 Install the four pump housing bolts [Figure 20-60-21].
Figure 20-60-22
Install the mounting flange housing on the pump housing
[Figure 20-60-19].

Figure 20-60-20
1 CD-15156
Tighten the bolts to 45 - 50 ft.-lb. (61 - 68 N•m) torque

CD-15154 [Figure 20-60-22].
Install the back-up seals / O-ring seals (Item 1) [Figure

20-60-20].
Install the large O-ring (Item 2) [Figure 20-60-20].
863 Bobcat Loader

232 of 970
HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N Figure 20-61-1
514449483 & BELOW)
Checking The Output Of The High Flow Pump

1
1
WARNING 1
1
1
Failure to use jackstands can allow the machine to 1
W-2017-0286
1
2
N-23027
NOTE: This procedure is the same for 863 and 863H in
the standard flow mode.
Remove the seven bolts (Item 1) [Figure 20-61-1] and
The tools listed will be needed to do the following cover (Item 2) [Figure 20-61-1].
procedure:
Figure 20-61-2
MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit

NOTE: Make sure all the air is removed from the
hydraulic system before beginning the test.
Air in the system can give an inaccurate test. 1
*Relief pressure must be per specification

before the test is done.

Remove the right side rear wheel.

N-18597
Disconnect the OUTLET hose from the pump fitting (Item

1) [Figure 20-61-2]. Remove the fitting (Item 1) [Figure
20-61-2] and install a 90° elbow fitting.
Connect the INLET hose from the tester to the OUTLET

of the pump. Connect the OUTLET hose from the tester
to the hose which was disconnected from the pump.
Start the engine and ran at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM.
863 Bobcat Loader

233 of 970
HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N
514449483 & BELOW) (CONT’D)
Checking The Output Of The High FLow Pump

WARNING
(Cont’d)
Warm the fluid to 140° F (60° C) by turning the restrictor the lift arms are secured by an approved lift arm
control on the tester about 1000 PSI (6895 kPa). DO support device. Failure to use an approved lift arm
NOT exceed the system relief pressure. Open the support device can allow the lift arms or attachment
restrictor control and record the free flow (GPM) at full to fall and cause injury or death.
RPM. W-2059-0598
Push the mode switch (on the remote start switch) to Figure 20-61-3
engage the front auxiliary hydraulics, the light will come
ON. Push the button (on the right steering lever) for fluid
pressure to the quick coupler (Fluid pressure will go over
main relief). Record the highest pressure (PSI) and flow
(GPM). The high pressure flow must be at least 80% of
free flow.
%= x100
FREE FLOW (GPM)
1
A low percentage may indicate a pump problem.


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

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

234 of 970
514449483 & BELOW) (CONT’D)
Figure 20-61-5
N-18595
Remove the inlet fitting (Item 1) [Figure 20-61-5] from

the pump.

Figure 20-61-6
N-18596
Loosen and remove the two pump mounting bolts (Item

1) [Figure 20-61-6]. (Both sides.)
Installation: Install a new gasket. Tighten the mounting

bolts (Item 1) [Figure 20-61-6] to 25 - 27 ft.-lb. (34 - 37
N•m) torque.
863 Bobcat Loader

235 of 970
514449483 & BELOW) (CONT’D)
1 2 3
4
5 7
6
10
9
6
5 9
4
12
11
13

14 15
16
17
18
20
15
14 13 19
21
23
22
24
25 26 TS-1078C
Ref. Description Ref. Description
1. Bolt 14. Seal

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

236 of 970
514449483 & BELOW) (CONT’D)
Disassembly
IMPORTANT
1
3
damage the system.
I-2003-0888 2
CD-15017
Figure 20-61-7
Remove the four pump housing bolts (Item 1) [Figure 20-
Mark
61-8] from the small gear pump end housing.
Remove the small gear pump end housing (Item 2)

[Figure 20-61-8].

Remove the small gear pump housing (Item 3) [Figure
20-61-8] from the center housing.
Figure 20-61-9
Mark
CD-15159
Mark the pump sections for correct assembly [Figure 20-

61-7].
1
2
CD-15018

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

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

237 of 970
514449483 & BELOW) (CONT’D)
Figure 20-61-10
CD-15021
1 Remove the drive and idler gear from the bearing

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

20-61-10].
Figure 20-61-11
1
CD-15022
Remove the two hex bolts (Item 1) [Figure 20-61-13] and

two allen head bolts (Item 2) [Figure 20-61-13] from the
mounting flange housing (Item 3) [Figure 20-61-13].
Remove the mounting flange housing (Item 3) [Figure

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

housing [Figure 20-61-11].
863 Bobcat Loader

238 of 970
514449483 & BELOW) (CONT’D)
Figure 20-61-14
1
2
2 CD-15025
CD-15023 Remove the back-up seal / O-ring seal (Item 2) [Figure

20-61-16].
Remove the O-ring (Item 1) [Figure 20-61-14]. Figure 20-61-17

20-61-14].
Figure 20-61-15
CD-15026
Remove the bearing housing / gears assembly from the

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

from the large gear pump housing.
863 Bobcat Loader

239 of 970
514449483 & BELOW) (CONT’D)
Figure 20-61-18
1
CD-15031
Check the connecting coupler (Item 1) [Figure 20-61-20]

in the center housing. If worn or damaged, use a press
CD-15027 and correct size driver tool to remove it from the center
housing.
Remove the drive and idler gear from the bearing
housings [Figure 20-61-18].

Figure 20-61-19
1
CD-15032
Remove the two seals (Item 1) [Figure 20-61-19] from

the mounting flange housing.
863 Bobcat Loader

240 of 970
514449483 & BELOW) (CONT’D)
Inspection
Wash all parts in clean solvent.
Use air pressure to dry them.
Make a visual inspection of all the parts.
After visual inspection, those parts which are of

questionable condition must be replaced.
Figure 20-61-21
CD-15029
Check the drive and idler gears for the large and small
pumps [Figure 20-61-22].
If excessive wear is visible on the journal, side or face of

the gears they must be replaced. If the splines are worn,
replace the drive gear(s).

Figure 20-61-23
CD-15028
Check the bushings in the large and small bearing

housings [Figure 20-61-21].
If the bushings are worn, scratched, and etc., replace

them as needed.
CD-15030
Check the large and small pump housing [Figure 20-61-

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

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

241 of 970
514449483 & BELOW) (CONT’D)
Assembly
IMPORTANT 1

damage the system.
I-2003-0888
CD-15026
Figure 20-61-24
Install the large drive and idler gears into the bearing
housing (Item 1) [Figure 20-61-25].
Figure 20-61-26

1
2
1
CD-15032

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

26].
863 Bobcat Loader

242 of 970
514449483 & BELOW) (CONT’D)
Assembly (Cont’d)
Figure 20-61-27
2
1
CD-15036
Install the mounting flange housing (Item 1) [Figure 20-

61-29] on the large pump housing.
CD-15034
Figure 20-61-30
Turn the large pump housing around; install the back-up
seal / O-ring seal (Item 1) [Figure 20-61-27].

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

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

the large pump housing.
863 Bobcat Loader

243 of 970
514449483 & BELOW) (CONT’D)
Assembly (Cont’d)
Figure 20-61-31
1
2
1
CD-15017
Install pump housing on the center housing [Figure 20-

61-33].
CD-15020
Install the drive and idler gears into the bearing housing Install the back-up seal / O-ring seal (Item 2) [Figure 20-
(Item 1) [Figure 20-61-31].

61-33].
Figure 20-61-32 Install the end housing.
Install the four pump housing bolts.
Figure 20-61-34
1 2
CD-15019
Install the bearing housing / gears assembly into the

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

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

244 of 970
514449483 & BELOW) (CONT’D)
Assembly (Cont’d)
Figure 20-61-35
CD-15038
Tighten the large pump housing bolts (hex head & allen
head) to 33 - 41 ft.-lb. (46 - 56 N•m) torque [Figure 20-

61-35].
863 Bobcat Loader

245 of 970
863 Bobcat Loader

246 of 970
HYDRAULIC PUMP (CAST IRON) (S/N 514449260 & Figure 20-62-1
ABOVE)
Check The Output Of The Hydraulic Pump Without

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

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

W-2059-0598

procedure: 2 1
MEL1563 - Remote Start Tool

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

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

247 of 970
HYDRAULIC PUMP (CAST IRON) (S/N 514449260 &
ABOVE) (S/N 514449260 & ABOVE) (CONT’D)

Power Bob-Tach (Cont'd)
Figure 20-62-3
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
Hydraulic Control
Valve
1
BH-00196
Sample tester connection shown [Figure 20-62-3].

Start the engine and run at low idle RPM. Make sure the
RPM*.
Warm the fluid to 140° F (60° C) by turning the restrictor

control (Item 1) [Figure 20-62-3] on the tester to about
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free
flow (GPM) at full RPM.
Push the maximum / variable flow switch (on the remote

start tool) to engage the front auxiliary hydraulics, the
light will come ON. Push the button (on the right control
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (PSI)
and flow (GPM). The high pressure flow must be at least
80% of free flow.
%= HIGH PRESSURE FLOW (GPM) X100
FREE FLOW (GPM)
A low percentage may indicate a failed pump.
*See “Hydraulic System” on page SPEC-10-3 for system

relief pressure and full RPM.
863 Bobcat Loader

248 of 970
ABOVE) (CONT’D)
Check The Output Of The Hydraulic Pump With

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

WARNING from the top of the Power Bob-Tach block.

W-2059-0598
The tools listed will be needed to do the following 2 1

procedure:

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

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

249 of 970
ABOVE) (CONT'D)
Check The Output Of The Hydraulic Pump With DANGER

Figure 20-62-6
EXAMPLE: TESTER
CONNECTION
Reservoir
P-90328
AVOID DEATH
Hydraulic Pump tubeline, hose, fitting, component or a part failure
Out In can cause lift arms to drop.
Hydraulic Control
Valve • Keep out of this area when lift arms are raised
1 support. Replace if damaged.
BH-00196 D-1009-0409

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

250 of 970
ABOVE) (CONT’D)
Figure 20-62-7
1 1
P-26316
Remove the two mounting bolts (Item 1) [Figure 20-62-

9] from the hydraulic pump.
P-34154
(37 - 50 N•m) torque.
Disconnect and cap the hoses from the outlet fitting (Item
1) [Figure 20-62-7] of the hydraulic pump.

Figure 20-62-10
Figure 20-62-8
1 1
1
2
1
P-26348 P-26318
P-34155
Remove the hydraulic pump from the hydrostatic pump
[Figure 20-62-10].
Disconnect and cap the inlet hoses (Item 1) [Figure 20-
62-8] from the front of the hydraulic pump. Remove the coupler (Item 1) [Figure 20-62-10] from the
hydraulic shaft.
Reverse the removal procedure to install the hydraulic

pump.
Installation: Use a new O-ring when installing the

hydraulic pump.
See Disassembly And Assembly on Page 20-62-7 for the

proper procedure.
863 Bobcat Loader

251 of 970
ABOVE) (CONT’D)
Identification
15
8
7
6
14
12 13
11

9 10
7
1 4 5
3
B-16050A
REF. DESCRIPTION REF. DESCRIPTION
1 RETAINING RING 8 DRIVE GEAR

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

252 of 970
ABOVE) (CONT’D)
Disassembly And Assembly 1
IMPORTANT
damage the system.
I-2003-0888
P-26353
Figure 20-62-11
Remove the pump end section (Item 1) [Figure 20-62-
12].
1 Figure 20-62-13
P-26352

2
2
1
P-26351
Mark the pump sections for correct assembly [Figure 20- 2

62-11]. P-26354
Remove the four smaller pump housing bolts (Item 1)

[Figure 20-62-11].
Remove the four larger pump housing bolts (Item 2)

[Figure 20-62-11].
Installation: Tighten the four smaller bolts (Item 1)

[Figure 20-62-11] to 30 ft.-lb. (40,7 N•m) torque. Tighten
the four larger bolts (Item 2) [Figure 20-62-11] to 54 ft.-
lb. (73,2 N•m) torque.
863 Bobcat Loader

253 of 970
ABOVE) (CONT’D)
Disassembly And Assembly (Cont'd)
Figure 20-62-14 1
1 P-26358
2 Figure 20-62-16
P-26355
Remove the wear plate (Item 1) [Figure 20-62-13] & 1

[Figure 20-62-14] and section seal (Item 2) [Figure 20-

62-13] & [Figure 20-62-14] from the pump end section.
NOTE: Position wear plate (Item 1) [Figure 20-62-14]

inlets and traps as shown with bronze side
toward gears.
NOTE: Inspect the pump end section (Item 3) [Figure

20-62-14] and bushings (Item 4) [Figure 20-62-
14]. If excessive wear or damage is visible, the
pump must be replaced. P-26359
Remove the pump center section (Item 1) [Figure 20-62-

15] & [Figure 20-62-16] from the pump end section.
NOTE: Inspect the pump center section (Item 1)

[Figure 20-62-16]. If excessive wear or
damage is visible, the pump must be
replaced.
863 Bobcat Loader

254 of 970
ABOVE) (CONT’D)
Figure 20-62-17
1
P-26391
Figure 20-62-20
P-26389
Figure 20-62-18

1
P-26364
1
1
P-26362
To remove the drive gear (Item 1) [Figure 20-62-19] from

the pump end section, locate and remove the retaining
P-26390 ring (Item 1) [Figure 20-62-20] from the spline end of the
drive gear.
Remove the idler gear (Item 1) [Figure 20-62-17] &

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

pump must be replaced.
863 Bobcat Loader

255 of 970
ABOVE) (CONT’D)
Figure 20-62-21
P-26394

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

NOTE: Inspect the drive gear (Item 1) [Figure 20-62-
1
P-26396
Figure 20-62-22
1 P-26395
Remove the load seal (Item 1) [Figure 20-62-24].

2
P-26393
Remove the wear plate (Item 1) [Figure 20-62-22] &

863 Bobcat Loader

256 of 970
ABOVE) (CONT’D)
Disassembly And Assembly (Cont'd) 1
Figure 20-62-25
1
2
P-26398
1
P-26374

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

257 of 970
863 Bobcat Loader

258 of 970
HYDRAULIC PUMP (CAST IRON HIGH FLOW) (S/N Figure 20-63-1
514449484-514450945)

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

WARNING from the pump.

W-2059-0598

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

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

259 of 970
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N Check The Output Of The Hydraulic Pump With
514449484-514450945) (CONT’D) Power Bob-Tach

Figure 20-63-3
WARNING
EXAMPLE: TESTER
CONNECTION Put jackstands under the front axles and rear corners
Reservoir of the frame before running the engine for service.
W-2017-0286
Out
Hydraulic Pump
In
Hydraulic Control
WARNING
Valve
1 the lift arms are secured by an approved lift arm
BH-00196 support device. Failure to use an approved lift arm

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

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

260 of 970
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N Figure 20-63-6
514449484-514450945) (CONT'D)
EXAMPLE: TESTER
Check The Output Of The Hydraulic Pump With CONNECTION
Reservoir
Figure 20-63-4
1 Hydraulic Pump
Out In
Hydraulic Control
Valve
2
1
BH-00196
P-34689 tester is connected correctly. If no flow is indicated on the

RPM*.
from the top of the Power Bob-Tach block.
Figure 20-63-5 control (Item 1) [Figure 20-63-6] on the tester to about
flow (GPM) at full RPM.
Push the maximum / variable flow switch (on the remote

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

261 of 970
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N Remove the hoses from the Power Bob-Tach block if
514449484-514450945) (CONT’D) equipped. (See Removal And Installation on Page 20-
120-1.)
Figure 20-63-7
DANGER
2 1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic P-34689
Disconnect and cap the outlet hose (Item 1) [Figure 20-
63-7] from the back of the hydraulic pump.

Disconnect and cap the hose (Item 2) [Figure 20-63-7]
D-1009-0409
from the high flow section of the hydraulic pump.
Figure 20-63-8
WARNING
1
W-2059-0598
Page 10-20-1.)
P-34688
Lift and block the rear of the loader. (See LIFTING AND Disconnect and cap the hoses from the inlet fitting (Item
BLOCKING THE LOADER on Page 10-10-1.) 1) [Figure 20-63-8] of the hydraulic pump.

on Page 10-30-1.)

863 Bobcat Loader

262 of 970
HYDRAULIC PUMP (CAST IRON HI FLOW) (S/N
514449484-514450945) (CONT’D)
Figure 20-63-9
1 1
P-28067


Installation: Tighten the mounting bolts to 27 - 37 in.-lb.
(37 - 50 N•m) torque.
Remove the hydraulic pump from the hydrostatic pump.
Remove the coupler and the O-ring.

pump.

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

proper procedure.
863 Bobcat Loader

263 of 970
514449484-514450945) (CONT’D)
Identification
26
22
19 23
27
24 25
23
18 21
16 17
15 20 8
7
14

13
11 12
1
6 7 9 10
4 5
3
2
B-16051A
REF. DESCRIPTION REF. DESCRIPTION
1 RETAINING RING 14 PUMP CENTER SECTION

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

264 of 970
514449484-514450945) (CONT’D)
Disassembly And Assembly

1
IMPORTANT
damage the system.
I-2003-0888
P-26624
Figure 20-63-10
Remove the pump end section (Item 1) [Figure 20-63-
11].
1
P-26623

2
2
1 P-26622
Mark the pump sections for correct assembly [Figure 20-

63-10].
Remove the four smaller pump housing bolts (Item 1)

[Figure 20-63-10].
Remove the four larger pump housing bolts (Item 2)

[Figure 20-63-10].
Installation: Tighten the four smaller bolts (Item 1)

[Figure 20-63-10] to 30 ft.-lb. (40,7 N•m) torque. Tighten
the four larger bolts (Item 2) [Figure 20-63-10] to 54 ft.-
lb. (73,2 N•m) torque.
863 Bobcat Loader

265 of 970
514449484-514450945) (CONT’D)
Figure 20-63-12
1
1
P-26627
Figure 20-63-15
2 P-26625
Figure 20-63-13

4
3 1
1 P-26628
2
Remove the pump section (Item 1) [Figure 20-63-14] &
P-26626 [Figure 20-63-15] from the pump center section.
NOTE: Inspect the pumps center section (Item 1)

replaced.
toward gears.

863 Bobcat Loader

266 of 970
514449484-514450945) (CONT’D)
Figure 20-63-16
P-26631
Figure 20-63-19
P-26629
Figure 20-63-17

1
1
P-26632
Remove the drive gear (Item 1) [Figure 20-63-18] &

[Figure 20-63-19].
P-26630
Remove the idler gear (Item 1) [Figure 20-63-16] & pump must be replaced.
[Figure 20-63-17].

863 Bobcat Loader

267 of 970
514449484-514450945) (CONT’D)
Figure 20-63-20
P-26636
1
1
P-26635
2 Remove the load seal (Item 1) [Figure 20-63-22].
P-26633 Figure 20-63-23
Figure 20-63-21
1

P-26638
1
1
2
P-26637
P-26634 Remove the pre-load seal (Item 1) [Figure 20-63-23].

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

toward gears.
863 Bobcat Loader

268 of 970
514449484-514450945) (CONT’D)
Figure 20-63-24
2 P-26657


Remove the pump center section (Item 1) [Figure 20-63- [Figure 20-63-26] and bushings (Item 4)
24] from the pump sections.

Figure 20-63-25 replaced.
Figure 20-63-27
P-26655
P-26659
([Figure 20-63-26]) and section seal (Item 2) [Figure 20-
63-25] & ([Figure 20-63-26]) from the pump section. Remove the pump section (Item 1) [Figure 20-63-27]
from the pump end section.
863 Bobcat Loader

269 of 970
514449484-514450945) (CONT’D)
Figure 20-63-28
1
1
P-26662

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

63-28]. If excessive wear or damage is visible,

the pump must be replaced.
Figure 20-63-29
P-26661

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

270 of 970
514449484-514450945) (CONT’D)
Figure 20-63-31
1
P-26666
Remove the drive gear (Item 1) [Figure 20-63-33] from

the pump end section.
P-26663
Figure 20-63-32 pump must be replaced.

Figure 20-63-34
P-26665
1 1
P-26664
P-26674
To remove the drive gear (Item 1) [Figure 20-63-31] from
the pump end section, locate and remove the retaining
ring (Item 1) [Figure 20-63-32] from the spline end of the Remove the spline shaft (Item 1) [Figure 20-63-34] from
drive gear. the end of the drive gear.
NOTE: Inspect the spline shaft (Item 1) [Figure 20-63-

863 Bobcat Loader

271 of 970
514449484-514450945) (CONT’D)

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

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

P-26672
1
1


toward gears.
863 Bobcat Loader

272 of 970
514449484-514450945) (CONT’D)
Figure 20-63-39
P-26673


863 Bobcat Loader

273 of 970
863 Bobcat Loader

274 of 970
HYDRAULIC PUMP (CAST IRON HI FLOW) clockwise to free flow. Shut the front auxiliary hydraulics
(514450846 & ABOVE) off.
Hydraulic Pump Test If flow and pressure specs are not obtained, go to the
Inline Standard Hydraulic Pump Test. (See Removal And
The tools listed will be needed to do the following Installation on Page 20-61-2.) If flow and pressure specs
procedure: are obtained continue on to the next paragraph.
MEL10103 - Hydraulic Tester With the engine running at low idle RPM. Press the Front
MEL10106 - Hydraulic Test Kit Auxiliary button. Engage the front auxiliary with the
trigger on the right handle. Make sure the tester is
Figure 20-64-1 connected correctly. If no flow is indicated on the tester,
the hoses are connected wrong. With the hoses
RPM*.
1 Warm the fluid to 140° F (60° C) by turning the restrictor

control on the tester to about 1000 PSI (6895 kPa).
NOTE: DO NOT EXCEED 3300 PSI.
Turn the restrictor control on the tester counter clockwise,

to obtain free flow, the flow should be at 20 GPM. Press
the High Flow button. The flow should increase to 30

GPM. Start turning the restrictor clockwise, causing more
restriction on the flow. The GPM should drop off slightly
2 until the pressure reaches approximately 2700 PSI. At
approximately 2700 PSI the flow should start decreasing
rapidly until the pressure reaches 3000 PSI. At 3000 PSI
P-16903 P-31821 the flow should be at 0 GPM. Turn the restrictor counter
clockwise to free flow. Shut the front auxiliary hydraulics
off.
Install a hydraulic tester (Item 1) [Figure 20-64-1] onto
the front auxiliary quick couplers. If the specs from above are reached, the high flow
hydraulic pump is OK.
This procedure will require a operator in the cab and one
operator running the tester. If the flow and pressure were not obtained, go to the
Inline High Flow Hydraulic Pump Test (See Checking The
Start the engine and run at low idle RPM. Press the Front Output Of The High Flow Pump on Page 20-61-1.)
Auxiliary button. Engage the front auxiliary with the
trigger on the right handle. Make sure the tester is *Refer to SPECIFICATIONS Contents Page SPEC-01 for
connected correctly. If no flow is indicated on the tester, system relief pressure and full RPM.
the hoses are connected wrong. With the hoses
RPM*.

Turn the restrictor control on the tester counter clockwise

to obtain free flow, the flow should be at 20 GPM. Start
turning the restrictor clockwise, causing more restriction
on the flow. The GPM should drop off slightly until the
pressure reaches approximately 2800 PSI. At
approximately 2800 PSI the flow should start decreasing
rapidly until the pressure reaches 3000 PSI. At 3000 PSI
the flow should be at 0 GPM. Back the restrictor counter
863 Bobcat Loader
275 of 970
HYDRAULIC PUMP (CAST IRON HI FLOW) Figure 20-64-2
(514450846 & ABOVE) (CONT’D)
Inline Hydraulic Pump Test (Standard)

1
procedure:

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

Disconnect the standard pump OUTLET hose (Item 1)
W-2017-0286
[Figure 20-64-2] from the tubeline.
Figure 20-64-3

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

276 of 970
HYDRAULIC PUMP (CAST IRON HI FLOW) Record the flow (GPM) at 2700 PSI, this is the high
(514450846 & ABOVE) (CONT’D) pressure flow. The high pressure flow must be at least
80% of free flow.
Inline Hydraulic Pump Test (Standard) (Cont'd)
%= X 100
FREE FLOW (GPM)
IMPORTANT A low percentage may indicate a failed pump.
The hydraulic tester must be in the fully open *Refer to SPECIFICATIONS Contents Page SPEC-01 for
position before you start the engine. system relief pressure and full RPM.
I-2024-0284
Figure 20-64-4
EXAMPLE: TESTER
CONNECTION
Reservoir

Hydraulic Pump
Out In Hydraulic Control
Valve
BH-196
Sample tester connection shown [Figure 20-64-4]].
RPM*.

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

(GPM) at full RPM.
863 Bobcat Loader

277 of 970
HYDRAULIC PUMP (CAST IRON HI FLOW)
(514450846 & ABOVE) (CONT’D)
Inline Hydraulic Pump Test (High Flow)

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

procedure:
MEL10103 - Hydraulic Tester 1



Figure 20-64-5 2
1 P-34844
Disconnect the high flow pump OUTLET hose (Item 1)

[Figure 20-64-6] from the fitting (Item 2) [Figure 20-64-
6] at the control valve.
Figure 20-64-7
P-34847
2
1
Install a jumper hose (Item 1) [Figure 20-64-5] onto the
front auxiliary quick couplers.
Page 10-20-1.)
P-34851
on Page 10-30-1.)
the tester to the OUTLET hose (Item 1) [Figure 20-64-6]
of the pump. Connect the OUTLET hose (Item 2) [Figure
20-64-7] from the tester to the tubeline (Item 2) [Figure
20-64-6] at the control valve.
Lower the cab down.
863 Bobcat Loader

278 of 970
HYDRAULIC PUMP (CAST IRON HI FLOW) Turn the restrictor control on the tester clockwise to 3000
(514450846 & ABOVE) (CONT’D) PSI and the flow should go to zero GPM. If the pressure
readings are not obtained go to the High Flow Relief
Inline Hydraulic Pump Test (High Flow) (Cont’d) Pump Adjustment (See Contents Page 20-61-6). If the
pressure readings are correct, continue on to the next
paragraph.
IMPORTANT Open the restrictor control and record the free flow
(GPM) at full RPM.
The hydraulic tester must be in the fully open Record the flow (GPM) at 2500 PSI, this is the high
position before you start the engine. pressure flow. The high pressure flow must be at least
I-2024-0284 80% of free flow.
Figure 20-64-8 HIGH PRESSURE FLOW (GPM)

%= X 100
FREE FLOW (GPM)
EXAMPLE: TESTER
CONNECTION
Reservoir
*Refer to SPECIFICATIONS Contents Page SPEC-01 for
system relief pressure and full RPM.

Hydraulic Pump
Out In Hydraulic Control
Valve
BH-196
Start the engine and run at low idle RPM. Press the Front
Auxiliary button. Press the High Flow button. Engage the
front auxiliary with the trigger on the right handle. Make
sure the tester is connected correctly. If no flow is
indicated on the tester, the hoses are connected wrong.
With the hoses connected correctly, increase the engine
speed to full RPM*.

1000 PSI (6895 kPa).
863 Bobcat Loader

279 of 970
(514450846 & ABOVE) (CONT’D)
High Flow Relief Adjustment Procedure

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


Remove the right rear tire. 2
Figure 20-64-9
P-34844
1 Disconnect the high flow pump OUTLET hose (Item 1)

from the fitting (Item 2) [Figure 20-64-10] at the control
valve.
Figure 20-64-11
2
P-34847 1
Install a jumper hose (Item 1) [Figure 20-64-9] onto the

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

the tester to the OUTLET hose (Item 1) [Figure 20-64-
10] of the pump. Connect the OUTLET hose (Item 2)
[Figure 20-64-11] from the tester to the tubeline (Item 2)
[Figure 20-64-10] at the control valve.
Lower the cab down.
863 Bobcat Loader

280 of 970
(514450846 & ABOVE) (CONT’D)
High Flow Relief Adjustment Procedure (Cont’d)
Figure 20-64-12
1
1
P-34919
Start the engine and run at low idle RPM. Press the Front
Auxiliary button. Press the High Flow button. Engage the
N-23027 front auxiliary with the trigger on the right handle. Make
sure the tester is connected correctly. If no flow is
indicated on the tester, the hoses are connected wrong.
Remove the access cover mounting bolts (Item 1) and With the hoses connected correctly, increase the engine
the cover (Item 2) [Figure 20-64-12] from the frame.

speed to full RPM*.
Figure 20-64-13 Warm the fluid to 140° F (60° C) by turning the restrictor
Turn the restrictor control clockwise on the tester to

cause more restriction on the flow. The GPM should drop
off slightly until the pressure reaches approximately 2600
1 PSI. At approximately 2600 PSI the flow should start
decreasing rapidly until the pressure reaches 3000 PSI.
At 3000 PSI the flow should be at 0 GPM. Turn the
restrictor counter clockwise to free flow. Shut the front
auxiliary hydraulics off.
If the specs from above are reached, the pump is OK.

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

(Item 1) [Figure 20-64-14] will need to be turned
Remove the cap (Item 1) [Figure 20-64-13] from the
clockwise a 1/4 turn and retested with the procedure
pump.
above. (1/4 turn equals about 400 PSI.)
NOTE: If the relief plug has been turned in 1/4 turn and
the pressure remains the same, go to the
relief valve removal and installation section.
(See Removal And Installation on Page 20-
100-2.) If relief valve has been checked and is
OK, go to the high flow pump disassembly
and assembly section. (See Disassembly on
Page 20-61-5.)
If the pump reaches 3000 PSI and there is flow, the relief
plug must be turned counter clockwise 1/4 turn and
retested with the procedure above.
863 Bobcat Loader

281 of 970
(514450846 & ABOVE) (CONT’D)
High Flow Relief Valve Removal and Installation
1
WARNING 1
1
W-2017-0286
P-37082
Remove the access cover mount bolts (Item 1) and the
Remove the right rear tire. access cover (Item 2) [Figure 20-64-16] from the frame.
Figure 20-64-15 Figure 20-64-17

1
P-34847 P-34846
Install a jumper hose (Item 1) [Figure 20-64-15] onto the Remove the cap (Item 1) [Figure 20-64-17] from the
front auxiliary quick couplers. pump.
Page 10-20-1.)
WARNING
W-2059-0598
863 Bobcat Loader

282 of 970
(514450846 & ABOVE) (CONT’D)
1
High Flow Relief Valve Removal and Installation
(Cont’d) 2
Figure 20-64-18
3
P-34696
Inspect the relief valve (Item 1), spring (Item 2), and plug
(Item 3) [Figure 20-64-19] for damage and replace as
needed.
P-34919
Inspect the relief valve seat in the pump for damage or
wear.
Remove the Relief Plug (Item 1) [Figure 20-64-18] from

the pump. Install the relief valve (Item 1) and spring (Item 2) [Figure
20-64-19] into the pump.
Install the plug (Item 3) [Figure 20-64-19] and turn it in

until it makes contact with the spring. Then turn the plug
one full turn clockwise. Go to the High Flow Relief
Adjustment section to finish setting the relief. (See
Checking The Output Of The High Flow Pump on Page
20-61-1.)
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283 of 970
HYDRAULIC PUMP (CAST IRON HI FLOW) Remove the hoses from the Power Bob-Tach block. If so
(514450846 & ABOVE) (CONT’D) equipped.) (See Removal And Installation on Page 20-
120-1.)
Figure 20-64-20
DANGER 3
1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic P-34855
Disconnect and cap the hoses from the outlet fitting (Item
1) of the hydraulic pump. Disconnect and cap the hoses

from the High Flow outlet fitting (Item 2) and the low
pressure return hose (Item 3) [Figure 20-64-20].
D-1009-0409
Figure 20-64-21
WARNING
1
W-2059-0598
Page 10-20-1.) P-34852

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

on Page 10-30-1.)

863 Bobcat Loader

284 of 970
(514450846 & ABOVE) (CONT’D)
Figure 20-64-22
1
P-34849

P-34854
(37 - 50 N•m) torque.
Disconnect the electrical connector (Item 1) [Figure 20-
64-22] from the high flow solenoid.

Remove the hydraulic pump from the hydrostatic pump.
Remove the coupler and the O-ring.

pump.

hydraulic pump.
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285 of 970
(514450846 & ABOVE) (CONT’D)
Identification
1. Retaining Ring
2. Pump End Section
3. Pre-Load Seal
4. Load Seal
5. Section Seal
6. Wear Plate
7. Pins
8. Drive Gear
9. Idler Gear
10. Pump Section
11. Wear Plate 26
12. Section Seal
13. Spline Shaft
14. Pump Center Section
23
15. Pre-Load Seal 19 22
16. Load Seal

27
24 25
23
18 20 21
17
15 16
8
7
14
13
12
11
1
9 10
6 7
4 5
3
17. Section Seal 2

18. Wear Plate
19. Drive Gear
20. Idler Gear
21. Pump Section
22. Wear Plate
23. Pins
24. Section Seal
25. Pump End Section
26. Bolts (4)
27. Bolts (4)
B-16051A
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286 of 970
(514450846 & ABOVE) (CONT’D)

1
IMPORTANT
damage the system.
I-2003-0888
P-34693
Figure 20-64-24
Remove the valve cartridge (Item 1) [Figure 20-64-25].
1
Installation: Tighten the solenoid valve to 35 - 40 ft.-lb.
2 (47 - 54 N•m).
Figure 20-64-26

2
P-34692
Mark the pump sections for correct assembly.
Remove the solenoid nut (Item 1) [Figure 20-64-24]. 1

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

64-26] and replace as needed.
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287 of 970
(514450846 & ABOVE) (CONT’D)
1
2
Figure 20-64-27
P-34696
Inspect the check valve (Item 1), spring (Item 2), and
plug (Item 3) [Figure 20-64-29] for damage and replace
P-34708 as needed.
Figure 20-64-30
Remove the cap (Item 1) [Figure 20-64-27].

Installation: Tighten the cap to 13 - 16 ft.-lb. (18 - 22
N•m) after the relief valve has been set.
Figure 20-64-28
2 1
P-34699
1
Remove the eight bolts (Item 1) [Figure 20-64-30].
Installation: Tighten the assembly bolts to 45 - 50 ft.-lb.

P-34695 (60 - 67 N•m).
Remove the washer (Item 1) [Figure 20-64-28].
Remove the set screw, spring and relief valve (Item 2)

[Figure 20-64-28].
Installation: See High Flow Relief Valve Adjustments.

(Pages 20-61-6.)
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288 of 970
(514450846 & ABOVE) (CONT’D)
Figure 20-64-31 1
1
P-26627
Remove the pump center section (Item 1) [Figure 20-64-

33] & [Figure 20-64-34] from the pump center section.
P-34697
Figure 20-64-34
Remove the wear plate (Item 1) [Figure 20-64-31] and
section seal (Item 2) [Figure 20-64-31] & [Figure 20-64-

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

2
P-34698 replaced.

toward gears.
NOTE: Inspect the pump end section (Item 3) and

bushings (Item 4) [Figure 20-64-32]. If
excessive wear or damage is visible, the
863 Bobcat Loader

289 of 970
(514450846 & ABOVE) (CONT’D)
Figure 20-64-35
P-26631
Figure 20-64-38
P-26629

[Figure 20-64-36].

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

[Figure 20-64-38].


863 Bobcat Loader

290 of 970
(514450846 & ABOVE) (CONT’D)
1
Figure 20-64-39
P-26636
1
1
P-26635
2
P-26633 Figure 20-64-42
Figure 20-64-40 1

P-26638
1
1
2
P-26637

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

toward gears.
863 Bobcat Loader

291 of 970
(514450846 & ABOVE) (CONT’D)
Figure 20-64-43
4
1
1
2
P-26657

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

Remove the pump center section (Item 1) [Figure 20-64- bushings (Item 4) [Figure 20-64-45]. If
43] from the pump sections.

Figure 20-64-44
Figure 20-64-46
P-26655
P-26659

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

292 of 970
(514450846 & ABOVE) (CONT’D)
Figure 20-64-47
1
1
P-26662

Figure 20-64-50
NOTE: Inspect the pump section (Item 1) [Figure 20-
64-47]. If excessive wear or damage is visible,

the pump must be replaced.
Figure 20-64-48
1
P-26665
1
P-26664
Remove the retaining ring (Item 1) [Figure 20-64-50]

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

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

293 of 970
(514450846 & ABOVE) (CONT’D)
Figure 20-64-51
P-26674
Remove the spline shaft (Item 1) [Figure 20-64-53] from

the end of the drive gear.
P-26663
NOTE: Inspect the spline shaft (Item 1) [Figure 20-64-
Remove the drive gear (Item 1) [Figure 20-64-51] from pump must be replaced.

Figure 20-64-54
Figure 20-64-52
1
1
P-26667
P-26666
Remove the wear plate (Item 1) and section seal (Item 2)

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

863 Bobcat Loader

294 of 970
(514450846 & ABOVE) (CONT’D)
Figure 20-64-55
P-26671
Remove the pre-load seal (Item 1) [Figure 20-64-57].
P-26668 Figure 20-64-58
Inspect the wear plate (Item 1) and the section seal (Item
2) [Figure 20-64-55]. 1

toward gears.
Figure 20-64-56 2
P-26673
P-26670
NOTE: Inspect the pump end section (Item 1) and
1 bushings (Item 2) [Figure 20-64-58]. If
P-26669
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HYDRAULIC / HYDROSTATIC FILTER Raise the lift arms and install lift arm support device. (See
LIFT ARM SUPPORT DEVICE on Page 10-20-1.)
Housing Removal And Installation
on Page 10-30-1.)
DANGER Disconnect the wires (Item 1) [Figure 20-70-1] from the

hydraulic filter sender and switch.
Figure 20-70-2
2 3
P-90328 1
AVOID DEATH

N-19745
D-1009-0409
Disconnect the hose clamp and hose (Item 1) [Figure

20-70-2] from the filter housing.
WARNING Disconnect the hydraulic tubeline (Item 2) [Figure 20-70-
2].
the lift arms are secured by an approved lift arm Remove the four mounting bolts (Item 3) [Figure 20-70-
support device. Failure to use an approved lift arm 2].
to fall and cause injury or death. Installation: Tighten the mounting bolts to 25 ft.-lb. (34
W-2059-0598 N•m) torque.
Figure 20-70-1 Remove the filter housing / filter assembly.
N-19744
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HYDRAULIC FLUID RESERVOIR Removal And Installation
Draining The Fluid Reservoir Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Figure 20-80-1
Drain the fluid from the reservoir [Figure 20-80-1].

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

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

1 And Installation on Page 20-100-2.)
Figure 20-80-2
N-19496
Remove the side cover from the loader frame. Pull the 2
reservoir drain hose (Item 1) [Figure 20-80-1] out the

side of the loader frame.
Remove the hose end cap and drain fluid in a container

[Figure 20-80-1]. 1
N-19727
Remove the two bucket position valve mount bolts (Item

1)[Figure 20-80-2].
Remove the mount bracket.
Remove the two fill hose clamps (Item 2) [Figure 20-80-

2].
Remove the hydraulic fill hose.
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HYDRAULIC FLUID RESERVOIR (CONT’D) Figure 20-80-5
Figure 20-80-3 1
2
N-19730
At the left motor cover hole, remove the drain hose

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

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

Remove the reservoir from the loader.
Figure 20-80-4
Figure 20-80-6
1 1
N-19729
N-19731
Remove the two bolts (Item 1) [Figure 20-80-4].

Remove the rear tank bracket (Item 1) [Figure 20-80-6]
Installation: Tighten the bolt to 16 - 20 ft.-lb. (21 - 27 from the loader.
N•m) torque.
Remove the mounting strap.
Slide the reservoir forward.
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HYDRAULIC FLUID RESERVOIR (CONT’D) Figure 20-80-8
Hydraulic Fluid Screen

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

N-19610 replacing.

Remove the two hose clamps (Item 1) [Figure 20-80-7]
and remove the hydraulic fill hose (Item 2) [Figure 20-80-
7] from the hydraulic reservoir.
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863 Bobcat Loader

302 of 970
BUCKET POSITION VALVE Figure 20-90-3
Solenoid Removal And Installation

1
Disconnect the steering levers from the pump. (See
Hydraulic Pump Removal & Installation on Page 30-40- 2
7.)
Figure 20-90-1
N-18191
1 Inspect the solenoid stem and replace the O-rings (Item

1) [Figure 20-90-3] and the back-up washer (Item 2)
[Figure 20-90-3].
N-23648

20-90-1] from the bucket position shutoff solenoid.
Remove the solenoid nut (Item 2) [Figure 20-90-1].
Installation: Tighten the solenoid nut to 60 in.-lb. (6,78

N•m) torque.
Figure 20-90-2
N-23649
Remove the solenoid stem (Item 1) [Figure 20-90-2]

from the bucket position valve.
Installation: Put oil on O-rings and back-up washers and

tighten the solenoid stem to 30 - 35 ft.-lb. (40,8 - 47,6
N•m) torque.
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303 of 970
BUCKET POSITION VALVE (CONT’D)
Solenoid Testing WARNING

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

on Page 10-30-1.)
Figure 20-90-5
P9175
Use a test meter to measure coil resistance (Item 1)

[Figure 20-90-4]. Coil wires do not have polarity. Correct

resistance for the pressure relief (small) coil is 7-10 ohm
and the other coils 5 - 8 ohm.
Replace the test meter with 12 volt power. You can see 1
Start the engine. Raise the lift arms and install an

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

Installation: Tighten the nut to 60 in.-lb. (6,78 N•m)
torque.
Remove the solenoid (Item 2) [Figure 20-90-6] and

solenoid stem (Item 3) [Figure 20-90-6].
2
Figure 20-90-7
1
1
N-23653
1 Disconnect the tubeline (Item 1) [Figure 20-90-9] from

the C port on the bucket position valve.
C is bottom is rod end of tilt.
Disconnect the tubeline (Item 2) [Figure 20-90-9] from

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

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

Installation: Tighten the mounting bolts and nuts to 15
ft.-lb. (20 N•m) torque. Figure 20-90-12
Remove the bucket position valve from the loader.

2
N-19070
Remove the solenoid (Item 1) [Figure 20-90-12] and the

solenoid stem (Item 2) [Figure 20-90-12].
Installation: Tighten the solenoid stem to 30 - 35 ft.-lb.

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

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

Figure 20-90-16
NOTE: Always install new O-rings before any parts
are installed into the vale. Check the parts for
wear or damage and replace as needed.
Figure 20-90-14
3
N-19042
Remove the tilt cylinder check valve (Item 1) [Figure 20-

1 90-16], spring (Item 2) [Figure 20-90-16] and plug (Item
N-19041 3) [Figure 20-90-16]. Check for wear, check the O-ring
and replace as needed.
Remove the plug (Item 1) [Figure 20-90-14].
863 Bobcat Loader

307 of 970
Figure 20-90-17
1
N-19046
Remove the plug (Item 1) [Figure 20-90-18], spring (Item

N-19045 2) [Figure 20-90-18] and unloading spool (Item 3)
[Figure 20-90-18].
Remove the plug [Figure 20-90-17]. Check all parts and replace as needed. Install a new O-
ring on the plug before installing.
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308 of 970
SELECT VALVE Figure 20-100-2
Checking The High Flow Pump Relief Valve (S/N

514450945 & Below)
3 1
IMPORTANT
2
I-2024-0284
B-15551
WARNING Start the engine and run at low idle RPM. Push the mode
Put jackstands under the front axles and rear corners switch (Item 1) [Figure 20-100-2] once (on the
of the frame before running the engine for service. instrument panel) to engage the front auxiliary hydraulics
Failure to use jackstands can allow the machine to momentarily, the light (Item 2) [Figure 20-100-2] will
fall or move and cause injury or death. come ON.
W-2017-0286

Push the high flow switch (Item 3) [Figure 20-100-2] for
fluid pressure to the secondary quick couplers.
Figure 20-100-1
Push the left handle rocker switch to engage the flow to
the secondary quick couplers.
2 Watch the flow meter on the hydraulic tester to make

sure the flow is correct. Increase the engine speed to full
RPM.
The free flow should be approximately 10.0 GPM (37,85

L/min.). Turn the restrictor control, on the tester, until the
main relief valve opens. The correct pressure for the
main relief is approximately 3000 PSI (20685 kPa).
1
Release the rocker switch (Item 3) [Figure 20-100-2] to
disengage the flow to the secondary quick couplers.
P-9153

procedure:


Connect the IN port of the hydraulic tester to the female

quick couplers (Item 1) [Figure 20-100-1] on the loader.
Connect the OUT port of the hydraulic tester to the male

quick coupler (Item 2) [Figure 20-100-1] on the loader.
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SELECT VALVE (CONT’D) Removal And Installation
Checking The High Flow Pump Relief Valve (Cont’d) Raise the operator cab. (See Contents, Page 10-01.)
Figure 20-100-3 Figure 20-100-4
3 1
2
2
2 P-9174 P13047 1 2
P-13046
If the relief pressure is not correct, stop the engine. Disconnect the controls harness at the left side steering
Remove and inspect the relief valve (Item 1) [Figure 20- lever connectors (Item 1) [Figure 20-100-4].

100-3]. Inspect the O-rings (Item 2) [Figure 20-100-3]
and back-up ring (Item 3) [Figure 20-100-3] for damage. Disconnect the controls harness at the select valve
connectors (Item 2) [Figure 20-100-4].
Replace the relief valve if required. This relief valve is not
adjustable. Remove the rear bolt on the left side pedal link (Item 3)
[Figure 20-100-4] and lower link.
NOTE: Steering panel brace is removed for photo

clarity.

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SELECT VALVE (CONT’D) Figure 20-100-7
Removal And Installation (Cont’d) 1
Figure 20-100-5
3
P-13048
2
Disconnect the tubelines (Item 1) [Figure 20-100-7].

P-13047
Remove the select valve.
Loosen the clamp (Item 1) [Figure 20-100-5] and Installation: Connect controls harness to select valve
disconnect the hose. solenoids. See Disassembly And Assembly on page 20-

100-4 for solenoid identification and correct controls
Disconnect the tubeline (Item 2) [Figure 20-100-5]. harness wire color.
Disconnect the hose (Item 3) [Figure 20-100-5].
Install caps and plugs on open connections.
Figure 20-100-6
P-9166
Remove mounting bolts (Item 1) [Figure 20-100-6]

located on the outside left frame.
NOTE: The select valve will drop down for wrench

clearance.
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IMPORTANT 1
damage the system. 2
I-2003-0888
P-9177
Figure 20-100-8
Figure 20-100-10
2
1
3

1
4 2
5 2
P-9168 2 2
P-9169
Clean the select valve to remove dirt before disassembly.
Remove the solenoid valve coils in [Figure 20-100-8]. Assembly: The coils largest opening (Item 1) [Figure
20-100-9] must position on the valve shoulder (Item 2)
NOTE: The controls wiring harness colors are listed [Figure 20-100-9]. Install the washer (Item 1) [Figure
below for identification during select valve 20-100-10] between the double coils. Install the coils and
assembly installation. tighten the nuts (Item 2) [Figure 20-100-10] to 5 ft.-lb.
(6,7 N•m) torque.
Second aux. male coupler (Item 1) [Figure 20-100-8]
Brown
Second aux. female coupler (Item 2) [Figure 20-100-8]

White
Second aux. pressure relief (Item 3) [Figure 20-100-8]

Green
High flow (Item 4) [Figure 20-100-8] Blue
Second aux. diverter (Item 5) [Figure 20-100-8] Yellow
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Figure 20-100-11
1 3
1 2
P-9171
2 Remove the relief valve (Item 1) [Figure 20-100-12].

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

Figure 20-100-13
Remove the 2-way solenoid valve (Item 2) [Figure 20-
100-11].
Remove the 2-way solenoid valves (Item 3) [Figure 20-

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

Wash all parts in clean solvent. Use air pressure to dry 1
them. Install new O-rings and back-up washers.
5 4
Assembly: Put oil on O-rings and back-up washers. 2
Install and tighten the solenoid valves (Items 1&3)
[Figure 20-100-11] to 25 ft.-lb. (33,9 N•m) torque.
3
Tighten the solenoid valve (Item 2) [Figure 20-100-11] to
20 ft.-lb. (27,1 N•m) torque. N-0503 P-9172
Remove the load shuttle (Item 1) [Figure 20-100-13].

Remove the fitting (Item 2) [Figure 20-100-13]. Remove
the check valve (Item 3) [Figure 20-100-13].
Inspect the relief valve, check valves, piston, load shuttle

and fitting for contamination or damage. Wash all parts in
clean solvent. Use air pressure to dry them. Install new
O-rings and back-up washers.
The load shuttle (Item 1) [Figure 20-100-13] has a ball

(Item 5) [Figure 20-100-13] that must move free inside
the shuttle, the plug (Item 4) [Figure 20-100-13] can be
removed to clean the shuttle and ball.
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Figure 20-100-14
P-9175
Use a test meter to measure coil resistance [Figure 20-

P-9176 100-15]. Coil wires do not have polarity. Correct
resistance for the pressure relief (small) coil is 7 - 10 ohm
and the other coils 5 - 8 ohm.
The fitting (Item 2) [Figure 20-100-13] and [Figure 20-
100-14] has a poppet valve. The poppet valve allows flow Replace the test meter with 12 volt power. You can see

out of the select valve only. Inspect the poppet for and hear the spool shift.
smooth opening and closing.
Assembly: Put oil on O-rings and back-up washers and

pilot piston (Item 3) [Figure 20-100-12]. Install and
tighten the relief valve (Item 1) [Figure 20-100-12] to 25
ft.-lb. (33,9 N•m) torque. Install the pilot piston (Item 3)
[Figure 20-100-12] in the port between the check valves
(Item 2) [Figure 20-100-12] and (Item 3) [Figure 20-100-
13]. Install the check valves and load shuttle (Item 1)
[Figure 20-100-13] and tighten to 20 ft.-lb. (27,1 N•m)
torque. Install the fitting (Item 2) [Figure 20-100-13] and
tighten to 35 ft.-lb. (47,4 N•m) torque.
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REAR AUXILIARY DIVERTER VALVE Figure 20-110-2
Disassembly
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888 2
N-0529
Figure 20-110-1
Remove the pilot check valves from block ports PC1 and
PC2 (Item 1) [Figure 20-110-2].
Remove the shuttle check valve from block port SH1

(Item 2) [Figure 20-110-2].

Figure 20-110-3
1 4
1 1
N-0527 2
3
5 2
Clean the diverter block to remove dirt before
disassembly. Block ports are labeled for correct 2
assembly.
Remove the logic cartridge valves from block ports LC1

3
and LC2 (Item 1) [Figure 20-110-1]. 2 1 N-0528
Remove the nuts (Item 1) [Figure 20-110-3], seal

washers (Item 2) [Figure 20-110-3] and solenoid valve
coils (Item 3) [Figure 20-110-3].
Remove the diverter control solenoid valve (Item 4)

[Figure 20-110-3] from port SV1. Remove the pressure
relieving solenoid valve (Item 5) [Figure 20-110-3] from
block port SV2.
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REAR AUXILIARY DIVERTER VALVE (CONT’D) Assembly
Inspection Put oil on O-rings and back-up washers.
Inspect cartridges, check valves, solenoid valves and Tighten the logic cartridge valves (Item 1) [Figure 20-
sealing washers for contamination or damage. Wash all 110-1] to 65 ft.-lb. (88 N•m) torque.
parts in clean solvent. Use air pressure for drying them.
Install new O-rings and back-up washers. Tighten the pilot check valves (Item 1) [Figure 20-110-2],
shuttle check valve (Item 2) [Figure 20-110-2] to 35 ft.-lb.
Inspect diverter block cavities for contamination. Wash (47 N•m) torque.
block in clean solvent. Use air pressure to dry.
Tighten the solenoid valves (Items 4 & 5) [Figure 20-110-
Solenoid Testing 3] to 12 ft.-lb. (16,3 N•m) torque. Install the sealing
washers (Item 2) [Figure 20-110-3] and coils (Item 3)
Figure 20-110-4 [Figure 20-110-3]. Tighten the nuts (Item 1) [Figure 20-
110-3] to 10 in.-lb. (1,13 N•m) torque.

P-9137
Use a test meter to measure coil resistance [Figure 20-

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

damage the system.
I-2003-0888
DANGER 1
N-23028

Disconnect the two solenoid connectors (Item 1) [Figure
20-120-1] from the loader harness.
Remove the right rear tire from the loader.

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

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

5].
N-23030
(34 - 38 N•m) torque.
that goes to the control valve.

Remove the POWER BOB-TACH BLOCK (6676547-
Aluminum).
that goes to the hydrostatic pump.
Figure 20-120-4
N-23029
Disconnect the two hydraulic hoses (Item 1) [Figure 20-

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

2
P-16282
N-22662
Clean the diverter block (Item 1) [Figure 20-120-6] to

remove dirt before disassembly. Block ports are labeled Remove the plug (Item 1) [Figure 20-120-7] & [Figure
for correct assembly. 20-120-8].
Installation: Tighten until plug makes metal to metal

contact, then tighten until fully seated, (no more than 1/6
turn) or 22 ft.-lb. (30 N•m) torque.
Remove the 0.02 screened orifice (Item 2) [Figure 20-

120-8].
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(CONT’D)
Figure 20-120-9
P-16257
Figure 20-120-11
N-22663
Check the screened orifice (Item 1) [Figure 20-120-9]

and replace as needed. 1

Installation: Hand tighten until snug. Do Not use thread
locking agent.
P-16258
Remove the reducing valve (Item 1) [Figure 20-120-10]

& [Figure 20-120-11].
The valve is set at 2000 PSI (1379 kPa).
Installation: Put oil on O-rings and back-up washers.

Tighten to 25 ft.-lb. (33,9 N•m).
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(CONT’D)
Figure 20-120-12
P-16255

1
P-16259 Installation: Put oil on O-ring. Tighten to 40 ft.-lb. (54
N•m).
Figure 20-120-13 Figure 20-120-15

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

1
P-16272
Remove the logic cartridge valve (Item 1) [Figure 20-

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

Tighten to 108 - 120 in.-lb. (12,2 - 13,5 N•m).
Figure 20-120-21 Figure 20-120-23

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

Figure 20-120-25
1
P-16276
P-16267 Use a test meter to measure coil resistance [Figure 20-

120-27]. Coil wires do not have polarity. Correct
resistance is approximately 9 ohm.
Remove BASE end fitting (Item 1) [Figure 20-120-25].
Replace the test meter with 12 volt power. You can see
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(CONT’D)
Figure 20-120-28
2
1 1
P-16335
Remove the check ball (Item 1) [Figure 20-120-29].
P-16277 Remove the spring (Item 2) [Figure 20-120-29].
Remove the solenoid valve (Item 1) [Figure 20-120-28].

Tighten the solenoid valve to 12 ft.-lb. (16,3 N•m) torque.
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POWER BOB-TACH BLOCK (6678554-CAST IRON) Figure 20-121-1
DANGER
1
P-26244
P-90328
AVOID DEATH Disconnect and cap the two solenoid connectors (Item 1)
• Disconnecting or loosening any hydraulic [Figure 20-121-1] from the loader harness.
support. Replace if damaged. IMPORTANT

D-1009-0409
WARNING tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
the lift arms are secured by an approved lift arm Figure 20-121-2
to fall and cause injury or death. 1
W-2059-0598

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

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

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

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

3]. 2

Installation: Tighten the mounting bolts to 25 - 28 ft.-lb. 1
(34 - 38 N•m) torque.
3 P-26103
Remove the power Bob-Tach block.

Remove the spring (Item 1) [Figure 20-121-5] and
compensator (Item 2) [Figure 20-121-5].
Figure 20-121-4
Check the O-ring (Item 3) [Figure 20-121-5] on the plug
1 Figure 20-121-6
P-26100
1
Clean the block (Item 1) [Figure 20-121-4] to remove dirt

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

Installation: Tighten the plug to 46 ft.-lb. (62,4 N•m)
torque.
Installation: Tighten the plug to 120 in.-lb. (13,6 N•m)
torque.
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(CONT’D)
1
Figure 20-121-7
P-26208
3
2
1
4
2 5 P-26112
1 3
Remove the pressure reducing valve plug (Item 1)
[Figure 20-121-8] & [Figure 20-121-9].
P-26107
Installation: Tighten the pressure reducing valve plug to
to 46 ft.-lb. (62,4 N•m) torque.
Remove the spring (Item 1) [Figure 20-121-7] and check
ball (Item 2) [Figure 20-121-7].

Remove the relief piston (Item 2) [Figure 20-121-9],
spring (Item 3) [Figure 20-121-9], ball seat spring guide
Check the O-ring (Item 3) [Figure 20-121-7] on the plug (Item 4) [Figure 20-121-9].
Check the O-ring (Item 5) [Figure 20-121-9] on the
Figure 20-121-8 pressure reducing valve plug and replace as needed.
NOTE: The relief valve seat (Item 6) [Figure 20-121-9]

is a non-serviceable part. If seat is damaged,
order a new power Bob-Tach block from
Bobcat parts.
1
P-26109
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(CONT’D)
Figure 20-121-10
P-26116
Figure 20-121-13
1
P-26113
Figure 20-121-11 4

3 2
P-26117
3
Remove the nut (Item 1) [Figure 20-121-12] & [Figure

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

replace as needed.
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(CONT’D)
Figure 20-121-14
1
1
P-26123
Figure 20-121-17
P-26120
Remove the stem (Item 1) [Figure 20-121-14].

Installation: Tighten the stem to 20 ft.-lb. (27,1 N•m)
torque.
Figure 20-121-15
2
1
1
3 P-26309
Remove the plug (Item 1) [Figure 20-121-16] & [Figure

20-121-17].

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

P-26122 17].

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

replace as needed.
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(CONT’D)
Figure 20-121-18
P-26128
Figure 20-121-21
1
P-26125
Figure 20-121-19

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

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

121-24].
P-26130
Figure 20-121-23

2
1
3 P-26132

20-121-23].

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

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

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

torque.
Figure 20-121-26 Figure 20-121-28

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

121-26].

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

torque.
Figure 20-121-30 Figure 20-121-32

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

clean the work area before disassembly and keep all 2
parts clean. Always use caps and plugs on hoses, 4
damage the system. 3
I-2003-0888
Figure 20-130-1 P-34661
Figure 20-130-3
2 1

1
3
6 2
4 5
3
P-34899
P-34760
Disconnect the auxiliary tubelines (Item 1) [Figure 20-
130-1] and drain tubeline (Item 2) [Figure 20-130-1] from
the coupler block. Remove the male coupler (Item 1) [Figure 20-130-2] &
[Figure 20-130-3].
1] Installation: Tighten the male coupler (Item 1) [Figure
20-130-2] & [Figure 20-130-3] to 59 ft.-lb. (80 N•m).
Remove the drain coupler (Item 2) [Figure 20-130-2] &

[Figure 20-130-3].
Installation: Tighten the drain coupler (Item 2) [Figure

20-130-2] & [Figure 20-130-3] to 37 ft.-lb. (50 N•m).
Remove the female coupler (Item 3) [Figure 20-130-2] &

[Figure 20-130-3].
Installation: Tighten the female coupler (Item 3) [Figure

20-130-2] & [Figure 20-130-3] to 59 ft.-lb. (80 N•m).
Remove the fittings (Item 4) [Figure 20-130-2] & [Figure

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

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

rings (Item 2) [Figure 20-130-6] for damage and replace
as needed.
P-34663
Figure 20-130-7
Check the O-ring (Item 1) [Figure 20-130-4] for damage

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

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

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

Hydrostatic Charge Pressure Sender Removal And Installation 30-30-1
SAFETY &
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1 MAINTENANCE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-2
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Tensioner Pulley Removal And Installation . . . . . . . . . . . . . . . . 30-50-2
Tensioner Pulley Tension Spring . . . . . . . . . . . . . . . . . . . . . . . . 30-50-4
HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 HYDROSTATIC

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-8 SYSTEM
Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-14
Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-13
Carrier Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-12
Carrier Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 30-20-11
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-7
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-3

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

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-16
Charge Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-8
Hydraulic Pump Removal & Installation. . . . . . . . . . . . . . . . . . . 30-40-7
Parts Identification (Left Half). . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-6
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-3
Replenishing / High Pressure Relief Valve . . . . . . . . . . . . . . . . 30-40-1
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . 30-10-1

Replentishing The Valve Function . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

Removal And Installation With STC (Seal Tight Connector) . . . 30-60-1
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE
SPECIFICATION FOR BOLTS, SPEC-01) UNLESS OTHERWISE SPECIFIED.
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HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4, 5
The loader does not move in a straight line. 2, 3, 5, 6, 7
The hydrostatic system is overheating. 8, 9, 10, 11
Service code HP 2 appears (Warnings, low charge pressure) or the warning light 8, 11, 12, 13, 14
comes on.
KEY TO CORRECT THE CAUSE

1. The hydrostatic pump replentishing valves not seating.

2. The steering linkage needs adjustment.
3. The hydrostatic pump has damage.
4. The final drive chains are broken.
5. the hydrostatic motor has damage.
6. The tires do not have the correct tire pressure.
7. The tires are not the same size.
8. The hydrostatic fluid is not at the correct level.
9. The oil cooler has a restriction.
10. The temperature sending switch is not operating correctly.
11. The loader is not being operated at the correct RPM.
12. The sender is defective.
13. Pump is defective or worn hydrostatics.
14. Hydraulic filter is plugged.
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HYDROSTATIC SYSTEM INFORMATION (CONT’D) The functions of the replentishing valves are:
• To give replacement fluid to the low pressure side of

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

Function 1 Valve Moves for
Charge Oil
Replacement
Function 2 Valve Stays on Seat

to Hold High
Pressure for
Drive
B-2804
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HYDROSTATIC MOTOR Figure 30-20-1
DANGER 1
N-17874
P-90328
AVOID DEATH Disconnect the case drain hose (Item 1) [Figure 30-20-
• Disconnecting or loosening any hydraulic 1].
can cause lift arms to drop. Disconnect the high pressure hoses (Item 2) [Figure 30-
• Keep out of this area when lift arms are raised 20-1].

Figure 30-20-2
D-1009-0409
WARNING
1 2 1
W-2059-0598
Lift and block the loader. (See LIFTING AND BLOCKING N-17876
Raise the lift arms and install the lift arm support device. Remove the ten mounting bolts (Item 1) [Figure 30-20-
(See LIFT ARM SUPPORT DEVICE on Page 10-20-1.) 2].
Raise the operator cab. (See Raising The Operator Cab NOTE: The two bolts (Item 2) [Figure 30-20-2] mount
on Page 10-30-1.) the cam ring to the motor, and do not have to
be removed, to remove the motor from the
Remove the motor cover. loader.
Mark the hoses for correct installation. Remove the motor / cam ring section from the loader.
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HYDROSTATIC MOTOR (CONT’D)
Figure 30-20-3
P-5405
Remove the piston / roller section (Item 1) [Figure 30-20-

3] from the loader, if it was not removed with the motor /

cam ring.
To remove the motor carrier. (See Carrier Removal And

Installation on page 30-20-11.)
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3
1 2 3
5
6
4 7
8
9
12 4 10
11
13
15
23 14
26
27 25

28
29
16
22
24 21
20
19
18
30 17
C-3374A
Ref. Description Ref. Description

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

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

1
Figure 30-20-5
N-17864
Remove the stop pin (Item 1) [Figure 30-20-7] from the

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

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

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

1 2 the distributor.
Figure 30-20-11

N-17865
Use a brass drift punch, thru the stop pin hole (Item 1)
[Figure 30-20-8] to remove the distributor (Item 2)
[Figure 30-20-8].
1
Figure 30-20-9
N-17870

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

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

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

and poppet (Item 4) [Figure 30-20-12].
Figure 30-20-13
1
4 2
2 3
N-17871
Remove the plug (Item 1) [Figure 30-20-13], springs

(Item 2) [Figure 30-20-13], spool (Item 3) [Figure 30-20-
13] and washer (Item 4) [Figure 30-20-13].
Inspect all parts and replace as needed.
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Inspection
Clean all parts in clean solvent and use air pressure to

dry them. DO NOT use cloth or paper because small
pieces of material can get into the system and cause
damage.
Before the motor is assembled, check the following

items:
Figure 30-20-15
P-5759
Check the cylinder block surface for scratches [Figure

30-20-17].
Check all the roller / piston assembly for scratches and

wear [Figure 30-20-17].

N-17870
Check the distributor surface for scratches [Figure 30-

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

damage the system.
I-2003-0888
N-17870
NOTE: Always use new O-rings and seals when
assembling the hydrostatic motor.
Install new O-rings and seals (Item 1) [Figure 30-20-19]
Figure 30-20-18 on the distributor.
Figure 30-20-20

2
1
1
P-5765
N-17869
Install the roller (Item 1) [Figure 30-20-18] in the piston
(Item 2) [Figure 30-20-18].
Put grease on the springs (Item 1) [Figure 30-20-20] to
Dip the roller / piston assembly into oil and install into the hold them in place.
bore in the cylinder.
Install the springs into the distributor.
Repeat for each roller / piston assembly.
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HYDROSTATIC MOTOR (CONT’D) Install the two O-rings into the housing.
Assembly (Cont’d) Figure 30-20-23
Figure 30-20-21
4
1 2 3 1
1
N-17866
N-17871
housing, over the top of the O-rings, with minimum
Install the spring (Item 1) [Figure 30-20-21], spool (Item distortion.
2) [Figure 30-20-21], washer (Item 3) [Figure 30-20-21]

and spring into the rear housing. Lightly smear grease over the seals.
Replace the O-ring (Item 4) [Figure 30-20-21] on the Figure 30-20-24

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

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

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

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

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

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

Figure 30-20-26
N-17861
Install the piston / roller section (Item 1) [Figure 30-20-

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

Install the cam ring (Item 1) [Figure 30-20-26] on the bolts to 110 ft.-lb. (149,2 N•m) torque.
rear housing and align the mounting bolt holes.
NOTE: Before operating the hydrostatic motor, make
sure it is full of oil. There are several methods
to fill the motor with oil; (1) with the case drain
hose disconnected, fill the motor with oil
through the case drain port; (2) with the case
drain hose disconnected, BICS™ brake
locked, engine running, stroke the steering
until oil comes out of the case drain port.
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Carrier Removal And Installation
Figure 30-20-29
P-5467
Lift and block the loader. (See Contents Page 10-01.)

Raise the lift arm and install an approved lift arm support
20-1.)

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

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

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

(447 N•m) torque.
Slide the motor carrier toward the rear and remove the
rear drive chain.
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Carrier Parts Identification
1
2 3
5 5
6
7

8
TS-1227A
Ref. Description
1. Shaft
2. Bearing
3. Race
4. Housing
5. Seal (2)
6. Race
7. Bearing
8. Snap Ring
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Carrier Disassembly
Figure 30-20-31
P-5756
Remove the snap ring (Item 1) [Figure 30-20-33] and

P-5760 washer from the shaft.
Figure 30-20-34
Remove the large O-ring from the groove (Item 1)
[Figure 30-20-31] in the housing.

Figure 30-20-32
P-5768 P-5766
Put the motor carrier in a hydraulic press [Figure 30-20- Use a hydraulic press, remove the shaft from the housing
32]. [Figure 30-20-34].
Put a small amount of pressure on the shaft to release

the pre-load on the snap ring.
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HYDRAULIC MOTOR (CONT’D) Carrier Assembly
Carrier Disassembly (Cont’d) Figure 30-20-37
Figure 30-20-35
P-5764
P5761
The tool listed will be needed to the following procedure:
Install the bearing puller tool under the bearing flange, MEL1431 - Seal Driver Tool
use the hydraulic press to remove the bearing from the

shaft [Figure 30-20-35]. Install the first seal (Item 1) [Figure 30-20-37] into the
housing with the seal lip facing away from you.
Figure 30-20-36
Use the tool (Item 2) [Figure 30-20-37] as shown in the
figure.
Figure 30-20-38
2
1
2
P-5763

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

sides) and replace as needed. Install the second seal (Item 1) [Figure 30-20-38] into the
housing with the seal lip facing towards you.
Use the tool (Item 2) [Figure 30-20-38] as show in the

figure.
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Carrier Assembly (Cont’d)
Figure 30-20-39
1
1

P-5769
P-5767 Install the bearing (Item 1) [Figure 30-20-40] using the

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

D-1009-0409
WARNING
2
W-2059-0598
N-22484

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

N-22485 from the motor.
Figure 30-21-6
that goes to the case drain filter.

Figure 30-21-4
N-22487
2
Remove the 10 (12 mm) mount bolts (Item 1) [Figure 30-

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

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

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

7] and hold it in place with a light cover of lithium base

grease. Tighten the 10 mounting bolts to 110 ft.-lb. (149
N•m) torque.
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1. Motor
2. Distributor
3. Spring
4. Seal / O-Ring
5. Seal / O-Ring
6. Seal / O-Ring
1
7. Seal / O-Ring
8. Seal / O-Ring 8
9. Bushing 7
10. Roller
11. Piston 5
4 6
12. Block 3
13. Cam 2
14. Quad Ring
15. Plug
16. O-Ring 29 30
17. Locating Pin 28
18. Housing 27
9 25 26
19. Shim
20. O-Ring

16 32 25
21. Poppet 31
22. Spring
23. Plug 15
24. Bolt
25. Spring 10
26. Spool 34
39
27. Washer 33
28. O-Ring 11
29. Plug
30. Housing
18 38
31. Quad Ring 21 3637
32. Bushing 19 24 35
33. Snap Ring 17 22
20 48
34. Snap Ring
23
35. Spool 14 47 49
36. Spring 46
37. Washer 13 45
38. Quad Ring 12 44
39. Bolt 43
40. Shaft
41. Brake Disc-Outer
42. Brake Disc-Inner 42
41
43. Piston
44. O-Ring 40
45. Washer
46. Washer
47. Gasket
48. Cover
49. Bolt
B-16657A
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Disassembly
Figure 30-21-8
N-22491
Remove the cover plate gasket (Item 1) [Figure 30-21-

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

NOTE: Mark the motor, brake and motor carrier 10] and the disk spring (Item 3) [Figure 30-21-10] from
housings for proper alignment for ease of the brake housing.

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

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

Remove the brake housing (Item 2) [Figure 30-21-12]
from the rear housing.
1
Figure 30-21-13
1 N-22497
Remove the seal (Item 1) [Figure 30-21-15] from the

brake housing.
N-22495
Remove the brake disks (Item 1) [Figure 30-21-13] from

the brake shaft.

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

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

Remove the two-sped spool (Item 1) [Figure 30-21-16] N•m) torque.
from the housing assembly.

Remove the plugs (Item 2) [Figure 30-21-18] from the
Figure 30-21-17 housing.
Installation: Tighten the plugs to 9 - 11 ft.-lb. (12 - 15

N•m) torque.
1
Figure 30-21-19
1
4
3
2
N-22501
Inspect the spool (Item 1) [Figure 30-21-17], the spring

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

N-22504 from the housing.
Figure 30-21-23
Remove the spring (Item 1) [Figure 30-21-20], washer
(Item 2) [Figure 30-21-20] and rear spring (Item 3)

[Figure 30-21-20] from the spool (Item 4) [Figure 30-21-
20].
Inspect all parts and replace as needed.
Figure 30-21-21
1
1 2
3
N-22507
Inspect the poppet (Item 1) [Figure 30-21-23], shim

(Item 2) [Figure 30-21-23] and spring (Item 3) [Figure
30-21-23] for wear and replace as needed.
N-22505

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

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

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

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

Figure 30-21-27
Turn the housing, cam ring, and rotating group assembly
over and place on a stand.
Remove the cam ring mount bolts, and remove the cam
ring from the housing.
Figure 30-21-25 1
2
N-22512
Remove the brake shaft (Item 1) [Figure 30-21-27] from

the housing.
N-22509
Remove the cylinder block (Item 1) [Figure 30-21-25]

from the housing.

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

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

the motor.
Figure 30-21-29
1
1
N-22521
N-22515 Remove the locating pin (Item 1) [Figure 30-21-31] from

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

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

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

from the distributor.

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

distributor, if worn or scratched.
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Inspection
Figure 30-21-35
N-22510
2
Check the cam ring inside surface for wear and scratches
N-22498 [Figure 30-21-37].
Figure 30-21-38
Clean all parts in clean solvent and use air pressure to
dry them. Do Not use cloth or paper because small

pieces of material can get into the system and cause
damage. 3
Before the motor is assembled, check the following 1

items:
Check the brake piston (Item 1) [Figure 30-21-35] and

seal (Item 2).[Figure 30-21-35] and replace as needed.
Figure 30-21-36 2
N-22526
Check all rollers (Item 1) [Figure 30-21-38], pistons (Item

2) [Figure 30-21-38] and piston rings (Item 3) [Figure
NOTE: Put all roller / piston assembly back in their

original position.
N-22520
Check the surfaces of the distributor for wear and

scratches [Figure 30-21-36].
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HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D) Assembly
Inspection (Cont’d) Figure 30-21-40
Figure 30-21-39
1
N-22511
N-22514
NOTE: Always use new O-rings and seals when
assembling the motor and brake assemblies.
Check the brake shaft (Item 1) [Figure 30-21-39] for
wear and replace as needed. Dip the roller / piston assembly (Item 1) [Figure 30-21-

40] in oil and replace back in its original bore.
Check the brake shaft snap ring (Item 2) [Figure 30-21-
39] and replace as needed. Repeat the procedure for each roller / piston assembly.
Figure 30-21-41
N-22518
Apply a small amount of grease to the locating pin (Item

1) [Figure 30-21-41] and install the locating pin in the
housing.
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Assembly (Cont’d)
Figure 30-21-42
1 1
N-22515
Install the distributor (Item 1) [Figure 30-21-44] in the

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

Figure 30-21-43
1 1
N-22516
Align the locating pin (Item 1) [Figure 30-21-45] in the

N-22522 housing with the alignment hole in the distributor, and tap
the distributor in place with a rubber mallet.
Install new O-rings and seals on the distributor [Figure

30-21-43].
NOTE: When installing seals, apply a light coating of

oil to the seal and the mating surfaces of the
distributor. Install the O-rings and seals, allow
30 minutes for the seals to set on the
distributor before installing the distributor in
the housing.
Using a small amount of grease, install the twelve springs

into the distributor valve [Figure 30-21-43].
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Assembly (Cont’d)
Figure 30-21-46
1 1
N-22509
Install the cylinder block assembly (Item 1) [Figure 30-

N-22513 21-48] to the brake shaft.
Install the cam ring to the rear housing and start the
Install the brake shaft (Item 1) [Figure 30-21-46] in the mount bolts and finger tighten.
housing.

Figure 30-21-49
Figure 30-21-47
1 1
N-22508
N-22512
Turn the motor so that it sets on the cam ring, and

Apply a light coating of grease, and install the O-ring cylinder block [Figure 30-21-49].
(Item 1) [Figure 30-21-47] to the housing.
NOTE: Be careful when turning or moving the motor
so the cylinder block stays in the motor
housing.
Tighten the two cam ring mounting bolts (Item 1) [Figure

30-21-49] to 26 - 29 ft.-lb. (35 - 39 N•m) torque.
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Assembly (Cont’d)
Figure 30-21-50
1 N-18348
Measure the thickness of the individual brake disc’s

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

Install the two speed spool (Item 2) [Figure 30-21-50]. If the individual disc’s thickness is 0.037 in. (0.95 mm) or
less, replace the complete disc pack.
Figure 30-21-51
Figure 30-21-53
1 2
1
N-22496
N-22529
Install a new O-ring on the housing assembly (Item 1)

[Figure 30-21-51] and lightly smear with grease. Install the brake housing (Item 1) [Figure 30-21-53] on
the motor housing and align the marks.
Install the eight mounting bolts (Item 2) [Figure 30-21-

53] and tighten evenly to 52 - 57 ft.-lb. (70 - 77 N•m)
torque.
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Assembly (Cont’d)
Figure 30-21-54
N-22533
Install the brake seal (Item 1) [Figure 30-21-56].

N-22530
Figure 30-21-57
Install the brake disc pack starting with an outer disc

(Item 1) [Figure 30-21-54] and alternating with an inner

disc, throughout the pack.
Figure 30-21-55
1
1
N-22498
Lightly coat the piston with oil and install a new piston
seal (Item 1) [Figure 30-21-57].
N-22532
End the disc pack with an outer disc (Item 1) [Figure 30-
21-55].
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Assembly (Cont’d)
Figure 30-21-58
2 1
N-22534
With the motor in a hydraulic press and the

N-22493 predetermined amount of pressure applied on the
piston, use a straight edge, and measure the distance
from the top of the brake housing (Item 1) [Figure 30-21-
Install the piston (Item 1) [Figure 30-21-58] in the brake 59] to the top of the piston (Item 2) [Figure 30-21-59].
housing.

Record the measurement to three decimal places.
NOTE: If the brake pack was not replaced, the
procedure described below for determining Remove the motor from the hydraulic press.
brake washer thickness, need not be
performed. Figure 30-21-60
Install the motor assembly in a hydraulic press. Apply a

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

pressure required by the press. It is the 2
amount of downward force applied by the
press.
The amount of force applied to the brake piston, by the

press, is determined by the diameter of the piston on the
press cylinder and the PSI applied to press cylinder
piston.
N-22492
Determine the diameter of the piston on the press
cylinder d and use the following formula to determine the
PSI of pressure to apply to the press cylinder piston. Install the brake plate (Item 1) [Figure 30-21-60].
1432 Install the end plate gasket (Item 2) [Figure 30-21-60].

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

press cylinder. Apply 159 PSI (1,096 kPa) pressure to
the press cylinder piston.
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Assembly (Cont’d)
Figure 30-21-61
N-22490
Install the brake end cover (Item 1) [Figure 30-21-62].

N-22491
Install the twelve end cover mount bolts and tighten
evenly to 10 - 12 ft.-lb. (14 - 16 N•m) torque.
The correct washer thickness must be determined before
the washer (Item 1) [Figure 30-21-61] can be installed.

Use the recorded measurement obtained in [Figure 30-
21-59]. Plus the thickness of the gasket (Item 2) [Figure
30-21-60], which is 0.12 in. (0,3 mm). Minus the
thickness of the brake plate (Item 1) [Figure 30-21-60],
which is 0.281 in. (7,15 mm).
Select a washer, or combination of washers to suit the

calculated thickness within ± 0.6 in. (0,15 mm)
Install the proper brake washer or washers.
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863 Bobcat Loader

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CHARGE PRESSURE
Hydrostatic Charge Pressure Sender Removal And

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

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

sender.
Remove the hydraulics hose (Item 2) [Figure 30-30-1]

from the charge pressure sender.
Remove the charge pressure sender from the control

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

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

There are four replenishing / high pressure relief valves damage and replace as needed.
(Item 1) [Figure 30-40-1] in the hydrostatic pump. Two

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

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

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

kPa).

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

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

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

Remove the hydrostatic pump / engine assembly from N•m) torque.
the loader. (See Removal And Installation on Page 70-

80-1.) Figure 30-40-9
Remove the belt shield clips (Item 1) [Figure 30-40-6]

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

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

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

Figure 30-40-11 and drive belt housing.

1
N-15342

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

70 ft.-lb. (89 - 95 N•m) torque. Make sure the key (Item 2)
[Figure 30-40-10] is installed.
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HYDROSTATIC PUMP (CONT’D)
Parts Identification (Right Half)
8 5
7 4
6
9 3
2 1
13
14
10 15
17
11 12 19
21
23
25
27 16
18
29
20
22

24
26
3837
28
36 33
34
30 32
31
46
41 35 48
42 40
43
45
44 49
39 47 D-2427
Ref. Description Ref. Description Ref. Description Ref. Description

1. BOLT 14. O-RING 26. RETAINER 38. BOLT
2. END CAP 15. RELIEF VALVE 27. RETAINER 39. SHAFT
3. PLUG 16. PIN 28. PISTON ASSEMBLY 40. SNAP RING
4. O-RING 17. VALVE PLATE 29. PLATE 41. BEARING
5. PLUG 18. RETAINER 30. SWASHPLATE 42. SNAP RING
6. O-RING 19. WASHER 31. PIN 43. SNAP RING
7. O-RING 20. SPRING 32. HOUSING 44. PLUG
8. RELIEF VALVE 21. WASHER 33. PLUG 45. O-RING
9. BOLT 22. BLOCK 34. BEARING 46. BEARING
10. GASKET 23. RETAINER 35. SEAL 47. O-RING
11. BEARING 24. PIN 36. O-RING 48. PLATE
12. PLUG 25. WASHER 37. COVER 49. BOLT
13. O-RING
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HYDROSTATIC PUMP (CONT’D)
Parts Identification (Left Half)
4
16 8 6
13 11
14
12
10
1
2
17 3
23 5
15 9 7
24
18
19
21 22 26
20 28
30
32
34 25
36
38 27

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

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

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

removing the two mounting bolts (Item 2) [Figure 30-40-
13].
Figure 30-40-14
2
1
2
1
N-17356
Remove the gasket (Item 1) [Figure 30-40-16] and

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

coupler (Item 2) [Figure 30-40-14] with the hydraulic
pump.
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Disassembly
Pump Separation
Figure 30-40-17
N-17234
Separate the two hydrostatic pumps [Figure 30-40-19].
Charge Pump Disassembly

N-17230
Figure 30-40-20

Figure 30-40-18
1
1
2 2
1 N-17235
N-17233
Remove the two O-rings (Item 1) [Figure 30-40-20] from
the grooves in the gerotor spacer on the charge pump.
Remove the mounting bolts (Item 1) [Figure 30-40-17] &
[Figure 30-40-18]. Remove the O-rings (Item 2) [Figure 30-40-20] from the
charge pump housing end cap.
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2
Charge Pump Disassembly (Cont’d)
Figure 30-40-21
3
1
4
N-17185
Inspect the gerotor spacer (Item 1) [Figure 30-40-23] the

gerotor assembly (Item 2) [Figure 30-40-23], drive
coupling (Item 3) [Figure 30-40-23] and drive pin (Item 4)
N-17236 [Figure 30-40-23] for wear and replace as needed.
Figure 30-40-24

Figure 30-40-22
1 2
1
2
2
N-17186
N-17237
Remove the locating pin (Item 1) [Figure 30-40-24] from

Remove the gerotor assembly (Item 1) [Figure 30-40-21] the pump end cap.
& [Figure 30-40-22] from the charge pump.
NOTE: The charge pump rotation is determined by the
position of the gerotor spacer and locating
pin (Item 1) [Figure 30-40-24] in the pump end
cap, and must be noted for proper installation.

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

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

installation. 1
Mark the trunnion cover (Item 3) [Figure 30-40-25] and

pump case for proper installation.
Figure 30-40-26
N-17194
1
Check the valve plate locating pin (Item 1) [Figure 30-40-

28] for wear and replace if needed.
Check the needle bearing (Item 2) [Figure 30-40-28] for

wear and replace if needed.
N-17192
Remove the charge pump (Item 1) [Figure 30-40-26]

from the hydrostatic shaft end pump.
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1
Figure 30-40-29
N-17199
Remove the ball guide retainer (Item 1) [Figure 30-40-

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

3
Figure 30-40-30
1 2 1
3
3
2
N-17200
Check the ball guide retainer (Item 1) [Figure 30-40-32]

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

N-17201 30-40-35] from the pump housing.
Figure 30-40-36
Remove the thrust plate (Item 1) [Figure 30-40-33] from
the pump housing.

Figure 30-40-34
1
2
N-17240
3
Remove the snap ring (Item 1) [Figure 30-40-36] from
N-17481 the pump housing and remove the driveshaft and bearing
from the housing.
Remove the driveshaft key (Item 1) [Figure 30-40-34],

the snap ring (Item 2) [Figure 30-40-34] and the support
washer (Item 3) [Figure 30-40-34] from the drive shaft
end of the pump.
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Figure 30-40-37
1 1
1 N-17243
Remove the four mount bolts (Item 1) [Figure 30-40-39]

N-17241 form the lower trunnion cover. Remove the cover.
Figure 30-40-40
the driveshaft and remove the bearing.

Figure 30-40-38
2
1
N-17244
Remove the O-ring (Item 1) [Figure 30-40-40] and

N-17242 bearing race (Item 2) [Figure 30-40-40] from the pump
housing.
Check the bearing for wear and replace if worn.
Check the pump shaft (Item 1) [Figure 30-40-38] for

wear and replace if needed.
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Figure 30-40-41
1
1
2
N-17247
Remove the upper trunnion cover (Item 1) [Figure 30-40-

N-17245 43].
Figure 30-40-44
Check the bearing race (Item 1) [Figure 30-40-41] and
O-ring (Item 2) [Figure 30-40-41] for wear and replace

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

trunnion cover and replace as needed.
N-17246
Remove the four mount bolts (Item 1) [Figure 30-40-42]

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

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

bearing race (Item 2) [Figure 30-40-45] from the pump

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

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

N-17253 the swashplate shaft.
Figure 30-40-52
Install the lower bearing (Item 1) [Figure 30-40-49] on
the swashplate.

Figure 30-40-50
N-17248
Install the bearing race (Item 2) [Figure 30-40-51] and O-

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

[Figure 30-40-50].
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HYSROSTATIC PUMP (CONT’D) Figure 30-40-55
Assembly (Cont’d)
Figure 30-40-53
1 N-17245
Figure 30-40-56
N-17247
Install the upper trunnion seal (Item 1) [Figure 30-40-53]

and cover.

Figure 30-40-54
1
N-17244
Install the bearing race (Item 1) [Figure 30-40-55] and O-

ring (Item 2) [Figure 30-40-55] at the lower trunnion as
shown in [Figure 30-40-56].
N-17246
Install the steering bracket (Item 1) [Figure 30-40-54]

and the four mounting bolts and tighten to 18 - 22 ft.-lb.
(24 - 30 N•m) torque.
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Assembly (Cont'd)
Figure 30-40-57
N-17241
Install the bearing and snap ring (Item 1) [Figure 30-40-

N-17243 59] on the pump shaft.
Figure 30-40-60
Align the marks on the lower trunnion cover and pump
housing as shown in [Figure 30-40-57].

Install the four mounting bolts and tighten to 18 - 22 ft.-lb.
(24 - 30 N•m) torque.
Figure 30-40-58
1
1
N-17240
Install the pump shaft into the pump housing [Figure 30-
40-60].
Install the snap ring (Item 1) [Figure 30-40-60].

N-17242
Install the snap ring (Item 1) [Figure 30-40-58] on the

pump shaft.
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Assembly (Cont'd)
Figure 30-40-61
1 2 3
N-17198
Assemble the piston assemblies into the slipper guide

N-17200 [Figure 30-40-63]. Lubricate the pistons and cylinder
block bores and insert the piston assemblies into the
cylinder bores [Figure 30-40-63].
Install the four slipper pins (Item 1) [Figure 30-40-61]
into the cylinder block. Figure 30-40-64

Apply a small amount of grease to the washer (Item 2)
[Figure 30-40-61] and install into the ball guide retainer
(Item 3) [Figure 30-40-61].
Figure 30-40-62
N-17197
Lay the pump housing on its side and install the cylinder
block, piston assembly into the housing.
N-17199 Place the pump on a work surface with the end cap
opening up [Figure 30-40-64].
Install the ball guide retainer and washer (Item 1) [Figure

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

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

the charge pump.
Figure 30-40-68
Figure 30-40-66
1
2
1
N-17192
N-17196
Coat a new end cap gasket (Item 1) [Figure 30-40-68]

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

40-66] will protrude from 1.65 - 0.185 in. (4,19 - 4,70 mm)
from the surface of the charge pump.
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HYDROSTATIC PUMP (CONT’D) Charge Pump Assembly
Assembly (Cont'd) Figure 30-40-71
Figure 30-40-69 1
N-17186
N-17191
Install the locating pin (Item 1) [Figure 30-40-71] in the
charge pump end cap.
Align the marks on the charge pump with the pump
housing and install the charge pump [Figure 30-40-69]. NOTE: The charge pump rotation is determined by

the position of the gerotor space and locating
When the charge pump is properly installed, the cylinder pin (Item 1) [Figure 30-40-71] in the pump end
block spring will hold the charge pump end cap away cap.
from the housing approximately 0.125 in. (3 mm).
Prior to assembly, lubricate the gerotor assembly with
Figure 30-40-70 clean hydraulic oil.
Figure 30-40-72
1 1
1
1
1
N-17186
N-17187
Install the four mounting bolts (Item 1) [Figure 30-40-70]
and tighten evenly to 35 - 45 ft.-lb. (47 - 61 N•m) torque.
Install the gerotor assembly (Item 1) [Figure 30-40-72]
into the charge pump housing.
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Assembly (Cont'd)
Charge Pump Assembly (Cont’d)
Figure 30-40-73
1
2
1
N-17190
1 A spanner wrench may be used in the two holes (Item 1)

[Figure 30-40-75] to slightly rotate the gerotor spacer to
align with the locating pin.
N-17188
When the spacer is properly installed the surface of the
gerotor spacer and charge pump face are flush [Figure

Apply petroleum jelly to the gerotor drive pin (Item 1) 30-40-75].
[Figure 30-40-73] and install the gerotor pin into the
drive coupler (Item 2) [Figure 30-40-73]. Figure 30-40-76
NOTE: The gerotor drive coupler (Item 2) [Figure 30-

40-73] must be installed with the longer 3 1
portion down toward the rear of the charge
pump.
2 2
Figure 30-40-74
3
2
N-17235
Install the two large O-rings (Item 1) [Figure 30-40-76]

into the gerotor cap.
1
Install the two smaller O-rings (Item 2) [Figure 30-40-76]
N-17189 in the charge pump housing end cap.
Install the two aligning pins into the alignment holes (Item
Install the coupler and drive pin into the gerotor, be sure 3) [Figure 30-40-76] in the charge pump.
the pin engages the gerotor slot (Item 1) [Figure 30-40-
74].
Install the gerotor spacer (Item 2) [Figure 30-40-74] into

the charge pump end cap.
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Assembly (Cont'd)
Charge Pump Assembly (Cont’d) 1
Figure 30-40-77
N-17233
Figure 30-40-79
N-17234 1

Slide the two sections of the pumps together [Figure 30-
40-77].
N-17230
Install the four mounting bolts (Item 1) [Figure 30-40-78]

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

pump shaft while tightening the mount bolts.
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DRIVE BELT Adjustment
Shield Removal And Installation Figure 30-50-3
Figure 30-50-1
P-5554
P-28478
2
Stop the engine.

Open the rear door.
Remove the three belt shield holddown clips (Item 1)

[Figure 30-50-1].
Figure 30-50-2 1
P-4681
The drive belt idler arm stop is located on the left side of
the engine below the air cleaner [Figure 30-50-3].
Loosen the two bolts (Item 1) [Figure 30-50-3] and slide

the stop against the idler arm. Tighten the bolts.
There is no adjustment for the spring, just make sure the

spring bolt (Item 2) [Figure 30-50-3] is tight.
P-28479
Remove the belt shield from the drive belt housing

[Figure 30-50-2].
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DRIVE BELT (CONT’D) Tensioner Pulley Removal And Installation
Replacement Figure 30-50-5
Figure 30-50-4
1
P-5552
P-7894
Remove the belt shield clips (Item 1) [Figure 30-50-5].
Remove the belt shield. (See Shield Removal And Remove the belt shield (Item 2) [Figure 30-50-5].

Figure 30-50-6
Loosen the two stop mounting bolts (Item 1) [Figure 30-
50-3].
Loosen the spring tension bolt (Item 2) [Figure 30-50-3]. 2
Remove the fan drive belt from the tensioner pulley.

1
Remove the drive belt from the hydrostatic pump pulley
and flywheel pulley.
Remove the drive belt [Figure 30-50-4]
P-5554
Remove the two stop mounting bolts (Item 1) [Figure 30-

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

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

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

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

Remove the end cap (Item 1) [Figure 30-50-7] from the Check for wear and replace as needed.
tensioner pulley arm.

Figure 30-50-10
Figure 30-50-8
1
1
P-5553
P-5555
Check the arm seal (Item 1) [Figure 30-50-10]. Replace

Remove the mounting bolt (Item 1) [Figure 30-50-8] from the seal as needed.
the tensioner pulley arm.
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DRIVE BELT (CONT’D) Tensioner Pulley Tension Spring
Tensioner Pulley Removal And Installation (Cont’d) Figure 30-50-13
Figure 30-50-11
P-5551
P-5561
Remove the base end bolt (Item 1) [Figure 30-50-13]
from the spring block.
Remove the pulley mounting bolt [Figure 30-50-11].
Remove the tension spring from the engine housing.

Figure 30-50-12
Figure 30-50-14
P-5559
P-5563
Disassemble the pulley and bearings as shown in

[Figure 30-50-12]. Remove the end block (Item 1) [Figure 30-50-14] (both
ends) from the spring.
Check parts for wear and replace as needed.
Check the spring for wear etc. Replace the spring as
needed.
Check the spring end blocks for wear and replace as

needed.
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OIL COOLER Figure 30-60-3
Removal And Installation With STC (Seal Tight

Connector)
IMPORTANT 1

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

Figure 30-60-4
Figure 30-60-1

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

Raise the rear grill [Figure 30-60-1]. connector will release [Figure 30-60-3] & [Figure 30-60-
4].
Figure 30-60-2
Disconnect the inlet and outlet hoses (Items 1 & 2)
[Figure 30-60-1] from the oil cooler (Item 3) [Figure 30-
60-1]
1 NOTE: When installing the cooler hoses, the fittings

should make a clicking sound when pushed
together.
Lift up the oil cooler and remove the cooler from the
loader.
Reverse the removal procedure to install the oil cooler.
N-19345
Install tool 10 STC (Item 1) [Figure 30-60-2] to outside of

rubber sleeve (Item 1) [Figure 30-60-3].
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DRIVE SYSTEM
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-10-3
Pedal Disassembly And Assembly . . . . . . . . . . . . . . . . . . 40-10-2 SAFETY &
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-10-1 MAINTENANCE
BRAKE (TWO-SPEED) (S/N 514449389 & BELOW) . . . . . . . 40-11-1

Block Disassembly And Assembly. . . . . . . . . . . . . . . . . . . 40-11-2
Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-11-1
BRAKE (TWO-SPEED) (S/N 514449390 & ABOVE) . . . . . . . 40-12-1

Block Disassembly And Assembly. . . . . . . . . . . . . . . . . . . 40-12-3
Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-12-1
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Front Chaincase Cover Removal And Installation . . . . . . . 40-30-1 DRIVE
Rear Chaincase Cover Removal And Installation . . . . . . . 40-30-1 SYSTEM
DRIVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . 40-20-1

ELECTRICAL
Axle, Sprocket And Bearings Removal And Installation. . . 40-20-3 SYSTEM &
Drive Chain Removal And Installation . . . . . . . . . . . . . . . . 40-20-8 ANALYSIS
ENGINE
SERVICE
SPECIFICATIONS
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BRAKE Figure 40-10-3
Pedal Removal And Installation
Figure 40-10-1
1 1
N-19614

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

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

1
Figure 40-10-2
N-19615
2 2 Remove the mounting bolts (Item 1) [Figure 40-10-4]

from the parking brake pedal.
Remove the parking brake pedal assembly from the

loader.
N-19613
Remove the two mount bolts (Item 1) [Figure 40-10-2]

from the fuse cover.
Remove the fuse cover.
Remove the four mounting bolts from the lower panel

(Item 2) [Figure 40-10-2].
Pull the lower panel toward the front of the loader.
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BRAKE (CONT’D) Figure 40-10-6
Pedal Disassembly And Assembly
Figure 40-10-5 1
2
6
1
4
P-4156
2 Remove the harness mounting clamp (Item 1) [Figure

3
P-4189 40-10-6] from the pedal mounting bracket (Item 2)
[Figure 40-10-6].
Loosen and remove the mounting bolt (Item 1) [Figure Remove the sensor harness from the pedal mounting
40-10-5] and nut from the spring mounting bracket (Item bracket.

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

Remove the traction lock solenoid (Item 1) [Figure 40-

D-1009-0409
10-8], spring (Item 2) [Figure 40-10-8] and spring cup
(Item 3) [Figure 40-10-8].
Remove the wedge assembly (Item 4) [Figure 40-10-8]

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

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

N-19669 40-10-12].
Remove the chaincase cover / guides assembly.

Remove the hairpin clip and cross-pin from the control
valve lift spool (Item 1) [Figure 40-10-10]. Installation: Replace the chaincase cover gasket.

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

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Disc Removal And Installation (Cont’d)
Figure 40-10-14
1
1
1
P-7865
Remove the disc (Item 1) [Figure 40-10-16] from the

P-7801 shaft.
Figure 40-10-17
Remove the two disc bolts (Item 1) [Figure 40-10-14 on
Page 5] from the disc. 3 3

Figure 40-10-15
2
P-13003
Installation: Bolting the disc to the snap ring provides

P-7800 proper disc alignment. Disc and shaft are shown
removed for photo clarity. The snap ring end gap (Item 1)
[Figure 40-10-17] must be between the disc bolts (Item
A snap ring pliers with 90° tips are needed for removing 2) [Figure 40-10-17] and sprocket teeth (Item 3) [Figure
the brake disc snap ring. 40-10-17] after the brake disc is installed on the shaft.
Pull the disc away from snap ring.

the end of the carrier shaft.
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BRAKE (TWO-SPEED) (S/N 514449389 & BELOW) Figure 40-11-3
Block Removal And Installation
Figure 40-11-1
1
1
2
N-22538
2

N-22536 11-3] from the brake / two-speed block.
Figure 40-11-4

Raise the operator cab. (See Raising The Operator Cab 1
on Page 10-30-1.)
Remove the steering shock (Item 1) [Figure 40-11-1]. 2
Mark all hydraulic hoses for proper installation.
Disconnect the four hydraulic hoses (Item 2) [Figure 40-

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

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

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

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

Disconnect the wire harness connector (Item 1) [Figure from the block.
40-11-5] from the make-up valve solenoid.

Figure 40-11-8
Figure 40-11-6
1 1 2
N-22579
N-22577
Remove the check valve (Item 1) [Figure 40-11-8] from

Turn the hydraulic fitting (Item 1) [Figure 40-11-6] to the two-speed valve.
allow for clearance to remove the mounting bolt.
Remove the check valve (Item 2) [Figure 40-11-8] from
Remove the two mounting bolts (Item 2) [Figure 40-11-6] the brake valve.
from the valve.
NOTE: The check valves (Items 1 & 2) [Figure 40-11-8]
Remove the brake / two-speed block from loader. are interchangeable.
Remove the pedal from the pedal mounting bracket.
[Figure 40-11-6] show the parking brake disassembled

to identify the existing parts in the brake assembly.
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(CONT’D)
Block Disassembly And Assembly (Cont’d)
Figure 40-11-9
1
N-22583
Use a test meter and test the solenoid [Figure 40-11-11]

for resistance.
N-22580
The resistance value for the solenoid coil can be found
on the electrical schematic. (See Solenoid Test on Page
Check the back-up washers (Item 1) [Figure 40-11-9] 60-10-8.).
and O-rings (Item 2) [Figure 40-11-9] for wear and

replace as needed. Figure 40-11-12
Figure 40-11-10
N-22582
N-22581
Remove the solenoid valve (Item 1) [Figure 40-11-12]
from the block.
Loosen the electrical solenoid nut (Item 1) [Figure 40-11-
10] from the make-up valve solenoid.
Assembly: Tighten the nut to 60 - 84 in.-lb. (6,78 - 9,49

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

N-22584
Figure 40-11-16
Assembly: Always install new O-rings and back-up
washers [Figure 40-11-13]. Tighten the solenoid valve to

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

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

N•m) torque.

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

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

Figure 40-11-20
60-10-8.)
Figure 40-11-18
1
1
N-22587
Remove the brake solenoid nut (Item 1) [Figure 40-11-

20].

N•m) torque.
N-22588

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

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

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

The resistance value for the solenoid can be found on the
electrical schematic. (See Solenoid Test on Page 60-10-
8.)
Figure 40-11-22
N-22612

from the block.
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BRAKE (TWO-SPEED) (S/N 514449390 & ABOVE) Figure 40-12-3
Block Removal And Installation
Figure 40-12-1
1
1
2
P-34092
2

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

Raise the operator cab. (See Raising The Operator Cab 1
on Page 10-30-1.)
Remove the steering shock (Item 1) [Figure 40-12-1].
Mark all hydraulic hoses for proper installation.
Disconnect the four hydraulic hoses (Item 2) [Figure 40-

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

40-12-4] from the brake solenoid.

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

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

40-12-5] from the make-up valve solenoid.

Figure 40-12-6
P-34095

6] from the valve.
Remove the brake / two-speed block from the loader.
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(CONT’D)
Block Disassembly And Assembly

1
Figure 40-12-7
1 2
1
N-22580
1
1
Check the back-up washers (Item 1) [Figure 40-12-9]
and O-rings (Item 2) [Figure 40-12-9] for wear and
P-34097 replace as needed.
Figure 40-12-10
Mark all hydraulic hoses and fittings for proper
installation.

Remove the hydraulic fittings (Item 1) [Figure 40-12-7]
from the block.
Figure 40-12-8
1 1
1 2 P-34099
Loosen the electrical solenoid nut (Item 1) [Figure 40-12-

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

P-34098 10] from the brake solenoid.

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

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

from the block.
P-34112
Remove the brake solenoid (Item 1) [Figure 40-12-13]
from the block.

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

[Figure 40-12-12] for resistance.

60-10-8.)
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(CONT’D)
Figure 40-12-15
1 P-34103
Check the O-rings (Item 1) [Figure 40-12-17] on the

plugs and replace as needed.
P-34105
Figure 40-12-18
Assembly: Always install new O-rings. Tighten the

Check the O-rings and replace as needed [Figure 40-12-
15]
Figure 40-12-16
1
P-34104
Remove the two speed solenoid nut (Item 1) [Figure 40-

12-18].

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

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

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

from the block.
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DRIVE COMPONENTS Figure 40-20-2
Axle Seal Removal And Installation
WARNING
NEVER STAND IN-LINE OF THE HUB WHEN
REMOVING A HUB FROM AN AXLE. The hub has a
tapered fit on the axle end and can come off the axle
with great force and cause serious injury.
W-2186-0395 1
Figure 40-20-1 P-4849
2
Install the puller (Item 1) [Figure 40-20-2] on the wheel
hub.
Remove the hub from the axle.
Figure 40-20-3

1 1
2 P-4850

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

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

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

across from each other.
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DRIVE COMPONENTS (CONT’D) Figure 40-20-5
Axle Seal Removal And Installation (Cont’d)
Figure 40-20-4
Taper
B-13493
1
Place the taper on the wear ring so it faces the outside
P-4817 [Figure 40-20-5].
Place the seal with the lip facing in [Figure 40-20-5].

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

Remove the axle seal.

procedure:
MEL1407 - Seal Installation Tool
If the axle is damaged or worn, and axle repair sleeve kit

is available from Melroe Parts Sales in Chicago.
NOTE: If a new wear ring is being installed with new

seal, put Loctite® sealant in the inside
diameter of the wear ring.
P-4814
Use a hammer, install the new axle seal until the tool is
flush with the edge of the axle tube [Figure 40-20-6].
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DRIVE COMPONENTS (CONT’D)
Axle Seal Removal And Installation (Cont’d) WARNING

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

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

P-10553 installation of the axle, sprocket and bearings
is for a front axle. This procedure will be the
same for the rear axle.
NOTE: S/N 514416546 & Above the axle (Item 1)
[Figure 40-20-7] finish specification was Raise the lift arms and install an approved lift arm support

changed to provide the correct surface for the device. (See LIFT ARM SUPPORT DEVICE on Page 10-
axle seal (Item 2) [Figure 40-20-7]. These 20-1.)
loaders MAY or MAY NOT have a wear ring
installed. When ordering the axle seal, check Lift and block the loader. (See LIFTING AND BLOCKING
to see of the axle uses a wear ring. THE LOADER on Page 10-10-1.)
Axle, Sprocket And Bearings Removal And Raise the operator cab. (See Raising The Operator Cab
Remove the front panel / steering lever assembly. (See

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

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

Installation WARNING
Figure 40-20-8 NEVER STAND IN-LINE OF THE HUB WHEN
REMOVING A HUB FROM AN AXLE. The hub has a
tapered fit on the axle end and can come off the axle
with great force and cause serious injury.
W-2186-0395
2 Figure 40-20-10
P-4810
Remove the axle sprocket bolt (Item 1) [Figure 40-20-8]

and backing washer (Item 2) [Figure 40-20-8]. 1
Installation: Tighten the axle sprocket bolt to 475 - 525

ft.-lb. (644 - 710 N•m) torque. P-4849
Figure 40-20-9
Install a puller (Item 1) [Figure 40-20-10] on the wheel
hub.
2
Remove the hub from the axle.
Figure 40-20-11
1
2
P-4850
Remove the bolts (Item 1) [Figure 40-20-9] and plate.
Installation: Tighten the bolts to 175 - 190 ft.-lb. (240 -

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

across from each other. Install a Port-a-Power ram between the two sprockets
[Figure 40-20-11].
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Installation (Cont’d)
Figure 40-20-12
P-4171
Press the splined end of the axle free from the bearing
1
[Figure 40-20-14].
P-4808
Installation: Put the spline end of the axle shaft into the
bearing and press the bearing onto the axle.
Push the axle out until the ram is at the end of the stroke.
Add a spacer and push the axle out again. Repeat this

procedure until the axle is out of the sprocket. NOTE: Hold on to the axle during installation as it will
slide freely after the bearing is pressed over
Remove the drive chain from the sprocket. the splined end of the shaft.
Remove the sprocket (Item 1) [Figure 40-20-12] and
inner bearing (Item 2) [Figure 40-20-12]. Figure 40-20-15
Installation: Pack the inner and outer bearing with

grease before installing them.
Figure 40-20-13
P-4175
Put a piece of tubing (Item 1) [Figure 40-20-15] that

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

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

inner race and press the bearing off the mounting surface
of the axle [Figure 40-20-13].
NOTE: Hold onto the axle during removal as it will
slide freely after the bearing is removed from
the mounting surface.
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Figure 40-20-16
P-4816
Use the slide hammer and remove the bearing cup from
the axle tube [Figure 40-20-18].
P-4812
Figure 40-20-19
Use the tools provided in the MEL1202B Axle Bearing

1

Service Set for bearing cup removal and installation. A
slide hammer is also needed.
Use the long rod and bearing cup tool to remove the
inner bearing cup [Figure 40-20-16].
To remove the outer bearing cup, install a bearing cup

tool on the slide hammer.
Figure 40-20-17 3
P-4807
Use the bearing cup installation tools (Item 1) [Figure 40-

20-19] and (Item 1) [Figure 40-20-20].
Put the inner cup (Item 2) [Figure 40-20-19] in the axle

tube.
Install the long threaded rod (Item 2) [Figure 40-20-20]

into the axle tube and through the installation tool (Item
1) [Figure 40-20-19].
P-4818
Install the nut (Item 3) [Figure 40-20-19].
Leave the bearing cup tool loose until the tool is installed
inside the tube [Figure 40-20-17].
Pull the tool against the bearing cup and tighten the nut.
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Figure 40-20-20
P-4813
Hit the driver handle with a hammer until the bearing cup
is seated inside the axle tube [Figure 40-20-21].
P-4811
To install the outer bearing cup, install the bearing cup
tool on the driver handle.
Install the installation tool (Item 1) [Figure 40-20-20] on

the threaded rod. Install the nut. Install the bearing cup into the axle tube, and put the tool
into the bearing cup.
Hold the inside nut (Item 3) [Figure 40-20-19] with a
wrench and tighten the outside nut [Figure 40-20-20].
Tighten the nut until the bearing cup is seated.
Remove the installation tools and threaded rod.
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DRIVE COMPONENTS (CONT’D) Remove the front (or rear) chaincase cover. (See Front
Chaincase Cover Removal And Installation on Page 40-
Drive Chain Removal And Installation 30-1.)
Remove the front (or rear) axle and sprocket. (See Axle,
DANGER Sprocket And Bearings Removal And Installation on
Page 40-20-3.)
Figure 40-20-22
Rear Chain
P-90328
AVOID DEATH
can cause lift arms to drop. Front Chain
P-7866

D-1009-0409
Remove the front (or rear) drive chain from the
chaincase.
The tool listed is needed for the following procedure:
WARNING MEL1037 - Chain Link Tool

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

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

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


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

2].
Figure 40-30-3
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic 1
D-1009-0409
P-7935
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Remove the eight mounting bolts from the rear chaincase
cover (Item 1) [Figure 40-30-3].
NOTE: The auxiliary tubeline at the rear port of

hydraulic control valve may need to be
disconnected to provide clearance for cover
front bolt removal.
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MAINFRAME
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Bob-Tach Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-4 SAFETY &
Pivot Pin Bushing And Seal Replacement . . . . . . . . . . . . . . . . 50-40-5 MAINTENANCE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
CONTROL HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

Lever Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . 50-110-1
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Linkage Neutral Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-5
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . 50-110-2 DRIVE
SYSTEM
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS)
ADVANCED HAND CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . 50-113-1
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-113-1
Control Handle Disassembly and Assembly . . . . . . . . . . . . . 50-113-6
Control Handle Removal And Installation . . . . . . . . . . . . . . . 50-113-5
Control Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-113-8
Control Lever Removal And Installation. . . . . . . . . . . . . . . . . 50-113-7

Handle Sensor Removal And Installation . . . . . . . . . . . . . . . 50-113-1 MAINFRAME
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) . . 50-111-1
Actuators Disassembly And Assembly . . . . . . . . . . . . . . . . . 50-111-9
AHC Controller Removal And Installation . . . . . . . . . . . . . . . 50-111-4 ENGINE
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1 SERVICE
Handle Control Unit Connector . . . . . . . . . . . . . . . . . . . . . . . 50-111-5
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/ PUSH SPECIFICATIONS

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

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

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

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

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

Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2

LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

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

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

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

Pivot Pin Bushing And Seal Replacement . . . . . . . . . . . . . 50-41-4
Power Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . 50-41-2
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MAIN FRAME (CONT’D)
REAR DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Adjusting The Rear Door Latch (S/N 514449208 & Below) 50-70-2
Removal And Installation (S/N 514449208 & Below). . . . . 50-70-1
REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

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

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

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

Raise the seat bar (Item 1) [Figure 50-10-1]. torque.

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

N-19224
from the cab harness.
Lower the seat bar. Remove the seat bar (Item 1) [Figure 50-10-4] from the
operator cab.
Raise the loader operator cab. (See Raising The
Operator Cab on Page 10-30-1.) Reverse the above procedure to install the seat bar into
the operator cab.
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SEAT BAR (CONT’D) Seat Bar Mount (Item 1)
Mounting Bolt (Item 2)
Assembling Components Keyed Plastic Bushing (Item 3)
Seat Bar (Item 4)
Figure 50-10-5 Magnetic Bushing Assembly (Item 5)
Pivot Bushing (Item 6)
6 Sensor Bracket (Item 7)
4 5
Sensor Mounting Nut (Item 8)
Sensor Mounting Bolt (Item 9)
7 Mounting Nut (Item 10)
3
Installation: Tighten the mounting bolt (Item 2) [Figure
50-10-5] & [Figure 50-10-6] to 50 - 70 in.-lb. (5,6 - 7,9
2 N•m) torque.
9 8
1 10
N-19383
Figure 50-10-6

4 5 8
9
2 10
6
7
N-19219
Assemble the parts as shown for the left side of the seat
bar pivot assembly [Figure 50-10-5] & [Figure 50-10-6].
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SEAT BAR (CONT’D) Seat Bar Mount (Item 1)
Mounting Nut (Item 2)
Assembling Components (Cont’d) Pivot Bushing (Item 3)
Spacer Bushing (Item 4)
Figure 50-10-7 Seat Bar (Item 5)
Keyed Plastic Bushing (Item 6)
5 Mounting Bolt (Item 7)
4
Installation: Tighten the mounting bolt (Item 7) [Figure
3 6 50-10-7] & [Figure 50-10-8] to 50 - 70 in.-lb. (5,6 - 7,9
N•m) torque.
2 7
N-19340
Figure 50-10-8

5
4 6
3
N-19220
Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-7] & [Figure 50-10-8].
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SEAT BAR (CONT’D) Figure 50-10-10
Compression Spring Assembly And Assembly 6 7
Figure 50-10-9
1
5 6
4
3
2
1 N-19384
Disassemble and assemble the seat bar compression

spring and parts as shown in [Figure 50-10-10].
Bolt (Item 1)
Bushing (Item 2)
Spring (Item 3)

Clevis (Item 4)
Retaining Pin (Item 5)
Pin (Item 6)
Bushing (Item 7)
N-19222
Turn the bolt (Item 1) [Figure 50-10-9] & [Figure 50-10-

10] out of the clevis.
Assembly: Apply Loctite® #518 adhesive to the bolt

threads. Adjust the compression spring by turning the
bolt in past the end of the clevis three turns.
NOTE: For procedures requiring the use of Loctite®

#518 adhesive, thoroughly clean and dry
affected parts before the application of
Loctite® #518.
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OPERATOR CAB Figure 50-20-2
Gas Cylinder Removal And Installation
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death.
W-2113-0288
Figure 50-20-1 1
N-19621
Remove the bolts (Item 1) [Figure 50-20-2] from the gas

2 cylinder mounting bracket.
Figure 50-20-3

1
1
N-19619
Remove the operator cab stop (Item 1) [Figure 50-20-1]

(both sides).
NOTE: If the operator cab is equipped with a rear

N-19651
window, the rear grill and rear grill mounts
(Item 2) [Figure 50-20-1] must be removed to
prevent window damage. Use a pliers to unlock cotter pin (Item 1) [Figure 50-20-3]
& [Figure 50-20-4 on Page 2].
on Page 10-30-1.)
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OPERATOR CAB (CONT’D) Gas Cylinder Bracket Disassembly And Assembly
Gas Cylinder Removal And Installation (Cont’d) Figure 50-20-5
Figure 50-20-4
2
1
P-1008
N-19652
Remove the clevis (Item 1) [Figure 50-20-5] and washer
(Item 2) [Figure 50-20-5] from the end of the gas
NOTE: Cotter pin (Item 1) [Figure 50-20-4] is shown in cylinder.
locked position.

Remove the gas cylinder from the outer housing.
Remove the cotter pin.
Assembly: Install a replacement cylinder inside the
Remove the gas cylinder. cylinder housing.
Installation: Twist the ends of cotter pin to re-lock it. Figure 50-20-6
P-1006
Apply a small amount of Loctite® on the threads of the

cylinder rod [Figure 50-20-6].
Reinstall the washer and clevis on the cylinder rod.
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Figure 50-20-7
1
1
N-19365
1
Remove the cab nut and holddown plate (Item 1) [Figure
50-20-7] (both sides).

N•m) torque.
N-19623
Disconnect the wiring harness connectors (Item 1)

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

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

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

sling.
Install the sling under the pivot bolt and pivot of the
Remove both gas cylinders. (See Gas Cylinder Removal operator cab [Figure 50-20-11].
Figure 50-20-12
After the gas cylinders are removed, lower the operator
cab using the chain hoist.
Figure 50-20-10
1
N-19648
Connect the slings to a chain hoist and remove the

N-19620 operator cab from the loader [Figure 50-20-12].
Remove the nut (Item 1) [Figure 50-20-10] from the pivot

bolt (both sides).
Installation: Tighten the pivot bolt and nut to 25 - 35 ft.-

Remove the pivot bolt (both sides).
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OPERATOR SEAT Seat Belt Removal And Installation.
Removal And Installation Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
on Page 10-30-1.) Figure 50-30-3
Figure 50-30-1
1
1
N-20729A
N-20729
Locate the seat belt bolts under seat pan insulation (Item

1 & 2) [Figure 50-30-3] and peel back or cut insulation to
Remove the seat mounting nuts (Item 1) [Figure 50-30- gain access to the head.
1] and washers from the operator seat mounting studs.
Figure 50-30-4
Installation: Tighten the mounting nuts to 20 ft.-lb. (27
N•m) torque.
NOTE: Ensure the washers are installed.
Figure 50-30-2
2
N-20655
Remove the two nuts (Item 1 & 2) [Figure 50-30-4].
Installation: Tighten nut (Item 1) [Figure 50-30-4] to 54

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

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

on Page 10-30-1.)
Figure 50-31-1
1
2
N-20974
NOTE: Assure seat tethers are securely fastened to

seatbelt studs (Item 1) [Figure 50-31-3] and
seat rail studs (Item 2) [Figure 50-31-4].
N-20647 Figure 50-31-4

Remove the four seat mounting nuts (Item 1) [Figure 50-
31-1] and washers from the operator seat mounting
studs.
Installation: Tighten the mounting nuts to 20 ft.-lb. (27

N•m) torque.
Figure 50-31-2
N-20973
NOTE: Verify the front two seat rail studs have

washers attached (Item 1) [Figure 50-31-4].
P-10564 P-10563
Lower the cab and install one of the mounting washer

and nut (Item 1) [Figure 50-31-2].
NOTE: With the seat removed the cab will raise.

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

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

Figure 50-31-5
1
1
2 2
1
1

N-18587
Remove the two slide rail mounting bolts (Item 1) [Figure

50-31-5].
Remove the slide rail (Item 2) [Figure 50-31-5] from the

bottom of the seat frame.
Reverse the procedure to install the operator seat slide

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

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

Figure 50-31-7
2
1
N-18580
Inspect the seat ride adjustment [Figure 50-31-9].

N-18582
seat back.
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OPERATOR SEAT (SUSPENSION) (CONT’D) Shock Removal And Installation
Back Removal And Installation Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Figure 50-31-10
Remove the operator seat. (See Removal And
1 Installation on Page 50-30-1.)
Figure 50-31-12
N-18583
1 2
Pull the seatback adjustment lever (Item 1) [Figure 50-

31-10] and tilt the seat back all the way forward.
N-18584

Figure 50-31-11
Figure 50-31-13
1
2
1 1
N-18578
N-18585
Remove the two mounting screws (Item 1) [Figure 50-

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

[Figure 50-31-14] are replaceable.

seat shock.
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BOB-TACH Figure 50-40-3
Figure 50-40-1
P-7695
Remove the rod end pivot pin (Item 1) [Figure 50-40-3].

P-7694
Figure 50-40-4
With the lift arms all the way down, tilt the Bob-Tach
forward so it is parallel to the floor [Figure 50-40-1].

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

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

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

P-3910 Tach pivot pin.
Install the slide hammer into the adapter and pull the
Installation: Use two pieces of shim stock (light pivot pin from the lift arms/Bob-Tach.
cardboard), install the rod end of the tilt cylinder into the

Bob-Tach [Figure 50-40-5]. NOTE: Always inspect Bob-Tach pivot pin bushings
and seals in lift arm for wear or damage.
Be careful not to damage the seal during installation. Replace as needed.
NOTE: Removal procedure is show for the right side.

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

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

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

Bob-Tach lever, spring and wedge.
Figure 50-40-8
P-7681
Remove the Bob-Tach lever (Item 1) [Figure 50-40-10].
Figure 50-40-11
P-7694

With the lift arms fully down, tilt the Bob-Tach forward so
it is parallel with the floor [Figure 50-40-8].
Figure 50-40-9 1
P-7682
Remove the roll pin (Item 1) [Figure 50-40-11] from the

Bob-Tach wedge assembly.
3
2
1
P-7680
Remove the lever mounting nut (Item 1) [Figure 50-40-

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

N•m) torque.
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BOB-TACH (CONT’D) Reverse the removal procedure to install the Bob-Tach
lever and wedge assembly.
Bob-Tach Lever and Wedge (Cont’d)
Bob-Tach Stops
Figure 50-40-12
Figure 50-40-14
P-7683
P-7952
Remove the spring, bolt and clevis assembly (Item 1)

[Figure 50-40-12]. Remove and replace the Bob-Tach stop (Item 1) [Figure
50-40-14] (both sides) if worn or damaged.

Remove the wedge from the Bob-Tach frame.
NOTE: The Bob-Tach stop (Item 1) [Figure 50-40-14]
Always replace bent or broken wedges. must contact the lift arm at the same time the
tilt cylinder reaches full extension. Use
Figure 50-40-13 available shims to adjust the Bob-Tach stop
and tilt cylinder sequence as closely as
possible.
4
3
P-7684
If the bolt (Item 1) [Figure 50-40-13], handle pivot (Item

2) [Figure 50-40-13] or clevis (Item 3) [Figure 50-40-13]
are damaged, put the assembly in the vise for
disassembly. Loosen and remove the bolt (Item 1)
[Figure 50-40-13] with a 5/16 in. allen wrench.
Replace the worn or damaged parts as needed.
Before installation of the parts, put grease on the handle

pivot (Item 2) [Figure 50-40-13], Bob-Tach handle pivot
(Item 5) [Figure 50-40-13] and bolt (Item 1) [Figure 50-
40-13].
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Pivot Pin Bushing And Seal Replacement
Figure 50-40-15
P-7950
Use a driver to install new seals. The pivot pin can be

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

15] on both sides of pivot bushing.

Figure 50-40-16
P-7949
Remove and replace bushing with a driver tool and

hammer [Figure 50-40-16].
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POWER BOB-TACH Figure 50-41-2
Figure 50-41-1
2 1
3
1
N-18545
Remove the pivot pin (Item 1) [Figure 50-41-2] from the

N-21401 tilt cylinder rod end (both sides).
Remove the tilt cylinder rod end from the Bob-Tach (both
Tilt the Bob-Tach forward, so it is parallel to the floor. Put sides).
blocks (approximately 3 in.) under each side of the Bob-

Tach [Figure 50-41-1]. Loosen the bolt (Item 2) [Figure 50-41-2] at the Bob-
Tach pivot pin.
Lower the Bob-Tach onto the blocks.
Installation: Tighten the bolt to 350 ft.-lb. (475 N•m)
Remove the hoses to the cylinder fittings [Figure 50-41- torque.
1].
Figure 50-41-3
NOTE: The hose with the 45° end (Item 1) [Figure 50-
41-1] is connected to the base end fitting on
the cylinder.
Remove the hose clamp on the hoses and us the bolt

(Item 2) [Figure 50-41-1] on the tilt cylinder pivot pin to
secure the clamp.
Remove the retainer bolt (Item 3) [Figure 50-41-1] and 1

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

N-18547
Strike the head of the bolt (Item 1) [Figure 50-41-3] to

push the pivot pin into the Bob-Tach frame.
Remove the bolt.
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POWER BOB-TACH (CONT’D) Power Bob-Tach Lever And Wedge
Figure 50-41-4
N-21401
P-13099
Use the following procedure to remove and install the
Bob-Tach lever (Item 1) [Figure 50-41-5], spring and
Use a punch to drive the pivot pin and cap (Item 1) wedge.
[Figure 50-41-4] out of the Bob-Tach frame.

Figure 50-41-6
Remove the Bob-Tach pivot pin (both sides).
Remove the Bob-Tach from the lift arms.
N-18559
Use a punch and hammer, remove the roll pin (Item 1)

[Figure 50-41-6] from the Bob-Tach Wedge and spring
clevis.
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POWER BOB-TACH (CONT’D) Figure 50-41-9
Power Bob-Tach Lever And Wedge (Cont’d)
Figure 50-41-7
4
3 2
1
N-20625
If the bolt (Item 1) [Figure 50-41-9], handle pivot (Item 2)

N-18560 [Figure 50-41-9], spring (Item 3) [Figure 50-41-9], or
clevis (Item 4) [Figure 50-41-9] are damaged, put the
assembly in a vise.
Remove the Wedge (Item 1) [Figure 50-41-7].
Remove the bolt and replace the damaged parts as

Always replace bent or broken wedges. needed.
2
1 1
3
4
5
N-21401 N-18563
Remove the washers and bolts (Item 1) [Figure 50-41- Use a punch and hammer to drive the roll pin (Item 1)
8]. Tighten the bolts to 25 - 28 ft.-lb. (24 - 28 N•m) torque. [Figure 50-41-10] flush with the face of the Bob-Tach.
Remove the cylinder off the lever points. Position the rod
end to the left with the grease fitting holes to the top
[Figure 50-41-8].
Remove the lever mounting nut (Item 2) [Figure 50-41-

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

N•m) torque.
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POWER BOB-TACH (CONT’D) Pivot Pin Bushing And Seal Replacement
Power Bob-Tach Lever and Wedge (Cont’d) Figure 50-41-12
Figure 50-41-11
2 1
N-18557
N-18562
Remove the power Bob-Tach. (See Removal And
Reverse the removal procedure to install the Power Bob-
Tach lever and wedge [Figure 50-41-11]. Use a seal pick to remove seal (Item 1) [Figure 50-41-

12] on the Bob-Tach.
Remove and replace bushing (Item 2) [Figure 50-41-12]

with a driver tool and hammer.
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LIFT ARMS Figure 50-50-3
The items listed are necessary for the following

procedure:
Three Lifting Straps - 7 ft. in length (with looped ends)

Chain Hoist
Install jackstands under rear of the loader.
Remove the Bob-Tach from the lift arms. (See Removal 1

Figure 50-50-1 P-7725
Remove the tubeline mounting clamp (Item 1) [Figure

50-50-3] from the back of the lift arm crossmember.
In the operator cab, turn the ignition key in the ON

position.

1 Press the PRESS TO OPERATE button.
1
Place the seat bar in the down position.
Place the loader lift pedal (Handle, with ACH) in the float
position.
P-7729
Remove the two auxiliary tubeline clamps (Item 1)

[Figure 50-50-1] from the left lift arm (if so equipped).
Figure 50-50-2
N-19654

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

P-7726 the lift arms.
Remove the tilt tubelines from the lift arms and put the tilt
Wrap the lifting strap around the lift arm crossmember as cylinder on the floor.
shown in [Figure 50-50-4]. Connect both loops of the

lifting strap to a chain hoist. Figure 50-50-6
Raise the lift arms enough to remove the auxiliary

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

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

4] from the pivot pin for the base of the tilt cylinder. 3
Remove the pivot pin from the base end of the cylinder
(Item 2) [Figure 50-50-4].
P-7728
Remove the lift arm support device mounting bolt and nut
(Item 1) [Figure 50-50-6].
Installation: Tighten the mounting bolt and nut to 15 - 17


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

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LIFT ARMS (CONT’D) Figure 50-50-8
Remove the pivot pin from the lift cylinder (both sides).
1
NOTE: Drive out all pivot pins from the opposite side
that the retainer bolt was removed from.
Remove the lift arm support device (Item 3) [Figure 50-

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

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

ft.-lb. (220 - 230 N•m) torque.
1

Remove the pivot pin (Item 2) [Figure 50-50-8] from the
lift arms (both sides).
Figure 50-50-9
P-7731
Install the lift strap on the lift arm as shown in [Figure 50-
50-7] (both sides).
Install the pivot pin (Item 1) [Figure 50-50-7] retainer bolt

and nut (both sides).
Connect the loops of the lifting straps to the chain hoist

(both lift straps).
P-7733
Raise the lift arms with the chain hoist so the lift arms are
free from the loader.
Pull the lift arms away from the loader [Figure 50-50-9].
Lower the lift arms slowly and put them on the floor.
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REAR GRILL Figure 50-60-3
Figure 50-60-1 1
P-7946
Remove the cotter pin and the pivot pin (Item 1) [Figure
N-19411 50-60-3] (both sides).
Figure 50-60-4
Raise the rear grill [Figure 50-60-1].

Support the rear grill.
Figure 50-60-2
P-7947
Remove the grill from the loader [Figure 50-60-4].
N-19412
Remove the nut (Item 1) [Figure 50-60-2] to disconnect

the gas cylinder from the rear grill.
Lower the rear grill.
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REAR DOOR Figure 50-70-2
Open the rear door.
Figure 50-70-1 2
1
1
N-10889

Disconnect the light harness connector (Item 1) [Figure
50-70-1] from the engine harness.
Remove the light bulbs from the light housing and

remove the light housing (Item 2) [Figure 50-70-1] from
the rear door (both sides).
N-19657
Install a nylon sling (Item 1) [Figure 50-70-2] through the

holes for the light housings.
Connect a chain hoist (Item 2) [Figure 50-70-2] to the

nylon sling.
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REAR DOOR (CONT’D) Adjusting The Rear Door Latch (S/N 514449208 &
Below)
(Cont’d) Figure 50-70-4
Figure 50-70-3
2 1
N-19320
The door catch (Item 1) [Figure 50-70-4] can be adjusted

side to side for alignment with the door latch.

Figure 50-70-5
1 1
N-19658
Remove the nuts from the top and bottom hinge bolts N-19321
(Item 1) [Figure 50-70-3] and remove the hinge bolts.
Installation: Tighten the mounting bolts and nuts to 25 - The door latch (Item 1) [Figure 50-70-5] can be adjusted
28 ft.-lb. (34 - 35 N•m) torque. The door stop (Item 2) forward or backward for alignment with the door catch.
[Figure 50-70-3] is installed in the top hinge bolt.
Remove the rear door from the loader frame and lay it flat
on the floor.
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REAR DOOR (CONT'D) Adjusting The Striker (S/N 514449209 & Above)
Striker Removal And Installation (S/N 514449209 & Figure 50-70-7

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

70-6]. holes.
Remove the striker assembly from the loader. Tighten the striker assembly, top mount bolt only, until it
will hold the striker assembly in the enter of the mounting
slots.
Shut the rear door. (This will align the striker assembly to
the correct position.)
Open the rear door.
Tighten both striker mount bolts (Item 1) [Figure 50-70-

7].
Close the rear door.
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REAR DOOR (CONT'D) Latch Removal And Installation (S/N 516815094,
517515071, 518915872 & Above.) (Cont’d)
Latch Removal And Installation (S/N 514449209 &
Above) Figure 50-70-10
Figure 50-70-8
1
2
P-31128
1
P-31125
Remove the lever (Item 1) [Figure 50-70-10] from the
rear door.
Disconnect the spring (Item 1) [Figure 50-70-8] from the

tailgate.
Remove the bolt and nut (Item 2) [Figure 50-70-8] from

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

door handle.
Remove the spring (Item 2) [Figure 50-70-9] from the

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

lever.
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FUEL TANK Figure 50-80-3
Figure 50-80-1
1
P-4855
Disconnect the fuel fill hose (Item 1) [Figure 50-80-3].

P-1616
Disconnect the tank vent hose (Item 2) [Figure 50-80-3].
Remove the cover (Item 1) [Figure 50-80-1] which is Figure 50-80-4

installed over the drain plug.

Figure 50-80-2
P-7918
P-1619 Remove the bolts (Item 1) [Figure 50-80-4] from the

battery hold down plate.
Remove the drain plug (Item 1) [Figure 50-80-2]. Remove the battery hold down plate from the loader.
Drain the fuel into a container.
Check the drain plug and replace if necessary.
Remove the engine / hydrostatic pump assembly from

the loader. (See Removal And Installation on Page 70-
80-1.)
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FUEL TANK (CONT’D) Fuel Level Sender
Figure 50-80-5
P-7921
P-7923
Remove the fuel level sender (Item 1) [Figure 50-80-6].
Remove the mounting plate (Item 1) [Figure 50-80-5] for Figure 50-80-7
the battery hold down plate.

Lift the fuel tank and remove it from the loader frame.
P-7922
Check the fuel level sender with an ohmmeter as follows

[Figure 50-80-7]:
Fuel Level - 30 Seconds Delay
Full - 30 ohms
Empty - 270 ohms
Short - 0 ohms
Open - 300 + ohms
Fuel float and magnet must slide freely on the shaft

[Figure 50-80-7].
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CONTROL PEDALS Pedal Adjustment
Figure 50-90-1 WARNING

1 Adjust locking tabs on control linkage so that lift and
tilt control pedals or (Mechanical Hand Controls) are
locked in neutral when the seat bar is up.
W-2104-0199
After installing the pedal, adjust the pedal so that there is

clearance under the rear of the pedal. The valve spool
must travel full stroke without the pedal hitting the floor
panel.
N-19233
Remove the bolt (Item 1) [Figure 50-90-1] and nut from

the pedal linkage.

Installation: Tighten the bolt and nut to 21 - 25 ft.-lb. (28
- 34 N•m) torque.
Check the rubber bushing in the pedal for wear and

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

2] from the pedal mounting bracket.
Remove the pedal assembly from the loader.
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CONTROL PEDALS (CONT’D) Figure 50-90-3
Crossbar Linkage Removal And Installation
DANGER 1
P-24756
P-90328
Remove the crossbar pivot bolt (Item 1) [Figure 50-90-
AVOID DEATH 3].
tubeline, hose, fitting, component or a part failure Figure 50-90-4

D-1009-0409
1
WARNING
support device can allow the lift arms or attachment P-24758
W-2059-0598
Remove the bolt and nut (Item 1) [Figure 50-90-4] to
disconnect the lift pedal linkage from crossbar.
20-1.)
on Page 10-30-1.)
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CONTROL PEDALS (CONT’D) Lift Foot Pedal Linkage Removal And Installation
Crossbar Linkage Removal And Installation (Cont’d) Figure 50-90-7
Figure 50-90-5
1
P-24760
P-24757
disconnect the lift foot pedal linkage from the crossbar
Remove the hairpin clip and cross-pin from the control linkage.
valve lift spool (Item 1) [Figure 50-90-5].

Figure 50-90-8
Disconnect the crossbar from the control valve.
Figure 50-90-6 1
P-24759
1
P-24763 Remove the bolt (Item 1) [Figure 50-90-8] and nut from
the pedal linkage.
Remove the crossmember from the pivot [Figure 50-90- Installation: Tighten the bolt and nut to 21 - 25 ft.-lb. (28
6]. - 34 N•m) torque.
Installation: Check the nylon bushing (Item 1) [Figure

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

disconnect the tilt foot pedal linkage from the control

valve.
Figure 50-90-10
P-26008
Remove the bolt (Item 1) and nut from the pedal linkage.
Installation: Tighten the bolt and nut to 21 - 25 ft.-lb. (28

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

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

Pull the pin (Item 1) [Figure 50-91-1] holding the foot 10,2 N•m) torque.
pedal linkage to the sensor.

Figure 50-91-4
Disconnect the two connectors (Item 2) [Figure 50-91-1]
from the sensor and lock solenoid.
1
Figure 50-91-2
P-21924
Remove foot lock solenoid (Item 1) [Figure 50-91-4].

P-21935
Installation: Apply a drop of oil to the solenoid threads
and tighten the solenoid to 35 - 40 ft.-lb. (47 - 54 N•m)
Tilt the foot pedal up and remove the two nuts (Item 1) lubed torque.
[Figure 50-91-2].
Remove the two bolts (Item 2) [Figure 50-91-4] from the
Remove the foot pedal and sensor assembly from the bracket and sensor assembly.
loader.
N•m) torque.
Remove the sensor assembly.
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CONTROL PEDALS (ACS) (CONT’D) Foot Pedal Linkage Disassembly And Assembly
Foot Sensor Removal And Installation (Cont’d) Figure 50-91-7
NOTE: The calibration procedure must be followed

when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Contents, Page 60-01.)
Foot Pedal Removal And Installation
Figure 50-91-5
1
2
P-21931

linkage (Item 2) [Figure 50-91-7] to the side of the foot
pedal.

Figure 50-91-8
1
P-21940
Remove the pin (Item 1) [Figure 50-91-5] holding the

2
linkage to the sensor.
Figure 50-91-6
1
3
P-21935
1
P-21932
Remove the spacer (Item 1) [Figure 50-91-8],linkage

(Item 2) [Figure 50-91-8] and nut (Item 3) [Figure 50-91-
8] from the foot pedal.
P-21934
Tip the foot pedal up [Figure 50-91-6] and remove the

two nuts (Item 1) [Figure 50-91-6].
Remove the foot pedal assembly.
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CONTROL PANEL Figure 50-100-1
WARNING 2

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

100-1]. (See Removal And Installation on Page 70-20-1.)
Loosen the jam nut from the bypass control knob (Item 2)
[Figure 50-100-1].

Remove the control knob, jam nut and rubber washer.
W-2059-0598
Disconnect the control harness wiring connector (Item 3)

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

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

1
Figure 50-100-3
2 1
2
N-19665
1
Remove the control panel mounting bolts (Item 1)

N-19664 [Figure 50-100-5] from the right side of the control panel.
Installation: Tighten the control panel mounting bolts to

Scribe a mark across the top of the steering linkage bars 25 - 28 ft.-lb. (34 - 38 N•m) torque.
(Item 1) [Figure 50-100-3].

Remove the four steering linkage mounting bolts (Item 2)
[Figure 50-100-3].
Installation: Tighten the steering linkage mounting bolts

to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
Figure 50-100-4
N-19663

[Figure 50-100-4] from the right side control panel.

25 - 28 ft.-lb. (34 - 38 N•m) torque.
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Figure 50-100-6
1 1
N-19667
1
1
N-19666 [Figure 50-100-6] & [Figure 50-100-7] from the left side
of the control panel.

25 - 28 ft.-lb. (34 - 38 N•m) torque.

Remove the control panel from the loader.
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CONTROL HANDLE Lever Disassembly And Assembly
Lever Removal And Installation Figure 50-110-2
Figure 50-110-1
1 1
3 3
2
2
N-17639
N-17643
Disassemble the right and left steering shafts from the
cross shaft assembly.
Loosen both U-bolts (Item 1) [Figure 50-110-1] at the
steering lever (both sides). NOTE: Some loaders may have a sleeve (Item 1)

[Figure 50-110-2] between the bearing (Item 2)
Remove the steering cross shaft mounting bolts (Item 2) [Figure 50-110-2] and the bell crank (Item 3)
[Figure 50-110-1] (both sides). [Figure 50-110-2].
Installation: Tighten the mounting bolts to 25 ft.-lb. (40 Figure 50-110-3

N•m) torque.
Remove the steering cross shaft from the control panel. 1
N-17640
Check the bearings (Item 1) [Figure 50-110-3] for wear

Check the fiber washers (Item 2) [Figure 50-110-3] for

wear and replace as needed.
Replace the wave washer (Item 3) [Figure 50-110-3] if

worn.
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CONTROL HANDLE (CONT’D) Linkage Removal And Installation
Lever Disassembly And Assembly (Cont’d) Figure 50-110-6
Figure 50-110-4
N-17601
2 P-13773
Remove the nut (Item 1) [Figure 50-110-6] from the end
of the centering spring shoulder bolt (Item 2) [Figure 50-
Check the end bearing (Item 1) [Figure 50-110-4] and 110-6].
fiber washer (Item 2) [Figure 50-110-4] and replace as

needed. Remove the shoulder bolt / spring assembly.
Figure 50-110-5 Installation: Tighten the centering spring shoulder bolt

and a NEW lock nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque.

1 Reservoir on Page 20-80-1.)
2 Figure 50-110-7
3
4 P-13774
NOTE: Some loaders may have a spacer (Item 1) 2

[Figure 50-110-5] between the bearing (Item 2) 1
[Figure 50-110-5] and the bell crank (Item 3)
[Figure 50-110-5].
N-19736
Check the fiber washer (Item 4) [Figure 50-110-5] and

replace all worn parts. Remove the hydraulic hoses (Item 1) [Figure 50-110-7].
Remove the hydraulic fitting (Item 2) [Figure 50-110-7]

from the pump.
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Linkage Removal And Installation (Cont’d) 2

5
1
Figure 50-110-8
1 2
3
2 4
3
N-17609
The centering plate / centering spring assembly consists

3 N-19737 of the following parts [Figure 50-110-10]:
Item Description
1 Bolt
Slide the plate (Item 1) [Figure 50-110-8] to the right and
2 Washer
remove it from the two guide pins (Item 2) [Figure 50-
3 Sleeve

110-8].
4 Bushing
5 Spring
NOTE: The two guide bushings (Item 3) [Figure 50-
110-8] will be loose and can fall out of the plate
as soon as it is removed from the guide pins. Figure 50-110-11
Figure 50-110-9
1
1
2
4
1
N-17607
2
3 N-17608
Check the wear on the centering blocks (Item 1) [Figure
50-110-11].
The centering plate / centering spring assembly consists
of the following parts [Figure 50-110-9]:
Item Description
1 Centering Spring Assembly
2 Guide Bushings
3 Lock Nut
4 Centering Plate
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Linkage Removal And Installation (Cont’d)
Figure 50-110-12
N-17611
Remove the linkage bar nut (Item 1) [Figure 50-110-14]

N-17606 from the torsion bushing.
The bolt is threaded into the linkage bar, remove the bolt
If the centering blocks need replacement, remove the from underneath the pintle arm.
bolts (Item 1) [Figure 50-110-12]. Remove the centering

blocks. Installation: Tighten the bolt to 11 - 13 ft.-lb. (21 - 25
N•m) torque, then tighten the nut (Item 2) [Figure 50-
Installation: Tighten the centering block bolts to 25 - 28 110-16 on Page 5] to 21 - 25 ft.-lb. (28 - 33 N•m) torque.
Figure 50-110-15
Figure 50-110-13
1
2
1
N-17612
N-19738
Remove the linkage bar (Item 1) [Figure 50-110-15] from

Check the surface of the four pintle cams (Item 1) the pintle arm. Remove the torsion bushing (Item 2)
[Figure 50-110-13]. [Figure 50-110-15].
If worn replace the cam. Remove the nuts (Item 1) [Figure 50-110-16 on Page 5]
from both shock absorber ball joint ends.
N•m) torque. Installation: Tighten the nuts to 25 - 28 ft.-lb. (34 - 38
N•m) torque.
Disconnect the shock absorbers from the linkage bars.
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CONTROL HANDLE (CONT’D)
Linkage Removal And Installation (Cont’d)

DANGER
Figure 50-110-16
2 P-90328
1
AVOID DEATH
N-17624
D-1009-0409
Remove the nuts (Item 2) [Figure 50-110-16] from the
linkage bar mounting bolt. The bolts are threaded into the

linkage bars, remove the bolts.
Installation: Tighten the bolts to 11 - 13 ft.-lb. (21 - 25 WARNING

N•m) torque, the tighten the nuts to 21 - 25 ft.-lb. (28 - 33
N•m) torque. Never work on a machine with the lift arms up unless
The torsion bushings can now be removed from the support device. Failure to use an approved lift arm
steering bell cranks. support device can allow the lift arms or attachment
The linkage and the centering plate must be readjusted W-2059-0598
for neutral after the components have been reassembled.
See “Linkage Neutral Adjustment” on Page 50-110-5 for
Raise the lift arms and install an approve lift arm support
the neutral adjustment procedure.
20-1.)
Linkage Neutral Adjustment
WARNING Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
of the frame before running the engine for service. Connect the remote start switch. (See REMOTE START
Failure to use jackstands can allow the machine to on Page 10-60-1.)
W-2017-0286 Pre-load tension in the torsion bushings must be
removed before adjusting the steering linkage.
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CONTROL HANDLE (CONT’D) Figure 50-110-19
Linkage Neutral Adjustment (Cont’d)
Figure 50-110-17
2
1
3 1
N-17619
Move the right side steering lever to the rear and install a
N-17624 3 - 8 in. (10 mm) thick spacer (Item 1) [Figure 50-110-19]
between the pintle arm cam (Item 2) [Figure 50-110-19]
and the centering block (Item 3) [Figure 50-110-19].
Loosen the nut (Item 1) [Figure 50-110-17] (three to four
turns), then loosen the bolt. The bolt is threaded into the Figure 50-110-20

linkage bar (Item 2) [Figure 50-110-17]. The bolt must be
loosened enough to allow the torsion bushing to turn
freely between the steering bellcrank and the linkage bar.
Figure 50-110-18
3
1
2
N-17620
Move the right side steering lever forward and install a

2 15/16 in. (24 mm) thick spacer (Item 1) [Figure 50-110-
N-17613 20] between the centering plate (Item 2) [Figure 50-110-
20] and the mounting plate (Item 3) [Figure 50-110-20].
Loosen the nut (three to four turns), then loosen the bolt This will allow the pintle arms to move freely while
at the linkage bar (Item 1) [Figure 50-110-18]. The bolt is adjusting the steering linkage for full forward travel
threaded into the linkage bar (Item 2) [Figure 50-110- speed.
18]. The bolt must be loosened enough to allow the
torsion bushing to turn freely between the pintle arm and Remove the 3/8 in. (10 mm) thick spacer (Item 1) [Figure
the linkage bar. 50-110-19].
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Figure 50-110-21
N-17623
Move the left side steering lever to the full forward

N-17616 position (Until the steering lever hits the stop), then pull
forward on the left side rear linkage bar until the pintle
arm is rotated to the front as far as possible. Use a
Check that the pintle arm mounting bolt (Item 1) [Figure clamping plier and clamp the two linkage bars together
50-110-21] is tight, 25 - 28 ft.-lb. (34 - 38 N•m) torque and [Figure 50-110-23].

that there is no play between the pintle arm and the
square pump shaft. Also check that the cam mounting Tighten the nuts and bolts to 25 - 28 ft.-lb. (34 - 38 N•m)
bolts (Item 2) [Figure 50-110-21] are tight, 45 - 50 ft.-lb. torque.
(62 - 68 N•m) torque.
Check the lever movement to make sure that the pintle
Figure 50-110-22 arm and the steering lever are both at full stroke at the
same time. This will allow for maximum forward speed.
Repeat the procedure for the right side steering linkage

bar.
1
After both sides of the linkage bars have been adjusted,
the feel of both levers at full stroke should be the same.
Readjust the linkage if necessary.
Figure 50-110-24
1
N-19664
Loosen the two bolts and nuts (Item 1) [Figure 50-110-

22] on each steering linkage bar.
N-17620
Remove the spacer (Item 1) [Figure 50-110-24].
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The following tool listed will be needed to so the following

procedure:
MEL1429A - Remote Start Switch 1
Connect the remote start switch to the engine harness.

(See REMOTE START on Page 10-60-1.)
Figure 50-110-25
N-19581
Move the traction lock override switch (Item 1) [Figure

50-110-27] to the OFF position so the traction function is
unlocked. The wheels are now able to turn.
Move the left hand steering lever until the tires do not turn
(neutral position).

1
Move the left side centering block to the left until it
contacts both pintle cams and the steering lever is still in
N-19736 the neutral position [Figure 50-110-26].
Tighten the bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque.

Loosen the four bolts (Item 1) [Figure 50-110-25] holding
the two centering blocks. Move the right side centering
block to the right as far as possible.
NOTE: Bolt holes are slotted for pintle arm centering

adjustment.
Figure 50-110-26
N-17621
Adjust the left side centering block first [Figure 50-110-

26].
Start the engine and run at high RPM.
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Figure 50-110-28
N-19736
Tighten the two linkage bar bolts to 11 - 13 ft.-lb. (15 - 17

N-17618 N•m) torque, then tighten the two nuts to 21 - 25 ft.-lb. (28
- 33 N•m) torque at the pintle levers (Item 1) [Figure 50-
110-29].
Adjust the right side centering block [Figure 50-110-28].
Figure 50-110-30

Move the right side steering lever until the tires do not
turn (neutral position).
Move the right side centering block to the left until it

contacts both pintle cams and the steering lever is still in
the neutral position [Figure 50-110-28].
1
Tighten the bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
2
Test both levers by moving them backward and forward
and letting them return to neutral by the return spring
force.
If the levers do not return to neutral and the tires do not

come to a complete stop, repeat the adjustment N-17624
procedure again.
Stop the engine. Tighten the two linkage bar bolts to 11 - 13 ft.-lb. (15 - 17
N•m) torque, then tighten the two nuts to 21 - 25 ft.-lb. (28
- 33 N•m) torque at the steering cross shaft (Items 1 & 2)
[Figure 50-110-30].
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CONTROL HANDLE (ADVANCED HAND CONTROL) Figure 50-111-3
(AHC)
Components Identification
Figure 50-111-1
1
1
P-13797
2
ACH controller (Item 1) [Figure 50-111-3].
N-17774 N-17783 Figure 50-111-4
Control handle (Item 1) [Figure 50-111-1].

Handle control unit (Item 2) [Figure 50-111-1] (both 1
sides).
Figure 50-111-2
P-28360A
ACH error indicator (Item 1) [Figure 50-111-4].
NOTE: The AHC icon will illuminate when an error

occurs. The error is stored as a service code.
1 (See DELUXE INSTRUMENTATION SERVICE
N-19112 CODES on Page 60-80-1.)
Control Valve Actuators (Item 1) [Figure 50-111-2].
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CONTROL HANDLE (ADVANCED HAND CONTROL) (ACH) (CONT’D)
Trouble shooting Guide
The Advanced Hand Control System (AHC) has a built-in diagnostic function which uses an icon on the right instrument
panel to indicate the condition of the AHC System. The system also records the alarm condition as a service code.
The control module continually checks the system in the order listed. The checks start with the lift handle controller and
then the lift actuator. If no problems are present, it will then check the tilt handle controller and the tilt actuator. The system
will stop its check at the first problem and then luminate the icon.
The system starts its diagnostics and calibration when the ignition key is turned ON.
The following list shows the probable causes when the icon is luminated.
Advanced General Fuel Level System Engine Oil Engine Air Filter
Hand Warning Voltage Pressure Coolant
Controls Temperature

B-16640
Attachment Two Speed Glow Plugs Seat Belt Hydraulic Hydraulic Oil Hydraulic
Control Charge Temperature Filter
Device Pressure
Advanced Hand Controls
Errors - lights solid with 3 beeps

32-31 - Tilt actuator fault
32-33 - Tilt actuator wiring fault
B-16624
32-33 - Tilt handle wiring fault
32-34 - Tilt actuator not calibrated
32-35 - Tilt handle not calibrated
32-36 - Lift actuator fault
32-37 - Lift actuator wiring fault
32-38 - Lift handle wiring fault
32-39 - Lift actuator not calibrated
32-40 - Lift handle not calibrated
32-41 - Invalid Frequency
To see what error occurred, check the service code on the left instrument panel. (See Contents Page 60-01.)
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CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (CONT’D)
C-428
C-430

C-431
C-429
TS-1957
P/N PIN DESCRIPTION

P/N PIN DESCRIPTION
C-430 CONNECTOR, METRI-PACK
C-428 CONNECTOR, 8 WAY PLUG (LIFT) (TOP
Orange/White A SWITCHED BATTERY POWER
ACTUATOR)
Black B GROUND
Dk. Blue/White 1 LOW REFERENCE TO RESISTIVE INPUTS
C-431 MALE, 10-WAY
Lt. Green/White 2 SIGNAL FROM LIFT ACTUATOR
Brown/Dk A SIGNAL FROM LIFT CONTROL
Dk. Blue 3 HIGH REFERENCE TO RESISTIVE UNITS
Green
4 OPEN
HANDLE INPUT
Brown/White 5 LIFT SPOOL ACTUATOR MOTOR (-)
Purple/Yellow B FLOAT SWITCH ON/OFF
6 OPEN
Pink/Dk. Green C SIGNAL FROM TILT CONTROL
7 OPEN
HANDLE INPUT
Brown/Yellow 8 LIFT SPOOL ACTUATOR MOTOR (+)
Dk. Blue D TILT HIGH REFERENCE TO
RESISTIVE INPUTS C-429 CONNECTOR, 8 WAY PLUG (TILT) (BOT-
TOM ACTUATOR)
Dk. Blue/White E TILT LOW REFERENCE TO
RESISTIVE INPUTS Dk. Blue/White 1 LOW REFERENCE TO RESISTIVE INPUTS
Dk Blue/White F LIFT LOW REFERENCE TO Lt. Blue/White 2 SIGNAL FROM TILT ACTUATOR
RESISTIVE INPUTS Dk. Blue 3 HIGH REFERENCE TO RESISTIVE INPUTS
Dk. Blue G LIFT HIGH REFERENCE To 4 OPEN
RESISTIVE INPUTS Pink/White 5 TILT SPOOL ACTUATOR MOTOR (-)
Purple/White H BICS INPUT STATUS 6 OPEN
Purple/Red J AHC STATUS OUTPUT 7 OPEN
K OPEN Pink/Yellow 8 TILT SPOOL ACTUATOR MOTOR (+)
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CONTROL HANDLE (ADVANCE HAND CONTROL) Figure 50-111-7
(AHC) (CONT’D)
AHC Controller Removal And Installation
Figure 50-111-5
1
1
N-19643

7] from the controller.
N-18882
Remove the controller from the loader.
Loosen the bottom bolts and remove the top bolt.

Remove the right front panel (Item 1) [Figure 50-111-5]
from the loader.
Figure 50-111-6
N-19642
Disconnect the wiring harness connectors from the

controller (Item 1) [Figure 50-111-6].
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CONTROL PANEL (ADVANCED HAND CONTROL) Figure 50-111-10
(AHC) (CONT’D)
Handle Control Unit Connector
Figure 50-111-8
1
2 3
P-13733
With a pointed tool, lift the tab (Item 1) [Figure 50-111-

1 10] and pull the wire from the connector.
N-17392
Assembly: Install the wires into the connector as listed
below [Figure 50-111-10]:
The wire connector (Item 1) [Figure 50-111-8] can be
removed from the handle control unit wires, use the

1 - Terminal - Red
following procedure. 2 - Terminal - Black
3 - Terminal - Green
Figure 50-111-9
1 1
P-13725 P-13732
Remove the wedge (Item 1) [Figure 50-111-9] from the

connector.
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(AHC) (CONT’D)
Control Handle Removal And Installation
Figure 50-111-11
3 2 1
P-13735
Using a pointed tool, press down on the tab (Item 1)

[Figure 50-111-13] and pull the wire from the connector.
Installation: Install the wires into the conductor as listed


Right Control Lever Switch Handle
1 - Terminal - Pink/Red
2 - Terminal - Pink/Black
1 3 - Terminal - Pink/Green
Left Control Lever Switch Handle

N-17786
1 - Terminal - Brown/Red
2 - Terminal - Brown/Black
Remove the handle control unit from the control lever. 3 - Terminal - Brown Green
(See AHC Controller Removal And Installation on Page
50-111-4.)
To remove the switch handle, the connector (Item 1)

[Figure 50-111-11] must be removed from the wires.
Figure 50-111-12
1
P-13725 P-13732

connector.
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CONTROL HANDLE (ADVANCED HAND CONTROL) Installation: The wire colors of the control lever harness
(AHC) (CONT’D) are as follows:
Control Handle Removal And Installation (Cont’d) Right Switch Handle
Figure 50-111-14 Ten-Pin Connector

A - Terminal - Orange
1 B - Terminal - White
C - Terminal - White/Black
D - Terminal - White/Red
E - Terminal - Dk. Green
F - Terminal - White/Lt. Green
G - Terminal - Blank
H - Terminal - Lt. Green
J - Terminal - Yellow
K - Terminal - Blank
2 Three-Pin Connector
A - Terminal - Pink/Red
B - Terminal - Pink/Black
N-17779 C - Terminal - Pink/Lt. Green
Left Switch Handle

Disconnect the right switch handle connectors (Items 1 &
2) [Figure 50-111-14] from the loader wiring harness

Ten-Pin Connector
connectors.
B - Terminal - Dk. Blue
Figure 50-111-15
C - Terminal - White
D - Terminal - Blank
E - Terminal - Blank
1 F - Terminal - Yellow/Red
2 3 G - Terminal - Yellow/Green
4 H - Terminal - Blank
J - Terminal - Blank
Three-Pin Connector
A - Terminal - Brown/Red
B - Terminal - Brown/Black
C - Terminal - Brown/Lt. Green
Two-Pin Connector
N-17772
A - Terminal - Orange/Blue
B - Terminal - Orange/White
Disconnect the left switch handle connectors (Items 1, 2,
3 & 4) [Figure 50-111-15] from the loader wiring harness Five-Pin Connector
connectors. A - Terminal - Dk. Green
B - Terminal - Brown
Remove the connector locks and connectors from the C - Terminal - Blank
wires the remove the switch handle from the control D - Terminal - Yellow
handle. E - Terminal - Blank
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(AHC) (CONT’D)
Control Handle Removal And Installation (Cont’d)
Figure 50-111-16
2
2
N-17471
1
Installation: When installing the switch handle and

wiring harness assembly into the control handle, route
N-17382 the harness (Item 1) [Figure 50-111-18] to assure proper
return of the control handle to neutral position.
Roll the grip handle cover (Item 1) [Figure 50-111-16]
down.

Using a small screwdriver, lift the handle tabs (Item 2)
[Figure 50-111-16] and slightly rotate the switch handle.
Figure 50-111-17
N-17383
Pull the switch handle and wiring harness assembly (Item

1) [Figure 50-111-17] from the control lever.
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(AHC) (CONT’D)
Actuators Disassembly And Assembly
Figure 50-111-19 3
2
1
N-18941
1
Remove the rubber strap (Item 1) [Figure 50-111-21]

from the mounting shaft collar (Item 2) [Figure 50-111-
N-18912 21].
Remove the mounting bracket (Item 3) [Figure 50-111-

Remove the actuator (Item 1) [Figure 50-111-19] from 21].
the hydraulic control valve. (See Actuator Removal And

Installation (In Loader) on Page 20-41-1.) Check the rubber strap, mounting shaft collar and
mounting bracket for wear and replace as needed.
Installation: Tighten the mount bolts to 90 - 100 in.-lb.
(130,2 - 11,3 N•m) torque. Figure 50-111-22
Figure 50-111-20
1
2
1 N-17742 N-17741
N-18940
Check the actuator wiring harness connector (Item 1)
[Figure 50-111-22] and replace if broken.
Check the mounting block (Item 1) [Figure 50-111-20]
and bolts for wear and replace as needed. Installation: Install the wires into the connector as listed
on the next page. The terminal numbers are written in the
back of the connector (Item 2) [Figure 50-111-22].
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CONTROL HANDLE (ADVANCED HAND CONTROL
(AHC) (CONT’D)
Actuators Disassembly And Assembly (Cont’d)
Lift and Tilt Actuator
1 - Terminal - Black/Green - Larger diameter wire (16

gauge)
2 - Terminal - Green - Larger diameter wire (16
gauge)
3 - Terminal - Red/Green - Larger diameter wire (16
gauge)
4 - Terminal - Open
5 - Terminal - Red - Smaller diameter wire (18 gauge)
6 - Terminal - Open
7 - Terminal - Open
8 - Terminal - Black - Smaller diameter wire (18
gauge)
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(AHC) (W/ PUSH BUTTON FLOAT)
Figure 50-112-1
1
1
P-13797
2
ACH controller (Item 1) [Figure 50-112-3].
P-16536 N-22797 Figure 50-112-4

Handle sensor (Item 2) [Figure 50-112-1].
1
Figure 50-112-2
P-28360A
ACS error indicator (Item 1) [Figure 50-112-4].
NOTE: The ACS icon will illuminate when an error

1 occurs. The error is stored as a service code.
N-19112 (See DELUXE INSTRUMENTATION SERVICE
CODES on Page 60-80-1.)
Control Valve Actuators (Item 1) [Figure 50-112-2].
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CONTROL HANDLE (ADVANCED HAND CONTROL) (ACH) (W/ PUSH BUTTON FLOAT) (CONT’D)
Trouble shooting Guide
The Advanced Hand Control System (AHC) has a built-in diagnostic function which uses an icon on the right instrument
panel to indicate the condition of the AHC System. The system also records the alarm condition as a service code.
The control module continually checks the system in the order listed. The checks start with the lift handle controller and
then the lift actuator. If no problems are present, it will then check the tilt handle controller and the tilt actuator. The system
will stop its check at the first problem and then luminate the icon.
The system starts its diagnostics and calibration when the ignition key is turned ON.
The following list shows the probable causes when the icon is luminated.
Advanced General Fuel Level System Engine Oil Engine Air Filter
Hand Warning Voltage Pressure Coolant
Controls Temperature

B-16640A
Attachment Two Speed Glow Plugs Seat Belt Hydraulic Hydraulic Oil Hydraulic
Control Charge Temperature Filter
Device Pressure
Advanced Hand Controls
Errors - lights solid with 3 beeps

32-31 - Tilt actuator fault
32-32 - Tilt actuator wiring fault
32-33 - Tilt handle wiring fault
32-34 - Tilt actuator not calibrated
32-35 - Tilt handle not calibrated
32-36 - Lift actuator fault
32-37 - Lift actuator wiring fault
32-38 - Lift handle wiring fault
32-39 - Lift actuator not calibrated
32-40 - Lift handle not calibrated
32-41 - Invalid Frequency
To see what error occurred. Check the service code on the left instrument panel. (See Contents Page 60-01.)
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CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/ PUSH BUTTON FLOAT) (CONT’D)
Controller Connector and Wire Identification
C-428
C-430

C-431
C-429
TS-1957
P/N PIN DESCRIPTION

P/N PIN DESCRIPTION
C-430 CONNECTOR, METRI-PACK
C-428 CONNECTOR, 8 WAY PLUG (LIFT) (TOP
Orange/White A SWITCHED BATTERY POWER ACTUATOR)
Black B GROUND Dk. Blue/White 1 LOW REFERENCE TO RESISTIVE INPUTS
C-431 MALE, 10-WAY Lt. Green/White 2 SIGNAL FROM LIFT ACTUATOR
Brown/Dk A SIGNAL FROM LIFT CONTROL Dk. Blue 3 HIGH REFERENCE TO RESISTIVE UNITS
Green
4 OPEN
HANDLE INPUT
Brown/White 5 LIFT SPOOL ACTUATOR MOTOR (-)
Purple/Yellow B FLOAT SWITCH ON/OFF
6 OPEN
Pink/Dk. Green C SIGNAL FROM TILT CONTROL
7 OPEN
HANDLE INPUT
Brown/Yellow 8 LIFT SPOOL ACTUATOR MOTOR (+)
Dk. Blue D TILT HIGH REFERENCE TO
RESISTIVE INPUTS C-429 CONNECTOR, 8 WAY PLUG (TILT) (BOT-
TOM ACTUATOR)
Dk. Blue/White E TILT LOW REFERENCE TO
RESISTIVE INPUTS Dk. Blue/White 1 LOW REFERENCE TO RESISTIVE INPUTS
Dk Blue/White F LIFT LOW REFERENCE TO Lt. Blue/White 2 SIGNAL FROM TILT ACTUATOR
RESISTIVE INPUTS Dk. Blue 3 HIGH REFERENCE TO RESISTIVE INPUTS
Dk. Blue G LIFT HIGH REFERENCE To 4 OPEN
RESISTIVE INPUTS Pink/White 5 TILT SPOOL ACTUATOR MOTOR (-)
Purple/White H BICS INPUT STATUS 6 OPEN
Purple/Red J AHC STATUS OUTPUT 7 OPEN
K OPEN Pink/Yellow 8 TILT SPOOL ACTUATOR MOTOR (+)
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(AHC) (W/ PUSH BUTTON FLOAT) (CONT’D)
AHC Controller Removal And Installation
Loosen the bottom bolts and remove the top bolt.

1
Figure 50-112-5
N-19643

7] from the controller.
Remove the controller from the loader.

N-22656

Remove the right front panel (Item 1) [Figure 50-112-5]
from the loader.
Figure 50-112-6
N-22673
Disconnect the wiring harness connectors from the

controller (Item 1) [Figure 50-112-6].
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Handle Sensor Removal And Installation
Figure 50-112-8
1 N-22803
Remove the handle sensor connector (Item 1) [Figure

50-112-10] from the clip.
P-16581
NOTE: Pry out with a small screwdriver and push the
connector down.
Lift the boot cover (Item 1) [Figure 50-112-8].

Figure 50-112-11
Figure 50-112-9
1
1
N-22790
N-22801
Use an allen wrench, remove one of the two mounting

Disconnect the harness connector (Item 1) [Figure 50- screws (Item 1) [Figure 50-112-11] from the handle
112-9] from the handle sensor connector. sensor.
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CONTROL PANEL (ADVANCED HAND CONTROL) Figure 50-112-14
Handle Sensor Removal And Installation (Cont’d) 3
Figure 50-112-12
1
3
1 2
3 2
P-16576
Remove the handle sensor (Item 1) [Figure 50-112-14]

from the handle assembly.
P-16580 N-22793
NOTE: The sensor (Item 1) [Figure 50-112-14] can
only be replaced as a complete assembly.
Remove the two plastic spacers (Item 1) [Figure 50-112-
12] and the metal spacer (Item 2) [Figure 50-112-12]

Check the spacers (Item 2) [Figure 50-112-14] and
from the handle sensor. screws (Item 3) [Figure 50-112-14] and replace as
needed.
Figure 50-112-13
Figure 50-112-15
1
1
P-16574
N-22799
Remove the top mounting bolt (Item 1) [Figure 50-112-

13] from the handle sensor. Installation: When installing the handle sensor into the
control handle, check the routing of the switch handle
wire harness (Item 1) [Figure 50-112-15] to assure
proper return of the control handle to neutral.
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Handle Sensor Connector
Figure 50-112-16
1
3
2
1
1 P-13733
With a pointed tool, lift the tab (Items 1) [Figure 50-112-

18] and pull the wire from the connector.
P-16578
Assembly: Install the wires into the connector as listed
The wire connector (Item 1) [Figure 50-112-16] can be
removed from the handle sensor wires, use the following

1 - Terminal - Red
procedure. 2 - Terminal - Black
3 - Terminal - Green
Figure 50-112-17
1 1
P-13725 P-13732
Remove the wedge (Items 1 & 2) [Figure 50-112-17]

from the connector.
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Control Handle Removal And Installation
Figure 50-112-19
3 2 1
P-13735
1
Using a pointed tool, press down on the tab (Item 1)
[Figure 50-112-21] and pull the wire from the connector.
N-22794
Installation: Install the wires into the connector as listed
To remove the switch handle, the connector (Item 1)
[Figure 50-112-19] must be removed from the wires.

Right Control Lever Switch Handle
1 - Terminal - Red/White
Figure 50-112-20 2 - Terminal - Black/White
3 - Terminal - Purple/White
Left Control Lever Switch Handle

1 - Terminal - Red/White
2 - Terminal - Black/White
3 - Terminal - Purple/White
1
P-13725 P-13732

connector.
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CONTROL HANDLE (ADVANCED HAND CONTROL) Installation: The wire colors of the control lever harness
(AHC) (W/ PUSH BUTTON FLOAT) (CONT’D) are as follows:
Control Handle Removal And Installation (Cont’d) Right Switch Handle
Figure 50-112-22 Ten-Pin Connector

B - Terminal - White
C - Terminal - White/Black
1 D - Terminal - White/Red
E - Terminal - Dk. Green
F - Terminal - White/Lt. Green
G - Terminal - Blank
H - Terminal - Lt. Green
J - Terminal - Yellow
Three-pin connector
A - Terminal - Pink/Red
2
B - Terminal - Pink/Black
N-17779 C - Terminal - Pink/Lt. Green
Left Switch Handle

Figure 50-112-23

Ten-Pin Connector
A - Terminal- Orange
B - Terminal - Dk. Blue
2 C - Terminal - White
1 3 D - Terminal - Purple
4
E - Terminal - Blank
F - Terminal - Tan
G - Terminal - Pink
H - Terminal - Blank
J - Terminal - Blank
Three-Pin Connector
A - Terminal - Red/White
N-17772
B - Terminal - Black/White
C - Terminal - Purple/White
Disconnect the right switch handle connectors (Items 1 &
2) [Figure 50-112-22] from the loader wiring harness Two-Pin Connector
connectors. A - Terminal - Black
B - Terminal - Red
Disconnect the left switch handle connectors (Items 1, 2,
3 & 4) [Figure 50-112-23] from loader wiring harness Five-Pin Connector
connectors. A - Terminal - Dk. Green
B - Terminal - Brown
Remove the connector locks and connectors from the C - Terminal - Blank
wires to remove the switch handle from the control D - Terminal -Yellow
handle. E - Terminal - Blank
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(CONTROL HANDLE (ADVANCED HAND CONTROL) Figure 50-112-26
(AHC) (PUSH BUTTON FLOAT (CONT’D)
Control Handle Removal And Installation (Cont’d)
Figure 50-112-24
2 2
N-22794
1
Installation: When installing the switch handle and
wiring harness assembly in the control handle, route the
N-22783 harness (Item 1) [Figure 50-112-26] to assure proper
return of the control handle to neutral position.
Roll the pistol grip handle cover (Item 1) [Figure 50-112-
24] down.

Using a small screwdriver, lift the handle tabs (Item 2)
[Figure 50-112-24] and slightly rotate the switch handle.
Figure 50-112-25
N-22784
Pull the switch handle and wiring harness assembly (Item

1) [Figure 50-112-25] from the control lever.
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Actuators Disassembly And Assembly
Figure 50-112-27
2
1
1
N-17742 N-17741
Check the actuator wiring harness connector (Item 1)

[Figure 50-112-29] and replace if broken.
N-18940
Installation: Install the wires into the connector as listed
below. The terminal numbers are written on the back of
Remove the actuator. (See Actuator Removal And the connector (Item 2) [Figure 50-112-29].
Installation (In Loader) on Page 20-41-1.)

Check the mounting block (Item 1) [Figure 50-112-27]
and bolts for wear and replace as needed.
Figure 50-112-28
2
1
N-18941
Remove the rubber strap (Item 1) [Figure 50-112-28]

from the mounting shaft collar (Item 2) [Figure 50-112-
28].
Remove the mounting bracket (Item 3) [Figure 50-112-

28].
Check the rubber strap, mounting shaft collar and

mounting bracket for wear and replace as needed.
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CONTROL HANDLE (ADVANCED HAND CONTROL)
Actuators Disassembly And Assembly (Cont’d)
Lift and Tilt Actuator
1 - Terminal - Black/Green - Larger diameter wire (16

gauge)
2 - Terminal -Green - Larger diameter wire (16 gauge)
3 - Terminal - Red/Green - Larger diameter wire (16
gauge)
4 - Terminal - Open
5 - Terminal - Red - Smaller diameter wire (18 gauge)
6 - Terminal - Open
7 - Terminal - Open
8 - Terminal - Black - Smaller diameter wire (18
gauge)
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CONTROL HANDLE (ADVANCED CONTROL Handle Sensor Removal And Installation
SYSTEM) (ACS) ADVANCED HAND CONTROL
Figure 50-113-3
Figure 50-113-1
1
1
P-16581
To remove the handle sensor, slide the rubber handle

cover (Item 1) [Figure 50-113-3] up the handle.
Figure 50-113-4

2
P-16572 1

P-24909
Figure 50-113-2
Disconnect the loader control harness (Item 1) [Figure
50-113-4] from the handle sensor harness.
Disconnect the loader control harness (Item 2) [Figure

50-113-4] from the handle connector.
P-24909
Handle Sensor (Item 1) [Figure 50-113-2].
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CONTROL PANEL (ADVANCED CONTROL SYSTEM) Figure 50-113-7
(ACS) ADVANCE HAND CONTROL (CONT’D)
Handle Sensor Removal And Installation (Cont’d)
Figure 50-113-5
1 1
2
1
P-24912
Using an allen wrench, remove one of the two mounting

screws (Item 1) [Figure 50-113-7] from the handle
P-24910 sensor.
Installation: Tighten the handle sensor mounting screws

Using a small screwdriver remove the handle sensor to 32 - 28 in.-lb. (3,6 - 4,3 N•m) torque.
electrical connector (Item 1) [Figure 50-113-5] from the

clip by pushing the connector down out of the connector
clip (Item 2) [Figure 50-113-5].
Figure 50-113-6
P-24911
Using a small screwdriver, remove the electrical

connector (Item 1) [Figure 50-113-6] from the clip by
pushing the connector down out of the connector clip
(Item 2) [Figure 50-113-6].
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CONTROL PANEL (ADVANCED CONTROL SYSTEM) EARLIER VERSION HAND CONTROLS ONLY;
(ACS) ADVANCE HAND CONTROL (CONT’D)
Figure 50-113-10
Figure 50-113-8
2
2
1
P-24914
P-24915 Remove the mounting bolt and nut (Item 1) [Figure 50-
113-10] from the control handle and shaft.
Figure 50-113-9 NOTE: Be careful not to loose the recessed nut on the

other side of the handle.

from the control handle.
Installation: Tighten the mounting bolt to 32 - 28 in-lb.

(3,6 - 4,3 N•m) torque.
Figure 50-113-11
1
5
P-24913
Remove the spacers (Item 1) [Figure 50-113-8] & 1

1
[Figure 50-113-9] while removing the mounting pin (Item
2) [Figure 50-113-8] 4
3
3
2
P-24917
NOTE: The handle sensor (Item 1) [Figure 50-113-11]

can only be replaced as a complete assembly.
Check the spacers (Item 2) [Figure 50-113-11], screws

(Item 3) [Figure 50-113-11], mounting pin (Item 4)
[Figure 50-113-11], bolt / nut (Item 5) [Figure 50-113-11]
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CONTROL HANDLE (ADVANCED CONTROL Figure 50-113-14
(CONT’D)
CURRENT VERSION HAND CONTROLS:

1
Figure 50-113-12
P-24909
Installation: When installing the handle sensor into the

wire harness (Item 1) [Figure 50-113-14] to assure
proper return of the control handle neutral.
1
P-21880

Remove one of the two mounting screws (Item 1) [Figure
50-113-12] from the handle sensor.
Installation: Tighten bolt to 32 - 38 in.-lb. (3,6 - 4,3 N•m)

torque.
Figure 50-113-13
1
3
4
3
2
P-24918


Check the spacers (Item 2) [Figure 50-113-13], screws

(Item 3) [Figure 50-113-13], mounting pins (Item 4)
[Figure 50-113-13] and replace as needed.
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(CONT’D)
Control Handle Removal And Installation 1

Figure 50-113-15
N-17384
Remove the rubber handle cover (Item 1) [Figure 50-

113-17] from the handle.
P-24909 Figure 50-113-18
Remove the handle sensor (Item 1) [Figure 50-113-15].

(See Handle Sensor Removal And Installation on Page
50-114-1.)
1
Figure 50-113-16
2
2
N-17385
Using a small screwdriver, hold the handle spacer (Item

1) [Figure 50-113-18] and remove the allen head screws
(Item 2) [Figure 50-113-18] from the handle assembly.
P-16534 Installation: Tighten the allen head screws to 35 in.-lb.

(4 N•m) torque.
Remove the switch handle (Item 1) [Figure 50-113-16].
(See Switch Handle Removal And Installation on Page
60-121-8.)
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CONTROL HANDLE (ADVANCED CONTROL
(CONT’D)
Control Handle Disassembly and Assembly
Figure 50-113-19
2
1 N-17394
Remove the handle sleeve (Item 1) [Figure 50-113-19]

and bushings (Item 2) [Figure 50-113-19] from the
handle.
Check all parts for wear and replace as needed.
Figure 50-113-20
N-22796
Check the mounting bolt (Item 1) [Figure 50-113-20] that

connects the handle to the handle sensor unit for wear,
replace as needed.
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(CONT’D)
Control Lever Removal And Installation
Figure 50-113-21
18.25”
1
1
B-16618
1
Installation: Tighten the u-bolts so the lever can not be

moved either right or left when seated in the operator
seat. Control lever end (Item 2) [Figure 50-113-22]
N-22667 should be flush with bellcrank. Be sure the control lever
does not interfere with the operator cab when lowering or
raising the cab. The distance between handles should be
Disconnect the electrical connectors (Item 1) [Figure 50-

18.25 in. [Figure 50-113-23].
113-21] from the control lever switch handle.
Remove the lever from the cross shaft and control panel.
Remove the electrical connectors from the control lever
switch handle. (See Switch Handle Removal And
Figure 50-113-24
Figure 50-113-22
1
2
2
P-13734
N-22658 The control lever (Item 1) [Figure 50-113-24] must be

replaced as a complete unit.
Loosen the two u-clamps (Item 1) [Figure 50-113-22]
The connector clip (Item 2) [Figure 50-113-24] can be
nuts.
replaced separately from the control lever.
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(CONT’D)
Control Lever Boot
Figure 50-113-25
1
N-22659
To replace the rubber boot (Item 1) [Figure 50-113-25]

on the control panel, remove the control lever. (See
Control Lever Removal And Installation on Page 50-113-
7.)
Drill out the four rivets (Item 2) [Figure 50-113-25]

located on the flange of the rubber boot and remove old
boot.
Install the new boot and reinstall the control lever. (See
6.)
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CONTROL HANDLE (ADVANCED CONTROL Handle Sensor Removal And Installation
SYSTEM) (ACS) SELECTABLE HAND / FOOT
CONTROL Figure 50-114-3
Figure 50-114-1
1 1
P-21864
Loosen the nuts (Item 1) [Figure 50-114-3].


seat. Be sure the control lever does not interfere with the
operator cab when lowering or raising the cab.
Figure 50-114-4
P-16572
Figure 50-114-2 1
P-21837
Tilt the control handle (Item 1) [Figure 50-114-4] to the

center of the loader.
1 Lift the boot cover (Item 2) [Figure 50-114-4].
P-21879
Handle Sensor (Item 1) [Figure 50-114-2].
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CONTROL (CONT’D)
Figure 50-114-5
1
P-21860
Remove the handle lock solenoid connector (Item 1)

2 [Figure 50-114-7] from the clip.
P-21836 NOTE: Pry out with a small screwdriver and push the
connector down.

Figure 50-114-8
114-5] from the handle sensor connector.
1
114-5] from the handle lock solenoid.
5
Figure 50-114-6 2
4
1
1 P-21862

50-114-8] from the handle sensor.
P-21861 Installation: Tighten the screws to 32 - 38 in.-lb. (3,6 -

4,3 N•m) torque.
Remove the handle sensor connector (Item 1) [Figure
While removing the mounting pin (Item 2) [Figure 50-
50-114-6] from the clip.
114-8] from the handle sensor, remove the one plastic
spacer (Item 3) [Figure 50-114-8], the spring (Item 4)
NOTE: Pry out with a small screw driver and push the
[Figure 50-114-8] and washer (Item 5) [Figure 50-114-
connector down.
8].
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CONTROL PANEL (ADVANCED CONTROL SYSTEM) Figure 50-114-10
(ACS) SELECTABLE HAND / FOOT CONTROL
(CONT’D)
7
3
EARLIER VERSION HAND CONTROLS ONLY;
1
Figure 50-114-9
4
3
5 6
8
2
P-21791

1 from the handle assembly.
NOTE: The handle senor (Item 1) [Figure 50-114-10]

P-21863

Check the spacer (Item 2) [Figure 50-114-10] and
screws (Item 3) [Figure 50-114-10], mounting pin (Item
Remove the top mounting bolt (Item 1) [Figure 50-114-9]
4) [Figure 50-114-10], spring (Item 5) [Figure 50-114-
from the handle sensor.
10], washer (Item 6) [Figure 50-114-10], bolt / nut (Item
7) [Figure 50-114-10], stop strap (Item 8) [Figure 50-
NOTE: Be careful not to loose the recessed nut on the
114-10] and replace as needed.
other side of the handle.

torque.
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CONTROL HANDLE (ADVANCED CONTROL 7) [Figure 50-114-12], stop strap (Item 8) [Figure 50-
SYSTEM) (ACS) SELECTABLE HAND / FOOT 114-12] and replace as needed.
CONTROL (CONT’D)
Figure 50-114-13
CURRENT VERSION HAND CONTROLS:
Figure 50-114-11
1
1
P-21878
Figure 50-114-14
P-21880

50-114-11]from the handle sensor.

torque.
Figure 50-114-12
4
3 8
1
1
P-21799
Installation: When installing the handle sensor into the

4
3 wire harness (Items 1) [Figure 50-114-13] & [Figure 50-
114-14] to assure proper return of the control handle
neutral.
5 6
2 NOTE: The calibration procedure must be followed
P-21882
when replacing handle sensor, actuator or
ACS Controller (See Actuators Disassembly
Remove the handle sensor (Item 1) [Figure 50-114-12] and Assembly on Page 60-122-11.)

can only be replaced as a complete unit.
Check the spacer (Item 2) [Figure 50-114-12] and

screws (Item 3) [Figure 50-114-12], mounting pin (Item
4) [Figure 50-114-12], spring (Item 5) [Figure 50-114-
12], washer (Item 6) [Figure 50-114-12], bolt / nut (Item
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CONTROL (CONT’D)
Control Handle Removal And Installation 1

Figure 50-114-15
1
N-17384
Remove the rubber handle cover (Item 1) [Figure 50-

114-17] from the handle.
P-21879 Figure 50-114-18
Remove the handle sensor (Item 1) [Figure 50-114-15].

(See Handle Sensor Removal And Installation on Page
50-114-1.)
1
Figure 50-114-16
1 2
2
N-17385
Using a small screw driver, hold the handle spacer (Item

1) [Figure 50-114-18] and remove the allen head screws
(Item 2) [Figure 50-114-18] from the handle assembly.
P-16534 Installation: Tighten the allen head screws to 35 in.-lb.

(4 N•m) torque.
Remove the switch handle (Item 1) [Figure 50-114-16].
(See Switch Handle Removal on Page 60-122-6.)
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CONTROL HANDLE (ADVANCED CONTROL Control Lever Removal And Installation
CONTROL (CONT’D) Figure 50-114-21
Control Handle Disassembly and Assembly
Figure 50-114-19 1
1
1
2
N-22667
2
Disconnect the electrical connectors (Item 1) [Figure 50-
1 N-17394 114-21] from the control lever switch handle.
Remove the electrical connectors from the control lever

Remove the handle sleeve (Item 1) [Figure 50-114-19]

switch handle. (See Switch Handle Removal on Page 60-
and bushings (Item 2) [Figure 50-114-19] from the
122-6.)
handle.
Check all parts for wear and replace as needed.
Figure 50-114-20
N-22796
Check the mounting bolt (Item 1) [Figure 50-114-20] that

connects the handle to the handle sensor for wear,
replace as needed.
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CONTROL (CONT’D)
Figure 50-114-22
2
1
P-13734
The control lever (Item 1) [Figure 50-114-24] must be

N-22658 replaced as a complete unit.
The connector clip (Item 2) [Figure 50-114-24] can be

Figure 50-114-23
replaced separately from the control lever.

18.25”
B-16618
Loosen the two u-clamps (Item 1) [Figure 50-114-22]

nuts.

seat. Control lever end (Item 2) [Figure 50-114-22]
should be flush with bellcrank. Be sure the control lever
does not interfere with the operator cab when lowering or
raising the cab. The distance between handles should be
18.25 in. [Figure 50-114-23].
Remove the control lever from the cross shaft and control
panel.
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CONTROL (CONT’D)
Control Lever Boot
Figure 50-114-25
1
N-22659
To replace the rubber boot (Item 1) [Figure 50-114-25]

on the control panel, remove the control lever. (See
Contents Page 50-01.)
Drill out the four rivets (Item 2) [Figure 50-114-25]

located on the flange of the rubber boot and remove old
boot.
Install the new boot and reinstall the control lever. (See
6.)
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ELECTRICAL SYSTEM & ANALYSIS
ADVANCED CONTROL SYSTEM (ACS) ADVANCED HAND

CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-122-1
ACS Controller Removal And Installation . . . . . . . . . . . . 60-122-4 SAFETY &
Actuators Disassembly and Assembly. . . . . . . . . . . . . . 60-122-11 MAINTENANCE
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . 60-122-1
Controller, Connector And Wire Identification . . . . . . . . . 60-122-3
Handle Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . 60-122-5
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-122-8
Switch Handle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 60-122-6
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-122-2
DRIVE
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND /
FOOT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-123-1
ACS Controller Removal And Installation . . . . . . . . . . . . 60-123-5
Actuators Disassembly and Assembly. . . . . . . . . . . . . . 60-123-12
Calibration Of The ACS System . . . . . . . . . . . . . . . . . . 60-123-15
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . 60-123-1 ELECTRICAL
Controller, Connector And Wire Identification . . . . . . . . . 60-123-4 SYSTEM AND
ANALYSIS
Foot Lock Solenoid Connector. . . . . . . . . . . . . . . . . . . . 60-123-20

Foot Lock Solenoid Removal And Installation . . . . . . . . 60-123-20
Foot Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . . 60-123-19
Foot Sensor Disassembly And Assembly . . . . . . . . . . . 60-123-18
Hand Controls Only Calibration Procedure . . . . . . . . . . 60-123-17
Handle Lock Solenoid Connector . . . . . . . . . . . . . . . . . 60-123-14 ENGINE
Handle Lock Solenoid Disassembly And Assembly. . . . 60-123-14 SERVICE
Handle Lock Solenoid Removal And Installation . . . . . . 60-123-13 HVAC
Handle Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . 60-123-6
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-123-3
Switch Handle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 60-123-7 SPECIFICATIONS
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-123-9
Switchable Hand / Foot Controls Calibration Procedure 60-123-15
ADVANCED HAND CONTROL SYSTEM (AHC) . . . . . . . . . 60-120-1

Actuators Disassembly And Assembly . . . . . . . . . . . . . . 60-120-9
AHC Controller Removal And Installation . . . . . . . . . . . . 60-120-4
Handle Control Unit Connector . . . . . . . . . . . . . . . . . . . . 60-120-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-3
Switch Handle Removal And Installation . . . . . . . . . . . . . 60-120-6
Trouble shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-2
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ELECTRICAL SYSTEM & ANALYSIS (CONT’D)
ADVANCED HAND CONTROL SYSTEM (AHC) (W/PUSH BUTTON

FLOAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-121-1
Actuators Disassembly And Assembly . . . . . . . . . . . . . 60-121-11
AHC Controller Removal And Installation . . . . . . . . . . . . 60-121-4
Controller Connector and Wire Identification . . . . . . . . . . 60-121-3
Handle Control Unit Connector . . . . . . . . . . . . . . . . . . . . 60-121-7
Handle Control Unit Removal And Installation . . . . . . . . . 60-121-5
Switch Handle Removal And Installation . . . . . . . . . . . . . 60-121-8
Trouble shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . 60-121-2
ALTERNATOR (55 AMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-6
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Rectifier (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-5
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . 60-30-5

Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-5
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
ALTERNATOR (90 AMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-1

Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . 60-31-1
Alternator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-1
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-7
Alternator Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-9
Charging System Check . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-2
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-7
High Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-4
ALTERNATOR (90 AMP) (CONT’D) . . . . . . . . . . . . . . . . . 60-31-4
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . 60-31-6
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-8
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-8
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-8
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-8
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing The Electrical System . . . . . . . . . . . . . . . . . . . . 60-20-3
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . 60-20-4
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BOBCAT CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

Identification Chart (S/N 514450763 & Below) . . . . . . . . . . . . . . 60-70-1
Identification Chart (S/N 514450764 & Above) . . . . . . . . . . . . . . 60-70-2
BICS™ SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Additional Inspection For Loaders With Advanced Hand Controls60-90-2
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine
STOPPED - Key ON). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Inspecting The BICS™ Controller (Engine STOPPED - Key ON) 60-90-1
Inspecting The Lift Arm Bypass Control. . . . . . . . . . . . . . . . . . . . 60-90-1
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . 60-90-1
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . 60-90-1
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-3
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-4
DELUXE INSTRUMENTATION SERVICE CODES . . . . . . . . . . . . . 60-80-1
ELECTRICAL / HYDRAULIC CONTROLS REFERENCE . . . . . . . 60-130-1

Controls Identification Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . 60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Relay Switches Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-3
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Changing The Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Deluxe Panel Removal And Installation (Right Side). . . . . . . . . . 60-50-9
Deluxe Panel Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Option And Field Accessory Panels. . . . . . . . . . . . . . . . . . . . . . . 60-50-7
Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Right Panel - (Deluxe) (With Keyless Start) . . . . . . . . . . . . . . . . . 60-50-3
Right Panel Setup Display Options (Deluxe) . . . . . . . . . . . . . . . . 60-50-4
Right Panel - Standard Instrument Panel (With Key Switch) . . . . 60-50-2
Standard & Deluxe Panel Removal And Installation (Left Side) 60-50-10
Standard Panel Removal And Installation (Right Side) . . . . . . . . 60-50-8
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LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-60-2
SEAT BAR SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

BICS™ Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
STARTER (NIPPONDENSO) . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
External Pinion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-6
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-7
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-11
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2
STARTER (VALEO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-1

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-1
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . 60-41-4
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-7
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-9
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-3
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Description Of The Control System (Two-Speed) . . . . . . 60-110-3
Inspecting The Control System (Two-Speed) . . . . . . . . . 60-110-3
Removal And Installation (Single Speed). . . . . . . . . . . . . 60-110-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
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RED = RED
BATTERY FEED 1000-1999 RED, RED/WHT, RNG
GROUND 2000-2999 BLK
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
CAB FRONT LIGHT
ACCESSORY 2740
2750
863 WIRING SCHEMATIC
CONNECTORS 2760
MONITORING 3000-3999 LBL DBL = DARK BLUE HARNESS 6718870
LGN = LIGHT FRONT WORKLIGHTS
HYDRAULIC 4000-4999 LGN
S/N 514440001-45999 WIRES CONNECT BY LETTER GREEN B B
C435
2750 2750
ACROSS CONNECTORS ATTACHMENT CONTROLS 5000-5999 YEL
DGN = DARK 6110 A A 6110
S/N 514540001-40999 A B LIGHTS 6000-6999 PNK GREEN
ACCESSORIES 7000-7999 WHT YEL = YELLOW
S/N 514640001-40999 B A
PNK = PINK A A
C434
ENGINE 8000-8999 TAN 6120 6120
WHT = WHITE
(PRINTED NOVEMBER 2002) SOME CONNECTOR
BODIES NOT SHOWN
COMMUNICATION 9000-9999 PUR
BRN = BROWN
2760 B B 2760
TAN = TAN LEFT PANEL
V-0003 FOR DRAWING CLARITY
PUR = PURPLE
GRY = GRAY
Printable Version Click Here FUEL SENDER FUSE 9
9340
2910
D
G
HEADLIGHTS
GROUND
FUSE 5 FUSE 1
20-270 ohm UNSWITCHED 1210 E PROTECTED POWER
TRACTION HEATER
FRONT & 25A
30A 25A REAR SWITCH 1910 F COMPUTER POWER
MARKER
A B FUSE 6 FUSE 2 LIGHT POWER FUSE 10 9210 K SYSTEM Rx
LIGHT
TAILGATE/ 2650
2640
C442
FUEL PULL
30A
FR & MK LT
15A
ATTCHMNT
25A
9110
9300
H
A
SYSTEM Tx
CLOCK/LATCH
2630 2600 A B FUSE 7 FUSE 3 FUSE 11
WORK LIGHTS 2620
2610
FUEL SENDER
REAR LT
15A GLOW FUEL

PULL
TRACTION
PULL
STARTER
ALT & KITS
25A
FUSE 12
CONNECTS TO
9310
9330
B
J
DATA
START
HARNESS FUSE 8 FUSE 4 PLUG C407
HARNESS 6716419 ON THIS PAGE
9320 C BUZZER
3100
3110
COMPUTER ACC PLUGS
6719422
RIGHT
TAILLIGHT 2610 6320
25A 25A
C407
A 9320 + BUZZER
A B C
2930 -
LEFT
2640 6330 C406 6100 8 8 6100
RIGHT PANEL
TAILLIGHT
A B C
MAIN FRAME 9340
9200
11
10
11
10
9340
9200 9330 J START
RIGHT
WORK 2620 6200 9
3100
3110
9 9100 9310 B DATA
HARNESS 6719112 9100
C408
LIGHT 6210
2900 4 4 2900 9300 A CLOCK/LATCH
1900 2 2 1900 9120 H SYSTEM Tx
LEFT WORK
2630 6210 1200 1 1 1200 9220 K SYSTEM Rx
LIGHT
C405
3700 A A AIR FILTER 9350 12 12 9350 1920 F COMPUTER POWER
3710 B B SWITCH 3900 5 5 3900 1220 E PROTECTED POWER
7100 3920 7 7 3920 2920 G GROUND
BACKUP 3910 6 6 3910 9350 D KEY/ENTER SWITCH
ALARM 2650
HYD FILTER 2740 3 3 2740 C OPEN
2600
7100
6200
6310
TO OPTIONS
(BACKUP HARNESS 6717247 2910
ALARM 2900 2920
SWITCH) t 2930
B F G D E C H A HYD TEMP SENDER
C404 3300 C C 3300 C
538-1824 ±30 ohm 3900
C103
C102
3310 D D 3310 SEAT
B A 3920 B
A+ BAR
3400 A A 3400 HYD CHARGE PRESS A
3910
B F G D E C H A 3420 E E 3420
C SENDER 0.5-7.5 V
3410 F F 3410
B - MAIN
2000 CAB
9340
2900
9350
9200
9100
1900
1200
3900
3920
3910
FRAME
7100
3430 B B 3430 HYD OIL FILTER
ENGINE PRESSURE SWITCH
6600
6500
6400
7100
2600
6200
6310
HARNESS 6719082 RIGHT HANDLE
E3
D2
D1
A1
A2
A3
D3
C3
C2
C1
B3
B2
B1
E1
E2
F2
F3
F1
J2 J4
3020
6310 N E1 4300 4300 B B WHT
+ 6200 S
3110 J1 J2
A 3310 3010 E3 4320 4320 D D WHT/RED
SEATBAR SENSOR
SEATBAR SENSOR
3500 PWM
FUEL SENDER SPARE ANAL OG
ENG COOLAN T SPARE ANAL OG
SPARE DIGITIAL
SENSOR SIGN AL
7100 R R C
SEATBAR
7100
GROUND
C
SUPPLY
ENG OIL PRESSURE C 3410 E2 4310 4310 WHT/BLK
IN 1
IN 2
IN 1
3900
3910
3920
A1
A2
A3
3520
A1
A2
A3
SENDER 0.5-7.5 V - 6400 W 3710
B 3510 K3
P TWO
TEMP SENDER
6500 J1
HYD TEMP
SENDER
C409
SIGNAL
SPEED
OPEN
OPEN
A1 F F
OPEN
3100
3200
3300
4910 4910 WHT/LGN
B1
B2
B3
B1
B2
B3
6600 V
ENGINE COOLANT
t
3010 F2 G G
HYD CHARGE
HYD CHARGE
PRESSURE +
DIGITAL IN 2
PRESSURE
SENDER 3200 DETENT
SIGNAL
SPARE
OPEN
OPEN
OPEN
3400
3420
E3 J3 J4 B1 E E
C1
C2
C3
C1
C2
C3
500-3000 ± 30 ohm 3430 4920 4920 DGN
3210 3020 H H 3020
3420 C2 K2 K K
RH TWO SPEED
BATTERY IN (1 )
BATTERY IN (2 )
BATTERY IN (3 )
LH AUX RIGH T
UNSWITCHED
UNSWITCHED
UNSWITCHED
BRAKE SW
4910
4810
4500
1110
1120
1130
BLACK
WHITE
C1 C1 J
A1
A2
A3
3400
A1
A2
A3
4930 4930
IN
J YEL
J1
J2
3610 SKI
SPEED SENSOR (VR) 3300 B3 D1 4940 4940 H H LGN CONTROL
3600
LH AUX LEFT
ENG SPEED +
PRESSURE +
RH FRON T
BRAKE SW
SYSTEM Tx
SYSTEM R x
PRESSURE
DETEN T
GROUND
GROUND
3700 E2
ENG OIL
ENG OIL
A
SIGNAL
OPEN
RNG
4920
4820
1400
A
OU T
B3
2100
1400 1490
2110
OPEN
B1
B2
B3
(hall)
9100
9200
3500
3520
B1
B2
B3
D1
D2
D3
D1
D2
D3
3100 B1
F F
FUEL PULL RELAY
BRAKE SWITCH
RH SKI D OWN
FILTER SIGN AL
LH SKI D OWN
HYD CHARGE
EHC INPU T
HEADLIGH T
FUEL HOLD
COMPUTER
FEEDBAC K
ENG SPEED
FUEL PULL
KEY/ENTER
SIGNAL (vr)
AIR FILTER
SWITC H
SWITC H
POWER
SIGNAL
K D1 A3
4930
3500 K 3500 3500 4500 1450
4830
9400
8800
8110
8150
1900
9350
9340
C1
C2
C3
3600
3700
3430
GLOW PLUGS
C1
C2
C3
E1
E2
E3
E1
E2
E3
C403
0.4 ohm 3520 L L 3520 3520 D2 K1
STARTER REL AY
EHC OUTPU T
SIGNAL (hall )
PROTECTED
GLOW PL U G
ENG SPEED
BRAKE PULL
HR
GROUNDS
LH SKI U P
C C H
RH SKI U P
8560 3200 3200 3200 B2
GROUND
H
SENSOR
POWER
RELAY
RELAY
OPEN
OPEN
1200
2900
4940
4840
9410
3010
LEFT HANDLE
8210
4110
8510
D1
D2
D3
F1
F2
F3
F1
F2
F3
D1
D2
D3
3600 M M 3600 3600 E1 C3 9400 J J
0.4 ohm
X X F3 D3 9400 1480 A A RNG
PWM SIGN AL
GLOW PL U G
BRAKE PULL
FEEDBAC K
FEEDBAC K
FEEDBAC K
STARTER
HR
PWM +
PWM -
8570
4310
4320
4300
E1
E2
E3
8250
4150
8550
E1
E2
E3
2300 B B 2300 C3 D2 4840 4840 C C WHT SKI
C410
0.4 ohm J J A1 C2 4830 4830 B B DBL CONTROL
WHITE
HR
BLACK
8580 8500 8500 G W 6400 A3 B2 4820 4820 G G YEL/LGN
J4
PADDLE
J3
P 6500 F1 A2 4810 4810 F F YEL/RED MOMENTARY
0.4 ohm
SPOOL LOC K
FRONT BASE
FRONT R OD
REAR WKL T
MARKER L T
V 6600 D3 G2 4430 K K
RELAY
RELAY
4340
4330
4360
OPEN
F1
F2
F3
HR
6210
6320
8590
F1
F2
F3
T T A2 G1 4440 E
E
TRACTION HOL D
U 8250 800 SERIES J1 4460 D D
REAR BASE
REAR ROD
RESERVED
RESERVED
RESERVED
(R TURN)
(L TURN)
(HORN)
4440
4430
4200
G1
G2
G3
G1
G2
G3
G 8500 J2 4450
FUEL SHUT OFF B BRN
D 8200 J3 4480
C412 C411
TURN
RELAY OUTPU T
TWO SPEED
D
ATTACHMEN T
BICS LOC K
YEL
ACCESSOR Y
POSITION
BUCKET
KEY INPU T
CONTROL
TO OPTIONS SIGNAL
TRAVEL
E S F2
4410
4420
4350
2800 8100 8100 6200 4330
H1
H2
H3
8000
9800
4730
H1
H2
H3
(ACCESSORY A DGN
1800 A N 6310 F1 4340 CONNECTOR)
C
SPARE OUTPU T 1
SPARE OUTPU T 2
REAR BLEED
RED TO BLK= ALTERNATOR
HIGH FL OW
DIVERTER
8200 D E 8100 H1 4410
RESERVED
(ATT ACC )
4460
4450
4470
3.2 ohm
J1
J2
J3
E
J1
J2
J3
S 8250 U A 1800 F3 4360
TO OPTIONS
1020
G EXC
(SERIAL RIGH T)
(SERIAL LEFT)
H2 4420 (ACCESSORY A RNG/DBL
FUTURE
FUTURE
CAN SHIELD
1010 1800
CAN HIGH
CAN L OW
OPEN
K1
K2
K3
9500
9600
9700
H3 CONNECTOR) B
K1
K2
K3
BAT 4350 RNG/WHT HORN
G3 4200
STARTER 2600 REAR ROD
G3
G1
G2
B3
D3
B1
B2
H3
C1
E1
H1
C3
C2
D1
E3
D2
E2
A1
A2
A3
K1
K2
K3
H2
F3
F2
F1
J1
J2
J3
J3
M 2300 CONNECTS TO
C413
S C407 TO OPTIONS 4430 A A 7.5 ohm nominal
1010 8200 2800 (ACCESSORY
ON THIS PAGE BROWN TIE STRAP at 12 VDC
CONNECTOR)
2430 B B
R
120 ohm REAR BASE
8250
C407 C427
4110
8250
8210
2100
2110
4390
1110
1120
4730
8150
8110
1130
8000
8510
4150
6320
6210
8550
9500
9600
9700
9800
C414
4440 A A 7.5 ohm nominal
A E F H G C B A D ACD & REMOTE START
at 12 VDC
CONNECTOR WHITE TIE STRAP 2440 B B
2090
2090
LOCATED AT REAR OF HIGH FLOW
MACHINE
C415
4460 A A
6400
6500
6600
6300
4730
7.5 ohm nominal
at 12 VDC
BLUE TIE STRAP 2460 B B
6000
GROUNDS D C B A G F E DIVERTER
2480
TO OPTIONS TO OPTIONS
4450 A A
C426
C416
7.5 ohm nominal
2460 (ACCESSORY (ACCESSORY
YELLOW TIE STRAP at 12 VDC
CONNECTOR) CONNECTOR) 2450 B B
2360
2450
D C B A G F E REAR AUX RELIEF
2440 2400 C401 C402
C417
2430
B A D C B A GREEN TIE STRAP at 12 VDC
B A 2480 B B
9800
9700
9600
9500
2710
1160
1710
2340
FRONT ROD
2330 C458
C418
4330 A A
2730
1140
1700
1150
2100 3.3 ohm nominal
2720
1720
2420 B A 2330 B B at 10 VDC

2410 FRONT BASE
2380
C419
2370 2390 2340 B B at 10 VDC
2360 HYD LOCK VALVE
2350 HYDRAULIC
C420
MAKE-UP
2200 2410 B B at 12 VDC
2000 TILT SPOOL LOCK
C421
1800 4370 A A
2300 FUSE 11
2740 1720 7.7 ohm nominal
25A 2370 B B
2730 1700 1055
8000
6310
8500
8550
8510
4110
4150
4100
6000
6300
LIFT SPOOL LOCK
6320
2120
2720 FUSE 12
USED IN AHC
8100
8150
8110
6200
6210
8200
8210
C422
AHC POWER 25A 4380 A A
1140
2710 EQUIPPED 1730 7.7 ohm nominal

SWITCHED REAR 2380 B B
1150
1160
2110 LOADERS ONLY MARKER GLOW TRACTION
FUSE 10 POWER FUEL LIGHT STARTER LOCK
ATTACHMENT LIGHT PLUG
25A PULL BUCKET POSITION
1710
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A
1130
1110
1120
C423
HEATER 4420 A A 6.7 ohm nominal
30 85 2420 B B at 12 VDC
25A 30 85 30 85 30 85 30 85 30 85 85 30 UNSW
POWER
FUSE 1
2020
2030
TWO SPEED
1330
1050
2000
2010
1350
2040
2050
1320
2010
2020
1030
2060
1060
2030
2040
2050
2060
1360
RELAY GROUNDS 2000-2060 25A
C441
ARE CONNECTED IN SERIES FUSE 9 4350 A A
5.5 ohm nominal
2350 B B at 12 VDC
30A 15A 15A
1070
BATTERY FUSE 6 FUSE 2 FUSE 3 30A 25A SINGLE SPEED TRACTION LOCK

1050 FUSE 4
FUSE 5
- + 1300 TWO SPEED BRAKE LOCK
100A 1030 WHT TO BLK =
4200 A A HOLD A
C425
C425
0.26 ohm
1010 1060
2200 C C RED TO BLK= B 9.8 ohm
1310 10.9 ohm
4100 B B PULL C
1040
V-0003 (10-4-02)
Printed in U.S.A.
547 of 970
RED = RED
CAB FRONT LIGHT
863 WIRING SCHEMATIC BATTERY FEED 1000-1999 RED, RED/WHT, RNG
RNG = ORANGE
BLK = BLACK
HARNESS 6718870 ACCESSORY
CONNECTORS
2740
2750
2760 M M
WITH ADVANCED HAND CONTROL OPTION WIRES CONNECT BY LETTER
MONITORING 3000-3999 LBL
LBL = LIGHT BLUE
DBL = DARK BLUE
FRONT WORKLIGHTS
S/N 514440001-43831 B B
C435
ACROSS CONNECTORS HYDRAULIC 4000-4999 LGN LGN = LIGHT 2750 2750
A B ATTACHMENT CONTROLS 5000-5999 YEL GREEN 6110 A A 6110

S/N 514540001-40110 B A LIGHTS 6000-6999 PNK DGN = DARK
DGN
DGN
RED
RED
RED
RED
BLK
BLK
BLK
BLK
GREEN
S/N 514640001-40215 ACCESSORIES 7000-7999 WHT A A
C434
YEL = YELLOW 6120 6120
SOME CONNECTOR ENGINE 8000-8999 TAN PNK = PINK 2760 B B 2760
(PRINTED NOVEMBER 2002) BODIES NOT SHOWN
FOR DRAWING CLARITY COMMUNICATION 9000-9999 PUR WHT = WHITE
LEFT PANEL 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
BRN = BROWN
V-0004 FUEL SENDER
20-270 ohm TAN = TAN
TILT ACTUATOR LIFT ACTUATOR
PUR = PURPLE C428 C429

9340 D HEADLIGHTS
Printable Version Click Here FUSE 5 FUSE 1
GRY = GRAY
FUSE 9
2910 G GROUND
TILT ACTUATOR
1 2 3 4 5 6 7 8 1 2 3 4 5 6
LIFT ACTUATOR
7 8
TRACTION HEAT ER UNSWITCHED 1210 E PROTECTED POWER
FRONT & 25A
A B MARKER
FUSE 6 FUSE 2 LIGHT POWER FUSE 10 9210 K SYSTEM Rx
LIGHT
TAILGATE/ 2650
2640
C442
A B
FUEL PULL
30A
FR & MK LT
15A
ATTCHMNT
FUSE 11
25A 9110
9300
H
A
SYSTEM Tx
CLOCK/LATCH
2630 2600 FUSE 7 FUSE 3
WORK LIGHTS 2620
2610
FUEL SENDER
REAR LT
15A GLOW FUEL

PULL
TRACTION
PULL
STARTER
25A
ALT & KIT S
FUSE 12
CONNECTS TO
C407
9310
9330
B
J
DATA
START
ADVANCED HAND CONTROL MODULE
6674804 rev. B
HARNESS FUSE 8 FUSE 4 PLUG
HARNESS 6716419 ON THIS PAGE 9320 C BUZZER
3100
3110
6719422 COMPUTER ACC PLUGS
RIGHT
2610 6320
25A 25A
C407
TAILLIGHT
A 9320
A B C + BUZZER K H J C D E B A G F
A B
2930 -
LEFT C406 RIGHT PANEL C430 C431
2640 6330 6100 8 8 6100
TAILLIGHT
A B C
MAIN FRAME 9340
9200
11
10
11
10
9340
9200 9330 J START
A B K H J C D E B A G F
RIGHT
4580
9410
9400
4720
4700
4710
4620
4600
4610
6200 9
1740
2240
WORK 2620
3100
3110
HARNESS 6719113 9100 9 9100 9310 B DATA
C408
LIGHT 6210
2900 4 4 2900 9300 A CLOCK/LATCH
1900 2 2 1900 9120 H SYSTEM Tx
LEFT WORK
2630 6210 1200 1 1 1200 9220 K SYSTEM Rx
LIGHT
C405
3710 B B SWITCH 3900 5 5 3900 1220 E PROTECTED POWER
7100 3920 7 7 3920 2920 G GROUND
1730
BACKUP 3910 6 6 3910 9350 D KEY/ENTER SWITCH
2650
HYD FILTER
4720
4700
4710
4620
4600
4610
ALARM
2740 3 3 2740 C OPEN
2600
7100
6200
6310
TO BACKUP HARNESS 6717247 2910

POWER FROM
FUSE 12
ALARM 2900 2920 THIS PAGE C A B C A B
SWITCH 2930
t
B F G D E C H A HYD TEMP SENDER R HANDLE L HANDLE
C404 3300 C C 3300
538-1824 ±30 ohm C
3900 C432 C433
C103
C102
3310 D D 3310 SEAT
B A 3920 B CONNECTS TO CONNECTS TO
A + BAR
3400 A A 3400 HYD CHARGE PRESS A C432 C433
C 3910 ON THIS PAGE ON THIS PAGE
B F G D E C H A 3420 E E 3420 SENDER 0.5-7.5 V
F F 3410
B - MAIN
2000
9340
3900
2900
9350
3410
3920
9200
9100
3910
1900
1200
CAB
FRAME
7100
3430 B B 3430 HYD OIL FILTER RIGHT HANDLE
ENGINE PRESSURE SWITCH
2600
6600
6500
6400
7100
6200
6310
HARNESS 6719082
C432
AHC CONNECTOR A PNK/RED
D2
D1
D3
C3
C2
C1
B3
B2
B1
A1
A2
A3
E3
E2
F2
J2
F3
E1
F1
J4 CONNECTS TO TILT
C PNK/DGN
CONTROL
3020 C432
6310 N D3 9410 ON THIS PAGE B PNK/BLK
+ 6200 S
3110 J1 J2
A 3310 3010 C3 9400
SEATBAR SENSOR
SEATBAR SENSOR
SENSOR SIGNAL
3500
SPARE DIGITIAL
FUEL SENDER SPARE ANALOG
ENG COOLANT SPARE ANALOG
SEATBAR
R R
GROUND
7100 7100
SUPPLY
ENG OIL PRESSURE C 3410 E1 4300 4300 B B WHT
3900
3910
3920
IN 1
IN 2
IN 1
A1
A2
A3
A1
A2
A3
3520
SENDER 0.5-7.5 V - 6400 W 3710
B E3 4320 4320 D D WHT/RED
PWM
3510
TEMP SENDER
6500 P J1 E2 4310 4310 C C WHT/BLK
HYD TEMP
C409
SENDER
SIGNAL
OPEN
OPEN
OPEN
3100
3200
3300
B1
B2
B3
B1
B2
B3
6600 V
t K3
ENGINE COOLANT 3010 F2 TWO
HYD CHARGE
HYD CHARGE
PRESSURE +
DIGITAL IN 2
3200
PRESSURE
SENDER A1 4910 F F SPEED
SIGNAL
4910 LGN/WHT
SPARE
OPEN
OPEN
OPEN
3400
3420
C1
C2
C3
J3 J4
C1
C2
C3
500-3000 ± 30 ohm 3430 E3
3210 3020 H H 3020
3420 C2 G G
RH TWO SPEED
BATTERY IN (1)
BATTERY IN (2)
BATTERY IN (3)
LH AUX RIGHT
UNSWITCHE D
UNSWITCHE D
UNSWITCHE D
BRAKE SW
DETENT
1110
1120
1130
4910
4810
4500
WHITE
BLACK
C1 E E
A1
A2
A3
3400 B1 4920
A1
A2
A3
4920 DGN
IN
J2
J1
3610
SPEED SENSOR (VR) 3300 B3 K2 K K
3600
LH AUX LEFT
ENG SPEED +
BRAKE SW
RH FRONT
PRESSURE +
SYSTEM Rx
SYSTEM Tx
GROUND
GROUND
PRESSURE
DETENT
3700 E2 C1 4930 4930 J
ENG OIL
ENG OIL
J
OPEN
SIGNAL
4920
4820
1400
YEL
OPEN
2100
OUT
2110
9100
9200
(hall)
B1
B2
B3
3500
3520
B1
B2
B3
D1
D2
D3
D1
D2
D3
SKI
3100 B1 D1 4940 4940 H H LGN CONTROL
F F
FUEL PULL RELAY
RH SKI DOWN
LH SKI DOWN
FILTER SIGNAL
HYD CHARGE
COMPUTER
HEADLIGHT
KEY/ENTER
EHC INPUT
FUEL HOLD
ENG SPEED
A
FEEDBACK
SIGNAL (vr)
AIR FILTER
FUEL PULL
B3 1400 1490 A RNG
SWITCH
SWITCH
POWER
SIGNAL
K D1
4930
3500 3500 3500
4830
9400
K
1900
9350
9340
8800
8110
8150
C1
C2
C3
3600
3700
3430
GLOW PLUGS
C1
C2
C3
E1
E2
E3
E1
E2
E3
C403
0.4 ohm 3520 L L 3520 3520 D2 BRAKE SWITCH
STARTER RELAY
EHC OUTPUT
PROTECTED
SIGNAL (hall)
GLOW PLUG
ENG SPEED
BRAKE PULL
HR
GROUNDS
LH SKI UP
GROUND
C C B2 A3 H
RH SKI UP
8560 3200 3200 3200 4500 1450
POWER
SENSOR
H
OPEN
RELAY
RELAY
OPEN
1200
2900
4940
4840
9410
3010
F1
F2
F3
8210
4110
8510
D1
D2
D3
LEFT HANDLE
F1
F2
F3
D1
D2
D3
3600 M M 3600 3600 E1 K1 J J
0.4 ohm
X X F3 1480 A A
PWM SIGNAL
RNG
BRAKE PULL
GLOW PLUG
FEEDBACK
FEEDBACK
FEEDBACK
STARTER
HR
PWM +
PWM -
8570
4310
4320
4300
8250
4150
8550
E1
E2
E3
E1
E2
E3
2300 B B 2300 C3 D2 4840 4840 C C WHT SKI
C410
0.4 ohm J J A1 C2 4830 4830 B B DBL CONTROL
WHITE
HR G
BLACK
8580 8500 8500 G W 6400 A3 B2 4820 4820 G YEL/DGN
J4
PADDLE
J3
P 6500 F1 A2 4810 4810 F F YEL/RED MOMENTARY
0.4 ohm
FRONT BASE
TRACTION HOLD SPOOL LOCK
FRONT ROD
REAR WKLT
V
MARKER LT
6600 D3 G2 4430 K K
4340
4330
4360
RELAY
RELAY
OPEN
HR
F1
F2
F3
6210
6320
8590
F1
F2
F3
T T A2 G1 4440 E
E
U 8250 800 SERIES J1 4460 D D
REAR BASE
REAR ROD
RESERVED
RESERVED
RESERVED
(R TURN)
(L TURN)
(HORN)
4440
4430
4200
G1
G2
G3
G1
G2
G3
G 8500 J2 4450
FUEL SHUT OFF B BRN
D 8200 J3 4480
C433 C412 C411

TURN
RELAY OUTPUT
TWO SPEED
D
BICS LOCK
ATTACHMENT
POSITION
YEL
ACCESSORY
BUCKET
KEY INPUT
CONTROL
TO OPTIONS SIGNAL
TRAVEL
E S
4410
4420
4350
2800 8100 8100 6200 H3 4350
H1
H2
H3
8000
9800
4730
H1
H2
H3
(ACCESSORY A DGN
1800 A N 6310 F2 4330 CONNECTOR)
C
SPARE OUTPUT 1
SPARE OUTPUT 2
REAR BLEED
RED TO BLK=
HIGH FLOW
DIVERTER
8200 D E 8100 F1 4340
RESERVED
(ATT ACC)
4460
4450
4470
3.2 ohm
J1
J2
J3
ALTERNATOR E
J1
J2
J3
8250 U A 1800 H1 4410
S
(SERIAL RIGHT)
TO OPTIONS
(SERIAL LEFT)
F3 A RNG/DBL
CAN SHIELD
FUTURE
FUTURE
CAN HIGH
CAN LOW
OPEN
1020
G EXC (ACCESSORY
K1
K2
K3
9500
9600
9700
B
K1
K2
K3
1010 1800 H2 4420 CONNECTOR) RNG/WHT HORN
BAT G3 4200
STARTER AHC CONNECTOR
A BRN/RED
2600 LIFT
G3
G1
G2
H3
C1
H1
C3
C2
D1
B3
D3
B1
B2
D2
K1
K2
K3
H2
A1
A2
A3
E1
F3
F2
E3
E2
F1
J1
J2
J3
J3 CONNECTS TO C BRN/DGN
1010
M S
8200 2800
2300 CONNECTS TO
C407 TO OPTIONS
(ACCESSORY
C433
B BRN/BLK
CONTROL
ON THIS PAGE ON THIS PAGE
R CONNECTOR)
8250
C407 C427 120 ohm
4110
4730
8250
8000
8150
8110
6320
6210
8210
2100
8550
8510
2110
4150
4390
1110
1120
1130
9500
9600
9700
9800
A E F H G C B A D
ACD & REMOTE START
2090
2090
CONNECTOR REAR ROD
LOCATED AT REAR OF
6400
6500
6600
6300
4730
MACHINE 4430 A A
C413
7.5 ohm nominal
6000
BROWN TIE STRAP 2430 B B at 12 VDC

GROUNDS
2480
D C B A G F E REAR BASE
2460 C426 4440 A A
C414
(ACCESSORY (ACCESSORY 7.5 ohm nominal
2360
2450 CONNECTOR) CONNECTOR) WHITE TIE STRAP 2440 B B at 12 VDC

D C B A G F E
2440 2400 C401 C402 HIGH FLOW
2430 4460 A A
C415
B A D C B A B A 7.5 ohm nominal
9800
9700
9600
9500
2710
1160
1710
2340 BLUE TIE STRAP 2460 B B at 12 VDC
C458
2330 DIVERTER
2730
1140
1700
1150
2100 B A
2720
1720
4450 A A
C416
7.5 ohm nominal
2420 YELLOW TIE STRAP 2450 B B at 12 VDC
2410 REAR AUX RELIEF
9.8 ohm nominal
C417
2360 4480 A A at 12 VDC
2350 2390 GREEN TIE STRAP 2480 B B
HYDRAULIC
2240 TWO SPEED
MAKE-UP
5.5 ohm nominal
C441
2200 4350 A A
at 12 VDC
2000 2350 B B
FRONT ROD
2300 1800
FUSE 11 4330 A A
C419 C418
25A
2330 B B at 10 VDC
1700 1055
6310
6000
6300
2730
6320
8000
8500
8550
8510
4110
4150
4100
2120
2720 FUSE 12 FRONT BASE
GOES TO
8100
8150
8110
6200
6210
8200
8210
AHC POWER 25A
1140
2710 ADVANCED HAND
1730
2110 CONTROL MODULE
1150
1160
SWITCHED REAR TRACTION at 10 VDC

THIS PAGE FUSE 10 MARKER GLOW LOCK
2340 B B
POWER FUEL PULL LIGHT STARTER
ATTACHMENT 25A LIGHT PLUG HYD LOCK VALVE
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A
1710
1130
1110
1120
C420
HEATER at 12 VDC
30 85 30 85 30 85 30 85 30 85 30 85 85 30 UNSW 2410 B B
25A
POWER
BUCKET POSITION
2020
2030
FUSE 1
1330
1050
2000
2010
1350
2040
2050
1320
2010
2020
1030
2060
1060
2030
2040
2050
2060
1360
25A
RELAY GROUNDS 2000-2060
C423
FUSE 9 4420 A A 6.7 ohm nominal
ARE CONNECTED IN SERIES at 12 VDC
2420 B B
30A 15A 15A
1070

1050 FUSE 4
FUSE 5
1300 TWO SPEED BRAKE LOCK
- +
100A 1030 WHT TO BLK =
4200 A A HOLD A
C425
C425
0.26 ohm
1010 1060 9.8 ohm
2200 C C RED TO BLK= B
1310 10.9 ohm
4100 B B PULL C
1040
Printed in U.S.A. V-0004 (10-4-02)
548 of 970
863 WIRING SCHEMATIC BATTERY FEED 1000-1999 RED, RED/WHT, RNG
RED = RED
RNG = ORANGE
CAB FRONT LIGHT
WITH ADVANCED HAND CONTROL OPTION WIRES CONNECT BY LETTER
MONITORING 3000-3999 LBL BLK = BLACK HARNESS 6718870 ACCESSORY
CONNECTORS
2740
2750
2760 M M
S/N 514443832-45999 ACROSS CONNECTORS HYDRAULIC 4000-4999 LGN
ATTACHMENT CONTROLS 5000-5999 YEL
LBL = LIGHT BLUE
DBL = DARK BLUE FRONT WORKLIGHTS
A B
S/N 514540111-40999
C434 C435
LGN = LIGHT B
LIGHTS 6000-6999 PNK 2750 B 2750
B A GREEN
6110 A A 6110
S/N 514640216-40999 SOME CONNECTOR
ACCESSORIES 7000-7999 WHT
ENGINE 8000-8999 TAN
DGN = DARK
GREEN
DGN
DGN
RED
RED
RED
RED
BLK
BLK
BLK
BLK
(PRINTED NOVEMBER 2002) BODIES NOT SHOWN
FOR DRAWING CLARITY
COMMUNICATION 9000-9999 PUR YEL = YELLOW
PNK = PINK
6120 A A 6120
V-0119 WHT = WHITE 2760 B B 2760

BRN = BROWN LEFT PANEL 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
FUEL SENDER TAN = TAN
20-270 ohm PUR = PURPLE
GRY = GRAY C428 C429
9340 D HEADLIGHTS
2910 G GROUND
FUSE 5 FUSE 1 FUSE 9 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
TRACTION HEAT ER UNSWITCHED 1210 E PROTECTED POWER
FRONT & 25A
A B MARKER
LIGHT POWER
TAILGATE/ 2650
2640
C442
FUSE 6
FUEL PULL
30A
FUSE 2
FR & MK LT
15A
LIGHT
FUSE 10
ATTCHMNT
25A
9210
9110
K
H
SYSTEM Rx
SYSTEM Tx
2630 2600 A B 9300 A CLOCK/LATCH
WORK LIGHTS 2620
2610 FUEL SENDER
FUSE 7 FUSE 3
REAR LT
15A GLOW FUEL TRACTION

FUSE 11
25A
ALT & KIT S
CONNECTS TO
9310
9330
B
J
DATA
START
ADVANCED HAND CONTROL MODULE
STARTER C407
HARNESS 6716419 HARNESS FUSE 8 FUSE 4 PLUG PULL PULL FUSE 12
ON THIS PAGE 9320 C BUZZER
3100
3110
6719422 COMPUTER ACC PLUGS
RIGHT
TAILLIGHT 2610 6320
25A 25A C407
A 9320
A B C + BUZZER B A K H J B C D E A G F
LEFT 2930 -
TAILLIGHT
2640 6330 C406 RIGHT PANEL C430 C431
6100 8 8 6100 B A
RIGHT
A B C
MAIN FRAME 9340 11 11
10
9340
J
K H J B C D E A G F
2240
1740
6200 9200 10 9200 9330 START
4580
9410
9400
4640
4720
4700
4710
4620
4600
4610
WORK 2620
6210 9
3100
3110
LIGHT
HARNESS 6727131 9100 9 9100 9310 B DATA
C408
2900 4 4 2900 9300 A CLOCK/LATCH
LEFT WORK 1900 2 2 1900 9120 H SYSTEM Tx
2630 6210
LIGHT 1 1
1200 1200 9220 K SYSTEM Rx
1730
C405
3710 B B SWITCH 3900 5 5 3900 1220 E PROTECTED POWER POWER FROM
7100
7 7 FUSE 12
3920 3920 2920 G GROUND
BACKUP THIS PAGE
ALARM 2650 3910 6 6 3910 9350 D KEY/ENTER SWITCH
4720
4700
4710
4620
4600
4610
TO
HYD FILTER 2740 3 3 2740 C OPEN
2600
7100
6200
6310
OPTIONS
(BACKUP HARNESS 6717247 2910
ALARM 2900 2920 C A B C A B
SWITCH) 2930
B F G D E C H A t R HANDLE L HANDLE
HYD TEMP SENDER
C404 3300 C C 3300
538-1824 ±30 ohm C
3900 C432 C433
C103
C102
3310 D D 3310 SEAT
B A 3920 B CONNECTS TO CONNECTS TO
A + BAR
3400 A A 3400 HYD CHARGE PRESS A C432 C433
B F G D E C H A C 3910 ON THIS PAGE ON THIS PAGE
3420 E E 3420 SENDER 0.5-7.5 V
F F 3410
B - MAIN
2000
9340
3900
2900
9350
3410
3920
9200
9100
3910
1900
1200
CAB
FRAME
7100
HYD OIL FILTER
ENGINE 3430 B B 3430 RIGHT HANDLE
2600
6600
6500
6400
7100
6200
6310
PRESSURE SWITCH
HARNESS 6719082
C432
A PNK/RED
D2
D1
D3
C3
C2
C1
B3
B2
B1
A1
A2
A3
E3
E2
F2
J2
F3
E1
F1
J4 AHC CONNECTOR TILT
C PNK/DGN
CONTROL
6310 N 3020 CONNECTS TO
D3 9410 C432 B PNKBLK
+
A
6200 S 3110 J1 J2 ON THIS PAGE
3500 3310 3010 C3 9400
SEATBAR SENSOR
SEATBAR SENSOR
SENSOR SIGNAL
SPARE DIGITIAL
FUEL SENDER SPARE ANALOG
ENG COOLANT SPARE ANALOG
ENG OIL PRESSURE C 7100 R
SEATBAR
R
GROUND
7100
SUPPLY
3520 3410 E1 4300 4300 B B WHT
3900
3910
3920
IN 1
IN 2
IN 1
A1
A2
A3
A1
A2
A3
SENDER 0.5-7.5 V - 6400 W
B 3510 3710
E3 4320 4320 D D WHT/RED
6500 P PWM
TEMP SENDER
J1 E2 4310 4310 C C WHT/BLK
HYD TEMP
C409
SENDER
SIGNAL
OPEN
OPEN
OPEN
6600 V
3100
3200
3300
B1
B2
B3
B1
B2
B3
ENGINE COOLANT t K3
3200 3010 F2 TWO
SENDER
HYD CHARGE
HYD CHARGE
PRESSURE +
DIGITAL IN 2
PRESSURE
A1 4910 F F SPEED
SIGNAL
4910 WHT/LGN
SPARE
OPEN
OPEN
OPEN
500-3000 ± 30 ohm
3400
3420
C1
C2
C3
J3 J4
C1
C2
C3
3210 3020 H 3430 E3
H 3020
3420 C2 G G
RH TWO SPEED
BATTERY IN (1)
BATTERY IN (2)
BATTERY IN (3)
LH AUX RIGHT
UNSWITCHE D
UNSWITCHE D
UNSWITCHE D
BRAKE SW
DETENT
1110
1120
1130
4910
4810
4500
WHITE
BLACK
C1 E E
A1
A2
A3
3400 B1 4920
A1
A2
A3
4920 DGN
IN
3610
J2
J1
SPEED SENSOR (VR)
3600 3300 B3 K2 K K
LH AUX LEFT
ENG SPEED +
BRAKE SW
RH FRONT
PRESSURE +
SYSTEM Rx
SYSTEM Tx
GROUND
GROUND
PRESSURE
DETENT
3700 E2 C1 4930 4930 J
ENG OIL
ENG OIL
J
OPEN
SIGNAL
4920
4820
1400
YEL
OPEN
2100
OUT
2110
9100
9200
(hall)
B1
B2
B3
3500
3520
B1
B2
B3
D1
D2
D3
D1
D2
D3
SKI
F 3100 B1 D1 4940 4940 H H LGN CONTROL
F
FUEL PULL RELAY
RH SKI DOWN
LH SKI DOWN
FILTER SIGNAL
HYD CHARGE
COMPUTER
HEADLIGHT
KEY/ENTER
EHC INPUT
FUEL HOLD
ENG SPEED
K A
FEEDBACK
SIGNAL (vr)
AIR FILTER
FUEL PULL
3500 B3 1400 1490 A RNG
SWITCH
SWITCH
POWER
GLOW PLUGS
SIGNAL
D1
4930
3500 3500
4830
9400
K
1900
9350
9340
8800
8110
8150
C1
C2
C3
3600
3700
3430
C1
C2
C3
E1
E2
E3
E1
E2
E3
0.4 ohm
C403
3520 L
L 3520 3520 D2
HR
STARTER RELAY
8560 3200 C
EHC OUTPUT
PROTECTED
SIGNAL (hall)
GLOW PLUG
ENG SPEED
BRAKE PULL
GROUNDS
LH SKI UP
GROUND
C B2 A3 D
RH SKI UP
3200 3200 4500 1450 FLOAT
POWER
PUR
SENSOR
4640 D
OPEN
RELAY
RELAY
OPEN
1200
2900
4940
4840
9410
3010
F1
F2
F3
8210
4110
8510
D1
D2
D3
F1
F2
F3
D1
D2
D3
3600 M SIGNAL
0.4 ohm M 3600 3600 E1 K1 BRAKE SWITCH J J
X A
X F3 1480 A
PWM SIGNAL
RNG
HR 8570
BRAKE PULL
GLOW PLUG
FEEDBACK
FEEDBACK
FEEDBACK
STARTER
PWM +
PWM -
B
4310
4320
2300
4300
8250
4150
8550
E1
E2
E3
E1
E2
E3
B 2300 C3 D2 4840 4840 C C WHT SKI
C410
0.4 ohm J 4830 B CONTROL
J A1 C2 4830 B DBL
HR 8580 8500 8500 G
WHITE
G
BLACK
W 6400 A3 B2 4820 4820 G PNK
J4
PADDLE
J3
0.4 ohm P 6500 F1 A2 4810 4810 F F TAN MOMENTARY
FRONT BASE
TRACTION HOLD SPOOL LOCK
FRONT ROD
REAR WKLT
V
MARKER LT
HR 8590 6600 D3 G2 4430 K K
4340
4330
4360
RELAY
RELAY
OPEN
F1
F2
F3
6210
6320
F1
F2
F3
T A2
T G1 4440 E E
U 8250 800 SERIES J1 4460 H H
REAR BASE
REAR ROD
RESERVED
RESERVED
RESERVED
(R TURN)
(L TURN)
(HORN)
4440
4430
4200
G1
G2
G3
G1
G2
G3
FUEL SHUT OFF G 8500 J2 4450
B BRN
D 8200 J3 4480
C433 C412 C411

TURN
RELAY OUTPUT
TWO SPEED
D
BICS LOCK
ATTACHMENT
POSITION
YEL
ACCESSORY
E
BUCKET
2800 8100 8100
KEY INPUT
CONTROL
TO OPTIONS SIGNAL
TRAVEL
S
4410
4420
4350
6200 H3 4350
H1
H2
H3
8000
9800
4730
H1
H2
H3
1800 A (ACCESSORY A DGN
RED TO BLK=
N 6310 F2 4330 CONNECTOR)
C
SPARE OUTPUT 1
SPARE OUTPUT 2
8200 D
REAR BLEED
HIGH FLOW
DIVERTER
3.2 ohm E 8100 F1 4340
RESERVED
(ATT ACC)
ALTERNATOR
4460
4450
4470
J1
J2
J3
U E
J1
J2
J3
8250
S A 1800 H1 4410
(SERIAL RIGHT)
TO OPTIONS
(SERIAL LEFT)
F3 A BLK
1020
G EXC
CAN SHIELD
FUTURE
FUTURE
CAN HIGH
CAN LOW
OPEN
(ACCESSORY
K1
K2
K3
9500
9600
9700
1010 1800 K1
B HORN
K2
K3
H2 4420 CONNECTOR) RED
BAT
G3 4200
STARTER 2600 A RED/WHT
AHC CONNECTOR
LIFT
M 2300
G3
G1
G2
H3
C1
H1
C3
C2
D1
B3
D3
B1
B2
D2
K1
K2
K3
H2
A1
A2
A3
E1
F3
F2
E3
E2
F1
J1
J2
J3
S CONNECTS TO TO TOPTIONS J3 CONNECTS TO C PUR/WHT
CONTROL
1010 8200 2800 C407 C433
(ACCESSORY
ON THIS PAGE
B BLK/WHT
ON THIS PAGE CONNECTOR)
R
8250
C407 C427 120 ohm
4110
4730
8250
8000
8150
8110
6320
6210
8210
2100
8550
8510
2110
4150
4390
1110
1120
1130
9500
9600
9700
9800
LEFT HANDLE
A E F H G C B A D
ACD & REMOTE START
2090
2090
CONNECTOR REAR ROD
LOCATED AT REAR OF
6400
6500
6600
6300
4730
MACHINE 4430 A A
C413
7.5 ohm nominal
6000
BROWN TIE STRAP 2430 B B at 12 VDC

GROUNDS
2480
D C B A G F E REAR BASE
2460 C426 4440 A A
C414
(ACCESSORY (ACCESSORY 7.5 ohm nominal
2360
2450 CONNECTOR) CONNECTOR) WHITE TIE STRAP 2440 B B at 12 VDC

D C B A G F E
2440 2400 C401 C402 HIGH FLOW
2430 4460 A A
C415
B A D C B A B A 7.5 ohm nominal
9800
9700
9600
9500
2710
1160
1710
2340 BLUE TIE STRAP 2460 B B at 12 VDC
C458
2330 DIVERTER
2730
1140
1700
1150
2100 B A
2720
1720
4450 A A
C416
7.5 ohm nominal
2420 YELLOW TIE STRAP 2450 B B at 12 VDC
2410 REAR AUX RELIEF
9.8 ohm nominal
C417
2360 4480 A A at 12 VDC
2350 2390 GREEN TIE STRAP 2480 B B
HYDRAULIC
2240 TWO SPEED
MAKE-UP
5.5 ohm nominal
C441
2200 4350 A A
at 12 VDC
2000 2350 B B
FRONT ROD
2300 1800
FUSE 11 4330 A A
C419 C418
25A
2330 B B at 10 VDC
1700 1055
6310
6000
6300
2730
6320
8000
8500
8550
8510
4110
4150
4100
2120
2720 FUSE 12 FRONT BASE
GOES TO
8100
8150
8110
6200
6210
8200
8210
AHC POWER 25A
1140
2710 ADVANCED HAND
1730
2110 CONTROL MODULE
1150
1160
SWITCHED TRACTION at 10 VDC

THIS PAGE FUSE 10 MARKER GLOW LOCK
2340 B B
POWER FUEL PULL REAR STARTER
ATTACHMENT 25A LIGHT PLUG HYD LOCK VALVE
87A 87 86 87A 87 86 87A 87 86 LIGHT 87A 87 86
1710 87A 87 86 87A 87 86 86 87 87A
1130
1110
1120
C420
HEATER at 12 VDC
30 85 30 85 30 85 30 85 30 85 30 85 85 30 UNSW 2410 B B
25A
POWER
BUCKET POSITION
2020
2030
FUSE 1
1330
1050
2000
2010
1350
2040
2050
1320
2010
2020
1030
2060
1060
2030
2040
2050
2060
1360
25A
RELAY GROUNDS 2000-2060
C423
FUSE 9 4420 A A 6.7 ohm nominal
ARE CONNECTED IN SERIES at 12 VDC
2420 B B
30A 15A 15A
1070

1050
FUSE 5 FUSE 4
- 1300 TWO SPEED BRAKE LOCK
+ 1030 WHT TO BLK =
100A 4200 A A HOLD A
C425
C425
0.26 ohm
1010 1060
1310 10.9 ohm
4100 B B PULL C
1040
Printed in U.S.A. V-0119 (10-4-02)
549 of 970
* NOTE: THESE ARE NOT
FOUND ON ALL
LEFT RIGHT LEFT PANEL REAR ROD
C413
FRONT
WORKLIGHTS
4430 A A 7.5 ohm
MACHINES. 2910 G GROUND
863 WIRING SCHEMATIC B A
C434 C435
A B
9340
1210
D
E
HEADLIGHTS
PROTECTED POWER
BROWN TIE STRAP 2430 B
REAR BASE
B 12V
* LIFT ARM 1910 F COMPUTER POWER
C414
(WITHOUT ACS OPTION) RELEASE
SWITCH
B A A B
9110 H SYSTEM Tx
WHITE TIE STRAP
4440
2440
A
B
A
B
7.5 ohm
12V
2750
6110
6120
2760
WIRES CONNECT BY LETTER H H * 4030
9210
9300
K
A
SYSTEM Rx
CLOCK/LATCH
TILT SPOOL LOCK
(NOT Used With AHC or ACS)
S/N 514446001 - 514450763 ACROSS CONNECTORS SEE FUSE/RELAY

*
C421
C407
CENTER J J 1340 A A 4370 DIVERTER
9310 B DATA
C416
A B 7.7 ohm
(EUROPEAN A 6100 A A 6100 PWM B B 2370 4450 A A 7.5 ohm
S/N 514541001 - 514541103 B A LIGHTING)
THIS PAGE M M 2900
9330
9320
J
C
START
BUZZER LIFT SPOOL LOCK
YELLOW TIE STRAP 2450 B B 12V
RED = RED
S/N 514641001 - 514641254 RNG = ORANGE SOME CONNECTOR C C 9340 (NOT Used With AHC or ACS)
C422
BLK = BLACK BODIES NOT SHOWN D D 9200 7.7 ohm A A 4380
9320
(PRINTED NOVEMBER 2002) LBL = LIGHT BLUE FOR DRAWING CLARITY
SEE ACS E E 9100 +
- BUZZER PWM B B 2380
C408
DBL = DARK BLUE SEE CONTROL 2930
LGN = LIGHT GREEN CONNECTOR E B 4500 F F 4500 1930 RIGHT PANEL
V-0120 DGN = DARK GREEN THIS PAGE
MODULE J4
THIS PAGE 2740 S S 2740 2770
BRAKE
SWITCH
YEL = YELLOW 9330 J START
PNK = PINK P P 1900 HYD. LOCK VALVE REAR AUX RELIEF
BATTERY FEED 1000-1999 RED, RED/WHT, RNG 9310 B DATA
C417
WHT = WHITE
C420
R 1200 A A 4410 4480 A A
Printable Version Click Here BRN = BROWN
TAN = TAN
PUR = PURPLE
R
B B 9350
9300
9220
A
K
CLOCK/LATCH
SYSTEM Rx
9.8 ohm
12V B B 2410
GREEN TIE STRAP
2480 B B
9.8 ohm
12V
C
GRY = GRAY ATTACHMENT CONTROLS 5000-5999 YEL SEE ACS L L 3900
LIGHTS 6000-6999 PNK B SEAT BAR 9120 H SYSTEM Tx
2530 GROUNDS ACCESSORIES 7000-7999 WHT CONNECTOR D G G 3920
SENSOR
FRONT ROD HIGH FLOW / 900 LOAD SENSE
1920 F COMPUTER POWER
C418
C415
ENGINE 8000-8999 TAN THIS PAGE K K 3910 A A A 4330 4460 A A
2480 3.3 ohm 7.5 ohm
COMMUNICATION 9000-9999 PUR 1220 E PROTECTED POWER PWM 12V
2460 N N B B 2330 BLUE TIE STRAP 2460 B B
2910 9350 D RUN/ENTER SWITCH
9110
9210
2900
9340
9200
9100
1900
1200
9350
3900
3920
3910
2900 2920
2450 2930 MAIN 2920 G GROUND
2440 2400 2770 CAB 2000 FRONT BASE
FRAME C OPEN
FUEL SENDER 2750 2740
C419
2430 2760 3.3 ohm A A 4340
HARNESS - 6719422
2340 CAB HARNESS - 6727178 PWM
B B 2340
B3
B2
C3
B1
D2
D1
D3
C2
C1
E3
E1
E2
A1
A2
A3
F3
F2
F1
TWO SPEED
2330
C441
C406
2520 C C 4350 A A 5.5 ohm
J2 WHITE
C442
12V
2100 FUEL SENDER A A 3100 A A 3100 3100 B1 PROTECTED COMPUTER
SYSTEM Tx OPEN OPEN
SEATBAR SENSOR F1 4340 2350 B B
POWER POWER SUPPLY
30-270 ohm
2490 B B 3110 B B 3110 F1 F1 E1 D1 C1 B1 A1 F2 4330
CONTROL
900 FLOW
F3 1200 1900 9100 3900 H1 4410 BUCKET POSITION
K3
K2
K1
2420 OPEN
KEY/ENTER
SYSTEM R x OPEN OPEN
SEATBAR
C423
SWITCH SENSOR SIGNAL
2410 J2
K3 4420 A A 6.7 ohm
900 LOAD SENSE
F2 E2 D2 C2 B2 A2 12V
C405
WHITE
HIGH FLOW /
A 3700 E2
REAR AUX
DIVERTER
A 3700 K2 2420 B B
RELIEF
4460
2380
4470
2390 AIR FILTER 9350 9200 3920
4450
J3
J2
J1
HEADLIGHT SEATBAR SENSOR
GROUND OPEN OPEN OPEN
SWITCH B B 3710 3010 F2 SWITCH GROUND
F3 4360
2370
F3 E3 D3 C3 B3 A3
D3 G2 4430
TWO SPEED
SOLENOID
HYD LOCK
POSITION
2200
BUCKET
2900 9340 3910
4350
4420
4410
H3
H2
H1
2000
G1 4440
t J2 4450
TRACTION HOLD
2240
REAR BASE
REAR ROD
HYD TEMP SENDER C
4200
4430
4440
3300 C 3300 B3 J3
G3
G2
G1
RESERVED
4480
GROUNDS
DIGITAL 2
SENSOR
3010
SPARE
500-3000 ohm
(hall)
F3
F2
F1
D D
2800 +A
3310 3310
CONTROL MODULE J1 4460
C102
SPOOL LOCK
FRONT BASE
FRONT ROD
3400 A A 3400 C1 H3
FILTER SIGNAL
4350
HYD CHARGE
HYD CHARGE PRESS
J4 WHITE
4360
ENG SPEED
4330
4340
AIR FILTER
F3
F2
F1
3610
3700
SIGNAL
3600
SIGNAL
C
3430
E3
E2
E1
2300 SENDER 0.5-7.5 V 3420 E E 3420 C2 H2 4420
3510 - B 3410 F F 3410 D2 4840
PRESS SIGNAL
PRESSURE +
2600
WHITE
HYD OIL FILTER
ENG OIL
ENG OIL
B
J4
3430 B
3520
3430 E3
OPEN
3500
C2 4830
D3
D2
D1
BLACK
PRESSURE SWITCH
2110 SEE LEFT B2 4820
PWM SIGNAL
HYDRAULIC FILTER HARNESS - 6717247 HANDLE
PWM +
PWM -
4300
C A3
4310
4320
4640 A2 4810
E3
E2
E1
BLACK
CONNECTOR
J1
2740
THIS PAGE B3 1400
2730 SEE CAB CONNECTOR
EHC OUTPUT
PRESS SIGNAL
RH SKI UP
HYD CHARGE ENG COOLANT
HYD CHARGE
PRESSURE +
LH SKI UP
2120 A3 4500 B
RESERVED
(AC INPUT)
9410
4840
4940
3420
3400
D3
D2
D1
2720 THIS PAGE
C3
C2
C1
+ SEE
D1
J1
A 4940
2710 ENGINE OIL A A 3500 3500 D1
C107
CONTROL
C1
RH SKI DOWN
PRESSURE C 4930
LH SKI DOWN
FUEL SENDER
EHC INPUT
D2
HYDRAULIC
2350 C C 3520 3520 SPARE ACCESSORY STARTER UNSWITCHED
MODULE
9400
3300
SIGNAL
4830
4930
3100
3200
C3
C2
C1
SENDER - CAN HIGH OPEN OPEN STARTER REL AY FUEL HOLD
TEMP
TEMP
B3
B2
B1
OUTPUT 2 RELAY OUTPU T FEEDBACK OPEN BATTERY IN (1 )
0.5-7.5 V
B 3510
B1 4920 J1 THIS
B B K1 J1 H1 G1 F1 E1 D1 C1 B1 A1
8800
A1 4910 PAGE
LH AUX LEFT
9500 8000 8250 8210 1110
BRAKE SW
RH FRONT
ANALOG 2
ANALOG 1
DETENT
HANDLE
4640
ATTACHMEN T BRAKE PULL
SPARE
SPARE
REAR WKL T BRAKE PULL UNSWITCHED
FLOAT
1400
4820
4920
OUT
C106
E2
B3
B2
B1
CAN LOW OPEN FUEL PULL RELAY GROUND
4310
A3
A2
A1
KEY INPU T RELAY FEEDBACK RELAY BATTERY IN (2 )
SPEED A A 3600 3600 E1 C
J3
SENSOR K2 J2 H2 G2 F2 BLACK E2 D2 C2 B2 A2 E3 4320
B B 3610
RH TWO SPEED
LH AUX RIGHT
9600 9800 6210 4150 4110 8110 2110 1120
BRAKE SW
E1 4300
4500
4810
4910
TWO SPEED TRAVEL MARKER L T GLOW PLU G GLOW PLU G FUEL PULL UNSWITCHED
A3
A2
A1
C3
IN
CAN SELECT OPEN GROUND
MAKE-U P CONTROL RELAY FEEDBACK RELAY FEEDBACK BATTERY IN (3 )
ENGINE t 9700
K3 J3 H3
4730
G3 F3
6320
E3
8550
D3
8510
C3
8150
B3
2100
A3
1130 Dealer Copy -- Not for Resale K1
C3 9400
C104
4220
COOLANT A A 3200 3200 B2 D3 9410
SENDER
J3 BLACK
2520
4240
4810
4820
4830
4840
4640
1480
4300
4320
4310
4230
4910
4920
2530
4940
1490
4930
500-3000 ohm B B 3210 G3 4200
H3
G1
G3
G2
H1
D3
D1
C1
C3
C2
B2
B3
D2
H2
K1
K2
K3
B1
A3
A2
A1
F3
F2
E3
E1
E2
F1
J1
J2
J3
B D C G F E K J H A E H J A F G B C K D
ALTERNATOR SUPPLY
1020 C409 C410
C110
G B B E H J A F G B C K D
4730
4110
8000
6320
6210
8550
8510
8250
8210
8150
8110
2110
2100
4150
1130
1120
1110
9800
9500
9600
9700
6510
6410
7200
4390
B D C G F E K J H A
2360
B A A 1800
4 4
WHT/LGN
WHT/RED
YEL/RED
YEL/LGN
WHT/BLK
C101
3 3
DBL
2015 A B
DGN
WHT
RNG
YEL
RNG
LGN
WHT
1015
1 1 2800
STARTER 3.2 ohm
12V 2 2 8100
C458
M R
8250
FUEL SHUTOFF A B TWO-SPEED
MAKE-UP
B PWM
S 5 ohm
8200 TWO
12V SKI
SPD SIDE SKI
CTRL SHIFT CTRL
GLOW PLUGS DETENT
TAILGATE / WORKLIGHTS 6716419 1.0 ohms Each FLOW
LEFT HANDLE
F F RIGHT HANDLE
2600 B B 2600 HR HR HR HR
RIGHT TURN SIGNAL HORN
2620 6200 6200 H H 6200
WORKLIGHT
C103
6210 6310 A A 6310
8590
8580
8570
8560
9410
9400
LEFT
2630 6210 E E 6400
WORKLIGHT
D D 6500
RIGHT SEE CAB
2610 6320 G 6600
RNG/WHT
G B A
RNG/DBL
TAILLIGHT CONNECTOR
C404
BRN
DGN
YEL
BACKUP 7100 C C 7100 A TO OPTIONS
LEFT
2640 6330 ALARM B (BACKUP
THIS PAGE
C473
TAILLIGHT
2650 ALARM SWITCH) C407 B A
A
J 2730 ACS E B A D D B A
9420
2650
9420
P 6600 JUMPER
2640
C411 C412
6000
2630 2600 M 6500
2620 L 6400 (ACCESSORY (ACCESSORY
F 4730 CONNECTOR) CONNECTOR)
2610
D 4235
R
C488
C 4275 SINGLE SPEED TRACTION LOCK
E 4550 TWO SPEED BRAKE LOCK
N 6300 WHT TO BLK =
A
C425
4200 A HOLD A
C425
S 1700 0.26 ohm
A 1140 10.9 ohm
4100 B B PULL C
H 1150
B
G
K (ALTERNATOR TO OPTIONS
1800 & KITS) (ACS
TO OPTIONS CONNECTOR)
FUSE 11
(ACCESSORY CONNECTOR)
25A
8000
6300
6000
6310
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
1700 1055 J
P
C489
B 2720 MARKER REAR GLOW N

SWITCHED FUEL TRACTION
LIGHT LIGHT PLUG STARTER PULL 4220 M
(COMPUTER)
A 1720 1720 POWER LOCK
FUSE 4
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A 4275 L
25A
TO OPTIONS (ATTACHMENT)
FUSE 10 4550 K
(ACCESSORY 30 85 30 85 30 85 30 85 30 85 30 85 85 30
CONNECTOR) 25A 9720 E
1710
1050
2000
2010
1330
2020
2030
1320
2010
2020
1060
2030
2040
2060
1350
2040
2050
2050
2060
1360
1030
9620 D
C492
SEE CONTROL R
(HEATER) 120
FUSE 2 MODULE J2
FUSE 1 FUSE 3 FUSE 6 FUSE 5 OHM E 9210 G
25A 15A 15A 30A 30A THIS PAGE
RESISTOR S
MAINFRAME HARNESS 6729057 or 6730297 1140
9520 C
1150 1160 SEE CONTROL 2240 H
MODULE J2
1070 D 9110 F
RELAY GROUNDS 2000-2060 THIS PAGE
FUSE 9 FUSE 12 1740 B
ARE CONNECTED IN SERIES 25A 25A
FUSE / RELAY CENTER (UNSWITCHED
POWER) (ACS)
1170 A
FUSE 5 FUSE 1 FUSE 9

TRACTION HEATER UNSWITCHED
FRONT &
30A 25A REAR SWITCH 25A
MARKER
LIGHT POWER
1080
FUSE 6 FUSE 2 LIGHT FUSE 10
1040
FUEL PULL FR & MK LT ATTCHM NT
30A 15A 25A

REAR LT ALT & KITS
1160
1730
9800
9510
9610
9710
2710
15A GLOW FUEL TRACTION 25A
STARTER
FUSE 8 FUSE 4 PLUG PULL PULL FUSE 12
COMPUTER ACS 1050
25A 25A - + 1300
1060
F E D A B C G
TO OPTIONS
100A
1010 1030
C426 (ATTACHMENT
ACD & REMOTE CONTROL)
550 of 970 1310
1040
START CONNECTOR
V-0120 (10-4-02)
Printed in U.S.A. 1080
BATTERY
* NOTE: THESE ARE NOT
FOUND ON ALL
LEFT RIGHT LEFT PANEL REAR ROD
C413
FRONT
WORKLIGHTS
4430 A A 7.5 ohm
MACHINES. 2910 G GROUND 12V
BROWN TIE STRAP 2430 B B
9340 D HEADLIGHTS
863 WIRING SCHEMATIC * LIFT ARM
B A
C434 C435
A B 1210
1910
E
F
PROTECTED POWER
COMPUTER POWER
REAR BASE
C414
RELEASE B A A B 4440 A A 7.5 ohm
SWITCH
9110 H SYSTEM Tx 12V
WHITE TIE STRAP 2440 B B
WITH ACS OPTION
2750
6110
6120
2760
WIRES CONNECT BY LETTER H H * 4030
9210
9300
K
A
SYSTEM Rx
CLOCK/LATCH
TILT SPOOL LOCK
(NOT Used With AHC or ACS)
ACROSS CONNECTORS SEE FUSE/RELAY
*
C421
C407
CENTER J J 1340 A A 4370 DIVERTER
9310 B DATA
C416
A B 7.7 ohm
(EUROPEAN A 6100 A A 6100 B B 2370 4450 A A
S/N 514446001 - 514450763 B A LIGHTING)
M M 2900
9330 J START
PWM
YELLOW TIE STRAP 2450 B B
7.5 ohm
12V
THIS PAGE 9320 C BUZZER LIFT SPOOL LOCK
S/N 514541001 - 514541103 RED = RED
RNG = ORANGE
SOME CONNECTOR C C 9340 (NOT Used With AHC or ACS)
C422
BODIES NOT SHOWN D D 9200 A A 4380
S/N 514641001 - 514641254 BLK = BLACK
LBL = LIGHT BLUE FOR DRAWING CLARITY E E 9100
9320 + BUZZER
7.7 ohm
PWM B B 2380
SEE ACS -
C408
DBL = DARK BLUE SEE CONTROL 2930
(PRINTED NOVEMBER 2002) LGN = LIGHT GREEN CONNECTOR
THIS PAGE
E MODULE J4
B 4500
2740
F
S
F
S
4500
2740 2770
1930
BRAKE
RIGHT PANEL
DGN = DARK GREEN THIS PAGE SWITCH
V-0216 YEL = YELLOW
PNK = PINK BATTERY FEED 1000-1999 RED, RED/WHT, RNG
P P 1900
9330
9310
J
B
START
DATA
HYD. LOCK VALVE REAR AUX RELIEF
C417
C420
WHT = WHITE R R 1200 A A 4410 4480 A A
Printable Version Click Here BRN = BROWN
TAN = TAN
B B 9350
C
9300
9220
A
K
CLOCK/LATCH
SYSTEM Rx
9.8 ohm
12V B B 2410
GREEN TIE STRAP
2480 B B
9.8 ohm
12V
PUR = PURPLE ATTACHMENT CONTROLS 5000-5999 YEL SEE ACS L L 3900

GRY = GRAY LIGHTS 6000-6999 PNK B SEAT BAR 9120 H SYSTEM Tx
2530 GROUNDS ACCESSORIES 7000-7999 WHT CONNECTOR D G G 3920
SENSOR
FRONT ROD HIGH FLOW / 900 LOAD SENSE
1920 F COMPUTER POWER
C418
C415
ENGINE 8000-8999 TAN THIS PAGE K K 3910 A A A 4330 4460 A A
2480 3.3 ohm 7.5 ohm
COMMUNICATION 9000-9999 PUR 1220 E PROTECTED POWER PWM 12V
2460 N N B B 2330 BLUE TIE STRAP 2460 B B
2910 9350 D RUN/ENTER SWITCH
9110
9210
2900
9340
9200
9100
1900
1200
9350
3900
3920
3910
2900 2920
2450 2930 MAIN 2920 G GROUND
2440 2400 2770 CAB 2000 FRONT BASE
FRAME C OPEN
FUEL SENDER 2750 2740
C419
2430 2760 3.3 ohm A A 4340
HARNESS - 6719422
2340 CAB HARNESS - 6727178 PWM
B B 2340
B3
B2
C3
B1
D2
D1
D3
C2
C1
E3
E1
E2
A1
A2
A3
F3
F2
F1
TWO SPEED
2330
C441
C406
2520 C C 4350 A A 5.5 ohm
J2 WHITE
C442
12V
2100 FUEL SENDER A A 3100 A A 3100 3100 B1 PROTECTED COMPUTER
SYSTEM Tx OPEN OPEN
SEATBAR SENSOR F1 4340 2350 B B
POWER POWER SUPPLY
30-270 ohm
2490 B B 3110 B B 3110 F1 F1 E1 D1 C1 B1 A1 F2 4330
CONTROL
900 FLOW
F3 1200 1900 9100 3900 H1 4410 BUCKET POSITION
K3
K2
K1
2420 OPEN
KEY/ENTER
SYSTEM R x OPEN OPEN
SEATBAR
C423
SWITCH SENSOR SIGNAL
2410 J2
K3 4420 A A 6.7 ohm
900 LOAD SENSE
F2 E2 D2 C2 B2 A2 12V
C405
WHITE
HIGH FLOW /
A 3700 E2
REAR AUX
DIVERTER
A 3700 K2 2420 B B
RELIEF
4460
2380
4470
2390 AIR FILTER 9350 9200 3920
4450
J3
J2
J1
HEADLIGHT SEATBAR SENSOR
GROUND OPEN OPEN OPEN
SWITCH B B 3710 3010 F2 SWITCH GROUND
F3 4360
2370
F3 E3 D3 C3 B3 A3
D3 G2 4430
TWO SPEED
SOLENOID
HYD LOCK
POSITION
2200
BUCKET
2900 9340 3910
4350
4420
4410
H3
H2
H1
2000
G1 4440
t J2 4450
TRACTION HOLD
2240
REAR BASE
REAR ROD
HYD TEMP SENDER C
4200
4430
4440
3300 C 3300 B3 J3
G3
G2
G1
RESERVED
4480
GROUNDS
DIGITAL 2
SENSOR
3010
SPARE
500-3000 ohm
(hall)
F3
F2
F1
D D
2800 +A
3310 3310
CONTROL MODULE J1 4460
C102
SPOOL LOCK
FRONT BASE
FRONT ROD
3400 A A 3400 C1 H3
FILTER SIGNAL
4350
HYD CHARGE
HYD CHARGE PRESS
J4 WHITE
4360
ENG SPEED
4330
4340
AIR FILTER
F3
F2
F1
3610
3700
SIGNAL
3600
SIGNAL
C
3430
E3
E2
E1
2300 SENDER 0.5-7.5 V 3420 E E 3420 C2 H2 4420
3510 - B 3410 F F 3410 D2 4840
PRESS SIGNAL
PRESSURE +
2600
WHITE
HYD OIL FILTER
ENG OIL
ENG OIL
B
J4
3430 B
3520
3430 E3
OPEN
3500
C2 4830
D3
D2
D1
BLACK
PRESSURE SWITCH
2110 SEE LEFT B2 4820
PWM SIGNAL
HYDRAULIC FILTER HARNESS - 6717247 HANDLE
PWM +
PWM -
4300
C A3
4310
4320
4640 A2 4810
E3
E2
E1
BLACK
CONNECTOR
J1
2740
THIS PAGE B3 1400
2730 SEE CAB CONNECTOR
EHC OUTPUT
PRESS SIGNAL
RH SKI UP
HYD CHARGE ENG COOLANT
HYD CHARGE
PRESSURE +
LH SKI UP
2120 A3 4500 B
RESERVED
(AC INPUT)
9410
4840
4940
3420
3400
D3
D2
D1
2720 THIS PAGE
C3
C2
C1
+ SEE
D1
J1
A 4940
2710 ENGINE OIL A A 3500 3500 D1
C107
CONTROL
C1
RH SKI DOWN
PRESSURE C 4930
LH SKI DOWN
FUEL SENDER
EHC INPUT
D2
HYDRAULIC
2350 C C 3520 3520 SPARE ACCESSORY STARTER UNSWITCHED
MODULE
9400
3300
SIGNAL
4830
4930
3100
3200
C3
C2
C1
SENDER - CAN HIGH OPEN OPEN STARTER REL AY FUEL HOLD
TEMP
TEMP
B3
B2
B1
OUTPUT 2 RELAY OUTPU T FEEDBACK OPEN BATTERY IN (1 )
0.5-7.5 V
B 3510
B1 4920 J1 THIS
B B K1 J1 H1 G1 F1 E1 D1 C1 B1 A1
8800
A1 4910 PAGE
LH AUX LEFT
9500 8000 8250 8210 1110
BRAKE SW
RH FRONT
ANALOG 2
ANALOG 1
DETENT
HANDLE
4640
ATTACHMEN T BRAKE PULL
SPARE
SPARE
REAR WKL T BRAKE PULL UNSWITCHED
FLOAT
1400
4820
4920
OUT
C106
E2
B3
B2
B1
CAN LOW OPEN FUEL PULL RELAY GROUND
4310
A3
A2
A1
KEY INPU T RELAY FEEDBACK RELAY BATTERY IN (2 )
SPEED A A 3600 3600 E1 C
J3
SENSOR K2 J2 H2 G2 F2 BLACK E2 D2 C2 B2 A2 E3 4320
B B 3610
RH TWO SPEED
LH AUX RIGHT
9600 9800 6210 4150 4110 8110 2110 1120
BRAKE SW
E1 4300
4500
4810
4910
TWO SPEED TRAVEL MARKER L T GLOW PLU G GLOW PLU G FUEL PULL UNSWITCHED
A3
A2
A1
C3
IN
CAN SELECT OPEN GROUND
MAKE-U P CONTROL RELAY FEEDBACK RELAY FEEDBACK BATTERY IN (3 )
K3 J3 H3 G3 F3 E3 D3 C3 B3 A3
K1
ENGINE t 9700 4730 6320 8550 8510 8150 2100 1130 C3 9400
C104
4220
COOLANT A A 3200 3200 B2 D3 9410
SENDER
J3 BLACK
2520
4240
4810
4820
4830
4840
4640
1480
4300
4320
4310
4230
4910
4920
2530
4940
1490
4930
500-3000 ohm B B 3210 G3 4200
H3
G1
G3
G2
H1
D3
D1
C1
C3
C2
B2
B3
D2
H2
K1
K2
K3
B1
A3
A2
A1
F3
F2
E3
E1
E2
F1
J1
J2
J3
9410
9400
B D C G F E K J H A E H J A F G B C K D
ALTERNATOR SUPPLY
1020 C409 C410
C110
G B B B A B D C F E J H A G K E H J A F G B C K D
4730
4110
8000
6320
6210
8550
8510
8250
8210
8150
8110
2110
2100
4150
1130
1120
1110
9800
9500
9600
9700
6510
6410
7200
4390
2360
B A A 1800
C473
WHT/LGN
4 4
RNG/BLK
RNG/BLK
WHT/RED
WHT/BLK
YEL/RED
YEL/RED
C101
3 3 B A
TAN
PNK
DBL
2015 A B
DGN
RNG
YEL
LGN
WHT
WHT
PUR
RNG
1015
1 1 2800
STARTER 3.2 ohm
C458
9420
9420
12V 2 2 8100
M R
8250
FUEL SHUTOFF A B TWO-SPEED
MAKE-UP
1 3 2 2 1 3
B
S PWM C466 C465
8200 5 ohm ACS RIGHT
SKI 1 3 2 2 1 3
12V JUMPER ROCKER SIDE SKI FLOAT
GLOW PLUGS UP DETENTCTRL SHIFT CTRL
FLOW
TAILGATE / WORKLIGHTS 6716419 1.0 ohms Each
HANDLE
RIGHT HANDLE LOCK
HANDLE
F F LOCK LEFT HANDLE
2600 B B 2600 HR HR HR HR SINGLE SPEED TRACTION LOCK AHC TILT AHC LIFT TURN HORN
RIGHT HALL HALL
2620 6200 6200 H H 6200 SIGNAL
WORKLIGHT
C103
SENSOR SENSOR
6210 6310 A A 6310
8590
8580
8570
8560
LEFT WHT TO BLK =
A A
C425
2630 6210 6400 4200 HOLD
WORKLIGHT E E 0.26 ohm
RED/WHT
PUR/WHT
BLK/WHT
RED/WHT
PUR/WHT
C
BLK/WHT
6500 2200 C RED TO BLK=
D D
RIGHT 10.9 ohm
2610 6320 G G 6600 SEE CAB 4100 B B PULL
TAILLIGHT CONNECTOR
C404
DGN
BRN
YEL
BACKUP 7100 C C 7100 A TO OPTIONS THIS PAGE
RED
BLK
LEFT ALARM B (BACKUP
2640 6330
TAILLIGHT
2650 ALARM SWITCH) C407 1 3 2 1 3 2
TWO SPEED BRAKE LOCK
C450 C449
A A
C425
J 2730 1 3 2 1 3 2 E B A D D B A
2650 B 9.8 ohm
2640 P 6600
C A C B A C B C411 C412
6000
2630 2600 M 6500
L 6400 C469 C472 TO OPTIONS TO OPTIONS
2620
A C B A C B (ACCESSORY (ACCESSORY
2610 F 4730
CONNECTOR) CONNECTOR)
D 4235 13 ohm
13 ohm
1510
4650
2650
1610
4750
2750
R at 12V at 12V
FOOT PEDAL FOOT PEDAL
C488
C 4275 LOCK - LIFT LOCK - TILT

E 4550
N 6300 TILT ACTUATOR LIFT ACTUATOR
S 1700
M M
A 1140
C467 C468
H 1150
1 3 2 1 3 2
B
G
4270
2500
4280
2510
K
DGN
DGN
(ALTERNATOR TO OPTIONS
RED
RED
RED
RED
BLK
BLK
BLK
BLK
1800 & KITS) (ACS
TO OPTIONS CONNECTOR)
FUSE 11
(ACCESSORY CONNECTOR)
25A 4220
8000
6300
6000
6310
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
1700 1055 J M 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
P L 4275
C428 C429
C489
GLOW N A 1170
B 2720 SWITCHED MARKER REAR FUEL TRACTION
LIGHT LIGHT PLUG STARTER PULL 4220 M N 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
(COMPUTER)
A 1720 1720 POWER LOCK
FUSE 4
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A 4275 L K
25A
TO OPTIONS (ATTACHMENT)
K E
4790
4780
1630
4770
2770
4690
4680
1530
4670
2670
FUSE 10 4550
(ACCESSORY 30 85 30 85 30 85 30 85 30 85 30 85 85 30
CONNECTOR) 25A 9720 E D
1710
C492
1050
2000
2010
1330
2020
2030
1320
2010
2020
1060
2030
2040
2060
1350
2040
2050
2050
2060
1360
1030
9620 D R
C492
SEE CONTROL R S
(HEATER) 120
FUSE 2 MODULE J2
FUSE 1 FUSE 3 FUSE 6 FUSE 5 OHM E 9210 G J
25A 15A 15A 30A 30A THIS PAGE
RESISTOR S C
MAINFRAME HARNESS 6729057 or 6730297 1140
2260
2270
4260
4220
4780
4690
4680
1190
4790
1180
9520 C G
1150 1160 SEE CONTROL 2240 H H
MODULE J2
1070 D 9110 F B C B G E J K A H D F
RELAY GROUNDS 2000-2060 THIS PAGE
FUSE 9 FUSE 12 1740 B F
FUSE / RELAY CENTER
ARE CONNECTED IN SERIES 25A 25A 4550 C GRAY
(UNSWITCHED 1170 A P
POWER) (ACS) 9720 F J3
9620 E
UNSWITCHED
9520 D
TRACTION HEATER
FRONT & J1
30A 25A REAR SWITCH 25A 2250 G ADVANCED HYDRAULIC CONTROL MODULE
MARKER
LIGHT POWER
1080
FUSE 6 FUSE 2 LIGHT FUSE 10 2240 2280 H
1040
1740 B
30A 15A 25A J2
1500 A
FUSE 7 FUSE 3
REAR LT
FUSE 11
ALT & KITS
ACS HARNESS - BLACK
1160
1730
9800
9510
9610
9710
2710
15A GLOW FUEL TRACTION
STARTER
25A 6726925 OR A G B K C J D F H E
FUSE 8 FUSE 4 PLUG PULL PULL FUSE 12
COMPUTER ACS 1050 6733292 (6726925 Shown,
25A 25A - + 1300
1060
F E D A B C G
TO OPTIONS
See Schematic - S/N & Above
for 6733292)
100A
1010 1030
C426 (ATTACHMENT
2760
2660
CONTROL)
4760
1620
4660
1520
ACD & REMOTE TILT LIFT
1310 START CONNECTOR PEDAL PEDAL
1040
2 2 1 1
C470
C471
Printed in U.S.A. 1080
3 3 3 3
BATTERY V-0216 (10-4-02) 1 1 2 2
551 of 970
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH
COMPUTER POWER
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
REAR ROD (NOT Used With AHC or ACS)
CLOCK/LATCH A
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm A A 4430 4370 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
SYSTEM Tx H
12V
GROUND
B B 2430 2370 2
GROUND
BROWN TIE STRAP
BUZZER
BUZZER
START
START
OPEN
DATA
DATA
6733137 REAR BASE
C414
HIGH FLOW
WIRING SCHEMATIC A A 4440 BICS HYDRAULIC LOCK
G
C
D
E
B
A
K
E
F
F
J
J
7.5 ohm
C415
12V
C420
7.5 ohm A A 4460 A A 4460 B B 2440 WHITE TIE STRAP 4410 A A 9.8 ohm
12V B B 2460 B B 2460 BLUE TIE STRAP 2410 B B 12V
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
(Without ACS Option)
BUCKET POSITIONING FRONT ROD
C423
C418
A A
C441
TWO SPEED 7.5 ohm 4350 9.8 ohm A A 4420 4330 1 1 3.3 ohm
SOLENOID 12V 12V
B B 2350 B B 2420 2330 2 2 PWM FRONT BASE
C419 C106
863 (S/N 514450764 AND ABOVE) 4340 1 1
CAB 6727178
3.3 ohm
C437
TWO SPEED 5 ohm A A 4390 2340 2 2 PWM
(S/N 514541104 AND ABOVE) MAKE-UP 12V B B 2360

DIVERTER
A
3600 A
C416
SPEED
4450 A A 7.5 ohm SENSOR MAIN
3610 B B
WORKLIGHTS
YELLOW TIE STRAP 2450 B B 12V FRAME
WIRES CONNECT BY LETTER
FRONT
ACROSS CONNECTORS
V-0214 A B ENGINE
C104 C104
SWITCH
BRAKE
3200 A A COOLANT
1930
B A
2000
t SENDER
REAR AUX RELIEF 3210 B B
Printable Version Click Here C 500-3000 ohm
C417
C435
A A
RIGHT
4470 9.8 ohm 2760 B B
SOME CONNECTOR
GREEN TIE 12V B 3710
BODIES NOT SHOWN STRAP
2470 B B B B AIR FILTER 6120 A A
2530 GROUNDS FOR DRAWING CLARITY 3700 A A SWITCH
SEAT
CAB
2480
C434
BAR 6110 A A
LEFT
4330
4360
4340
4410
4440
4430
4420
2460 RED = RED
2770
3300
B
2100
2750 B
3600
3200
3700
4350
RNG = ORANGE
4470
4390
4460
4450
C476
FUEL
C406
2450 UNSWITCHED POWER 1000-1999 RED BLK = BLACK 3110 B B 3110 B B
7 SENDER
2440 2400 FUSED, UNSWITCHED POWER 1000-1999 RED/WHT LBL = LIGHT BLUE A 3100 A A - +8
A 30-270 ohm 2910
SWITCHED POWER 1000-1999 RNG DBL = DARK BLUE J1 J2 2920 2900
2430 C C
C
GROUND 2000-2999 BLK LGN = LIGHT GREEN 2930
A
2340 MONITORING 3000-3999 LBL DGN = DARK GREEN 6 31 18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
HYDRAULIC 4000-4999 LGN 6719422 2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
YEL = YELLOW 2760
2330 ATTACHMENT CONTROLS 5000-5999 YEL PNK = PINK SPOOL COOLANT ENG SPEED
SPARE FRONT COMPUT ER SYSTEM LH AUX L HAND PWM +8V
2520 LIGHTS 6000-6999 PNK WHT = WHITE LOCK ANALOG 1 ROD GROUND Tx RIGHT SERIAL IN
TEMP SIGNAL SUPPLY SIGNAL
ACCESSORIES 7000-7999 WHT 28 3100
2100 BRN = BROWN 1 2 3 4 5 6 7 8 9 10
ENGINE 8000-8999 TAN TAN = TAN
2360 COMMUNICATION 9000-9999 PUR 4360 4330 2900 9100 4810 9210 3200 4300 3600 N K G L B R P S F E D C M A J H
PUR = PURPLE D
11 9110
2420 GRY = GRAY R HAND
SERIAL IN
REAR
BASE
SPARE
ANALOG 2
PROTECTED
POWER
SYSTEM
Rx
LH AUX
LEFT
SPARE
DIGITAL 1
AIR FILT ER
SIGNAL
PWM -
RH FRONT
DETENT C408
2410 11 12 13 14 15 16 17 18 19 20 7 9210 E N K G L B R P S F E D C M A J H
11 9110 4440 1200 9200 4820 3700 4310 4920
2380 2390 + See C492
A
23 9400 F
A A FRONT REAR STATUS SEAT BAR LH SKI FUEL PWM RH SKI
3910
COMPUT ER
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2370 HYDRAULIC CHARGE BASE ROD IN +8v DOWN
OPEN
SENDER SIGNAL DOWN
PRESSURE SENDER
C
C
POWER
J2 42 9410 G
2200
C 21 22 23 24 25 26 27 28 29 30
0.5 - 7.5 V P05
-
B 3400 A A 3400 3400 15 3100
B B 4340 4430 9400 1900 3900 4830 4320 4930
2000 3420 E 47 3910 SEE FUSE/RELAY
E 3420 3420 BUCKET
KEY/ENT ER SEATBAR LH SKI RH SKI 35 A
POSIT ION OPEN OPEN GROUND OPEN UP CENTER
2240 HYDRAULIC 3410 F 3010 23
OPEN SWIT CH GROUND UP
45
C102
F 3410 3920 (EUROPEAN
31 32 33 34 35 36 37 38 39 40
C477
2350 TEMPERATURE
SENDER
B B 3310 D D 3310
4420 9350 3910 4840 2110 4940 25 3900 C407 LIGHTING)
A B
500-3000 ohm A 3300 C C 3300 C HYD LOCK STATUS
BRAKE SW HYDRAULIC 34 9350
SOLENOID FLOAT HEADLIGHT SEATBAR OPEN
OUT
3210 SEE J2 SEE J2 SWIT CH SIGNAL IN TEMP OPEN OPEN
14 1200
2800 HYDRAULIC OIL 41 42 43 44 45 46 47 48 49 50
FILTER SWITCH
3430 B B 3430 3 4410 9410 4640 9340 3920 4500 3300
24 1900
3610
2300 RESERVED HYD FILT ER TWO SPEED RESERVED TWO SPEED SPARE LEFT GLOW PLUG TRACTION LOCK 46 4500
RELAY
3510 (AC INPUT ) OPEN SIGNAL SWIT CH (BOOTSTRAP) MAKE-UP OUTPUT 1 BLINKER PULL / 963
5 9100
2600 1 2 3 4 5 6 7 8 9 10
15
2300
2110
HYDRAULIC FILTER 6717247 RESERVED STARTER
3430
UNSWIT CHED
4910
CAN HYD CHARGE
4390
TRACTION
6410
HIGH FLOW /
8510 4110
44
9200
9340
RIGHT REAR WKLT FUEL RELAY
(hall) FEEDBACK BATTERY (1) HIGH PRESS +8V BLINKER LOCK HOLD 900 LOAD RELAY HOLD
ENGINE OIL A A 3500 3500 37 4 2900
C107
2740 11 12 13 14 15 16 17 18 19 20
PRESSURE C 4940
C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
40
2730 SENDER -
B 4930
2120 0.5-7.5 V B B 3510 SPARE TRACTION LOCK SENSOR TRAVEL F&R AUX RESERVED UNSWIT CHED
30
2720 23
DIGITAL 2 PULL FEEDBACK GROUNDS
CAN
LOW CONTROL J1 RELIEF (SENSOR GRND) BATTERY (2)
DIVERT ER STARTER
RELAY
20 4920
21 22 23 24 25 26 27 28 29 30
2710
4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
TWO SPEED FUEL PULL UNSWIT CHED 29 4320
CAN GLOW PLUG ENG OIL MARKER FUEL PULL
SOLENOID FEEDBACK BATTERY (3) OPEN GROUND
SELECT FEEDBACK PRESS +8v LT RELAY RELAY
9 4300
31 32 33 34 35 36 37 38 39 40
4350 8150 1130 9700 8550 3500 2100 6320 8110
43 4640
HANDLE SWITCH PWR / RESERVED ATTACHMENT +5V ENG OIL 36 4840

SPARE HYD CHARGE RESERVED
POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY PRESS SIGNAL HORN PRESS SIGNAL (FAN OUTPUT )
OUTPUT 2
26 4830
41 42 43 44 45 46 47 48 49 50
16 4820
1400 8000 9800 3420 7200 3520
J1 6 4810
C101
FUEL 1 1 2800 J2
E3
D3
SHUTOFF 25 42 39 19 36 9 12 30 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
3.2 ohm 12V 2 2 8100
J1
4910
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
STARTER
1480
4810
4820
4830
4840
4640
4300
4320
4310
4910
4920
4930
4940
4230
2530
1490
2520
4240
M R Dealer Copy -- Not for Resale
C109
1015 B B 8250
S
C
D
E
G
F
B
D
C
H
A
K
F
J
J
A A 8200
Traction Lock C410 C409
C110
1020 B B 1020
G
H
C
D
G
E
A
F
D
C
H
B
K
J
J
1015
G A HOLD 10.9 ohm
A 1800 4200 A A
C425
BAT
YEL/LGN
WHT/RED
WHT/BLK
WHT/LGN
YEL/RED
A
A
B
B
C C
WHT
WHT
2200
PUR
DGN
RGN
YEL
DBL
LGN
RGN
ALTERNATOR C465 C466
2015 4100 B PULL 0.3 ohm
A
A
B
B
1.0 ohm each
TAILGATE / WORKLIGHTS 6716419
F F
+ - HANDLE
2600 B B 2600 HANDLE LOCK
HR HR HR HR
FLOAT
SHIFT
SKI CTRL
SIDE
RIGHT LOCK
2620 6200 6200 H H 6200 PWM
8590
8570
8560
8580
WORKLIGHT LEFT HANDLE
C103
TWO SPD
SKI CTRL
DETENT
6210 6310 A
FLOW
A 6310
HORN
LEFT AHC LIFT RIGHT
2630 6210 E E 6400 TURN SIGNAL
WORKLIGHT HALL SENSOR
D 6500 B HANDLE
D AHC TILT
RIGHT
B
C
A
2610 6320 2650 G G 6600 HALL SENSOR
RNG/WHT
8500
RNG/DBL
TAILLIGHT
C404
SEE CAB
7100 C 7100 A TO OPTIONS C450
DGN
C
BRN
YEL
CONNECTOR
B
C
A
LEFT B (BACKUP ALARM
2640 6330
C
A
B
TAILLIGHT BACKUP ALARM SWITCH) C407 C449
C
B
E
C
A
D
B
B
A
A
B
A
C
J 2730
B
C411
C
C412
A
P 6600 C469
6000
M 6500 C472
L 6400
F 4730
D 4235
C488
TO OPTIONS N 6300
(ACCESSORY
HARNESS C 4275
CONNECTOR) E 4550
S 1700
A 1140 1740
H 1150
R
B
G
K (ALTERNATOR
1800 & KITS)
FUSE 11
25A
8010
6300
6000
6310
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
1700 1055 4220 M
7200 J
C489
TO OPTIONS B 2720 SWITCHED MARKER REAR GLOW FUEL

(ACCESSORY POWER LIGHT LIGHT PLUG STARTER PULL TRACTION 4275 L
CONNECTOR) A 1720 1720
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A LOCK
25A
6410 P
(ATTACHMENT)
(COMPUTER)
6510 N
FUSE 4
FUSE 10 30 85 30 85 30 85 30 85 30 85 30 85 85 30
25A 4550 K
1730
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E
(HEATER) 9620 D
C492
FUSE 1 FUSE 2 FUSE 3 FUSE 6 FUSE 5
15A
G 9410 S
25A 15A 30A 30A
120
1140 F 9400 R
MAINFRAME HARNESS E 9210 G
6732061 1150 1160 9520

2240
C
H
RELAY GROUNDS 2000-2060 1070
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 1740 B
FUSE / RELAY CENTER 25A
(UNSWITCHED
POWER)
25A
(ACS)
1170
9110
A
F
D
1080
1040
TRACTION HEATER UNSWITCHED
FRONT &
30A 25A REAR SWITCH 25A
MARKER
1160
1730
9800
9510
9610
9710
2710
FUSE 6 FUSE 2 LIGHT POWER FUSE 10
LIGHT
30A 15A 25A 1050

G
D
C
- F
E
A
B
+ 1300
REAR LT ALT & KITS
1060 TO OPTIONS
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL)
ACD & REMOTE
COMPUTER ACS
1310 START CONNECTOR
25A 25A
1040
V-0214 (11-26-03)
Printed in U.S.A. BATTERY 1080
552 of 970
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH
COMPUTER POWER
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
REAR ROD (NOT Used With AHC or ACS)
CLOCK/LATCH
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm A A 4430 4370 1
SYSTEM Rx
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx
12V
GROUND
B B 2430 2370 2
GROUND
BROWN TIE STRAP (NOT Used With AHC or ACS)
BUZZER
BUZZER
C422
START
START
OPEN
DATA
4380 1
DATA
6733137 REAR BASE 2380 2
C414
HIGH FLOW
WIRING SCHEMATIC A A 4440 BICS HYDRAULIC LOCK
G
C
D
E
K
A
B
B
A
K
E
F
F
J
J
7.5 ohm
C415
12V
C420
7.5 ohm A A 4460 A A 4460 B B 2440 WHITE TIE STRAP 4410 A A 9.8 ohm
12V B B 2460 B B 2460 BLUE TIE STRAP 2410 B B 12V
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
(With ACS Option)
BUCKET POSITIONING FRONT ROD
C423
C418
A A
C441
TWO SPEED 7.5 ohm 4350 9.8 ohm A A 4420 4330 1 1 3.3 ohm
SOLENOID 12V 12V
B B 2350 B B 2420 2330 2 2 PWM FRONT BASE
C419 C106
863 (S/N 514450764 AND ABOVE) 4340 1
CAB 6727178
C437
TWO SPEED 5 ohm A A 4390 2340 2
(S/N 514541104 AND ABOVE) MAKE-UP 12V B B 2360
DIVERTER
A
3600 A SPEED
C416
4450 A A 7.5 ohm SENSOR MAIN
3610 B B
WORKLIGHTS
YELLOW TIE STRAP 2450 B B 12V FRAME
WIRES CONNECT BY LETTER
FRONT
ACROSS CONNECTORS
V-0215 A B ENGINE
C104 C104
REAR AUX RELIEF
SWITCH
BRAKE
3200 A A COOLANT
C417
1930
B A
2000
4470 A A 9.8 ohm t SENDER
3210 B B
12V C 815-1696 ohm
GREEN TIE
2470 B B
C435
STRAP
RIGHT
SOME CONNECTOR 2760 B B
BODIES NOT SHOWN B 3710 B B AIR FILTER 6120 A A
2530 GROUNDS FOR DRAWING CLARITY 3700 A A SWITCH
SEAT
CAB
2480
C434
BAR 6110 A A
LEFT
4330
4360
4340
4410
4440
4430
4420
2460 RED = RED
2770
3300
B
2100
2750 B
3600
3200
3700
4350
RNG = ORANGE
4470
4390
4460
4450
C476
FUEL
C406
2450 UNSWITCHED POWER 1000-1999 RED BLK = BLACK 3110 B B 3110 B B
7 SENDER
2440 2400 FUSED, UNSWITCHED POWER 1000-1999 RED/WHT LBL = LIGHT BLUE A 3100 A A - +8
A 30-270 ohm 2910
SWITCHED POWER 1000-1999 RNG DBL = DARK BLUE J1 J2 2920 2900
2430 C C
C
GROUND 2000-2999 BLK LGN = LIGHT GREEN 2930
A
2340 MONITORING 3000-3999 LBL DGN = DARK GREEN 6 31 18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
HYDRAULIC 4000-4999 LGN 6719422 2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
YEL = YELLOW 2760
2330 ATTACHMENT CONTROLS 5000-5999 YEL PNK = PINK SPOOL COOLANT ENG SPEED
SPARE FRONT COMPUT ER SYSTEM LH AUX L HAND PWM +8V
2520 LIGHTS 6000-6999 PNK WHT = WHITE LOCK ANALOG 1 ROD GROUND Tx RIGHT SERIAL IN
TEMP SIGNAL SUPPLY SIGNAL
ACCESSORIES 7000-7999 WHT 28 3100
2100 BRN = BROWN 1 2 3 4 5 6 7 8 9 10
ENGINE 8000-8999 TAN TAN = TAN
2360 COMMUNICATION 9000-9999 PUR 4360 4330 2900 9100 4810 9210 3200 4300 3600 N K G L B R P S F E D C M A J H
PUR = PURPLE D
11 9110
2420 GRY = GRAY R HAND
SERIAL IN
REAR
BASE
SPARE
ANALOG 2
PROTECTED
POWER
SYSTEM
Rx
LH AUX
LEFT
SPARE
DIGITAL 1
AIR FILT ER
SIGNAL
PWM -
RH FRONT
DETENT C408
2410 11 12 13 14 15 16 17 18 19 20 7 9210 E N K G L B R P S F E D C M A J H
11 9110 4440 1200 9200 4820 3700 4310 4920
2380 2390 + See C492
A
23 9400 F
A A FRONT REAR STATUS SEAT BAR LH SKI FUEL PWM RH SKI
3910
COMPUT ER
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2370 HYDRAULIC CHARGE BASE ROD IN +8v DOWN
OPEN
SENDER SIGNAL DOWN
PRESSURE SENDER
C
C
POWER
J2 42 9410 G
2200
C 21 22 23 24 25 26 27 28 29 30
0.5 - 7.5 V P05
-
B 3400 A A 3400 3400 15 3100
B B 4340 4430 9400 1900 3900 4830 4320 4930
2000 3420 E 47 3910 SEE FUSE/RELAY
E 3420 3420 BUCKET
KEY/ENT ER SEATBAR LH SKI RH SKI 35 A
POSIT ION OPEN OPEN GROUND OPEN UP CENTER
2240 HYDRAULIC 3410 F 3010 23
OPEN SWIT CH GROUND UP
45
C102
F 3410 3920 (EUROPEAN
31 32 33 34 35 36 37 38 39 40
C477
2350 TEMPERATURE
SENDER
B B 3310 D D 3310
4420 9350 3910 4840 2110 4940 25 3900 C407 LIGHTING)
A B
500-3000 ohm A 3300 C C 3300 C HYD LOCK STATUS
BRAKE SW HYDRAULIC 34 9350
SOLENOID FLOAT HEADLIGHT SEATBAR OPEN
OUT
3210 SEE J2 SEE J2 SWIT CH SIGNAL IN TEMP OPEN OPEN
14 1200
2800 HYDRAULIC OIL 41 42 43 44 45 46 47 48 49 50
FILTER SWITCH
3430 B B 3430 3 4410 9410 4640 9340 3920 4500 3300
24 1900
3610
2300 RESERVED HYD FILT ER TWO SPEED RESERVED TWO SPEED SPARE LEFT GLOW PLUG TRACTION LOCK 46 4500
RELAY
3510 (AC INPUT ) OPEN SIGNAL SWIT CH (BOOTSTRAP) MAKE-UP OUTPUT 1 BLINKER PULL / 963
5 9100
2600 1 2 3 4 5 6 7 8 9 10
15
2300
2110
HYDRAULIC FILTER 6717247 RESERVED STARTER
3430
UNSWIT CHED
4910
CAN HYD CHARGE
4390
TRACTION
6410
HIGH FLOW /
8510 4110
44
9200
9340
RIGHT REAR WKLT FUEL RELAY
(hall) FEEDBACK BATTERY (1) HIGH PRESS +8V BLINKER LOCK HOLD 900 LOAD RELAY HOLD
ENGINE OIL A A 3500 3500 37 4 2900
C107
2740 11 12 13 14 15 16 17 18 19 20
PRESSURE C 4940
C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
40
2730 SENDER -
B 4930
2120 0.5-7.5 V B B 3510 SPARE TRACTION LOCK SENSOR TRAVEL F&R AUX RESERVED UNSWIT CHED
30
2720 23
DIGITAL 2 PULL FEEDBACK GROUNDS
CAN
LOW CONTROL J1 RELIEF (SENSOR GRND) BATTERY (2)
DIVERT ER STARTER
RELAY
20 4920
21 22 23 24 25 26 27 28 29 30
2710
4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
TWO SPEED FUEL PULL UNSWIT CHED 29 4320
CAN GLOW PLUG ENG OIL MARKER FUEL PULL
SOLENOID FEEDBACK BATTERY (3) OPEN GROUND
SELECT FEEDBACK PRESS +8v LT RELAY RELAY
9 4300
31 32 33 34 35 36 37 38 39 40
4350 8150 1130 9700 8550 3500 2100 6320 8110
43 4640
HANDLE SWITCH PWR / RESERVED ATTACHMENT +5V ENG OIL 36 4840

SPARE HYD CHARGE RESERVED
POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY PRESS SIGNAL HORN PRESS SIGNAL (FAN OUTPUT )
OUTPUT 2
26 4830
41 42 43 44 45 46 47 48 49 50
16 4820
1400 8000 9800 3420 7200 3520
HOLD PULL
?? ohm B B 8820 A A 8800

J1 6 4810
KUBOTA
FUEL C C 2800 J2
E3
D3
SHUTOFF 25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
?? ohm A A 8120 B B 8100
J1
4910
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
STARTER
1480
4810
4820
4830
4840
4640
4300
4320
4310
4910
4920
4930
4940
4230
2530
1490
2520
4240
M R Dealer Copy -- Not for Resale
C109
1015 B B 8250
S
C
D
E
G
F
B
D
C
H
A
K
F
J
J
A A 8200
Traction Lock C410 C409
C110
1020 B B 1020
G
H
C
D

863 6900942 Bobcat PDF

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863 6900942 Bobcat PDF

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TURBO

Dealer Copy -- Not for Resale

Doosan purchased Bobcat Company from Ingersoll-Rand Company in

6900942 (10 ) Printed in U.S.A. © Bobcat Company 2010

CORRECT CORRECT CORRECT

P-90216 B-15590 B-15591

WRONG WRONG WRONG

Dealer Copy -- Not for Resale

B-15600 B-15601 B-6589

ADVANCED CONTROL SYSTEM ENGINE LUBRICATION SYSTEM .........................10-01

BASIC TROUBLESHOOTING ................................ 80-01 GENERAL AIR CONDITIONING SERVICE

Dealer Copy -- Not for Resale

ELECTRICAL / HYD. CONTROLS REFERENCE .. 60-01

863 Bobcat Loader

POWER BOB-TACH (OPTION)....................10-01, 50-01

Dealer Copy -- Not for Resale

863 Bobcat Loader

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . XI HYDROSTATIC

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

Dealer Copy -- Not for Resale

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

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

863 Bobcat Loader

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

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

Dealer Copy -- Not for Resale

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

6. Machine signs (decals) must 14. Check hydraulic fluid level,

7. Steering levers, hand controls 15. Inspect for fuel, oil or

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

Dealer Copy -- Not for Resale

22. Check for any field

863 Bobcat Loader

863 Bobcat Loader

Dealer Copy -- Not for Resale

• The Skid-Steer Loader Operator Training Course is

DANGER available through your local dealer or at

WARNING • The Skid-Steer Loader Safety Video is available from

863 Bobcat Loader

The dealer and owner / operator review the

Cutting or drilling concrete containing sand or rock

Call Before You Dig

Dealer Copy -- Not for Resale

863 Bobcat Loader

Check hydraulic tubes, hoses and fittings for damage

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

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

Dealer Copy -- Not for Resale

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

Check the spark arrestor exhaust system regularly to

Battery gas can explode and cause serious injury. Use

863 Bobcat Loader

Welding And Grinding

Always clean the machine and attachment, disconnect

Have good ventilation when grinding or welding painted

Dust generated from repairing nonmetallic parts such as

Dealer Copy -- Not for Resale

Always use the serial number of the loader when Figure 2

Loader Serial Number

Dealer Copy -- Not for Resale

The loader serial number plate is located on the inside of

Explanation of loader Serial Number:

6900942 (10 ) Printed in U.S.A. © Bobcat Company 2010