Bobcat 963 BICS SM 04670
Bobcat 963 BICS SM 04670
Bobcat 963 BICS SM 04670
Manual
BOBCAT INTERLOCK
INGERSOLL~AND
CONTROL SYSTEM (BICSTM) 6724545(11-97) Printed in U.S.A. © Melroe Company 1997
MAINTENANCE SAFETY
Instructions are necessary before gperating or servicin~ machine. Read
and understand the Op'eration & Maintenance Manuar, Handbook and
signs (decals) on machine. Follow warnings and Instructions in the
manuals when making repairs, adjustmenrs or servicing. Check for
correct function after adiustments, repairs or service. Untrained
operators and failure to folrow instructions can cause injury or death.
W-2003-0199
A Safety Alert Symbol: This symbol with a warning statement, means: "Warning, be alert I Your safety is
involved!" Carefully read the message that follows.
Ir---,-..--~-O-R-R-E-CT--'I I ~RRECTI
Ir---~'\-~-~~~-
\ t-/~-R-R-E-CT--'I ,-/_,-
WRONG
v~ 1 WRONG WRONG
.~·~V
\\~.(~
8-6590 8-6589
A Stop, cool and clean engine of A Keep body, Jewelry and clothing A Lead-acld batteries produce
flammable materials before away from moving parts, A flammable and explosive gases.
checking fluids. electrical contacts, hot parts and . . Keep arcs, sparks, flames and
A Never service or adjust loader
with the engine running unless A
exhaust.
Wear eye protection to guard
lighted tobacco away from
batteries.
A Instructed to do so In the manual. from battery acid, compressed A Batteries contain acid which
a. Avoid contact with leaking springs, fluids under pressure burns eyes or skin on contact.
hydraulic fluid or diesel fuel and flying debris when engines Wear protective clothing. If acid
under pressure. It can penetrate are running or tools are used. Use contacts body, flush well with
A the skin or eyes. eye protection approved for type water. For eye contact flush well
a. Never fill fuel tank with engine of welding. and get Immediate medical
running, while smoking or wllen A Keep rear door closed except for attention.
near open flame. service. Close and latch door
before operating the loader.
Maintenance procedures which are !;liven in the Operation & Maintenance Manual can be perlormed by
the owner/operator without any specific technical training. Maintenance procedures which are not in the
Operation & Maintenance Manual must be perlormed ONLY BY QUALIFIED BOBCAT SERVICE
PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course
is available from your Bobcat dealer. MSW01~99
ALPHABETICAL INDEX
BLOWER FAN ... .... ... .... .... .... .. . .. ... .. 7-1
FRONT CHAINCASE COVER ........... . .. . .... 4-1
A.H.C.-ADVANCED HAND CONTROL SYSTEM MONITOR SERVICE CODES . . . .. .... .. . ... .... . 8-1
Revised Mar. 99
ALPHABETICAL INDEX (Cont'd)
OIL COOLER . . .... . .... .. ... .. . ... .... ... ... . 3-1
OPERATION SENSING SYSTEM UNIT ... ..... . . 8-1
OPERATOR CAB ......... . ... .. . ... .. . . 1-1 & 5-1
OPERATOR CAB GAS CyLINDER ... . ... .. . 0 . 0 0 5-1
OPERATOR SEAT . 0 0 0 0 0 0 0 0 0 0 0 0 0 • 0 0 0 •• 0 0 0 0 • 0 0 0 5-1
Revised Mar. 99
CONTENTS
PREVENTIVE
MAINTENANCE
FOREWORD .. .. .. ....... . ...... . .... .. ...... . .... ... ........ . . . . . ii
DELIVERY REPORT . . ... . . . ...... . .... . ...... .. .......... ... ..... vii
MAIN FRAME .......... .. . .. . ....... ... . .. ....... ... . . ... . .... . . 5-1
HYDROSTATIC
ELECTRICAL SYSTEM ...... . ......... . ........... . .......... . ... 6-1
SYSTEM
ENGINE SERVICE .. . . . ........ . . . . . ........... .. ............ . ... 7-1
CALIFORNIA
MAIN
PROPOSITION 65 WARNING
FRAME
Diesel engine exhaust and some of its
constituents are known to the State of California
to cause cancer, birth defects and other
reproductive harm.
ELECTRICAL
SYSTEM
ENGINE
SERVICE
SYSTEMS
ANALYSIS
SPECIFICATIONS
ADVANCED
HAND CONTROL
SYSTEM
A general inspection of the following items must be made after the loader has had service or repair:
(Including sidescreens) is in • •
good condition and is not .
modified. !
~ £8
Melroe approved.
ma
~ condition.
~'\ ~I
\oj
12. Safety treads must in good
condition.
.~:;r
...'.~.
./~.~,
A.
-=,f..'
.~
f':
5. Check lift arm support device, 13. Check for correct function of
replace if damaged.
~ indicator lamps (Optional on
some models).
~
~
CD
jtl-r
•"
-r-
-r
7. Steering levers and foot pedals 15. Inspect for fuel, oil or hydraulic
must return to neutral. fluid leaks.
~~
~
the work lights.
/III,
l c=J )
~9
19. Check the electrical charging
system. <9
" fJ
- (""\\'
~, !
&
(()~
~~...f
~
-- -
. - -
~
21 . Inspect for loose or broken
parts or connections.
;
))))))Jl )))l )l ))j}})~
all functions.
;:
A WARNING
Instructions are necessary before operating or servicing machine. Read and understand the Operation &
Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the
manuals when making repairs, adjustments or servicing. Check for correct function after adjustments,
repairs or service. Untrained operators and failure to follow instructions can cause injury or death.
W-2003-0299
The following publications provide information on the safe use and maintenance of the loader and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine
is in safe operating condition .
• The Operation & Maintenance Manual delivered with the loader gives operating information as well as routine
maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement
Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.
• The loader has machine signs (decals) which instruct on the safe operation and care . The signs and their locations are
shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.
• The loader has a plastic Operator's Handbook fastened to the operator cab. Its brief instructions are convenient to the
operator. The Handbook is available from your dealer in an English edition or one of many other languages. See your
Bobcat dealer for more information on translated versions.
• The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do Shop-type service and
repair work.
• The Skid-Steer Loader Operator Training Course is available through your local dealer. This course is intended to provide
rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish version.
• The Service Safety Training Course is available from your Bobcat dealer. This course provides information for safe and
correct service procedures for Bobcat Skid-Steer loaders.
• The Bobcat Skid-Steer Loader Safety Video is available from your Bobcat Dealer.
AWARNING
IMPORTANT
• Safety Alert Symbol: This symbol with a warning statement, means: "Warning, be alert! Your safety is
involved!" Carefully read the message that follows.
S105-{)299
Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it will
increase the fire hazard. The loader must be cleaned as often as necessary to avoid this accumulation. Flammable debris
in the engine compartment is a fire hazard when the loader is parked with a hot engine.
The exhaust system is designed to control the emission of hot particles from the engine and exhaust system, but the muffler
and the exhaust gases are still hot.
• Do not use the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive
dust or gases.
• The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent
fire hazard and overheating.
• Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace
any damaged part.
• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check
for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel
for cleaning parts. Use commercial nonflammable solvents.
• Do not use ether or starting fluids on this engine. It has a glow plug . These starting aids can cause explosion and injure
you or bystanders.
• Always clean the loader and disconnect the battery before doing any welding. Cover rubber hoses, battery and all other
flammable parts. Keep a fire extinguisher near the loader when welding. Have good ventilation when grinding or welding
painted parts . Wear dust mask when grinding painted parts. Toxic dust or gas can be produced.
• Stop the engine and let it cool before adding fuel. No smoking!
• Use the procedure in the Operation & Maintenance Manual for connecting the battery.
• Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler.
• Know where fire extinguishers and first aid kits are located and how to use them.
A fire extinguisher is available from your local dealer. The fire extinguisher can be installed in the location shown [A].
SI04-0398
xxxx xxxxx
L Module 2. - Production
Sequence (Series)
Module 1. - Model/Engine
Combination
combination.
DELIVERY REPORT
~
signed by the owner or operator when the Bobcat loader
is delivered . An explanation of the form must be given to
the owner. Make sure it is filled out completely [C]. ==
OPERATOR SEAT
SEAT BAR
GRAB
HANDLES ::: ~.'.'.'~ .:u
STEERING ~ ';; ,. , \ r
LEVERS
t BUCKET ..."
AUXILIARY HYDRAULIC
BUCKET STEPS QUICK COUPLERS
• OPERATOR CAB
/ (ROPS & FOPS)
n ~ ~-
, -_-
. -
TAIL LIGHTS
REAR DOOR
TIRES* 8-15004
8-15005
* TIRES - Flotation tires (optional) are shown. The Bobcat loader is factory equipped with standard tires.
t BUCKET - Several different buckets and other attachments are available for the Bobcat loader.
• ROPS, FOPS - Roll Over Protective Structure, Falling Object Protective Structure, per SAE J1 040 and ISO 3471 ,
and Falling Object Protective Structure per SAE J1 043 and ISO 3449, Levell. 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).
ALTERNATOR BELT
BOB-TACH
FUEL SYSTEM
HYDRAULIC/HYDROSTATIC SYSTEM
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-4
OPERATOR CAB
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-29
SERVICE SCHEDULE
TIRE MAINTENANCE
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.
SERVICE SCHEDULE
level
A WARNING
Procedure
8--07023
Always park the loader on a level surface.
A WARNING
Stop the engine. Put the floor jack under the rear of the
loader. Lift the rear of the loader and install jackstands
[B].
N-15440
Put the floor jack under the front of the loader. Lift the front
-
of the loader and install jackstands under the axle tubes
[C].
NOTE: Make sure the jackstands do not touch the
tires.
"
963 Bobcat Loader
Revised Mar. 99 -1-4 Service Manual
TRANSPORTING THE LOADER
Procedure
A WARNING
Procedure
The towing chain (or cable) must be rated 1-1/2 times the
weight of the loader. (See SPECIFICA TlONS, Page 9-1 .)
Lift and block the rear of the loader. (See Page 1-4.)
Remove the plugs (Items 1 & 2) [A] from the motor (both
sides).
NOTE: The plug (Item 2) [B] and relief valve may have
to be removed so that the shuttle spool can
be removed from the housing bore.
Install and tighten the plugs.
A WARNING
If the lift arms must be raised for service, use the following
procedure:
Lower the lift arm support device on top of the lift cylinder.
Hook the free end of the spring (Item 1) [B] to the lift arm
support device so there will be no interference with the
support device engagement.
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine.
Raise the lift arms, until the lift arm support device lowers
onto the lift cylinder rod [C].
Lower the lift arms slowly until the support device is held
between the lift arm and the lift cylinder. Stop the engine.
Raise the seat bar and move foot pedals until both pedals
lock.
Install the pin (Item 1) [0] into the rear of the lift arm
support device below the cylinder rod.
A WARNING
Connect the spring (Item 1) [A] from the lift arm support
With the operator in the seat, seat belt fastened and seat
Raise the lift arms a small amount and the spring will lift
the support device (Item 1) [B] off the lift cylinder rod.
Raise the seat bar and move foot controls until both
controls lock.
Description
Structure per SAE J1 043 and ISO 3449, Levell. Level II .,.,
is available.
A WARNING
W-2069-1285
Loosen the nut (Item 1) [A] (both sides) at the front of the
operator cab.
.\ -= ~,
-
\
-10162
Emergency Exit
Rear Window:
Pull on the tag on the top of the rear window to remove the
rubber cord [A].
Push the rear window out of the rear of the operator cab.
Exit through the rear window opening of the operator cab .
Front Door:
NOTE: When the Operator Cab Enclosure Kit is
installed, the window of the front door can be
used as an emergency exit.
Pull the plastic loop at the top of the window in the front
door to remove the rubber cord [C].
Description
The operator controls the use of the seat bar. The seat bar
in the down position helps to keep the operator in the seat.
When the seat bar is up, the lift and tilt pedals are locked
when returned to the NEUTRAL POSITION .
A WARNING
Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down . Start the P-{)9790
engine . Press the greeen PRESS TO OPERATE Button.
Operate each foot pedal to check both the lift and tilt
functions . Raise the lift arms until the bucket is about 2
feet (600 mm) off the ground .
Raise the seat bar. Try to move each foot pedal. Pedals
must be firmly locked in NEUTRAL POSITION . There
must be no motion of the lift arms or tilt (bucket) when the
pedals ar pushed . .
Clean the debris or dirt from the moving parts [A] & [B].
Inspect the linkage bolts and nuts for tightness . The
correct torque is 25-28 ft.-Ibs. (34-38 Nm).
Check the air intake hose and air cleaner housing for
damage.
Replace the large (outer) filter element when the red ring
Install the new filter element and tighten the wing nut.
Replace the inner filter element every third time the outer
filter is replaced .
or... ..
the engine and run at full RPM. If the red ring shows again,
Fuel Specifications
A WARNING
Fuel Filters
. A WARNING
To drain the water from the fuel filters, loosen the drain
(Items 1 & 2) [A] to drain the water from the filter.
Loosen the drain (Items 1 & 2) [A] to drain the fuel from
the filters .
Support the filter and turn the clamp ring (Item 1) [B] & [C]
to the left. Remove the clamp ring.
Replace as needed.
Clean the filter heads. Push the filter into the filter head.
Hold the filter element and install the clamp ring. Turn the
clamp ring to the right to fasten the filer to the filter head.
Squeeze the priming bulb (Item 4) [C] until fuel flows from
the vent with no air bubbles showing.
Check the engine oil level every day before starting the
engine for the work shift.
Keep the oil level between the marks on the dipstick [B].
IIII -
SAE 40W or 20W-50
I-- SA E10W-30
~
I I
SAE 15W-40
~
B
- ' SAE30W Keep Oil
- ~
Level Between
- * SAE5W-30
-- These Marks
I ~ SAE20W-20
-I- t
"'(
r-
_ SAE 1~W
.,
-r I I I I
~NTHETIC OIL Use recommendation from Synthetic Oil Mf~r.
-40 -30
l
- 20 - 10
i
+1 0 +20 +30 +40 + 50 +60 +70 +80 +90
r
+1 00 + 110 +1 20
P P-10302
TEMPERATURE RANGE ANTICIPATED
Clean the filter housing surface. Put clean oil on the new
oil filter gasket. Install the new filter and hand tighten .
Install and tighten the drain plug .
Remove the filler cap (Item 2) [A].
Fill the engine crankcase with oil of the correct grade and
viscosity. (See Oil Chart above .) Capacity is 9 qts. (8,5 L.)
A WARNING
Start the engine and let it run for several minutes. Always clean up spilled fuel or oil. Keep heat,
flames, sparks or lighted tobacco away from
Stop the engine . fuel and oil. Failure to use care aro un d
combustibles can cause explosion or fire
Check for leaks at the oil filter and check the oil level. which can result in injury or death.
W-2103-1285
Add oil as needed if it is not at the top mark on the dipstick
Raise the oil cooler and clean the top of the radiator (Item
2) [B].
IMPORTANT
A WARNING
One gallon and one pint (4,3 L.) of propylene glycol mixed
with one gallon (3,8 L.) of water is the correct mixture of
coolant to provide a-34° F. (-37° C.) freeze protection.
Fill the radiator with coolant until full. Open the vent plug
(Item 1) [C] to remove the air from the engine block.
Tighten the vent plug. Continue to fill the radiator until full.
IMPORTANT
Move the alternator until the belt has 5/16 inch (8 ,0 mm)
movement at the middle of the belt span (Item 1) [8] with
15 Ibs. (66 N) of force .
Add the flu id as needed to bring the level to the top mark
on the dipstick [B)
P-10303
service interval.
seal contacts the housing . Put clean oil on the rubber seal
Add fluid to the reservoir until the fluid is at the top mark
on the dipstick. (See the SPECIFICA TlONS Section
Page 9-1 for type of fluid and capacity.) DO NOT fill
above the top mark on the dipstick.
Lower the operator cab. Start the engine and operate the
loader through the hydraulic and hydrostatic functions .
Stop the engine. Check the fluid level again and add as
. 'I~. ?~ ;;
needed . . ".
A WARNING
Cleaning Procedure
IMPORTANT
Remove the plug (Item 1) [A] from the bottom of the Never use machine in atmosphere with
muffler . explosive dust or gases or where exhaust can
contact flammable material. Failure to obey
warnings can cause injury or death.
W-2068-1285
A WARNING
Stop the engine. Install and tighten the plug. Close the
rear door.
Wheel Nuts
Tire Rotation
Rear tires usually wear faster than front tires. To keep tire
wear even , move the front tires to the rear and rear tires
to the front [B].
Tire Mounting
Tires and rims must always be checked for correct size E--Q1655
before mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust. The tire
bead and rim flange must be lubricated with a rubber
lubricant before mounting the tire.
A WARNING
IMPORTANT
If oil can be reached with the tip of the your finger through
the hole the oil level is correct.
If the level is low, add oil through the check plug hole until
the oil flows from the hole. Install and tighten the plug.
FAN GEARBOX
service interval.
If the level is low, add SAE 90W gear lube through the
check plug hole until the lubricant just below the fitting
hole.
When adding the gearbox lube, make sure the level does
Procedure
Procedure (Cont'd)
P- 10241
A WARNING
If the wedge does not contact the lower edge of the hole
[B] and [C], the attachment will be loose and can come
off the Bob-Tach.
J~
Look for cracked welds. Wedge
Procedure
A WARNING
Raise the lift arms and install an approved lift arm support
device . (See Page 1-7.)
A WARNING
Procedure (Cont'd)
P-04713
P-04714
Number
BICSTM VALVE
CONTROL PEDALS
H-Port Auxiliary Section ............ . . . .. . .... . . ... ... . .... .... 2-49
Inspection .. . ...... . ...... . . .. ... . .. ... ... . .. .. .. . .. ... .... ... 2-49
Lift Spool And Detent . .. .... . .. . . .. .... .. . ... .... .. .... . . ...... 2-42
Port Relief Valve (Lift Section) ..... . ...... .. . ... ........ .. ... ... 2-37
Tilt Spool And Centering Spring ....... . .................. . ... ... 2-46
HYDRAULIC CYLINDER
HYDRAULIC PUMP
HYDRAULIC/HYDROSTATIC FILTER
LIFT CYLINDER
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-25
TILT CYLINDER
TROUBLESHOOTING
Chart
PROBLEM CAUSE
The lift arms come down with the pedal in the neutral position. 4, 10, 11 , 12, 13
I
The bucket does not self-level. 14, 15, 16
The bucket will partially self-level. 14, 15
IMPORTANT
Tighten Procedures
A. WARNING
A WARNING
Lower the lift arms. Stop the engine. Pull up on the lift arm
by-pass control and move the lift pedal to release the
hydraulic pressure. Raise the seat bar
Engage the parking brake. Lower the seat bar. Start the
engine and push the top (toe) of the lift pedal.
Lower the lift arms. Stop the engine. Pull up on the lift arm
by-pass control and move the lift pedal to release the
hydraulic pressure. Raise the seat bar
Remove the retaining nut (Item 1) [AJ from the rod end of
the lift cylinder pivot pin.
Use a puller and remove the rod end and base end pins
from the lift cylinder [C].
Right Side Only: The lift arms will have to be raised using
a chain hoist or floor jack so there will be clearance when
removing the lift arm support device [D].
Remove the retainer bolt (Item 1) [A) spacer and nut from
the base end pivot pin.
A WARNING
Right Side
Engage the parking brake . Lower the seat bar. Start the
engine and push the bottom (heel) of the tilt pedal. If there
is leakage from the open port, remove the tilt cylinder for
repair.
Left Side
Engage the parking brake. Lower the seat bar. Start the
engine and push the bottom (heel) of the tilt pedal. If there
is leakage from the open port, remove the tilt cylinder for
repair.
Remove the snap ring and washer at the rod end of the
tilt cylinder (Item 1) [B].
Right Side
Remove the snap ring and washer from the pivot pin
(Item 2) [C].
Left Side
Remove the snap ring and washer (Item 1) [C] from the
pivot pin.
Check the seal at the rod end of the tilt cylinder [AJ.
Replace the seals if damaged as needed.
N-15366
Remove the bolt at the pivot pin (Item 1) [B]. Remove the
washer.
Install the bolt (without washers) into the pivot pin. Hit the
bolt with a hammer to remove the pin from the tapered
seat [C].
Remove the bolt and remove the pin (Item 1) [D) from the
lift arms.
1. Rod 9. O-ring
2. Case 10. Washer
3. O-ring 11. Head
4. Nut 12. Seal
5. Piston 13. Seal
6. Ri ng 14. Plug
7. O-ring 15. O-ring
8. Spacer 16. Tube
8 - (§)/--------------
7-0/ /
' /
14-i4/~ / / 1 ~
15-:
/
0'- 3 //
I / 13
12-0/
15- y/ ~ - 2
,!// / ~/
W
11-
/ 10/0/
------___ 9 -
----_J
0
-2-12
HYDRAULIC CYLINDER (Cont'd)
~~
4. Tube 14. a-ring
5. Nut 15. Head
6. Clam p 16. Seal
7.
8.
9.
Bolt
Nut
Piston
17. Seal
18. Rod
19. Seal
~j ~I~
10. Seal 20. Bushing
MC-01 688
3
I
2 -@.'O__
--
6 5
\\'.
~/\~-----
I
7 \
'I- \
\'
@- 8 ~ ---,
\
@-9
\
S-'5 \
\ \
0- 10 ~-16
\
\ \
0- 11 0- 17
0-
\
I
12
0-
\
13 \
\
MC-01688 19 20 19
0- 14 I
\ 0- -Q-O
I I
'- \
~
TS-01233
Disassemb ly
A
Use the following tools to disassemble the cylinder:
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.
P--07435
'.\.. ':'lij
') ~r ~
P--07428
i".
J-: , -':l\:."...
4i......
P--07434
Disassembly (Cont'd)
A
Standard Piston : Remove the seal (Item 1) [A], and
P-07430
P-07439
P-07422
Remove the wiper seat (Item 1) [D], and rod seal (Item 2)
[D]. o . ..:...~.,,~ ... yA'
Remove the O-ring (Item 3) [D] from the rod seal. ~}i
('-'.
ftJ'"' .
': ,.",(.or
~•• '~'~r
_2"
".,,'
, .
. 1'(1)
... ~
~'"
'-.:.... ,
tJ"-d
.;~.. : ;~;~I; /1
.., ••1
.. j"'
Assembly
. (1) . .~
it fits the piston [A].
.
Allow the seal to stretch for 30 seconds before installing
it on the piston. ~ ~
~ - .....
Standard Piston: Install the seal (Item 1) [B] and a-ring
(Item 2) [B] on the piston (Item 3) [B].
P-07430
P-D7438
P-D7427
Assembly (Cont'd)
A
Install the rod seal in the head [A].
Install the wiper seal with the wiper toward the outside of
the head.
P-07425
~~.~
~
~-....,-
P-07422
Lift Cylinder: Install the piston (Item 3) [C], and the nut
(Item 4) [C].
Tilt Cylinder: Install the head (Item 1) [0], and the piston I 0
(Item 2) [0]. The small diameter of the piston goes into the
cylinder tube first.
Assembly (Cont'd)
A
Put the base end of the hydraulic cylinder in a vise .
P--07435
Pull up on the lift arm by-pass control and move the lift
Left Side
Right Side
A WARNING
IMPORTANT
A WARNING
P-02152
Push the button (Item 1) [C] at the steering lever for fluid
flow to the quick couplers.
A WARNING
Start the engine and run at low engine idle RPM . Push the
heel of the tilt pedal (Bob-Tach fully back) Increase
engine speed to full RPM. The correct pressure should be
3025 PSI (20857 kPa) . Make record of this pressure.
Push the button (Item 1) [8] for fluid pressure to the quick
couplers. ~
P-02152
IMPORTANT
relief valve.
N-15656
Adjustment
N-15658
Adjustment (Cont'd)
N-15659
N-15660
A WARNING
torque.
c
Remove the fitting (Item 2) [A] from the BICS valve .
N-15664
Lock Valve
There are two lock valves on the BICS valve , lift lock valve
(Item 1) [A] and tilt lock valve (Item 2) [A].
Loosen and remove the lock valve(s) (Item 1) [B] & [C]
from the valve.
B
Installation : Tighten the lock valve(s) to 25 ft.-Ibs. (34
Nm) torque.
c"
'-~':~
Check Valve
..
.~
P-09057
.~~
p
Loosen and remove the solenoid cartridge (Item 1) [C]
from the valve.
IC
Installation : Tighten the cartridge to 20 ft.-Ibs. (27 Nm)
torque.
N-15671
D
Replace all the O-rings and back-up washers before
installation [0).
~
~
fi
N-15674
1 110-130 in .-Ibs.
(12,4-14,7 Nm)
2 190-210 in.-Ibs.
(21,5-23,7 Nm) 1, 2, 3, 4, 5 & 6
3* 190-210 in.-lbs.
(21,5-23,71\Im)
-
Raise the lift arms and install an approved lift arm support
device . (See Page 1-1 .)
A WARNING
A DANGER
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubefine, hose. fitting. component or a p.art
failure c~n cauae lift arms to drop.
• Keep oul of the area when lift arms ara
raised unla~s supported by an approved
liM arm support. Replace it damaged. >:l14S SW 98 srl1:Kl
tilt spool.
Disconnect the hose (Item 3) [8] which goes to the lift arm
by-pass valve.
valve.
Disconnect the hose (Item 1) [B] and tubellne from the lift
section of the control valve.
Identification Chart
A3 Auxiliary Hydraulics
B3 Auxiliary Hydraulics
F1 Anti-Cavitation Valve
IMPORTANT
8
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. s
1-2003-0888
N-15679
N-15680
1. Relief Valve
2. O-ring
3. Backup Washer
4. O-ring
N-15684
torque.
-......
...
,
,
i~
N-15686
Anti-Cavitation Valve
A -......
".
N-15688
1. Anti-Cavitation Valve
2. O-ring
3. Backup Washer
4. O-ring
CD-15102
A
Loosen the port relief valve (Item 1) [A].
.. ..::...
.~ )
( runo- O-@-O
I 3 4
Installation: Always use new O-rings and back-up
washers.
E-01509
1. Relief Valve
2. O-ring
3. Backup Washer
4. O-ring
N-15684
Rubber Boot
A
Remove the two screws (Item 1) [A] on the rubber boot
retainer.
N-15690
N-15691
procedure:
. .0, "
0 .;i/ @
N-15693
IMPORTANT
N-15696
N-15697
At the other end of the spool bore, remove the spool seal
(Item 1) [B].
. (if"
N-15698
:;; .'
Loosen the detent adapter [C].
.~~t' .
~ .
,~ .'
CD-15047
....
Remove the stud from the end of the spool [B].
B
Removal of the plastic plug:
b. Drill a hole all the way through the plug using a 7/64
inch tap drill.
c. Turn a 6-32 tap into the plug. Pull the tap and plug
out of the spool. Be careful, do not break the tap.
0.60 inch
(15,2 mm,r--)- - - - - 4
8-14712
~:'-.!...:;\
'- .~:'> ...
u .~,,=
..../'~
CD-15049
Install the detent balls and spring into the detent adapter.
Hold the detent balls in position with the tool (MEL 1278)
and install the detent adapter into the end cap [A].
'j" i
CO-1S047
'"
"
.. ~
,1
.'
.".~
.
• :"
A
Hold the detent balls and spring in position with the tool
(MEL1278) [A].
....];t-..,. .;
CD-15052
Install the detent sleeve (Item 1) [B] over the balls and
into position.
B /
N-15700
Auxiliary Spool
A
Remove the end cap screws (Item 1) [A] & [B].
N-15701
Remove the end cap (Item 2) [A] & [B], O-ring (Item 3)
[A] & [B].
Remove the large spring (Item 4) [A] & [B] and small
A
Remove the nut (Item 1) [A] from the end of the solenoid.
Nm) torque.
4_ ....... '
N-15704
N-15705
Remove the solenoid coil (Item 1) [C] and end plate (Item
2) [C].
IC
N-15706
t
'~.~'''' '
~'r.
Inspection
Check that the load check valve seats are not worn.
Check the rubber boots and retainers that they are not
worn or damaged.
Put clean oil on the spool seal. Install the spool seal (Item
1) [8] on the spool. Be careful not to damage the seal on
the sharp edges.
Slide the linkage end spool seal over the rubber boot
groove.
N-15700
Raise the lift arms and install an approved lift arm support
device. (See Page 1-1.)
A WARNING
A WARNING
A DANGER
AVOID DEATH
• Disconnecting or loosening any hydraulic
tube!ine. hose. fitting. ComponBnt or a part
failure com cause lift arms to d"op .
,
-" -,':::\-+
• Keep oul at the area when lift arms are
raised l.nlo"s supported by an approved
1it1 arm support. Replace it damaged. !>:1145 SW93 6117~
A
Disassembly And Assembly
P--06568
Use a drag link socket and loosen the plug for the flow
control spool (Item 1) [C]
P--06570
Raise the lift arms and install an approved lift arm support
device. (See Page 1-1.)
A WARNING
A DANGER \
~~
",
AVOID DEATH
• Disconnecting or loosening any hydraulic
IMPORTANT
A WARNING
A DANGER
AVOID DEATH
• Disconnecting or loosening any hydraulic
lubeline. hose, titting. CCfllportBnt or a part
failure c;ln caus e lift arms to drop .
• Keep out of ltie area when lift arms are
rai&ad mts lO& supported by an approved
liN ann support . Replace it damaged. .:h.5 sw 9.!: 6 711343
Remove the fan driver belt shield (Item 1) [A] and the fan
belt. (See Page 7-1.)
N-15712
IMPORTANT
Install the bolts (Item 1) [B) in the next set of holes in the
pulley. Turn the bolts in evenly to remove the pulley from
the hub.
.'
N-15715
__ _ .. __ __ __• N-15718
'-'
0 r
I
N-15719
~o
the bearing housing.
d s '.~ N-15720
Remove the drive gear (Item 1) [8] and idler gear (Item I
2) [B) from the pump housing. B
N-15721
Remove the snap ring (Item 1) [C] and seal (Item 2) [C]
~o.
,I<
,1 ;
1
N-15725
Remove the snap ring (Item 1) [0] and seal (Item 2) [0]
from the pump mounting flange .
N-15722
N-15723
parts as needed.
IMPORTANT
Raise the lift arms and install an approved lift arm support
device. (See Page 1-1 .)
A WARNING
2-63.)
hose.
Nm) torque.
IMPORTANT
Raise the lift arms and install an approved lift arm support
device. (See Page 1-1.)
A WARNING
A DANGER
AVOID DEATH ~:\,
~+
• Disconnecting or loosening any hydraulic
Remove the bolt and nut (Item 1) [AJ from the pedal
linkage.
Pedal Adjustment
under the rear of the pedal and the valve spool must travel
full stroke without hitting the floor panel.
A WARNING
Raise the lift arms and install an approved lift arm support
Install the new mounting bolts through the back of the side
panel.
Adjustment
If not, loosen the bolts and nuts (Item 2) [A] and adjust the
tab for correct engagement.
A WARNING
The locking tab should fit into the slot of the interlock as
shown in figure [A], when adjusted correctly.
Remove the front side panel (Item 1) [C] from the loader.
Remove the bolt and nut (Item 1) [A] at the lift pedal
linkage and crossbar.
Remove the three mounting bolts (Item 3) [0] from the left
side panel.
Remove the mounting bolt (Item 1) [8] from the left front
B ,-" .
side panel (Item 2) [8].
DRIVE BELT
Replacing The Drive Belt ............ . .......... . ...... . ...... " 3-63
HYDROSTATIC CONTROLLER
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-19
HYDROSTATIC MOTOR
HYDROSTATIC PUMP
DA Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-37
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-38
STEERING LEVERS
STEERING LINKAGE
TROUBLESHOOTING
Chart
PROBLEM CAUSE
IMPORTANT
~
The functions of the replenishing valves are:
1. To give replacement fluid to the low pressure side of
..
controlled flow to the oil cooler for cooling; Function
1 [Aj.
2. To keep high pressure fluid out of the low pressure
A WARNING
Raise the lift arms and install an approved lift arm support
device. (See Page 1-1 .)
A WARNING
Remove the nut, spring and bolt (Item 1) [C] or [0] from
the neutral cam bracket. (See Page 3-10 for cam bracket
neutral adjustment.)
, '0.
.. )~
Loosen the cam mounting bolt nut (Item 2) [B] and move
the cam to the rear to get free play in the left steering lever.
Tighten the cam bolt. Use a punch and hammer, hit the
cam nut (cam mounting bolt is still tight) until the free play
is removed from the left steering lever [C].
Detent •
Bracket
Pocket •
MC-01944
Loosen the cam mounting bolt nut (Item 2) [C] and move
the cam to the rear to get free play in the left steering lever.
Tighten the cam bolt. Use a punch and hammer, hit the
cam nut (cam mounting bolt is still tight) until the free play
is removed from the left steering lever [0].
Neutral Adjustment
Raise the lift arms and install an approved lift arm support
device. (See Page 1-1.)
A WARNING
Loosen the lock nuts (Item 1) [B] at the linkage rod clevis
at the controller.
Remove the retainer pin at the clevis pin (Item 2) [B) (both
sides) and disconnect the linkage rods at the controller.
Adjust the linkage rod (the rod has right handed threads
at one end and left handed threads at the other end),
turning it to the right or left, until the clevis pin slides
through the controller lever and clevis without the
controller lever moving. When adjusted correctly, there
will be a small amount of freeplay at the clevis pin.
The stop bolts must be set so the end of the steering lever
stroke force is against the stop bolt instead of the
controller lever.
The stop bolt (Item 1) [C) must be set so that with the
controller fully stroked (pushing the steering lever
forward) the bolt head is against the controller lever, then
turn the bolt about 1/2 turn further out so that the bolt limits
the end of the steering lever travel.
Remove the tamper proof cap and loosen the set screw
jam nut on the bottom of the motor (Item 1) [Cl
IMPORTANT
Raise the lift arms and install an approved lift arm support
device. (See Page 1-1.)
A WARNING
Disconnect the left side brace (Item 1) [B] from the shock
absorber mounting bolt. Reinstall the shock mounting
bolt.
Remove the bolts (Item 1) [6] and lever stop plate (Item
2) [6].
N-16053
A
Disassembly and Assembly (Cont'd)
N-16054
..) .~
N-16055
N-16056
A
Remove the rubber boot (Item 1) [A] from the lever.
N-16057
'>
N-1 6058
.
0 .,-,
\2j,--:
' ,--( ' .,'
N-16059
N-16060
~
.,.,".. .~ ct
~ r~
Item Description
1 GUIDE (I
'. ,• .
'I"
·., r. .
ct
" '. , I,
2 PLUNGER 4 3 2 , 1
""
3 SPOOUSPRING ASSEMBLY /,
4 RETURN SPRING
N-16061
Item Description
1 LOCKII\JG DISC
2 SPRII\JG GUIDE
3 CONTROL SPRING
4 SHIMS
5 SPOOL
N-16062
Adjustment
If not, loosen the lock nut (Item 2) [C] first, then loosen the
set screw (Item 1) [C] until a small amount of free play can
be felt between the plunger and set screw. If there is no
free play, steering lever neutral can not be obtained.
N-160S7
IMPORTANT
A WARNING
motor.
Remove only two bolts and one collar (Item 1) [8] and
disconnect the high pressure hose.
Throttle Control
IMPORTANT
Use a allen wrench and remove the top throt1le seat (Item
1) [8].
N-16081
Remove the top shut1le check valve plug (Item 1) [C].
c
Remove the plug (Item 3) [A].
..
~-' il ~~
.~
~'tj 1
Remove the shut1le check valve seat (Item 6) [C].
Ii
Remove the spool (Item 2) [0].
D I,
"
~
~
Inspect all the parts and replace as needed.
II
'~ :p
4
. 1.. _"
, .<:. ,
il '
N-16083
Flushing Valve
N-16085
~
Assembly: Always use new O-rings when installing 7
plugs . ~
3
N-16086
Disassembly
A ..
IMPORTANT
Remove the three O-rings (Item 1) [C] from the end plate
housing.
Remove the bolts (Item 1) [0] from the end plate housing.
Disassembly (Cont'd)
Remove the control lens (Item 1) [A] from the end plate
housing.
.'..
''l'
.,
N-16091
~
7'
N-16093
0-+-.'
N-16095
A
Disassembly (Cont'd)
.. - f. ~2
<~ ~
~
1 O
,
~·C> ." ." O.
.. •
. ..
'<I ;i
'
1<.
".
N-16100
~
Remove the bolt (Item 1) [0] and washer from the rotating
group.
N-16103
Disassembly (Cont'd)
Remove the center pin spring from the center pin [8].
B
N-16106
Inspection
Check the main shaft driver bearings (Item 1) [0] that they
are free of corrosion, erosion and with no damage to the
splines.
Remove the pin (Item 1) [A] from the control lens (Item
2) [A]. Check the face of the control lens for being smooth
and even, free of cracks and scoring.
~
J'
N-16113 N-16112
Check the cylinder block bores (Item 1) [B] that they are
:t
free of scoring and no evidence of wear. B
1
'..:
"
<iI••
'''I
:.,
IMPORTANT
Install the center spring into the center pin. Put grease on
the washer and install it in the cylinder block center bore
[A].
N-16115
Assembly (Cont'd)
.i .,"
N- 16116
~ 1:
Install a new drive shaft seal using a seal driver tool [B].
B
.
~ ,~-
j~
t;,.,
}.:~: j:~: t
N-16101
Install the washer and snap ring (Item 1) [C] into the
housing.
....
,;
motor housing .
N-16119
N-16117
Install the tool (Item 1) [B], bolt and washer(s) (Item 2) [B] I B ,,' ....-
on the end of the drive shaft.
Remove the bolt, washer and tool from the drive shaft.
N-16118
Remove the bolt and washer (Item 1) [C] from the rotating
group center pin.
N-16120
Install the pin (Item 1) [0] into the control lens (Item 2) [0]. D
o
'.1 .~
N-16113
Assembly (Cont'd)
Install the control piston (Item 1) [A] into the end plate
housing.
"":1.
N- 16092
Install the control lens (Item 1) [C] into the end plate IC
housing with the pin going into the control piston .
A
Assembly (Cont'd)
Fig. [0].)
~-'-;,
Remove the drive belt from the pump pulley. (See Page
3-63.)
Lift the hydrostatic pump with the chain hoist and remove
from the engine mounting bracket.
N-15848
N-15849
IMPORTANT
Two are located at the top of the pumps and two are
located at the bottom of the pumps.
/',
N-16125
IMPORTANT
N-16127
DA Controller
Disassembly
IMPORTANT
Disassembly (Cont'd)
N-16134
Use a punch and hammer to mark the charge pump
housing and port block housing for correct installation of
the charge pump [8).
N-16135
Remove the charge pump (Item 1) [0] from the port block.
N-16138
Disassembly (Cont'd)
Remove the coupler (Item 1) [A] and key from the pump
shaft.
N-16141
'::,
N-16142
D
Remove the four mounting bolts (item 1) [0] from the port
block.
N-16146
Disassembly (Cont'd)
housing.
Remove the valve plate (Item 1) [8] from the port block.
B
N-16150
0--+ ·,' 1:
N-16152
Disassembly (Cont'd)
N-16154
N-16159
Remove the four bolts (Item 1) [A] from the servo piston
cover.
/
I ',~
6167
. :~.
N-16169
Remove the snap ring , bushing and snap ring from the
housing [8]. I8
o
Left Pump : Remove the snap ring (Item 1) [C] at the pump
drive shaft seal.
Left Pump: Use a puller with a screw tip and remove the
shaft seal from the pump housing [0].
Disassembly (Cont'd)
A
Left Pump: Remove the snap ring (Item 1) [A] at the drive
shaft bearing . <.
.'
Right Pump: Remove the snap ring (Item 1) [C] from the
drive shaft seal.
Disassembly (Cont'd)
Right Pump: Use a puller with a screw tip and remove the
Inspection
Clean all the parts in solvent and use air pressure to dry
B
them . DO NOT use cloth or paper because small pieces
of material can get into the system and cause damage.
Check the charge pump gears for wear and damage [B].
N-16144
o
Check the servo piston (Item 2) [0] for wear or damage.
~
::-!
Inspection (Cont'd)
N-161 79 N-16181
.
';';"~
.... '.'
N-16180 N-16183
Check the shoe plate, the shoe plate must be flat with no
signs of cracks or wear.
N-16156
Check the pins (Item 2) [0] , the pins must not be bend and
the same length .
"f ~:,;.- it
-,..
N-16157
N-16177
Check the snap rings for not being bend [8]. Replace the
B
parts as needed .
o N-16172
Assembly
IMPORTANT
Right Pump: Install the drive shaft (Item 1) [A] into the
pump housing.
Right Pump: Install the snap ring (Item 1) [C] into the
pump housing.
Left Pump: Install the drive shaft and snap ring into the
pump housing.
Assembly (Cont'd)
Left Pump: Install the snap ring (Item 1) [A] into the
housing.
hoUsing.
Install the other snap ring (Item 3) [B] into the housing .
N-16171
Assembly (Cont'd)
A
Install the servo piston (Item 1) [A] into the pump housing .
CD :.~
" , '~11
.s> ~"'I':r"~~1t;
" t , . .(
-'
.
:-... . ""~0'1.~. '..~._. i
- " ". "-:..... 'I.
{;~. ,!r-.,;~".r
,
. " .':, :.., ':;~" r •
,. oj
.., ",,J
"-': 'J','
. .' "
"'. "• • ",.~ ___,_
~ .. _·c·". •
~ D N-16169
Install the servo piston cover by turning it clockwise [8].
N- 16182
Install the bearing (Item 1) [B] and linkage rod (Item 2) [B] IB
on the swashplate.
.
' ~~
N-16179
Remove the plug (Item 1) [C] and locating pin (Item 2) [C]
from the housing.
".
r
'0 ;
N-16186
Assembly (Cont'd)
cv--.
Hold the adjustment screw and tighten the lock nut [A].
N-16167
N-16189
Assembly (Cont'd)
Install the four bolts into the port block and tighten evenly
until a small amount of space (Item 2) [8] is left between
the pump housing and port block.
Assembly (Cont'd)
N-16147
Install the wear plate with the large opening (Item 1) [A]
toward the intake and pressure side of the charge pump
[B).
N- 16 141
B ". '''-,
.:,"
. ~' ,..
, ..
N- 161 40
Install the coupler (Item 1) [C] and key into the pump drive
shaft.
N-16145
p oi
N- 16 137
N-161 36
Install the large O-ring (Item 1) [B] into the charge pump.
N-161 31
Install the spring (Item 1) [C], seat (Item 2) [C] and charge
relief valve (Item 3) [C) into the port block.
~'.
,
'X
"
~'~~
,~.
Assembly (Cont'd)
N-16130
Start the engine and run at idle speed for 5-7 minutes
before operating the loader. Do Not run the engine above
idle speed while doing the above procedure .
Timing Procedure
The drive belt idler arm stop (Item 1) [A] is located on the
Slide the idler arm stop toward the front of the loader.
Loosen the two bolts (Items 2 & 3) [A] and slide the stop
(Item 1) [A] against the idler arm. Tighten the bolts.
Loosen the bolt (Item 1) [A] on the drive belt idler stop .
Remove the bolt (Item 2) [A] and spacer and slide the
Remove the end cap (Item 1) [0] from the tension pulley
arm.
Remove the bolt (Item 1) [A] from the drive belt tension
Tension Spring
Remove the end blocks (Item 3) [B] from the spring and
check for wear, replace if needed.
Remove the spring pivot pin (Item 4) [B] from the end
block by loosening the nut (Item 5) [B].
N-15842
Remove the arm seal (Item 1) [A] and arm bushing (Item
2) [A]. Check for wear and replace if needed.
><,-'
N-15852
N-15853
Pivot Shaft
N-15845
Remove the end cap (Item 1) [A] from the drive belt idler
pulley.
N-15840
IMPORTANT
Raise the oil cooler and lift from the loader frame .
AXLE SEAL
Removal And Installation ... . ...... . ............................ 4-13
PARKING BRAKE
Disassembly And Assembly .................... . ........... . ... 4-10
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-9
REDUCTIOt\1 GEARCASE
Disassembly And Assembly ..... . ...... . ...................... . 4-26
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-23
Loosen and remove the mounting bolt (Item 1) [A] and nut
from the spring mounting bracket (Item 2) [A].
' --;lj".-,
• ,1"",-----1
P-04156
Remove the bolt (Item 1) [B] and nut from the lift linkage
and crossmember linkage.
Disconnect the hose (Item 3) [C] which goes to the lift lock
valve.
N-15642
,fJ . . .
N-15640
'0
N-15641
N-15639
Remove the nut (Item 1) [8] and solenoid coil (Item 2) [8].
B
N-16067
.' N-16068
Remove the fitting (Item 1) [0] and the check valve (Item
2) [0] from the block. Check for correct function of the I0
check valve and replace as needed.
'p""
~
~'>
1 '
;'
N-16066
the chaincase.
0'
'of
, ~
'<.' -"
.~
N-15630
N-15637
N-15631
A
Disassembly And Assembly (Cont'd)
• I N-15632
N-15633
', . N-15634
Remove the three bolts from the hub end plate (Item 1)
[A].
Install two long puller bolts into the hub. Install the puller
cross-bar (Item 1) [0]. Install a spacer on the end of the
axle and against the Port-a-Power ram jack (Item 2) [0].
A WARNING
Install a puller into the drilled hole and remove the axle
seal [C].
Use a hammer and chisel and split the wear ring [0]. Be
careful not to damage the axle surface. Remove the wear
ring from the axle.
If the wear ring was removed from the axle, install a new
wear ring (Item 1) [A] into the axle seal.
Install the wear ring/seal or seal into the axle tube [C].
4-3.)
Remove the bolts (Item 1) [B] and end plate from the axle
sprocket.
Remove the end plate (Item 1) [C] and shim (Item 2) [C].
Push the axle out until the ram jack is at the end of the
stroke. Retract the ram, add spacer and push axle out
again. Repeat this procedure until axle is out of the
sprocket.
Using the long driver tool handle, install the bearing cup
tool (Item 1) [B] (MEL1202-13).
Remove the inner bearing cup from the axle tube [C].
Raise the lift arms and install an approved lift arm support
device. (See Page 1-1 .)
A WARNING
Page 3-1.)
4-5.)
3-1.)
Remove the eight bolts from the front cover (Item 1) [A].
The rear two bolts (Item 1) [C] , also attach the front of the
fuel tank sheild. The fuel tank shield will have to be lifted
a small amount so the rear cover can be removed from
the chaincase.
Raise the lift arms and install an approved lift arm support
device. (See Page 1-1.)
A WARNING
Page 3-1 .)
Page 2-1 .)
parking brakes.
Left Side Only: Disconnect the hose (Item 1) [A] from the
bucket position valve.
Left Side Only: Disconnect the hose (Item 1) [B] from the
bucket position valve .
Right Side Only: Remove the lift lock valve. (See Page
2-1.)
Right Side Only: Remove the front fuel tank bracket (Item
1) [C] from the reduction gearcase.
Page 3-1 .
,.,-;11,
Remove the three bolts (Item 1) [8] and plate at the drive
gear shaft.
Remove the large gear and idler gear from the gearcase
housing [A].
Remove the drain plug (Item 1) [A] and drain the oil into
a container.
LIFT ARMS
OPERATOR CAB
MAIN
REAR DOOR
REAR GRILL
SEAT BAR
Turn the bolt (Item 1) [C] into the clevis five turns (both
sides) .
Remove the retaining pin (Item 1) [0] and clevis pin (both
sides).
side) .
sides).
Wrap tape around the left pivot end (Item 2) [0] of the seat
bar.
Wrap tape around the cab grab handle (Item 3) [0] and
the front edge of the cab (Item 4) [0].
A
Removal And Installation (Cont'd)
Position the seat bar in the recess on the left side of the
cab (Item 1) [0]. Position the left side pivot end of the seat
bar between the cab and the grab handle (Item 2) [AJ.
Lift straight up on the right side (Item 3) [AJ of the seat bar.
Continue to lift on the right side of the seat bar and allow
the left side of the seat bar to rotate between the cab and
the grab handle (Item 1) [B].
Lift the right side of the seat bar until it clears the right side
screen of the cab [C].
Remove the left side of the seat bar pivot from between
the cab and grab handle and remove the seat bar from the
cab [0].
Assembling Components
Assemble the parts as shown for the left side of the seat
Washer (Item 2)
Assemble the parts as shown for the right side of the seat
T,2" ,.
,
,.
'9
",1
],
.
"
~
~G5
'
< . '. -
' .. (
Mounting Bolt (Item 6)
' 6 . 5
Loosen the lock nut (Item 1) [C] and turn the bolt (Item 2)
[C] out of the clevis.
Pin (Item 1)
Clevis (Item 3)
Washer (Item 5)
Spring (Item 6)
Bushing (Item 7)
Bolt (Item 8)
A
Remove the rubber stops (Item 1) [AJ (both sides).
~ j\:.
Cil
-~
..
Remove the pivot pin (Item 1) [A] at the top of the gas
cylinder.
Remove the cotter pin and pivot pin (Item 1) [B) at the
bottom mounting bracket.
A WARNING
Remove the nut (Item 1) [A] from the pivot bolt (both
sides).
Install the pivot bolt, washer (one on each side) and nut
(Item 1) [B] (both sides).
Install the sling under the pivot bolt and pivot of the
operator cab [B].
Remove the mounting bolt from each end of the track and
replace the adjustment track if necessary.
Seat
Reverse the removal procedure to install the operator Pan
seat.
\ MC-02043
Remove the bolt and washer (Item 1) [A] at the pivot pin
of the rod end of the tilt cylinder (both sides).
Hit the bolt with a hammer to remove the pivot pin from
the Bob-Tach frame (both sides).
N-15360
Remove the bolt at the pivot pin. Remove the pivot pin
from the rod end of the tilt cylinder [0] (both sides) .
Check the bushings in the lift arms for wear and damage,
replace as needed [0).
Use a punch and hammer, remove the roll pin (Item 1) [A]
from the clevis and wedge .
N-15369
." N-15372
Bob-Tach Stops
IMPORTANT
retainer plate.
Nm) torque.
Right Side: Remove the bolt (Item 1) [0] from the pivot pin
retainer plate and lift arm support device spacer (inside
the lift arm side frame).
Install a sling (Item 1) [AJ and chain hoist on the lift arms.
Remove the lift arm support device from the lift arms [8].
N-15421
N-15420
Remove the bolt (Item 1) [B] from the retainer plate pivot
pin (both sides).
.,',
N-15419
· A WARNING
Lift the rear door away from the loader frame and put the
door flat on the floor.
Turn the bolt (Item 2) [C] in or out until the door contacts
both the top and bottom of the loader frame with the lever
in the latched position .
NOTE: It takes approximately 501bs. (20 kg) of force
to push the lever down when the latch is
correctly adjusted.
With the set screw up, the flanges on the bolt must be to
the side so that the set screw aligns with the flat surface
at the end of the bolt.
Raise the lift arm and install an approved lift arm support
A WARNING
Remove the two bolts (Item 2) [B] from the gearcase and
(Item 2) [C].
Loosen the fuel lever sender in the fuel tank. Remove the
sender (Item 1) [0]. from the tank.
Raise the lift arm and install an approved lift arm support
device. (See Page 1-1.)
A WARNING
Disconnect the fuel fill hose (Item 1) [8] from the fuel tank.
Disconnect the vent hose (Item 2) [8], from the front fuel
tank.
Disconnect the vent hose (Item 3) [8] for the rear fuel
tank .
Remove the two bolts (Item 4) [8] from the fuel tank
shield.
Remove the bolt (Item 1) [C] from the fuel tank shield.
At the lower right side (Item 1) [A], of the rear fuel tank,
disconnect the hose for the cross-over tube to the front
fuel tank.
Remove the fitting (Item 1) [B) with the pickup tube from
the fuel tank.
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-14
BATTERY
FRONT LIGHTS
STARTER
TROUBLESHOOTING
Chart
PROBLEM CAUSE
3. Battery is damaged.
Description
The fuse capacity and circuits are listed below [B] & [C]:
Fuse ·~ m·
-=-"
. -" ,,--• • •••':::--...... .
2. 10 AMP BICSTM
3. 15 AMP BOSS
4. 10 AMP PWM
5. NOT USED
6. 25AMP ACCESSORY
7. 25AMP ACCESSORY
8. 25 AMP LIGHTS
RELAY SWITCHES
P-10300
Location
o
The switches are for the starter, switch power, starting aid
and brake.
BI
P
bracket and remove the relay switches.
;0 I 15
BOSS
I irJ
rLJ I 2ii
A,CC£88ORY
I
6803593
6803593
A WARNING
Remove the nuts and bolts from the hold down clamp
(Item 1) [0] and remove the holddown clamp.
A WARNING
A WARNING
A WARNING
After the engine has started, remove the ground (-) cable
(Item 4) [A] first.
A WARNING
Connect the fuel stop solenoid, start the engine and run
at 2600 RPM .
2600 RPM.
A WARNING
purposes [B].
IMPORTANT
Move the alternator until the belt has 5/16 inch (8,0 mm)
movement at the middle of the belt span (Item 1) [B) with
15 Ibs. (66 N) of force.
Use a soft jaw vise to hold rotor while removing pulley nut.
/@-----®--~- --0-:
-----------------~
1 23 I
Remove front case half from the rotor using a plastic
hammer.
,- ---
Un-solder the stator leads from the rectifier. Remove the
stator.
I
:
~o-5I . ~
4' ~
L_ (1)--~~\D\
:I
~2 -~--®-- ~---
_I .!f !,Q
~o I
7
$I ,t -, 8
-
I
I
o 6 II
,_ _------ -------------------- J
: /12
I ,---«>--C(c
~ _0c:=3 r-'" 13-' -
c----~:t~ ::d------~~-;
: : - ..
I r-':'''': __ -...J
-=_'§.~:!...=-..:--
I
I fi'lh-
c
I L...-":lr~,"
:.::;'"
1
@A :I
9
~--
I
. - - .. -~- ..
I .. - - ' - ..
I
L
15 --- C-03312
P-01369
Touch one probe to a bare stator lead and the other probe
:':}
P-D1365
P-D1378
Touch one probe to the diode and the other probe to the
connected heat sink and read the meter [0].
, !I
Reverse the probes to check the diode in the other
direction.
...
P-D1370
Touch one probe to the diode and the other probe to the
connected heat sink and read the meter [A].
Assembly
Place the rotor in soft jaws when tightening the shaft nut.
starter solenoid .
Remove the nuts (Item 1) [C] & [0] and mounting bolts
(flywheel side) from the starter.
Parts Identification
1 Felt Washer
2.
3.
4.
Bearing
Armature
Bearing 6
8
I
~
r ~
9 10
5. Field Windings
I
Housing Assy. I ~
6. Cover
~ ~/~
7. Brush Holder
8. Cover 11. Brushes
9. Bolt
4 . . 12. Cover
10. Bolt 13. Gasket
I. . ,~~
( , 14. Screw
" ® ,
/ -1
15.
16.
Pinion Shaft
Nut
/ 17. Washer
1 /
/
18. Nut
/
I /
19. Washer
~,,~" /
/
./
20. Roller
( "~ /
/
I I /
: 2 /
I
II
I
I
I
I
I
I / /
/"
"
//
//
/
/
/
I ' 0,I
II,
17
16
?1
~ " Ij ,
11
11
22
I
/ 1
// I
,,/ I
25 16 // I
24 17 /// I
// I
23 // I
I / I
I /// I
I / I
~/
I // 35 '
1 /
/ ) /
I / /
~I /
I " 34
21 . Retainer
: /",,/ 33
~
22. Pinion
I
~ "
23. Ball
31 24. Spring
I "
30
~,,/
~"~I \
25.
26.
Housing
Screw
27. Washer
I ,,/
/~,,~ 32 28.
29.
O-ring
Housing
30. Gear
/ Ii:( 31. Spring
CI "
/,," 32. O-ring
33. Drive
29 34. Spring
35. Shaft
O-<l2297
B-14441
Remove the through bolts from the drive end frame [B]. 8
Assembly: Tighten the through bolts to 60-104 in.-Ibs.
(6,8-11,8 Nm) torque.
B-14474
B-14442
- m-
B-14468
[A].
B-14446
B-14447
B-14448
Remove the pinion (Item 1) [0] from the drive end frame .
8-14449
A
Remove the retainer and rollers from the drive end frame
[A].
8-14450
Overrunning Clutch
Retainer and Rollers
Steel Ball
Return Spring
Armature Bearing
Felt Washer
8-14451
External Pinion
8-14452
8-14453
8-14457
ARMATURE (Cant' d)
8-14459
B
Service Limit - 0.008 inches (0,2 mm)
kF""-&- -=:: CD
usually indicates an open-circuit, and correct it using
8-14460
B-14461
U .-Bearing
.-Armature
I B-14439
963 Bobcat Loader
-6-24- Service Manual
STARTER (Cont'd)
FIELD WINDINGS:
Check all the connections for clean and tight solder joints.
OVERRUNNING CLUTCH:
D
Inspect the pinion , it must rotate freely in the direction of
the starter rotation and locked in the opposite rotation [0].
'~I
The starter should show smooth and steady rotation
immediately after the pinion is engaged, it should draw
+ I~,
,L._. J
less than the specified current.
Service Limit - 220 Amp. Maximum Draw Starter
8-14440
Pry the rubber light mount loose from the operator cab
(both sides) [A].
Lower the light from the operator cab and locate the three
instrument panel mounting bolts (Item 1) [8] (both sides).
Repeat steps [A] and [8]. Pull the right instrument panel
down and disconnect the wire harness connectors from
the panel. Remove the panel [0].
Pry the rubber light mount free from the operator cab [B].
Pull the light down and remove the three mounting bolts
(Item 1) [C] from the instrument panel.
BLOWER FAN
Installation .... . .. . . . .... . ..... . .... . ....... .... ........ . . . ... 7-65
COOLI NG SYSTEM
Rear Oil Seal Installation . . ............ . ........ . .... .. .... . .... 7-74
CYLINDER HEAD
ENGINE
Installation . .. ......... .... ........... . ..... . ..... .. ... . ...... 7-51
SERVICE
Removal ..... . ..... . .. . . . ......... . . ......... . .. . . . ......... . 7-49
ENGINE
ENGINE BLOCK
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7-88
Piston Cooling Jet Alignment .... . ...... . .... .. ........... .. . ... 7-88
EXHAUST MANIFOLD
FAN GEARBOX
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7-19
FLYWHEEL
Removal and Installation .... . .... .. .... . ..... ... ............. . . 7-39
INTAKE MANIFOLD
LUBRICATION SYSTEM
Oil Pressure Relief Valve Disassembly And Assembly ... . .......... 7-86
Oil Pump Removal ........ . . . ............ . . . ..... ' .... . ....... 7-84
Oil Screen And Pick-up Tube .... . . . ........ . ... . .......... .. ... 7-84
Number
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7-67
RADIATOR
ROCKER SHAFT
TROUBLESHOOTING
TURBOCHARGER
VALVE CLEARANCE
Chart
The following troubleshooting chart is provided as an assistance in locating and correcting problems which are most com
mon . Many of the recommended procedures must be done by authorized Service personnel only.
PROBLEM CAUSE
Slow crankinq speed. 1, 2 3,4
Enqine will not start (cold) 2, 5, 6, 7
Engine will not start 1, 2,3, 4,5,6,7, 8,9,10
Difficult to start. 1 2 3, 4,5,6,7, 8,9,10,11 , 12,13,14, 15,16 18,19,20,21
No ~ower from enqine 9,11,15, 16,17,18, 19,21,22, 25,26 , 27
Enqine mis-firing. 11, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24
Too much fuel consumption. 7 16 17 18 20 21 22 28 29 30
Black exhaust. 16,17,18,19, 20,22,25, 27
Blue/white exhaust. 4, 7,16,18,19,22,31,32
Low oil pressure. 4 31 32 33 34 35 37 38 39 48 51
Enaine knockina. 4 5 17 18 19 20 23 34 35 36 37 38
Enqine running rough. 7,8, 9, 10, 11,12,13,14,20,21,22, 25 , 26,27,28,29,40,52
Vibration. 16 30 50 51 52
High oil pressure. 4,33,36
Overheatina. 18 19 20 22 25 31 33 46 47 48 49
Too much crankcase pressure. 25 35 36 42
Poor compression. 17 18 22 23 30 32 34 35 36 44
Start and stop. 9 11 13 15 17 22 23 30
Excessive oil consumption. 4, 22,32,36,40,41 , 42, 43, 44,45
Raise the lift arms and install an approved lift arm support
Mark the front side of the stop bracket (Item 1) [B) and
remove the stop bracket
Remove the mounting bolt (Item 1) [B] on the top left side
of the engine heat shield.
Remove the four mounting bolts (Item 1) [B] that hold the
cleaner housing.
Remove the bolt and nut from the mounting strap (Item
2) [A] (both sides) .
A WARNING
A ... ; a l
Remove the hose clamp (Item 1) [A] from the right side
radiator hose.
Remove the hose clamp (Item 1) [B] from the right side
radiator hose.
N-15791
Raise the lift arms and install an approved lift arm support
Remove the fan drive belt from the hydraulic pump pulley.
Remove the two bolts (Item 1) [A] from the fan gearbox
housing.
Remove the fan tensioner pulley and belt from the loader
[C].
N-15732
Remove the idler pulley bolt (Item 1) [0] and nut (Item 2) I0
[0].
Remove the pulley (Item 3) [0] and belt guide (Item 4) [0].
N-15733
P-04956
Remove the bolt (Item 1) [C] , arm (Item 2) [C] and spring
(Item 3) [C] from the mounting bracket.
/D
N-15734
Check all the parts for wear and damage and replace as
needed [D]. I0
See the Parts Microfiche for the correct part numbers.
N-00303
Raise the lift arms and install an approved lift arm support
Remove the two mounting bolts (Item 1) [A] from the front
Remove the two nuts (Item 1) [B] at the rear of the fan
drive mounting plate.
Remove the two bolts (Item 2) [0] and remove the fan
gearbox mounting plate (Item 3) [0].
*'
.~
. torque.
Tighten the puller bolts evenly to loosen the fan from the
shaft.
Disassembly
Remove the three pulley bolts (Item 1) [A]. Turn them into
the next set of holes on the pulley. lighten the bolts evenly
until the pulley is removed from the hub.
N-15761
, ~~
N-15763
Long Housing
Remove the four mounting bolts and the part number tag
[A).
A WARNING
P-02966
Support the lower flange and press the shaft from the IC
bearing [C).
Support the bearing and press the shaft from the bearing I0
[0).
P-03298
Disassembly (Cont'd)
Short Housing
A WARNING
Remove the large snap ring from the flange end of the
housing [C].
P--02969
Disassembly (Cont'd)
shaft.
Remove the snap ring from the cap end of the housing I8
[B].
P-02998
Press the bearing from the tapered end of the shaft [0].
o
P-03088
Disassembly (Cont'd)
A
Press the bearing , shims and gear from the shaft [A].
P-Q3001
P-Q2972
Long Housing
[A].
of the housing .
Assembly (Cont'd)
A
Install the small snap ring in the groove above the shims
[A].
Install the gear key in the flange end of the shaft [B].
P-02967
P-02966
Assembly (Cont'd)
A
Short Housing
P-02969
Install the large snap ring in the groove above the shims
[C].
" P-02970
Align and press the gear on the shaft (teeth toward the
tapered end of the shaft) [0].
P-02971
Assembly (Cont'd)
After the gear is seated, drive the key down inside the
gear key way [A].
P--Q2975
P--Q2976
Install on the shaft, the same number and size shims that IC
were removed during disassembly [C].
P--Q2977
P--Q2974
Assembly (Cont'd)
Install the snap ring in the groove above the bearing [A].
P-02973
Checking Backlash
NOTE: For procedures requiring the use of LOCTITE
adhesive, thoroughly clean and dry affected
parts before the application of LOCTITE.
The backlash tolerance between the gears should be
0.005-0.008 inch (0,127-0,203 mm) .
Install the long key (Item 1) [0] and the pulley (Item 2) [0].
A
Put the fan nut (Item 1) [A] on the shaft and tighten snugly.
P--{)2982
two housings.
the gear on the screw end of the short shaft and add
shaft.
Replace as needed.
A
Removal And Installation (Cont'd)
~((Q)~@
~~
Install a dial indicator to check the flywheel run out [A].
Flywheel run out must be less than 0.012 inch (0,30 mm) .
Adjustment
A
Adjust the valve clearance as follows:
clearance is obtained.
Use the following sequence to set the valves [B] & [C]:
B-{)5569
~ Cylinder Number 1 2 3 4
Valve Number 1 2 3 4 5 6 7 8
Valve
I = Intake I E I E I E I E
E = Exhaust
Checking
Install a gauge to the outlet side of the lift pump. Turn the
Disconnect the fuel in-let hose (Item 1) [0] from the lift
pump.
mounting bolts.
torque.
torque .
Turn the crankshaft over slowly until the hole (Item 1) [C]
in the fuel injection pump gear, timing plate and the hole
in the hub, align with a hole in the body of the fuel injection
pump .
Remove the mounting bolts (Item 6) [A] from the fuel filter
mounting bracket.
Remove the fuel filter mounting bracket and fuel filter from
the engine.
torque .
Remove the fuel pump and timing pin from the engine .
A WARNING
Disconnect the tubelines (Items 3,4, & 5) [A] from the fuel
filter housing.
IMPORTANT
Loosen the nut (Item 1) [B] at the fuel injector and remove
it from the cylinder head.
N-16407
IMPORTANT -~~~
1-2027--0284
A WARNING
8-13330
Diesel fuel or hydraulic fluid under pressure
can penetrate skin or eyes causing serious
injury. Fluid leaks under pressure may not be
visible. Use a piece of cardboard or wood to
find leaks. Do not use your bare hand. Wear
safety goggles. If fluid enters skin or eyes, get
immediate medical attention.
W-2074-1285
Raise the lift arms and install the lift arm support device.
(See Page 1-1.)
A WARNING
Disconnect the hose (Item 2) [B) from the front side of the
hydraulic pump.
Disconnect and cap the hoses (Item 1) [A] from the fuel
filter.
Remove the mounting bolts (Item 2) [A] from the fuel filter
mounting bracket.
Remove the fuel filter and fuel filter mounting bracket from
the loader.
, ,
[A].
Removal
pump.
Remove the mounting bolts (Item 6) [A] from the fuel filter
mounting bracket.
Remove the fuel filter mounting bracket and fuel filter from
the engine.
injector pump.
IMPORTANT
Removal (Cont'd)
Remove the four nuts (Item 1) [B] and remove the rocker
shaft assembly [B]. (See Page 7-54) for disassembly
and assembly of the rocker shaft assembly.)
NOTE: There are three different length head bolts. - I (-- ,-- - --) - - ( - - -", - - { ...-- - -.....;- - - (--- --)-.... \
Figure [0] shows the three different bolt I I '7@l1S 1@18 ,.-(~\" '-Z@l2' 1@13 I I
lengths: S short; M medium & L long bolts. J \
,,\
,@19
'-': =--,
I I
vI I
...... ~@'
=
-.:::;:r; 9
/~ ~
II '~;I
I
..... ,
~f
(@}1
~,;;,
I I
1'-"
'- ,
~
", M\3
=:;:,;
I
;::
I, ~I
• '- I
1/
I /
q)
14"~/
m
/ ,
I \~ ) ( ) \. / \ ) \ . . ) \. ) "- I \ ./ I I
@ '20 t@)\ 10
", ,y @7 (@ 4
~"
15(®.... ,
Lift off the cylinder head and clean the bottom face.
(':t§121 (@ 22_ ~1 11 ~112~L ~~ (@s _ (@ 17') ~1 16"")
'-./ I ~ I '" t ) 0' ~ II ~I\ - .... ( \" ""l./ - ') \ ~
L- _ _ _ _ _ - - -i I l\--- ~/_ .J '- -
Remove the valves from the cylinder head. (See Page - -'
7-55.)
l 8-05561
Using a feeler gauge between the straight edge and head, II ''/ ''''':;:' '1 ' '1' ~G~ 't' __~?: 't' I 2
check for warpage .
Installation
Make sure the mating surfaces of the head and block are
clean.
Clean the engine block bolt bores with the correct size tap
to ensure correct torque for the cylinder head bolts.
-----
Clean any debris out of the cylinder bores. ~
~
NOTE: The locating pins (Item 1) [8] are pressed in ~
the engine block so the head gasket (Item 2)
[8] can be positioned correctly. @ e
The head gasket is installed with no sealer.
Place the head gasket in position with the Front Top (Item
2) [A] marks in the correct position.
Lower the cylinder head in position. -I r---r----)- -(--')- - - {.. ---- -...;- - - (...----..)---,
II I\ 'r@\18
'<:: ~,
1@18
/ ... ~
<"_"
(\
r:@i2'
'""',
~
r@13 I
J ~
Figure [C] shows the three different bolt lengths: S-short; "'- '\
(019
I I
1' '@J'9 1,-"
-1 1
=
(@) 1 I'~"
I
~)3
'\;."f I /'0.q )
14'=-/
I <~
;::'-::7
I I
"--:"
M-medium and L-Iong. ,
I t(~\--/ - \ I/' ..... \-~~ , - ( ~\--r~\ (-.....)--( ........ ~ r
I \~ ) ( J \ / \ ) ,, ) , , ) " I \ /. } I
Install all the cylinder head bolts in the correct location I~~~'~ - ~-' / _~~ ~ ~ -=~~
[C]. @:l120 f@\10 f@\7 (@')'4 15(®
d' "'" '># ~~ _~
Following the bolt tightening sequence shown in [C]. ( ':~121 1@l' 22. ~111 ~\lCL (®16 ~'5 _ (@ 17'l ~'16-~1
,-/,"" ~I ""~l' ) 0' "' 1f~1'- v -~ ( \""l/ ~;'\ ~
Tighten all cylinder head bolts to 80 ft.-Ibs. (108 Nm) - --' ~ _ -- -- _ --' I 1\ - - - ~ /- J '-- -
torque .
8--05561
Additional tightening of the head bolts requires the use of
a torque angle gauge (Item 1) [0]. Tighten the short bolts
150°, medium bolts 180° and long bolts 21 0°, in the same
sequence as shown in [0].
Installation (Cont'd)
A
If no angle gauge is available make a suitable mark on the S M L
head bolt corner. Make another mark on the cylinder head I
~ '~
the correct number of flats away [A]. Turn the head bolt
until the lines match.
1 I
8--05563
Tighten short bolts 2.5 flats , medium bolts 3 flats , and long
bolts 3.5 flats in the same sequence as shown in [B].
B
I-
-I (~( - ~;- - ( -- "'1- - I ~ -- ';- - - (-- -)---\
!' I\ '(@ils
-. : : Y, 1@l8
/__ '/
,_,
( "
'-C®2'
~ =--,
i@13
'J::- ~
I
) '"
I
",
0 19 1'
,,
-) 1
I I =
{fM\\9 1 ' ) 1 riM\ll 1'-"
I
" M )3 I'''j'
"'(I). )
~ 1'
14l ~
I I G~ I I I
~ ~? \'=/
11r~\ --/ - \ ( - " ~- /~, - (~\-/~\ (----)--;-----) r
,\..:::J , ..... t '- I \\JI '- I ,'- I
\. .
I \",
ri\\1 20
~
I (, )
-=--_.::::...- -= \ ~___
((m\lO
- = -=-_
/ \",)
_--=- ==- '-..~/
\._1 , _ I
-=
{~\7 (~\4
= \~/ J
_ Y ____J
15\@\
I
Y g ~ g g
('-f3121 (@' 22. {§jIll (®\12-L~16 ~5 _ (@ 17-\ ~' 16-"')
,
~ /,= I
-' L
"" '"
_ ~- _
t ) 0'
_ _
" '" 'I ~I\
_ I I
-
1\ - -
-
-
(
~ /
\" "'l_A
....I " -
~:1 '-..
-
r 8--05561
Install the push rods [C].
Install the rocker arm shaft. lighten the rocker arm nuts
(Item 1) [0] to 55 ft.-Ibs. (75 Nm) torque.
NOTE: Make sure the oil feed line seal (Item 2) [0] is
correctly positioned in the cylinder head.
Installation (Cont'd)
IMPORTANT
pump.
Install the fuel filter mounting bracket and fuel filter using
the mounting bolts (Item 1) [C].
housing.
pump.
A
Disassembly And Assembly
Remove the clips (Item 1) [A] from both ends of the shaft.
Remove the location screw (Item 2) [A] for the oil supply
connection.
c"
4) [A], rocker arm (Item 3) [A] and spring (Item 5) [A].
press in the new one making sure the oil holes line up.
inch
(mm) Inner Sprin
8-05552
r
Use the following chart to check valve guides.
Inside Diameter
(Item 1) [8] .. 0.3744-0.3764 inch (9,51-9,56 mm)
3
Outside Diameter
121~
(Item 2) [8] .. 0.6260-0.6264 inch (15,90-15,91 mm)
I nfJI-Q
Valve Guide Bore ...... .. ...... . 0.6248-0.6256 inch
(15,87-15,89 mm)
~lQ~
I
/
I
/
I I
Lift the valve (Item 2) [C] 0.60 inches (15,0 mm) and move
the valve in and away from the gauge (Item 1) [C]. Record
this reading.
8-05549
Valve Guide Installation
8-05548
Ref. Valve
1.
Specifications
Intake ... 4 .829-4.854 inch (122,66-123,30 mm)
fl~ ,
2
2.
Exhaust . 4.829-4.854 inch (122,66-123,30 mm)
(1,95 mm)
as possible [B].
~0
_ t" ao
. .~-:
P-08720
Assembly
A WARNING
Install the inner and outer springs (Items 4 & 5) [C] on the
washers with dampener coils (Item 6) [C] toward the Wear safety glasses to prevent eye injury when
cylinder head. any of the following conditions exist:
• When fluids are under pressure.
Place the valve caps on the springs (Item 7) [C].
8--05565
Description
~
The tool listed will be needed to do the following
procedure:
~~G
the timing cover around the crankshaft.
~55571
NOTE: If the cover is not centered correctly the
'10"
backlash between the injection pump gear
and water pump gear will be affected. This
can cause seizure of the injection pump. I I
Clean the gasket mating surfaces.
Hold the timing cover in position and install two bolts that
bolts.
Rotate the crank shaft until the timing marks (Item 1) [B]
are lined up.
Remove the three bolts (Item 3) [B] from the idler gear
(Item 4) [B].
A
Remove all the timing case bolts [A].
Remove the two bolts (Item 1) [A] from the front of the oil
pan.
P-0873T
Clean the mating surfaces. If the oil pan was not removed
trim the oil gasket flush with the block.
Using the three idler gear bolts, position the idler hub
(Item 3) [B] with the lubrication hole on top. Press the hub
on by tightening the bolts evenly.
Install the case cover gasket (Item 2) [B] and trim the
bottom to fit. Apply sealant to the bottom ends of the
gasket.
Tighten the two oil pan bolts (Item 1) [A] to 16 ft.-Ibs. (22
Nm) torque.
Place the fuel injection pump gear (Item 4) [0] in the case.
NOTE: Make sure all the timing marks (Item 5) [0] are
'. '..
in correct alignment.
Removal
A
Remove the timing case cover. (See Page 7-60.)
Turn the engine over and remove the oil pan mounting
bolts [A].
~''''')-~
Installation
A .. • ~
Clean and inspect the camshaft and tappets for
excessive wear and damage.
Check camshaft end play. The end play for a new engine
is 0.004 - 0.016 inch (0,10 - 0,41 mm), service limits
0.021 inch (0,53 mm).
Install the fuel pump and gasket. Tighten the bolts (Item
7-51.)
Removal
Remove all the carbon from the top of the cylinder liners.
Disassembly
A
Mark the piston to indicate the cylinder number (Item 1)
[A] as shown on the connecting rod .
B-05570
piston pin.
Push the piston pin (Item 3) [8] out by hand. If the pin
doesn't push out easily, heat the piston to 100°-120° F
(40°-50° C) for easier removal.
P-08747
) ® @
@
B-05571
B-05572
Install the oil control ring over the spring (Item 1) [A].
Install the cast iron ring with the tapered face (Item 2) [A]
in the second groove with the word TOP or symbol facing
~ ~ ~~
..
,
square and parallel within the limits of ± 0.01 0 ~ ~
inch (0,25 mm). 0.010"
0.010"
•
(±o.25 mm)
(±0.25 mm)
Measure this 5.0 inch (127 mm) on each side of the
connecting rod axis on a test fixture.
Press out the old bushing . Clean the bore and remove any
burrs.
Press in the new bushing making sure the oil feed holes
line up.
NOTE: Make sure the piston ring end gaps are 120 0
apart.
When the piston has cleared the cooling jet, rotate the
piston assembly so that the arrow or FRONT mark is I D
toward the front of the engine [0].
c==J
® ~
@
®
® @ ®
8--05579
Installation (Cont'd)
Removal
Remove the water pump. (See Page 7-78.)
7-60.)
piece.
installation .
Removal (Cont'd)
The main journals and the crank pins of standard size can
be machined 0.010 inch (0,25 mm) 0.020 inch (0,50 mm)
or 0.030 inch (0,75 mm) .
NOTE: See SPECIFICATIONS Section, Page 9-1 for
more crankshaft specifications.
A-02763
Installation
Make sure the main journals are clean and install the
crankshaft in the block [B].
Make sure the locating pins for the main caps are in
position.
Install the main cap bolts and torque in steps working from
the center outward.
Installation (Cont'd)
The seal can be installed from flush with the housing face
(Item 1) [B] to 0.27 inch (6,86 mm) (Item 2) [B] back from
~
the housing face. Install seal so that the seal lip does not
line up with any worn areas on the crankshaft. ----. .--@ 8--05581
~I~I~
correctly.
~I\-~
I nstall the seal replacer tool (PD 145-3) (Item 4) [0] on the
crankshaft.
Camfully push the seal and housing (Item 3) [0] over the
tool and crankshaft and into position on the dowels.
Remove the tool. c1fIr 8--05582
Pry the crankshaft to the rear of the cylinder block and set
the dial indicator to zero.
Remove the pry bar and record the dial indicator reading
[C].
IC
The end play specification is 0.0075 inch (0,019 mm)
maximum.
Description
The water pump is gear driven from the gear off the fuel
injection pump.
The oil cooler (Item 1) [B] is installed on the left side of the
engine. Coolant from the by-pass connection at the rear
of the coolant pump passes through a pipe to the oil
cooler.
Thermostat Testing
':
Remove the bolt and nut (Item 1) [A] that hold the
low-pressure fuel pipes to the top of the cooler.
Remove the support bracket (Item 1) [B] for the oil cooler.
Loosen the hose clamp (Item 1) [C] at the front of the oil
cooler.
N-16397
Description
Engine oil from the oil pan sump passes through a strainer
(Item 2) [A] and pipe to the suction side of the pump.
The engine oil passes from the outlet side of the pump
through a pipe to a relief valve (Item 3) [A], which is
installed in the bottom left side of the cylinder block. The
relief valves opens if the oil pressure is too high; this
allows some of the engine oil to return to the sump.
From the relief valve, engine oil passes to a plate type oil
cooler (Item 1) [B].
Oil flows through the oil tubes (Item 2) [B] to the filter.
The engine oil passes from the filter (Item 1) [C] to the
cylinder block.
Remove the oil cooler pipes (Item 1) [A] from the filter
adapter. Disconnect the turbocharger oil supply line.
Remove the four bolts (Item 1) [8] and the filter adapter
(Item 2) [B].
Remove the bolt (Item 1) [A] that holds the bracket (Item
flange .
air.
Replace as necessary.
3) [A].
Tighten the bolt (Item 1) [A] for the pick-up tube bracket.
cap.
Remove the snap ring (Item 1) [C] , idler gear (Item 2) [C],
and washer.
Lubricate with clean engine oil and install the washer, idler
backlash between the idler gear and oil pump gear [B].
(0,012/0,643 mm).
Install the oil screen and pick-up tube. (See Page 7-84.)
Install the outer rotor and check the outer rotor to body
clearance [A).
o
/
Clearance between the outer rotor and body must be
0.006-0.013 inch (0 ,15-0,34 mm).
B-{)5592
Install the cover and tighten the bolts to 16 ft.-Ibs. (22 Nm)
torque.
Oil Pressure
Assembly
Relief Valve Disassembly And
o
Press the end plate (Item 1) [0] in the valve body (Item
2) [0] and remove the snap ring (Item 3) [0].
Clean the parts in solvent and dry with compressed air. ftp(i)
Lubricate the bore of the valve body (Item 2) [0] , plunger
@)r
°1
(Item 5) [0] and the end plate (Item 1) [0] with clean
engine oil before assembly.
B-{)5606
Description
A
The cylinder block is made of cast iron and provides full
length support for the dry liners. •
The liners (Item 1) [A] are made of cast iron. Production
liners are a press fit and service liners are a transion fit.
Both types of liners are honed with silicon carbide tools to
a specially controlled finish to ensure long engine life and
low oil consumption.
Remove the oil filter and oil pan. (See Page 7-83.)
Page 7-66.)
Page 7-32.)
Remove the rear oil seal and the crankshaft. (See Page
7-71 .)
Inspect the jet tube (Item 1) [B] , mount bolt (Item 2) [B] I
and alignment pin (Item 3) [B] for damage . Replace as B
needed.
The tip of the rod must extend out the top of the cylinder
in an area 1.30 inch (33 mm) in height and 0.8 inch (21
mm) of width to provide proper cooling jet alignment to
cool the pistons [C].
.:
Inspection
Place the tool (Item 1) [C] over the center of the liner (Item
2) [C]. Make sure the flat bearing race (Item 3) [C] is
against the bottom of the recess.
Install the rod (Item 4) [C] through the handle (Item 5) [C].
B-D5556
started straight.
With the adapter (Item 2) [A] on the top of the liner, place
the bearing (Item 3) [A] in the recess at the top.
Turn the handle and press the liner in the bore , stopping
IMPORTANT
For the first five hours after the new liners have
been installed:
• Do not operate at full load.
• Do not operate at high speed.
• Do not allow engine to idle for extended
periods. 1-2117-1196
If the inside of the intake manifold is wet, check that there is not a fuel leak from the starting aid.
PROBLEM CAUSE
Not enough power 1, 4,5,6 , 7, 8 , 9, 10, 11 , 18, 20 , 21 , 22,25,26 , 27, 28
Black Smoke 1,4,5, 6 , 7 , 8, 9,10,11,18 , 20, 21 , 22,25 , 26 , 27,28
Blue Smoke 1, 2,4, 6, 8, 9 , 17, 19, 20,21 , 22, 30,31 , 32
High Lubricating Oil Consumption 2, 8 , 15, 17,19,20, 28,29, 31 , 32
Two Much Lubricatinq Oil At Turbine End 2, 7 , 8, 17,19, 20,22 , 28 , 30,31,32
Two Much Lubricating Oil At Compressor End 1,2, 4,5, 6, 8,19,20 , 21,28,31 , 32
Not Enough Lubrication 8 12 14 15 16 23 24 29 32 33 34 35
Lubricatinq Oil In The Exhaust Manifold 2 , 7,17, 18, 19, 20,22, 28 , 31,32
Inside The Induction Manifold Wet 1, 2 , 3, 4 , 5, 6, 8, 10, 11, 17, 18, 19, 20, 21, 28, 32 , 36, 37
Damaged Compressor Impeller 3 , 4 , 6,8, 12, 15, 16, 20,21 , 23,24, 29,32,33 , 35 , 36
Damaged Turbine Rotor 7,8,12 , 13, 14, 15,16, 18, 20, 22,23, 24, 25 , 27,29,
32, 33,35, 36
Rotating Assembly Does Not Turn Freely 3 , 6 , 7,8, 12, 13, 14, 15, 16, 18,20, 21,22, 23,24,
29 , 32, 33,34, 35
Worn Bearings, Bearing Bores, Journals 6, 7,8, 12,13,14,15, 16,23, 24, 29,33, 34, 35
Noise From Turbocharger 1, 3,4,5,6,7, 8,9, 10, 11,12,13, 14, 15,16, 17,18, 20,
21,22,23,24,29 , 32,33 , 34,35
Sludge or Carbon Deposit In Bearing Housing 2,11 , 13,14, 15,17,18, 24,29,33, 34, 35
Description
A WARNING
The oil flows from the filter adapter through the bearing
housing and returns to the engine block.
Remove the nuts (Item 2) [A] and remove the heat shield
(Item 3) [A].
Inspecting The Lift Arm By-Pass Control ...... ... ................ 8-3
Maintenance ..... . .......... . . . ........ . ... ... ........ ... . ... 8-3
Inspecting The Seat And Seat Bar Sensors (Engine RUNNING) ..... 8-5
BOSS® UNIT
PWM MODULE
Description .. . .. . .......... . ......................... . .
.... . .. 8-24
PWM TROUBLESHOOTING
Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-25
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-18
BICSTM Controller Seat Bar Sensor Circuit Test ..... . . ... . ......... 8-12
Removal And Installation .... . ..... . ..... . ........... . .... .. ... , 8-11
SEAT SENSOR
Seat Sensor Test . ..... .. .... . ..... . ...... . ........ . ........... 8-14
SERVICE CODES
Chart ..... .. ... ... .... . . .... .. .... .. ... . ............ . . . ... .. . 8-19
TRACTION LOCK
Troubleshooting Guide ... ... ......... . ....... . .... . . ..... .. .. " 8-17
Chart ... .. .......... .. .... . ...... . ..... . ..... .. . . ........ . ... 8-21
3,4& 5) [A].
should be OFF.
A WARNING
auxITiary hydraulics switch. The auxiliary switch light
will come ON. Raise the Seat Bar. The light should
be OFF.
AVOID INJURY OR DEATH
Inspecting The Seat Bar Sensor (Engine RUNNING)
The Bobcat Interlock Control System
5. Sit in the operator's seat. Lower the seat bar. (BICSTM) must deactivate the lift, tilt and
Engage the parking brake pedal. Fasten the seat traction drive functions. If it does not, contact
belt.
your dealer for service. DO NOT modify the
6. Start the engine and operate at low idle. Press the system.
11. Raise the lift arms about 6 feet (2 meters) off the
ground.
12. Turn the key OFF and wait for the engine to come
to a complete stop.
14. Move the right hand control away from the operator.
Troubleshooting Chart
The following list shows the effects which can happen to the loader, and the probable causes when the BICS Controller
lights are off or flashing. Have the service procedure performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL.
of Loader
Indicator When Light Is Numbero
Light Light ON Light OFF OFF Flashes Cause I
System PRESS TO PRESS TO Lift and tilt functions 2 Seat sensor circuit shorted to battery I
Activated OPERA TE button OPERATE button will not operate. voltage* .
is activated not activated 3 Seat sensor circuit shorted to ground
Seat Bar Seat Bar Down Seat Bar Up Lift, tilt and traction 2 Seat bar sensor circuit shorted to
functions will not battery voltage'.
U operate. 3 Seat bar sensor circuit shorted to
ground.
,
Valve Control Valve Can Control Valve Lift and tilt functions 1 Valve output circuit is open.
Be Used Cannot Be Used will not operate. 2 Valve output circuit shorted to battery I
~) voltage'.
3 Valve output circuit shorted to ground .
3 Valve output circuit is not grounded. ,
Traction Loader can be Loader cannot be Loader cannot be 1 Traction lock hold coil circuit is open.
3
Traction lock hold coil circuit shorted
to battery voltage'.
Traction lock hold coil circuit shorted
to ground.
4 Traction lock pull coil circuit is open.
5 Traction lock pull coil circuit is shorted
to battery voltag_e*.
6 Traction lock pull coil circuit is shorted
to ground.
Power BICS Controller BICS Controller is Lift, tilt and traction
+
I
is operating not operating functions will not N/A N/A
correctly. correctly. operate.
- - - - - - -
Normal S ICS operating voltage is less than the electrical system voltage. If voltage is more, the circuit is shorted
to system voltage.
NOTES:
(1) If the seat and/or seat bar sensor circuits are open, the corresponding lights will be OFF. If one of the lights
stay OFF, check the circuit for continuity. See Inspection & Maintenance Instruction. (See Page 8-1.)
(2) If all five lights flash repeatedly, the voltage supply is greater than 16 volts or less than 9 volts.
(3) Flashin g patterns will repeat every 3.25 seconds.
Troubleshooting Chart
The following list shows the effects which can happen to the loader, and the probable causes when the BICS Controller
lights are off or flashing. Have the service procedure performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL.
6
Seat Bar Seat Bar Down Seat Bar Up
will not operate.
3
Traction lock hold coil circuit shorted I
to battery voltage'.
Traction lock hold coil circuit shorted
'
to ground .
4 Traction lock pull coil circuit is open.
5 Traction lock pull coil circuit is shorted
to battery volta~e ·.
6 Traction lock pull coil circuit is shorted
to ground.
Power BICS Controller BICS Controller is Lift, tilt and traction
+ is operating
correctly.
not operating
correctly.
functions will not
operate.
6
- - -
down and Seat Sensor Override
has been activated
- - - - - - - - -
functions will operate. activated . Seat Sensor maintenance
is required.
-
NOTES:
(1) If the seat and/or seat bar sensor circuits are open , the corresponding lights will be OFF. If one of the lights
stay OFF, check the circuit for continuity. See Inspection & Maintenance Instruction. (See Page 8-1.)
(2) If all five lights flash repeatedly, the voltage supply is greater than 16 volts or less than 9 volts.
(3) Flashing patterns will repeat every 3.25 seconds.
(4) If seat indicator light does not go ON, check for debris, dirt or objects under or behind the seat. The Seat
Sensor Override. can be used if the seat sensor cannot be activated.
• On ly on later loaders, and early loaders which have had BICS Controller and switch replaced.
NOTE: If the Seat Bar is lowered before the seat sensor is activated, a 10 second delay will occur before the valve
and traction lights come on.
* Normal BICS operating voltage is less than the electrical system voltage. If voltage is more, the circuit is shorted
to system voltage.
Troubleshooting Guide
PROBLEM SOLUTION #
Power indicator light does not come ON. 1,2,3,6
Key ON , seat bar down, push the Press To Operate Button. The system
activated, valve and traction indicator lights do not come ON. 10
SOLUTION SUGGESTIONS
3. Check wiring and connections. Make sure the connector is securely connected
to the controller. Remove system controller and pull on connector to check.
4. Look at indicator light windows, if they are milky white in appearance , it is most
likely caused by moisture in the system controller. Allow to dry or replace the system
controller.
6. Check wire connections to make sure connectors are locked into place.
8. Move the system wiring back & forth to try to find area that may be causing the
intermittent connection.
9. Use sensor tester (MEL 1428) to isolate problem between sensor and system controller
and wiring.
10. Check the wiring and connections. Remove the left instrument panel and chek the
Press To Operate Button with an ohmmeter at the two-pin connector.
IMPORTANT
"i.
Troubleshooting Guide
PROBLEM SOLUTION #
Indicator light does not come ON when seat bar is lowered. 1, 2,3,4, 5,6
SOLUTION SUGGESTIONS
3. Use the BICS sensor tester (MEL 1428) to check sensor and system controller.
5. Check keyed bushing to make sure magnet collar rotates with seat bar.
P-{)4702
•
SEt:lSOR TEST
Lower the seat bar. The sensor test light (Item 1) [0]
should illuminate. D
Raise the seat bar. The sensor test light (Item 1) [0]
should go off. SEltSOfl. TEST
O~ = =t
If the above tests fails, there is a problem with the seat bar . . ',:
P-04702
IMPORTANT
~
': '
~ :"'.
sensor. • y
Refer to Page 5-1 for seat bar removal and installation Left Side
procedure. of Seat Bar
4
.... P-03284
Troubleshooting Guide
PROBLEM SOLUTION #
Seat indicator light does not come ON with operator in seat. 1,2,3,4,5,6,7,8,9,10,11 I
Seat indicator light stays ON when operator is out of seat. 2, 3, 6, 10, 11, 12, 13, 14
SOLUTION SUGGESTIONS
ENGINE .
sensor.
•
ENGINE. SEHSORTEST
Sit on the operator seat. The sensor test light (Item 1) [C]
should illuminate.
Get off the operator seat. The sensor test light (Item 1) [C]
should go OFF.
sensor.
IMPORTANT
c ,. 4' ~~
IMPORTANT
<:'~ . . P--04041
NOTE: Be sure not to lose the magnet collar
alignment pin (Item 4) [C] which is located in
the sensor (Item 3) [C] when removing the
sensor.
Remove the threaded bushing (Item 5) [C] from the seat
track mounting bolt (Item 1) [0].
P-04698
Troubleshooting Guide
PROBLEM SOLUTION #
I
SOLUTION SUGGESTIONS
3. Measure charge pump pressure, should be above 280 PSI (1930 kPa)
8. Red by-pass knob on the traction lock solenoid is not in the engaged position .
FUEL SENDER
Full .. ... . ..... . . . . .. . .... . . .. ... ....... 20 ohms
Empty .. . .. . ... . .. .... .. . .. ...... ..... 244 ohms
RPM SENSOR
Continuity Resistance . . . . . . . . . . . . . 3000-3500 ohms
Adjustment
Remove the engine drive belt shield. (See Page 3-1.)
Disconnect the connector (Item 1) [B] from the engine
harness. Loosen the jam nuts (one on top and one below
the flywheel housing) on the RPM sensor [B].
N-1 7552
Turn the RPM sensor (Item 1) [C] in until it makes contact
with the engine flywheel.
Turn the jam nut until it contacts the flywheel housing. The
jam nut should not be tightened , it needs to turn with the
RPM sensor when the sensor is turned back out for
adjustment.
Turn the RPM sensor and the jam nut out from the
flywheel. Set a clearance of 0 .050 inch (1,27 mm)
between the jam nut and the housing with a feeler gauge
(Item 2) [C]. Retighten the jam nuts.
NOTE: The p lastic tip on a NEW RPM SENSOR is
used as a gauge to set the correct clearance.
Turn sensor in until it just touches the
flywheel, the plastic tip is designed to come
off after the engine is started.
Chart
SERVICE CODES
-------------------
SUBJECT DISPLAY READS CON DITION
Engine Coolant Temp. EC-1.1 SHUTDOWN, Engine Temperature
1:0 1:0 0:0 0:0 0:0 [ ]
1_o '_0 0=0 0=00 0=0 EC-2.1 WARNING , Engine Temperature
EC 3 Wiring Not Connected
EC4 Wiring Shorted
EC 5 High Sensor Voltage
EC 7 Sensor Out Of Range
Engine Oil Pressure EP 1 SHUTDOWN, Pressure
1-0 I-I 0=0 0=0 0=0
1:0 '':0 0:0 0:0 00:0
[3] EP 2 WARNING , Pressure
EP 3 Wiring Not Connected
EP 4 Wiring Shorted
EP 5 High Sensor Voltage
EP 7 Sensor Out Of Range
Engine Speed ES 1 SHUTDOWN , Engine Speed Too High
Co 1:0 0:0 0:0 D:O
'_0 0_1 0=0 °=00D=O
[3] ES-2.1 WARNII\JG , Engine Speed Slightly High
ES-6 Sensor No Signal
ES-7 Sensor Out Of Range
Air Filter AF 2 WARNING , Restriction Too High
1:1 ':0 0: 0 D: O 0:0
1=1 .=0 0=0 0=°0 0=°
[3] AF 6 Sensor No Signal
Battery b-2.1 WARNING , Bad Battery
1=0 0=0 0=0 0=0 0=0
.:' 0::0 0:0 O:OoD::O
[3] b-2.2 WARNING , Battery Voltage
Fuel Level FUEL2 WARNING, Low Level
':0 1:1 .:0 .:0 0:0 [ ]
'=0 '_I '_0 '_°0= 0
0
FUEL3 Wiring Not Connected
FUEL4 Wiring Shorted
FUEL5 High Sensor Voltage
FUEL7 Sensor Out Of Range
~
Chart (Cont'd)
Hydrostatic Fluid
lei I-I D=O D=O 0"' 0
,;::, ':'0 0;;:0 0:'0 0:'0 0
0 HP 2 WARNING, Pressure
HP 3 Wiring Not Connected
- 4
HP 5
HP7 Sensor Out Of Range
Hydrostatic Fluid HC1 SHUTDOWf\I, Temperature
Temperature HC2 WARNING . Temoerature
lei '-0 o=a D=O 0=0
.;::_ '':0 0:'0 0;;:0 0: 0
[3J
0
HC 3
HC4
HC5 High Sensor Voltage
HC 7 S
BOSS Temperature related 112 volt supply and 1. Check stored defects with the BOSS tool.
shutdown codes BOSS failure . *2. If defect list has EC1, HC1, EC2.1, HC2. EP3,
when no heating EP7, HP7, B2.2, low fuel, Fuel 7 and last
occurs. occurrence hr. readings are within a hundredth,
the BOSS is defective and must be replaced.
* NOTE: You may have some or all of the 3. Using a voltmeter, check the alternator output.
codes listed. You will have high
temps, high press, low voltage
and low fuel.
LCD Display Intermittent code of I Sensor No Signal or 1. ES6 will occur if the loader is stalled or shutdown
ES6 while engine No RPM's. during run cycle . The code is generated due to the
running. lack of RPM and the existence of residual
pressure in the system.
I tf.I
~
"0
~
~
~
1t
0
~
0
_12_Vo_'_t-_B_ac;...k_L-,ig~h_t
1...'
t: - a.
~ -'='G""ro"-"u"'n"'d_ _ __
o :;
{ :; 1...1
Q.
* NOTE: The display has caused the 1*4. If messages are now received at the tool, the
the BOSS. 7. If the problem still exists, check the harness for
continuity.
Pry the rubber light mount free from the operator cab
(both sides) [A].
Lower the light from the operator cab to locate the three
instrument panel mounting bolts (Item 1) [B] (both sides).
Remove the three mounting bolts and pull the left panel
(Item 1) [C] down from the operator cab.
Remove the three mounting bolts and pull the right panel
(Item 1) [D] down from the operator cab.
Description
Fig. [A]:
Description (Cont'd)
A
Conditions
PWM fuse
Module failure.
Chart
The PWM module sends a diagnostic code to the
Auxiliary Hydraulic Switch lights when the conditions
listed in the chart below occur.
Light Blinking Light OFF Base End Solenoid or Wiring • Wires Disconnected
• Wires Shorted
• Wires Cut
• Solenoid failed . Perform solenoid
coil test.
• PWM module failed.
Light Off Light Blinking Rod End Solenoid or Wiring • Wires Disconnected
• Wires Shorted
• Wires Cut
• Solenoid failed. Perform solenoid
coil test.
• PWM module failed.
• Wires Shorted
• Wires Cut
• Solenoid failed. Perform solenoid
coil test.
• PWM module failed.
Handle Testing
A
2 2 2 K
* 3 1 1 K
~"
4 2 2,3 K,A,D
[i4[[]S m 1 1,3 K,A,C
m2[[]1~
5
1= :::;:_I!l
6 1 1,3 K,E
III
- );). 1
7 1 1,3 K,F
ENGINE SPECIFICATIONS
Piston And Piston Rings .... ... ..... . .................. . ........ 9-6
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-9
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-19
LOADER SPECIFICATIONS
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-3
LOADER TORQUE
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-12
83.7
(2126) 166.8
(4235)
128.0
(3252)
89.7 98.7
(2279) (2507)
-4
~
"8"
25° ' I >- <:: \ '- I /. 30°
,
"A" 9.4j -ii
0",
t
(239)
I~ 122.3 ~]; 8.6
(3105) )0 I~ m
0 (219)
6595532
"A" STD . TIRES - 78 .0" (1981) "B" STD . TIRES - 62.6" (1590) " C" 78" BUCKET WIDTH - 79 .6" (2022)
Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the
loader parts.
Performance
Rated Operating Capacity (SAE) .. . .. . 3000 Ibs. ~1362 k9~
Tipping Load (SAE Rating) .......... . 6000 Ibs. 2724 kg
Operating Weight .. ... : . ........... . 9900 Ibs. 4495 kg
SAE Breakout Force - Lift .. . .... . ... . 6050 Ibs. (26923 N)
- Tilt .. . ........ . 6300 Ibs. (28035 N)
Axle Torque ........ . ..... ......... . 9200 ft.- Ibs. (12475 Nm)
Travel Speed (Low) ...... ... . ....... . 5.2 MPH (8.3 km/hr.)
(High) ................. . 9.00 MPH (14.5 km/hr.)
Controls
Vehicle Steering ..... . ..... . . ..... . . Direction and Speed controlled by two hand levers.
LE~~~~~I~a~.II~~. ... . . .. . .......... . Controlled by separate foot pedals.
Front Auxiliary . ....... ............ . Controlled by electrical switch on RH steering lever.
Rear Auxiliary (optional) ........... . Controlled by electrical switch on LH steering lever.
Engine ............... . .... . ... .. . . . Hand lever throttle: Key-type starter switch and shutdown .
Starting Aid ...... .. ... .. .. ... ... . . . . Push button ether start system - Optional
Service Brake ... ...... . ..... ..... . Two independent hydrostatic systems controlled by two hand
operated steering levers .
Parking Brake Hydraulic Disc, foot operated pedal.
Engine
Make/Model ......... . .. . ...... .... . Perkins/1004.40T
Fuel/Cooling . . ..................... . Diesel/Liquid
Horsepower (ISO) . . . .. ........ . .. . . . Gross: 105 (78 kg)
Maximum Governed RPM ........... . 2200 RPM
Torque @ 1600 RPM (ISO) ........ . . . Gross: 308 Ibf. ft. (418 Nm)
Number of Cylinders ... . ...... . ..... . Four
Displacement , . .................... . 243 cu. in. (3,99 L)
Bore/Stroke . .. . ............. . ..... . 3.94/5.00 (100/127)
Lubrication ............ . .. ... . ..... . Pressure System W/Filter
Crankcase Ventilation .. . .... .. . ... . . . Open System
Air Cleaner ..... ...... .... ......... . Dry replaceable cartridge w/safety element
Ignition .. . ... ........ . . ...... . .... . Compression
Low Idle ... . ...... . ..... ... . ...... . 950-1000 RPM
High Idle .. . . , ... .. ..... , ..... ..... . 2335-2400 RPM
Electrical
Alternator ......................... . 50 amp open frame w/integral regulator
Battery ..................... . ..... . 12 volt, 1000 cold cranking amps. @ OaF. (-18°C);
180 minute reserve capacity
Starter ............................ . 12 volt, Gear Reduction Type
Instrumentation .................... . Gauges: Hourmeter, Voltmeter, Fuel, Engine Temperature.
Warning Lights: Engine Oil Pressure, Hydrostatic Charge Pressure,
Hydrostatic Fluid Temperature & Hydrostatic Filter.
Drive System
Main Drive .... . ... . .. . ........... . . Hydrostatic 4 wheel drive
Transmission ...................... . Infinitely variable tandem hydrostatic piston pumps, driving 2 fully
reversing hydrostatic motors. Separate gear type charge pump.
Final Drive ........................ . Double gear reduction & #120 HS endless roller chain & sprockets
in sealed chaincase with oil lubrication
Total Engine to Wheel
Reduction ........................ . N/A
Axle Size .......................... . 2.95 (75)
Wheel Bolts ....................... . (10) 3/4 inch
Capacities
Cooling System .................... . 20 qts. (18,9 L)
Fuel .............................. . 32.5 gals. (123,0 L)
Engine Oil W/Filter ................. . 8 qts. ;7,6 L)
Hydraulic Reservoir ................. . 28 qts. 26,5 L)
Hydraulic/Hydrostatic System ...... . . . NA
Chaincase Reservoir ............... . 20.5 gals. (77,6 L)
Tires
Standard .......................... . 8-19.5,8 ply rating
Flotation .......................... . 14-17.5,10 ply rating
Super Flotation .................... . 38 x 20-16, 8 ply rating
Solid ............................. . 9.00 -16
Recommended Pressure ..... . .... . Inflate tires to MAXIMUM pressure shown on the side wall of
the tire. DO NOT mix brands of tires used on the same loader.
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
General
Combustion System ................. . ........... . ... . ... . ... . ... . ..... . ... . .............. Direct Injection
Stroke ............................. . ............... . ... . ... . ... . ..... . ... . ... . ............ 5.000 (127)
Firing Order .... . ..... . .. . .. . ................ . ... . ... . ... . ....... . ............................. 1-3-4-2
Cylinder Head
Head Thickness After Machining (Minimum) ..... . .. . . ... . ... . ....... . .... . . ................... 4.035 (102,5)
Leak Test Pressure ...... . ....... . ....... . ... . .. . . .................... . .... . .. . ... . ..... 29 PSI (200 kPa)
Valve Guides
Inside Diameter ............................................................... 0.3744-0.3764 (9,51-9,56)
Outside Diameter ................ . .. . .... . ...... . .... . ...... . ... . ..... . ..... 0.6260-0.6264 (15,90-15,91)
Valve Guide Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0.6248-0.6256 (15,87-15,89)
Valve Guide Clearance In The Cylinder Head (Interference) .. . ... . ... . ..... . ..... 0.0018-0.0027 (0,047-0,007)
Overall Length:
Intake .................................................................................. 2.281 (57,94)
Exhaust ................ . .. . ......... . ... . .. . . ... . ................ . ..................... 2.406 (61,10)
Protrusion From Bottom ........................................................ 0.585-0.596 (14,85-15,15)
Exhaust Valves
Valve Stem Diameter ............................... . ... . ... . ... . .... . .......... 0.3515-0.3528(8,93-8,96)
Valve Guide Clearance ....................................................... 0.0016-0.0033 (0,040-0,84)
Maximum ............... . ................ . .. . ... .. ...... . ... . .... . . .................... 0.0041 (0,104)
Valve Face Angle .................................. . ... . ... . ... . .... . .... . .......................... 45°
Intake Valves
Valve Stem Diameter ......................................... . .......... . ...... 0.3525-0.3535 (8,95-8,98)
Valve Guide Clearance ... . ................ . .................................. 0.0010-0.0027 (0,025-0,069)
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0.005 (0,13)
Valve Head Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.688-1.698 (42,88-43,12)
Valve Face Angle ................................................................................... 45°
Overall Length ............. . ............ . ... . ... . .......................... 4.829-4.854 (122,66-123,30)
Seal Type ..................................................................................... Positive
Valve Seat Angle ................ . .. . .... . .................... : ..................................... 46°
Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0.008 (0,20)
Intake Depth (Production) ......................................................... 0.050-0.068 (1,27-1,60)
Intake Depth (Service) .............................. . ... . ............ . ...................... 0.077 (1,85)
Valve Springs
Double Valve Springs (Outer)
Installed Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.41 (35,8)
Installed Height Pressure ............................................... . ..... 39.5-43.7Ibs. (176-195 N)
Double Valve Springs (Inner)
Installed Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.34 (34,0)
Installed Height Pressure ......................................................... 20-23 Ibs. (89-104 N)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
Shaft Outside Diameter . .. . .......... . . . ... . ... . ... . . . . .. . .... ... . .............. 0.748-0.750(19,01-19,04)
Rocker Arm Bushing Bore Diameter ........................... . .. . .. ............. 0.875-0.876 (22 ,23-22,26 )
Outside Diameter of the Bushing . .... . .. . ... . ............. . .. . . .. .. ........ .. . . 0 .877-0.8783(22,28-22 ,31 )
Rocker Arm Bushing Clearance .. ...... . .. .. . ... . . .... . ........ .. ..... ... . .. . 0.0008-0.0035 (0,020-0 ,089 )
Inside Diameter of Reamed Rocker Bushing . . .......... . ..... . . ... . ... . .. . . ... . . . 0.750-0.752 (19,06-19 ,10)
Clearance Between Rocker Arm Bushing and Shaft ............ . . . .. . . . .. .... . .. .... 0 .001-0.0035 (0 ,03-0 ,09)
Maximum .. . . .. .. . . ...... ..... .... . .. ..................... ... . ... . .. ..... . ............... 0.005 (0,13)
Type .............. . ... ......... . . . ... ....... Fastram combustion bowl inserted top ring groove, graphitie skirt
Piston Projection Above the Block Deck ... .. . ... . .... . ... . ......... ... ... ..... ..... 0.006-0.014 (0,14-0 ,36)
Top Ring Groove Width ... .... . . . .. ... .. ... . . .. . ............ . . . ... .. . . . . . .. . ... . .............. . .. Tapered
Second Ring Groove Width ... . .. .. ... ....... .. ......... . ... ... ... .... . . ..... ... 0.1008-0.1016 (2 ,56-2 ,58)
Third Ring Groove Width .. .. .. .. .. . . ... ..... . .. . . . .. . ... .. ...... . .... ..... . . .. . 0.1591-0.1598 (4,04-4 ,06)
Top Ring . ................ . .. ... . .. ... ... . .. .... .. ... . .... . . . . . ... Barrel Face , Molybdenum insert, Wedge
Second Ring .. . . .. . . . . . . .. . . . . . . ... . .. . .. .. . .. .. .. ... . ... . ..... Taper Face, Cast Iron , Outside Bottom Step
Oil Control Ring . . ....... . . . .. . . . . .... . ... . . ...... . ......... . ..... .. . . . Coil Spring Loaded, Chromium Face
Top Ring Width ........ ... ... . ... . ..... .. . . .. .. . .. .. ... . ... .. ... . . .. . . . . .. . .. .. .. ..... ... . .. . . .. Tapered
Second Ring Width ... . .............. ... ... . .. . ... .. ... . .. . . ...... .. . .. . .. . ... . .. 0 .097-0 .098 (2,48-2,49)
Th ird Ring Width . . ... . ... . ....... . . . .. ....... ... ... ....... . ... . .. . . .... ..... .. 0.1366-0.1374 (3,47-3,49)
Top Ring Side Clearance . . ... . .. . ......... . .. . . .. .. ........ . . . .... ... . . . . ...... . .. ............... Wedge
Second Ring Side Clearance ... .. ... . . .. . .. ....... .. ............ . .... ... . ... . .. ... 0.003-0.004 (0,07-0 ,10)
Third Ring Side Clearance . . . .. ................. ............. . . .. .... ... .. . . . .... . 0.002-0.003 (0,05- 0,07)
Top Ring End Gap .............. ..... .. . .... . . .... . ................... . . . ........ 0.011-0.025 (0,28-0,63)
Top Ring End Gap (With Internal Step) . . ..... . . ..... . ................. ... . .... .... . 0.014-0.028 (0,35-0,70)
Second Ring End Gap .............. ...... ....... . ................ . . .. ... .... .... 0.012-0.030 (0,30-0,76)
Second Ring End Gap (With External Step) ...... . . . . .... . ... . . . . . . . . .. ... . ... .... .. 0.016-0.034 (0,40-0,85)
Piston Pin Type ................. ...... ...... . ... . . . ....... .. ... .. ... .. .. . .................. Full Floating
Piston Pin Outside Diameter ......... ...... .... . .. . .. . . ... ........... ...... . 1.5628-1 .5630 (39 ,694-39 ,700)
Piston Boss Clearance .... . ...... ..... . . .. .. ... . . .... .... . . ... ..... .. ..... .. 0.0001-0.0006 (0 ,003-0,015)
Bushing Type ...... . ... . .. . ... ..... ...... . .. . .. . .... . ... . ..... Steel Back, Lead Bronze lin Bearing Material
Bushing Outside Diameter . . .... . ......... . ........ . . .................... . . . . . 1.6972-1 .6988 (43,11-43,15)
Bushing Inside Diameter (Reamed) .... . ....... . ... . . . ...... . .. . . . ... . ...... 1.5638-1 .5645 (39,723-39 ,738)
Cran kshaft
Main Journals . .... . .. ... . . ..... . .. .. ... . ............... .. ... . .. . . ..... . . ...... 2.998-2 .999 (76,16-76,18)
Maximum Wear And Out Of Round Of The Journals And Crank Pins . .. .. .. ..... ... . .. .. ...... . . . 0.0016 (0,04)
Width Of Front Journal . .. .. . . .. .... .. ....... ...... .. . .... . . . . ... . ... ..... . .... 1.454-1.484 (36 ,93-37,69)
Width Of Center Journal .... .. . .. . . . . ... . ... . . ............... . ......... ... . .. . . 1.738-1.741 (44,15-44,22)
Width Of Other Journals ..... .. ... . .. ... . .. .... .... ...... . .... . .... . . . ... . . .. . . 1.545-1.549 (39,24-39 ,35)
Crank Pin Diameters .............. . . . . ..... . .. ..... . ... . .... . ..... . ... . . . . .. . . 2.499-2.500 (63,47-63,49)
Crankshaft End Play ............. . .. ... . . .. . .. ......... . .... . ........... . . . .. . . .. ........ 0.00075 (0,019)
Main Bearing Oil Clearance ......... .... . ... ................................. . 0.0022-0.0046 (0,057-0,117)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
Crankshaft (Cont'd)
Undersize Journals And Crank Pins .... ..... .... .. . . .... ... ..... . . . . ... 0.010 (0,25), 0.020 (0,51) , 0.030 (0,76)
With the crankshaft on V-blocks check the maximum run-out of the journals. They must not exceed these specifications
below and the difference in run-out between journals must not exceed 0.004 (0,10)
Journal #1 ... .. .. . .... .. . . . . ... . .... .... ............ ... ... .. ....... .. . .. .. .. ....... . .. ... . .. Mounting
Journal #2 .. . ... ... . .. .. ... . .... .. . .... . . . . ........ . . ... .. . .. .... ... . .. ..... . ....... . . .. . 0.003 (0,08)
Journal #3 ......... . . ..... . .. . . . ... ..... . . ...... ... . ....... ... . . ... .. .. . ... . .. . .. ........ 0.006 (0,15)
Journal #4 . . . .. . . .... ........ .. . .................. . .... . ..... . ... . .. . . ... ... .. . .. ...... . . 0.003 (0,08)
Journal #5 .. .. .... .. ... .. .... . .. . . .. ........ ..... . . ..... . ...... .... ..... . .. . .. ....... .. .. . . . Mounting
6 6
0.189 .-.I '-
(4,8)
- I I I
8
B-D5594
The finished sizes for crankshaft journals which have been ground undersize are given in the table below:
NOTE: Crankshafts that have been nitrided for 60 hours can be machined 0.010 (0,25) without the need to harden
again. Check the crankshaft for cracks before and after machining. Demagnetize the crankshaft after it
has been checked for cracks. Remove any sharp corners from the oil holes. Surface finish and fillet radii
must be maintained.
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
Main Bearings
Type .... .... ... ....... ... ..... . ... ... . . ....... . . ..... ... .. ..... .. . .. . . ... Steel Back, 20% Tin Aluminium
Center Bearing Width . . ..... .... . .... ... . . ............. .. ... . ............ . ..... 1.430-1.445 (36,32-36,70)
All Others . . . . ...... . ...... . .......... . . . . . ........ . . . .. .. ..... .... .... ...... 1.245-1 .255 (31,62-31,88)
Bearing Thickness (center) .. . . ... .. . ....... . . . . . ... . .. . .. . ... ... . . ....... .. . 0.0820-0.0823 (2 ,083-2,089)
Bearing Clearance . ... ...... .... ........ .. .. . . ... .. ... ...... ........ . . . .. , . . 0.0022-0.0046 (0,057-0,117)
Thrust Washers
Type .... ..... ...... . ..... . ..... . ... ...... . ...... , .. . ... ... ... . .... ...... . . .. .. , Steel back, Lead Bronze
Position .... . . . . . ....... .. . .. .... ... ....... ... . .. ..... ... . .. ...... .. ... Each Side Of Center Main Bearing
Standard . . . . . .. ..... .. . . .... . .. .. .. . . , ... . . .... .... . . ... ... . .. .. .. . .... . . ... . . . 0.089-0.091 (2 ,26-2 ,31 )
Oversize ........ . . . . ....... . . .. . . ... . .. . . . ... .. .... . . .. . , ..... .... . . .. .. . .. .... 0.096-0.098 (2 ,45-2 ,50 )
Journal #1 Diameter ....................... .... ... . ..... . . . .... . ........ ... . . .. 1.997-1.998 (50,71-50,74)
Journal #2 Diameter ........................ ..... . . ............ .. .... . ..... ... . 1.987-1.988 (50,46-50,48)
Journal #3 Diameter . .............. .. .. . ..... . . . .. ... ... ,...... .... .......... . . 1.967-1.968 (49,95-49 ,98)
Clearance On All Journals ............ . . . . ... . ... ... ...... ......... . ... . ........ 0.0024-0.0055 (0,06-0,14)
Cam Lift (Intake) ... . ........... . ..... ... .. . . . ......... ... ...... . ....... .. ..... 0.2999-0.3027 (7,62-7,69)
Cam Lift (Exhaust) ...................... .... . . ..... .. .... .. ... .. ........ .. . . . .. 0.3035-0.3066 (7,71-7,79)
Maximum Wear And Out Of Round ... . .. ... .. .. . ... .. . . ....... . .. . ...... .. .. ... .... .. . . ... . .. 0.002 (0,05)
Camshaft End Play ....... .... ..... . . .... ... .. ... . . . . . ...... .. . .... ... .... ... . ... 0.004-0.016 (0,10-0,41)
Service Limits ..... . .............. . . .. .... . . ... .. . . . ...... ..... .. . ... ........ ... ... . ...... 0.021 (0 ,53)
Thrust Washer Type .... . ............ . . .. . . ... . ..... ..... ............. . ....... . ........... . ........ 3600
Thrust Washer Thickness . .. . .. . ... . ..... . .. . ......... . ... . ........ . ...... . .. . .... 0.216-0 .218 (5,49-5,54)
Thrust Washer Recess Depth .. . . .. .. . .... " ... .... . . . . .. . .... . . . ... ...... . . .. .. .. 0.215-0.218 (5,46-5,54)
Bore #1 . ...... .. . ... ....... .. . . ... ... .. . . . . .... .... . . .... . .. ... ........ ...... 2.187-2.189 (55,56-55,59)
Bore #2 . ........ .... . . .... . . .. .. .. . . .. . ...... . .. . . . ......... . .. ..... . . , . . . ... 1.990-1.992 (50,55-50,60)
Bore #3 .. . . .. . . . .... . . .. . .. ... . ...... .. ...... . . . .. .. . ............. ... . . ...... 1.970-1.972 (50,04-50,09)
Cylinder Liners
Production .. ... . ..... . .. . .. ... . . ..... . . ..... . . .... ..... . . . .. Dry, Interference Fit, Flanged, With Flame Ring
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Dry, Interference Fit, Flanged, With Flame Ring
Production Liner Outside Diameter ... . ..... . .... . .......... . .......... ... . . ... 4.105-4.106 (104,25-104,28)
Production Liner Clearance . . ... . . ........ .. ...... . .. . ... ..... . . ... . .... ... . . .. . .. 0.001-0.003 (0,03-0,08)
Production Liner Inside Diameter .. ........ . ... . . . .. . . . ........ ... ....... .... . 3.937-3.938 (100,00-100,03)
Service Liner Clearance ..... . .. ... .... .... .... ...... ....... .. . . ........ .... .... ... . . ...... ±0.001 (±0,03)
Inside Diameter Of Service Liner With Flame Ring (Installed) . .. . .. .... ....... ..... 3.937-3.961 (100,0-100,63)
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,25)
Flange Thickness ....... ..... ..... .... . .. . . ... .. ....... ..... ...... ... . .. . . . . .. . . . 0.150-0.152 (3,81-3,86)
Liner Projection From Deck Surface . . . .... . ... ... ...... ..... . ... ... .. 0.004 (0,10) Above or 0.004 (0,10) Below
Hose Angle . .. . . .. .. ... ....... . . .. ...... ... . ..... .... . ......... . .. ....... .. ........ .... .... . . . .. 30/35 0
Piston Cooling Jets ... ........ ...... ...... .. ..... ..... .... . .. ... . . . .. ... . . .. . .. ....... .. 20 ft.lbs. (27 Nm)
Fuel Injectors
Working Pressure . .. . ..... . . .... ..... . .... .. ..... . ......... .... .. . .... . .. .. . .. .. .. 4263 PSI (29393 kPa)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
Camshaft Gear Bore Diameter .... . .. . ....... . ...... . ... . ....................... 1.375-1.376 (34,93-34,95)
Camshaft Gear Hub Gear Clearance . . ....... . .................. . ... . ........ 0.0003-0.0019 (0,008-0,048)
Crankshaft Gear Bore Diameter ...... . .... . .. . .. . ... . ........... . ........... 1.875-1.8760 (47,625-47,650)
Crankshaft Gear Clearance .......... . .... . ..... . ... . .. . ... . .... . .. . . -0.0008 - +0.0010 (-0,020 - +0,048)
Idler Gear Bore Diameter ............ . .... . ..... . ...... . ... . ... . ... . .... . ....... 2.250-2.251 (57,14-57,18)
Width Of Idler Gear And Bushing Assembly .......... . ... . ... . ....... . .... . ....... 1.186-1.187 (30,14-30,16)
(With Needle Bearings) ........... . .. . .... . .. . .......... . .... . ....... . .... . ... 2.164-2.165 (54,99-55,00)
Clearance Of Outer Rotor To Body ..... . .. . .... . ... . ................... . .... . ...... 0.006-0.013 (0,15-0,34)
Relief Valve Plunger Outside Diameter ... . .... . .. . ... . ... . ....................... 0.715-0.716 (18,16-18,18)
Pressure To Open Pressure Relief Valve ........................................... 60-68 PSI (415-470 kPa)
Oil Filter Type ........................................ . ... . ........... . .. Full Flow Screw-on Type Canister
Pressure To Open By-pass Valve In Oil Filter ......................................... 8-12 PSI (55-83 kPa)
Pressure To Open By-pass Valve In Oil Cooler .............. . ... . ....... . . .... . ... . ........ 25 PSI (172 kPa)
Minimum Engine Oil Pressure At Maximum Speed .......................................... 40 PSI (280 kPa)
Oil Pump Gear and Idler Gear Backlash ........................ . ... . ... . ......... . ... . ....... 0.003 (0,076)
Turbocharger
Type ....................................................................................... Garrett T20
Flywheel
Run-Out .................................................. . ....... . .... . . ... . .... Less than 0.012 (0,30)
Misalignment ... . ... . .. . .......................................................... 0.008 (0,203) @ 8 (203)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
Drive Gear Bore Diameter . .. . ... . . .... ... . . .. .. . ... ...... . ... .. . ............. . 0.744-0.750 (18 ,90-18,92)
Drive Gear Shaft Clearance .. .. . . ... . . . .... .... . .. . .... ....... . ... . . . .... . . ... . . 0.0012-0 .0024 (0,03-0,06)
Impeller Bore Diameter ..... ..... . .. . .. .. ...... . .. ... ..... . ... . ...... .. ..... . .. 0.625-0 .626 (15 ,87-15,89)
Impeller Shaft Outside Diameter .. .. . . .. . . . .. . . .. ........ . . . .. .. ....... ..... ..... 0.626-0 .627 (15 ,91-15,92)
Impeller Clearance On Shaft . ... .. . .. . ...... . ............. . . .... ........ . . . ...... 0.0007-0.002 (0 ,02-0,05)
Bearing Bore Diameter ..... ..... ............ ... . . ... . .. . . ..... ...... . ......... 1.498-1.499 (38 ,06-38,08)
Bearing Diameter . ............. ..... . . .... . ... . . . .. ..... ... .. ... ... . . . ........ 1.499-1.500 (38 ,09-38,10)
Bearing Clearance In Pump Body . .. . . ... . . . ...... ..... . . ... . ..... .. .. . ... . .. .... 0.0004-0.0016 (0,01-0,04)
Thermostat Type .... ... . . . . ...... ..... . .. . ..... ....... ...... .. . . . . . . . .... . . . Wax Pellet, By-pass Blanking
Engine Torque
Bridge Piece To Block . ... .. . . .. ..... . .... ... ..... ... ... .. . . . . . . ... .. . .. . ..... .. ... ...... .. ... .... .. 12 (16)
Camshaft Gear Bolt . .... . . .. ... ... . . . ... . . . . . .... . . . . .. .. ..... ... . . . . . . . . .. . . . .... . . .. .. ... . . . .... 58 (78)
Camshaft Gear Bolts (45 mm long) ... . .. .... ..... . ...... . ... ... ...... . .... . . . . ... .. ..... ... .... ... . 74 (100)
Connecting Rod Nuts
Step 1 ... . ............. .. . . ... . . ...... .. ...... .. ...... .. .... ...... . ..... .. . . ... . .. . . . .... . .. . .. . 45 (61)
Final .. ... . . .. ........ . .... . .... .... ..... . .. . .. ... ..... ... ..... . .. ..... .. . .. .. .. . . .. . . .. .. . .. . .. 92 (125)
Crank Pulley Bolts . ... .... . . . ... . . .. .. . .. . ..... .. . .... . . . ..... . .... .. . . . . . .. .... ... . . .. . . . ..... . . . 85 (115)
Cylinder Head Bolts
Step One .... ... .. .... . . ... ... .. .. . .. . . . . .. . ... . . .. ... . . . . .. .. ...... ... ..... .. . .. .... ... . . ... . . 80 (108)
Step Two - Short Bolts ... .... . . .. . .. .. ...... . .... .. .. . . ..... ..... .... .... .. .. . . .... ... .... ..... .. ... 150°
Step Two - Medium Bolts ..... .. . . .. ... .. . . .. . .. . .... . . . . . . . . . .... .... . . . ... ...... . ..... . . . .. .. ..... 180°
Step Two - Large Bolts ... . . ... . . ... .. . . .. ... .... ... . .. ....... ... . . . . ... . .. .. . .. . ... . . . .... .. .... ... 210°
Engine Lift Bracket Bolts . . ... . ....... . .. ... ......... . ..... .. .. . .. .... .. ... ... ..... .. .... .. . . ..... . . 33 (44)
Exhaust Manifold Nuts ..... ... .... .. ..... ... ............ . .... .. ....... ... . . ... .... ... ... ... .... .... 37 (50)
Flywheel Housing To Cylinder Block .... . . .... .... .. ...... .... . .. . .. ... ...... ...... . .... . ... . ...... . . 52 (70)
Flywheel To Crankshaft Bolts . .. .... . . . ... ... ... . . . . .... ... ... ... . ... .... .... . .... . ... . . . . .. .. . . ... 77 (105)
Fuel Injector Nut . ... ... .... .. . . .. .. . . ... .... ... .. . . ... .. . . .. . . . ..... . .. ... .... . .. .... .. ... .. . . .... 23 (30)
Fuel Injection Pump Gear Mounting Bolts .... ... ... ......... . .. .. ... . . ..... .. . . ... .. ... . . . .... .. . . .. .. 20 (28)
Fuel Injection Pump Gear Nut .... .. ....... . . .. ... ... .... .. . . .... . ........... . . .. ..... . . . .... . . .. ... . 59 (80)
Fuel Injection Pump Flange Nuts ..... ... ... ... ..... .. . . . .. . . .. ...... . .. .. . ..... . . . .... .. .... ... . . ... 16 (22)
Fuel Lift Pump Bolts . .... .. ..... .. . ..... . . . . ...... .. .. ..... ... .... ... .... .... ... . .. . . ... . . . . . .. ... . 16 (22)
High Pressure Fuel Lines Fittings .. . .. .. .. ..... .. .. . . . .... ... .... .... .. ... .. . . . . .. .. . .. .. .. ..... . . . .. 16 (22)
Idler Gear Hub Bolts . .. . . .. .. .. ... . . . . . .. ... . . .. ...... .. ..... . .... ..... .. . . . . .... . . . ... . ... . . ... . .. 33 (44)
Intake Manifold Bolts .. ..... .. ..... . ...... .. . . ....... . .. . ....... ... ... ... ...... . ...... . .... . . . .... . . 33 (44)
Oil Cooler Cover Bolts .... . . ..... .. ... .. ....... . ... . .. . .. .. . . ... ... ... ... .... . . .. . . . . . .. . 96 in-Ibs. (11 Nm)
Oil Cooler Mounting Bolts . . .. ... .. . . .. . ...... . . ........ . .......... ..... .. ... .... .. . . .... . ...... .. .. 16 (22)
Oil Cooler To Back Plate .. . . .. ... ... .... ... ..... . ...... . ..... ... ... .. ...... .. .. . ... . ... . .... .. .. . .. 42 (58)
Oil Pan Bolts ... ... . ...... . . . ... ... .... ..... .. . . . . . . .. . . . .. .. . ...... .. . . . . .... .. ... .... .. .... ... . . 16 (22)
Oil Pan Plug . . .. ... . .... . ... .. . .. ... ... . . . .. .. ..... .. .... ... .... . ....... ...... . .. . . ... .. . . ... . . .. . 25 (34)
Oil Pump Cover . .. .... ... .... ... .... ... .. ... . ... . . . .. . . . .. . ... ...... . ..... .. ..... . ..... . .... .. .... 21 (28)
Oil Pump To Front Main Cap .. . ..... . .... .... .. ... .. . .. ... ... ... ..... . .. . . ... . .. . .. .. . .. . ... ... ... .. 16 (22)
Oil Transfer Plate Bolts .... ..... . . .. ... . .. . . . .. ...... . .. .... .. ... .. . . .......... ... ... .... . . .. .... . . . 22 (30)
Piston Cooling Jets . ... . .. . ...... .. . .. .. . . .. .... . . . ... ... .... . ... .. .. . .. ... .... . ... . .. . .. . ..... .. . . 15 (20)
Rear Oil Seal Housing Bolts ... . .... . .... ..... . ... .. . ..... ... . . . . . . . ........... .. .... .. . ..... .. ... .. 16 (22)
Rear Oil Seal Housing Bolts (Torx) .. .... .. ..... .. ...... . ...... .. .... . . . .... . . . . . .... . ..... .. ..... ... . 16 (22)
Rear Oil Seal Housing To Bridge Piece (Torx also) . . ... ... ... ...... . .. . . . . . .... .... .. . . ... . . . .... .. . . .. 13 (18)
Rear Oil Seal Housing To Bridge Piece (Thread Size M6) .. . . ..... .. . ..... ..... . ... .... .... .. ... . . . ..... 10 (13)
Rocker Cover Nuts (With Shim Washer) .. . .. ... .. ..... .. ..... ... . .. . . .. .. . . ... ..... ... .. . ... . . .. . . ... 22 (30)
Rocker Cover Nuts . ..... .. ..... . .. .. .... .... . . . .... . ........ .. ... . . .. ..... .. ...... .. ............ .. 15 (20)
Rocker Shaft Bracket Nuts . .. . . ... ..... ... .... ... . . ...... . ...... . . .... ... .... . ............... . . ... . 55 (75)
Timing Case To Block (M8 Bolts) .... .... . . .... .. .. . ... .. ... .. . .. . . .. .... .. . . . .... .. ... ..... . ..... .. . 16 (22)
Timing Case To Block (M1 0 Bolts) ... .. .. .. . . ... .. . . . .... .. ....... . ..... . . .. . .... . .. . ... . .... .. .. . ... 33 (44)
Timing Case Cover To Timing Case Bolts .... .. . . ... .. ....... .. .. . ....... . .. . ..... . . . ..... .. ..... . .... 16 (22)
Timing Case Cover To Timing Case Nuts ....... ..... .. ... ... . . . ..... . . . .. ... . .. . . .. . . . . .... . . . . . .. ... 16 (22)
Turbocharger To Manifold Nuts .. .. . .. .. .. . . .. . .. .. . . . . . . .... .... .. .... .. ...... .. ..... .. .... ... ...... 33 (44)
Water Pump To Timing Case Bolts & Nuts .. ... . .. . . ... .. ...... . ....... . ..... . .... . .......... . ........ 16 (22)
Specifications
Axle Hub End Plate Bolts . ...... . .. . . ... . . .... ..... . ...... .. ............. ..... ... .. .... .. 210-230 (285-311)
Axle Sprocket End Plate Bolts ... .. . . ...... .. . . .. . .. . .... .... ......... ..... ... . .. . . . ...... 210-230 (285-311 )
Bob-Tach Lever Mounting Nut ... ... . .. ............ . .. . ........ . .......... . . . . . ... . . . . .. ..... 25-28 (34-38)
Bob-Tach Pivot Pin Bolt (Tilt Cylinder Rod End) ... .... .......... ...... ... . ... . .. . . . ...... .. 125-140 (170-190)
Bob-Tach Pivot Pin Retainer Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-20 (21-27)
Bucket Position Valve Mounting Bolts ....... ..... .......... ... ......... . .. . . .. . ... ....... . . .. ........ 15 (20)
Control Pedal Linkage Bolt and Nut . .... . .. . ..... . . ... ... . .. .. . . . ... . . . . .. . . ..... .... . . ..... . . 21-25 (28-43)
Hydraulic Control Valve Mounting Bolts . . ......... .... ....... . . .. .... .. . . . . . ...... . ... . . .. ..... .. . .. .. 25 (34)
Hydraulic/Hydrostatic Filter Housing Mounting Bolts . .. . .......... . .............. ... .... ... . ... ... . . . . . . 25 (34)
Hydraulic Pump Mounting Bolts . ........ . .. .. . .. ..... ... .... . . ..... .... . .. ... ........... .. ......... . 30 (40)
Hydraulic Pump Mounting Bracket Nuts ... . . . . . ..... . . . .. . . .. ... . .. . .... .. . .. . ... ....... .. . ... ....... 70 (95)
Hydrostatic Motor Cover Mounting Bolts ...... ......... .... ......... . .. ..... .... .. . .... . . .. 220-245 (298-332)
Hydrostatic Motor Mounting Bolts ......... .... . ... .... . . . ... .... . .... . . .. ......... ... ......... 65- 70 (88-95)
Hydrostatic Pump Pulley Nut .... ... . . .. ....... .. . . ...... . ..... ..... ... . . .... .. ... . .. . . .. . 175-200 (237-271)
Operator Cab Pivot Bolt and Nut . ........... ... . . .. .... . . . .... ......... .. . .. . ... . . .. .... . .... 25-35 (34-47)
Parking Brake Mounting Bolts .. . . . .. . .. .... . . . . .... ...... ....... .. . .... .... . ... . . .. .. . .. .. .. . ....... 70 (95)
Pedal Interlock Mounting Nuts . ..... .... .. . .... . . .. . . .. ....... . . .. . .. . .. . .. . ........ 84-95 in.-Ibs. (9 ,5-10,8)
Pedal Interlock Linkage Shield Mounting Nuts . ...... ..... . . . . . . .. .... .. . .. .. . .. ......... . . .... . 25-28 (34-38)
Rear Door Latch Nut .. . ................... . ... . .. ....... ...... . . . .. .. ......... . . .. ....... ... 65-70 (88-95)
Reduction Gearcase Mounting Bolts ......... .. ... ... ... .... ... ..... . .... ..... . .. .. ....... 220-245 (298-332)
Steering Cross Shaft Mounting Bolts . . .. ... . .. . .. ........... ...... ........... . . .. . .... ..... . . . 15-17 (21-23)
Tilt Cylinder Base End Pivot Pin Bolt .. . .. ... .... . . ..... . .. . ...... ..... . ............ . ... . . . 220-245 (298-332)
Wheel Nuts .... . ... . . . ..... . ... ... .... .. .... . .. ... . . . . . . . .. . . .. . .. .... . ... .. ... .... .. .. 320-350 (434-475)
The following table shows standard torque specifications for bolts with zinc
phosphate coating. Bolts purchased from Melroe that have zinc phosphate
coating are specified by the letter "H" following the part number.
THREAD
SIZE SAE GRADE 5 SAE GRADE 8
Material
Thread Size
(Dia. x Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M 5 x 0.8 3-4 ft.-Ibs.
(4-5 Nm)
IMPORTANT
Flare Fitting
~
Use the following procedure to tighten the flare fitting:
Tighten the nut until it makes contact with the seat. Make
a mark across the flats of both the male and female parts
@+il
of the connection (Item 1) [C].
Use the chart below to find the correct tightness needed BI Hex Flat Tightening Method
(Item 2) [B). If the fitting leaks after tightening, disconnect
~~/) ~
it and inspect the seat area for damage.
~/) rt=D
ITS-01619
* If a torque wrench is used to tighten a new fitting to a ** If using the hex flat tightening method to tighten a new
used hose/tubeline. fitting to a new hose/tubeline.
* If a torque wrench is used to tighten a used fitting to a ** If using the hex flat tightening method to tighten a new
new hose/tubeline. fitting to a used hose/tubeline.
* If a torque wrench is used to tighten a new fitting to a *** If using the hex flat tightening method to tighten a used
new hose/tubeline. fitting to a new hose/tubeline.
O-ring may come off the fitting and enter the system.
The hex portion of the nut does not contact the surface of
the component when the nut is tight.
Specifications
Use Melroe hydraulic/hydrostatic transmission fluid (P/N 6563328). If this fluid is not
available, use 10W-30 or 10W--40 SAE Motor Oil (5W-30 for OaF [-18°C] and
Below) .
DO NOT use automatic transmission fluids in the loader or permanent damage to the
transmission will result.
When temperatures below zero degree F (-18°C) are common , the loader must be
kept in a warm building. Extra warm-up time must be used each time the loader is
started during cold temperature conditions. Cold fluid will not flow easily and it makes
action of the hydraulic function slower. Loss of fluid flow to the hydrostatic
transmission pump (indicated by TRANS light ON) can cause transmission damage
in less than 60 seconds.
A.H.C. COMPONENTS
A.H.C'/PWM CONTROLLER
BICSTM VALVE
ADVANCED
Removal and Installation ........................ .. .......... . 10-21
HAND CONTROL
TROUBLESHOOTING (A.H.C.)
Identification
Chart
The Advance Hand Control System (A.H.C .) has a built-in diagnostic function which uses the two lights on the left handle
to indicate the condition of the A.H.C. System. The left light is lift and the right light is tilt.
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 flash the code. If the problem is in the tilt controller or actuator, the lift indicator
light will be ON and the tilt light flashing a code .
The system starts its diagnostics and calibration when the ignition key is turned ON. The left light will be ON for 0.5 second
and remain ON, then both lights will be ON for another 0.5 second . (This indicates the handles are wired properly and both
lights are working .)
LOADERS PRIOR TO PRESS TO OPERATE BUTTON-At this time one of the following will happen :
1. Both lights will continue to stay ON . (Normal Operation .)
2. Both lights go out, with no flashing code. (No BICS Signal, BICS Controller Not Satisfied.)
3. The System goes into a flashing code. (See chart below for the problem.)
LOADER WITH PRESS TO OPERATE BUTTO~At this time one of the following will happen:
1. Both lights will be OFF until the PRESS TO OPERATE BUTTON is engaged . (Normal Operation .)
2. The System goes into a flashing code . (See chart below for the problem .)
The following list shows the probable causes and troubleshooting procedures when the lights are flashing.
The system will continually flash the code Signal with the key in the RUN position.
*Actuator fault (5 flashes) will only occur while the loader is in operation. The controller sensed the actuator was out of
sync with the hand controller unit. Normally this is caused from dust build up in the actuator motor, which causes a poor
connection at the motor brush . This fault will cause a loss of power to the actuators. When the loader control unit is reset
(The loader key is turned to the OFF position then back to the ON position) you will not get an actuator fault (5 flashes),
the system will reset and say the system is OK or signal an alarm (2 or 4 flashes). When actuator faults (5 flashes) alarm
becomes more frequent replace the actuator.
Chart (Cont'd)
SOLUTION
1. Turn the key OFF, put the hand controller in neutral position, turn the key 0[\1. (The engine
does not have to be runninQ for system recalibration or diaQnostics).
2. Check wire connections for loose connector body, loose or bent pins in connectors.
3. Check for broken or damaged wire.
4. Check for stuck or sticky handle controller mechanism.
5. Turn the ke~ OFF check to ensure s(2ool moves freel~, returns to neutral, turn the ke~ ON .
6. Check the siQnal voltaQe from the handle controller unit. (See PaQe 10-8)
7. Check the Signal voltage from the lift or tilt spool actuator. (See Page 10-6)
8. Check to insure the actuator moves freely on the actuator mounting bolt.
NOTE: If during operation one or both indicator light(s) goes out, this represents a reduced performance state.
This is caused by the actuator not being able to reach (full stoke) as commanded by the handle controller.
When the handle controller is returned to neutral and the actuator reaches neutral, the condition wi ll clear
itself and the light will come back ON. Reduced speed in the lift or tilt circuits may be noticed. This will
not disable the loader, but may be an indication that an actuator is going bad.
When the wrong BICSTMcontroller, (Black face instead of Green face) is installed in an Advanced Hand
Control loader, and the key is turned to the ON position, the left light will come on for 0.5 seconds and
remain ON, then both lights will stay ON for an additional 0.5 seconds, then both lights will g o out with
n o flashing code, because there is no signal from the BICS to the control module. The BICSTM c o ntroller
light s will be ON , but the Advanced Hand Controller will not allow the loader hydraulics to function.
11'_.
I~I
, , 4"
~. ~ --•....;.
With Test Harness; ! /'."f - is, -.
• . 'r 1 ..'
fL· i.,. '"
l~ ~
I \ 'iril!lt.
- ,1(1 ,
1-1.)
:fP\J'
~ ,-_"b;L_
The test harness (MEL 1554) and a digital multimeter are I
necessary to complete the following procedure. ~~
Disconnect the actuator wire connector (Item 1) [A] for
,'.
...... ':'"it"
.... ,
"_:'" \1':
., "-'"
,
•...
1 '
the tilt or (Item 2) [A] for the lift circuit from the controls
harness. \ ; II' __
NOTE: Each actuator has to be checked separately.
Install the test harness (Item 1) [8].
Diagnosis Results For Tilt Actuator (top) Sensor Supply Voltage Test;
If the sensor supply voltage is 4.3 ± 0.1 volts, continue on and check the signal voltage.
If the sensor supply voltage is less than 4.3 ± 0.1 volts or 0 volts, check the PWM fuse , check for shorts or opens in the
wiring harness. If there are no apparent shorts or opens change the AHC/PWM controller. (See Page 10-13.)
If the sensor supply voltage is more than 4.3 ±0.1 volts check for a short of the power wires in the wiring harness. If there
are no apparent shorts change the AHC/PWM controller. (See Page 10-13.)
Diagnosis Results For Tilt Actuator Signal Voltage Test;
If the signal voltage is in the range of 1.55 to 1.85 volts, the system is functioning properly. The nominal voltage reading
is 1 .72 volts.
If the signal voltage is not in the range of 1 .55 to 1.85 volts check the hydraulic control valve spools for a centering problem
or replace the actuators. (See Page 10-27.)
Handle Out (Toward Side Screen):
1. Stop engine. Raise operator cab.
If the voltage reading is less than 0.13 volts, replace the actuator. (See Page 10-27.)
While holding the handle toward the side screen turn the key to OFF position and wait five seconds ..
7. Continue to hold the handle toward the side screen and turn the key to the ON position. Take a voltage reading .
(You will have a one blink alarm on the right indicator light.)
The voltage reading should be between 1.55 to 1.85 volts.
If the voltage is above 1.85 volts, repeat steps 5 thru 7, if the voltage is still above 1.85 volts change the actuator.
If the voltage is below 1.55 volts complete the following tests: (See Step 11 Below; Tests a & b .)
If the voltage is below 1.55 volts, repeat steps 8 thru 11 if the voltage is still below 1.55 volts change the actuator.
a. Remove the pin from the actuator to the control spool. Watch the spool, if the spool continues to move toward
neutral after the pin is removed, replace the actuator. Also check the mounting hardware on the actuators and
control valve for wear and correct torque.
b. If the spool does not move, check the control valve for a sticky spool or sticky centering mechanism. Also check
the mounting hardware on the actuators and control valve for wear and correct torque.
If the sensor supply voltage is 4.3 ± 0.1 volts, continue on and check the signal voltage.
If the sensor supPly voltage is less than 4.3 ± 0.1 volts or 0 volts, check the PWM fuse, check for shorts or opens in the
wiring harness. I there are no apparent shorts or opens change the AHC/PWM controller. (See Page 10-13.)
If the sensor supply voltage is more than 4.3 ± 0.1 volts check for a short of the power wires in the wiring harness. If there
are no apparent shorts change the AHC/PWM controller. (See Page 10-13.)
Diagnosis Results For Lift Actuator Signal Voltage Test;
!f the signal voltage is in the range of 1.55 to 1.85 volts, the system is functioning properly. The nominal voltage reading
IS 1.72 volts.
If the signal voltage is not in the range of 1 .55 to 1.85 volts check the hydraulic control valve spools for a centering problem
or replace the actuators. (See Page 10-27.)
Handle Out (Toward Side Screen):
1. Stop engine. Raise operator cab.
2. Connect the remote start switch (MEL1429A) to the loader.
3. Turn key to ON position with engine OFF to get a code indication from the indicator lights on the left control handle.
(See Page 10-4.)
If the voltage reading is less than 0.13 volts, replace the actuator. (See Page 10-27.)
7. While holding the handle toward the side screen turn the key to OFF position.
8. Wait five seconds, then put the handle to the float position. Turn the key to ON position and take a voltage reading .
(You will have a one blink alarm on the left indicator light.)
The voltage reading should be between 1.55 to 1.85 volts.
If the voltage is above 1.85 volts , repeat steps 5 thru 8, if still above 1.85 volts , change the actuator.
If the voltage is below 1.55 volts complete the following tests: (See Step 12 Below; Tests a & b.)
12. Continue to keep the handle in the float position. Turn the key to ON position. Take a voltage reading.
(You will have a one blink alarm on the left indicator light.)
The voltage reading should be between 1.55 to 1.85 volts.
If the voltage is below 1.55 volts, repeat steps 9 thru 12, if the voltage is still below 1.55 volts change the actuator.
a. Remove the pin from the actuator to the control spool. Watch the spool, if the spool continues to move toward
neutral after the pin is removed, replace the actuator. Also check the mounting hardware on the actuators and
control valve for wear and correct torque.
b. If the spool does not move, check the control valve for a sticky spool or sticky centering mechanism. Also check
the mounting hardware on the actuators and control valve for wear and correct torque.
Procedure
The test harness (MEL 1555) and a digital multi meter are
necessary to complete the following procedure.
Procedure (Cont'd)
Procedure (Cont'd)
3. Move right AHC handle out or toward the side screen, hold and take a voltage reading. The voltage should be 0.13
or greater. If the voltage is less than 0.13 volts change the handle controller.
4. Allow the handle to go to neutral. Take a voltage reading. The voltage should be 1.7 to 2.1 volts. If the voltage reading
is either higher or lower, check for loose mounting hardware, or a bad handle controller.
5. Move the right AHC handle in toward the center of the cab to full stroke. Hold in position and take a voltage reading .
The voltage reading should be 4.17 volts or less. If the voltage reading is higher, change the handle controller unit.
(See Page 10-17.)
6. Release the handle and allow it to go to neutral. Take a voltage reading. The voltage should be 1.7 to 2.1 volts.
If the voltage is either higher or lower, check for loose mounting hardware, or a bad handle controller.
3. Move left AHC handle out or toward the side screen, hold and take a voltage reading. The voltage should be 0.13
or greater. If the voltage is less than 0.13 volts change the handle controller.
4. Allow the handle to go to neutral. Take a voltage reading. The voltage should be 1.7 to 2.1 volts. If the voltage reading
is either higher or lower, check for loose mounting hardware, or a bad handle controller.
5. Move the left AHC handle in toward the center of the cab to float and take a voltage reading. The voltage reading
should be 3.2 volts or less. If the voltage reading is higher, change the handle controller unit. (See Page 10-17.)
6. Release the control handle and allow it to go to neutral from the float position. Take a voltage reading . The voltage
should be 1.7 to 2.1 volts. If the voltage is either higher or lower, check for loose mounting hardware, or a bad handle
controller.
Troubleshooting Chart
The following list shows the effects which can happen to the loader, and the probable causes when the BICS Controller
6
Seat Bar Seat Bar Down Seat Bar Up
will not operate.
3
Traction lock hold coil circuit shorted
to battery voltage' .
Traction lock hold coil circuit shorted
to ground .
4 Traction lock pull coil circuit is open.
5 Traction lock pull coil circuit is shorted
to battery voltage*.
6 Traction lock pull coil circuit is shorted
to ground.
Power BICS Controller BICS Controller is Lift, tilt and traction
+ is operating
correctly.
not operating
correctly.
functions will not
operate.
-
~)
- - - - - -- - -
functions will not operate.
-- -
condition OR Hand Controls not in
neutral when engine was started .
NOTES:
(1) If the seat and/or seat bar sensor circuits are open, the corresponding lights will be OFF. If one of the lights
stay OFF, check the circuit for continuity. See Inspection & Maintenance Instruction. (See Page 8-1.)
(2) If all five lights flash repeatedly, the voltage supply is greater than 16 volts or less than 9 volts.
(3) Flashing patterns will repeat every 3.25 seconds.
(4) If seat indicator light does not go ON, check for debris, dirt or objects under or behind the seat. The Seat
Sensor Override. can be used if the seat sensor cannot be activated.
• Only on later loaders, and early loaders which have had BICS Controller and switch replaced.
NOTE: If the Seat Bar is lowered before the seat sensor is activated, a 10 second delay will occur before the valve
and traction lights come on.
* Normal SICS operating voltage is less than the electrical system voltage. If voltage is more, the circuit is shorted
to system voltage.
963 Bobcat Loader
-10-12- Service Manual
A.H.C'/PWM CONTROLLER
Test
• The wiring harness connectors must be connected to
the controller [B].
'f'~r: ~
Both Green lights will be ON .
.
""t ::~.; .~:.;:". ".' .~'" ..'·~.
' ... ~ cOI)O ~J, . ii - ;·<l>"~'·'
"ii.jJ·""'i .' I • ~;-'
~ ~
~ 0" ,
~ .• ,'l.."'-.!-'
• For individual voltage readings see Page 10-14.
. ,. . . . . . <;: """ ,
I
Key Switch Item 1 [C]
'~.,! I\..~'
nt'
~.
I' ~
~ ~.:.'< F,
' '~'
I , ' f./!
e . :,· ;.:
> ~.~
",
."'.'. '.~~ .~;~eL'WJ::'-JI
I
...."'::':.·
, . ,,'
'""';8';~.~
0....,.". •. •. •., . . . .
.6
::::.
,"!¥
Auxiliary Hydraulic Switch
Momentary Light
Detent Light
Item
Item
Item
2
3
4
[C]
[C]
[C]
' . "':':::::-
_ .' .;i· .' f
_ t
. . . I
"t.'...'
. . . J....i.•·
.8
--<",!¥..
.t;. . .
,-a~
.-.- - ;
~,-,". - .~.• .• ~~.rg-
, .'
,'",_ -, 0 'f~ -~rr,''', i
' Ii.:.··
. . ;;;......
High Flow Switch Item 5 [C]
. . . . . . .
7 - - OltGREEN ~ L T.GREEN/REO - 3
30 OltGREEN/L T.GREEN LT .GREEN/PINK -21
18 - YELLOW - - - - , YELLOW/L T.GREEN - 10
2 9 - PINK/WHITE L T.GREENIBLUE - 22
~ OltCREENIL T.BLUE I
17 - BROWN/WH ITE III L~,,,,
PURPLE/WHITE - II
4 _PU:] GRAY 3
~-GRAY/BLA~K~ANGE/DK. CREEN- 2
6 - OPEN ~ORANGE/GRAY- I 27 - PURPLE/REO YELLOW/BROWN - 12
C4Z9 * PURPLE/BROWN - A
~ PURPLEIL T.BLUE-B
26 -ORANGE
L T.BLUE/ORANGE - 5
PWM fuse
Module failure .
Troubleshooting Chart
Light Blinking Light OFF Base End Solenoid or Wiring • Wires Disconnected
• Wires Shorted
• Wires Open
• Solenoid failed. Perform solenoid
coil test.
• PWM module failed.
Light Off Light Blinking Rod End Solenoid or Wiring • Wires Disconnected
• Wires Shorted
• Wires Open
• Solenoid failed. Perform solenoid
coil test.
• PWM module failed.
Handle Testing
A
The right side steering lever handle switch (Item 1) [A]
controls the proportional flowto front auxiliary. Use a Ohm
meter to test the switch .
N-17493
P-13737
Remove the mounting bolt and nut (Item 1) [A] from the
control handle and shaft.
0*
N-17392
N-17470
'"
N-17392
3732
below [C]:
1-Terminal- Red
2-Terminal - Black ..
3-Terminal - Green
'"
~~'
P-17333
N- 17505
P-13725 P-13732
2-Terminal - Pink/Black
3-Terminal - Pink/Green
2-Terminal - Brown/Black
3-Terminal - Brown/Green
P-17335
B -......;=----------------.
-~.,,~.
wr- t:I
Right Switch Handle
Eight-Pin Connecter
. "'- '-.-...
A-Terminal - Dark. OrangeIWhite
Fr ~
~ ..' -="';;''~1~>:~\
A : __ • Li \ I \ \ \
~ . rr~(I ~.,
B-Terminal- Green
• ~/"""
_.~7~~ "' \
G-Terminal - Pink/Black
H-Terminal - Pink/Gray
'.~
';f. ':
-.:: '-~. \>. ..,1;
Six-Pin Connector
~ 8' -~"if
. 1',;.
. ll . ...
:t°\'
~,-
. \, '" ,.--' -::, j
A-Terminal - Orange
",
....
" • ..J
D-Terminal - Yellow
E-Terminal - Blank
F-Terminal - Blank
Eight-Pin Connector
A-Terminal - Yellow
B-Terminal - Green
C-Terminal - Brown
D-Terminal - Orange
E-Terminal - Orange/Blue
F-Terminal - Brown/Red
G-Terminal - Brown/Black
H-Terminal - Brown/Green
Three-Pin Connector
A-Terminal - OrangeIWhite
B-Terminal - Yellow/Red
C-Terminal - Yellow/Green
Two-Pin Connector
A-Terminal- Purple
B-Terminal - Purple/Blue
A-Terminal - White
B-Terminal - Blue
Using a small screwdriver, lift the handle tabs (Item 2) [A] :~ '"
and slightly rotate the switch handle. ,,~'it '
1-'
~.
"\i.
t
.$'
handle.
N-17385
~
N-17394
control panel.
Remove the four pop rivets from the boot retainer (Item
1) [C] and control panel.
N-17737
Check the mounting block (Item 1) [B] and bolts for wear
and replace as needed .
.:', ...
N-17738
Remove the rubber boot (Item 1) [C] and tie strap from the
actuator shaft.
Check the rubber boot (Item 1) [C] for wear and replace
as needed.
(16 gauge)
4 - Terminal-Open
6 - Terminal-Open
7 - Terminal-Open
A WARNING
A DANGER
AVOID DEATH
• Disoonnecting or loosening any hydraulic
....
~'''::
~~
"
,:~I
.,
;,.
P-13727
Check Valve
A
Loosen and remove the check valve (Item 1) [A] .
Lock Valve
There are two lock valves on the BICS valve, lift lock valve
(Item 2) [A] and tilt lock valve (Item 3) [A].
P-13728
Loosen and remove the lock valve (Item 1) [C] from the
valve. IC
Installation: Tighten the lock valve(s) to 25 ft.-Ibs. (34
Nm) torque. Replace all the O-rings and back-up
washers before installation .
'0
N-17295
:
N-17298
c
»
Inspect the solenoid cartridge (Item 1) [C] for damage.
installation.
N-17299
A
Removal and Installation (Cont'd)
valve.
N-17507
2 190-210 in .-Ibs.
(21 ,5-23,7 Nm) 1, 2, 3, 4, 5 & 6
3* 190-210 in .-Ibs.
(21 ,5-23,7 Nm)
A WARNING
A DANGER
AVOID DEATH
• Disconnecting or loosening ony hydraulic
tuboone, hose, fitting, component or a part
failure can cause lift arms 10 drop .
• K Bep out of Ilia area when lift arms are
raised mle.s support9d by an approved
liN ann support. Replace it damaged. ~.,
Page 3-1.)
10-27.)
hydrostatic controller.
hydraulic reservoir.
Mounting Plate
Identification Chart
F1 Anti-Cavitation Valve
IMPORTANT
N-1 7511
N-1751 2
Remove the main relief valve (Item 1) [B] from the control IB
valve.
,! ' ~
' I"~
y
?
N-15681
Remove the port relief valve from the control valve [8].
(Port E2).
N-17285
N-17514
Anti-Cavitation Valve
c
Installation: lighten the anti-cavitation valve to 35-40
ft.-Ibs. (47-54 Nm) torque.
N-17277
Rubber Boot
.i'"
',.'
'--~
~'
N-17516
Remove the rubber boot from the other end of the spool.
Remove the two screws (Item 1) [A] from the end cap (lift
or tilt) .
0.~
· ..:.
(10,2-11,3 Nm) torque.
-;''\.
~ -
N-17286
At the other end of the spool bore , remove the spool seal
(Item 1) [C] and O-ring (Item 2) [C].
procedure;
..:
MEL1285 - Spring Tool
,.
.,t"".
spring.
?!
N-17290
Lift Spool Only: To remove the plastic plug from the lift
spool :
Drill a hole all the way through the plug using a 7/64 inch
tap drill.
Plastic --.1 1"
Turn a 6-32 tap into the plug. Pull the tap and plug out of Plug
the spool. Be careful, do not break the tap . 0.60 "
(15,2 mm)
Clean all the debris from the inside of the spool bore. . .-.----=--~
MC-D2421
Installation: Slide the O-ring over the nipple on the
plastic plug . Install the plastic plug in the spool. Install the
bolt so that the end of the plug is about 0.60 inch (15,2 IB
mm) from the end of the spool [A).
Inspection
:p -/
Check the spools for wear or scratches.
II '
Check that the centering springs are not broken .
N-17260
Check that the load check valve seats are not worn .
Check the rubber boots and retainers that they are not
worn or damage.
Auxiliary Spool
A
Remove the end cap screws (Item 1) [A] & [8].
Remove the end cap (Item 2) [A] & [8] , O-ring (Item 3)
[A] & [6].
Remove the large spring (Item 4) [A] & [8] and small
o
3; .t.: . .,.I?. '.
spring (Item 5) [A] & [6].
~J@
: '~
.. 4 ',
7) 0 ~J' ' ' '
N-17264
N-17263
Remove the nut (Item 1) [A] from the end of the solenoid.
Nm) torque.
N-17493
Remove the metal housing (Item 1) [B], coil (Item 2) [B] ,
and end plate (Item 3) [B].
N-17269
Nm) torque.
'. N-17495
'ii'llf~~
. ~~t
N-17266
N-17494
N-17284
CD-15080
Install the linkage end spool seal [C] into the control valve
(Item 1) [0].
963-1
INGERSOLL-RAND 0/ i,;'
®
Revision Number
8 June 1998
SERVICE MANUAL
Date
REVISION
ROUTE TO
ATTENTION
AFFECTING:
Product BOBCAT LOADER
PARTS MAN AGE R 0
NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.
Take out the pages shown and put in the revised pages as follows:
Revision Number
13 October 1998
SERVICE MANUAL
Date
REVISION
ROUTE TO
ATTENTION
AFFECTING:
Product BOBCAT LOADER
PARTS MANAGER D
SE RVICE MANAGER [&I
Model 963 SALES MANAGER D
Manual No. 6724545 (11-97)
NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.
Take out the pages shown and put in the revised and/or added pages as follows :
TAKE OUT
PUT IN
ALPHABETICAL INDEX
ALPHABETICAL INDEX
7-17thru7-18
7-17 thru 7-18
MElROE
INGERSOLL-RAND ~~ bobcat
0/ it;'
®
963-3
Revision Number
4 December 1998
SERVICE MANUAL
Date
REVISION
ROUTE TO
ATTENTION
AFFECTING:
Product BOBCAT LOADER
PARTS MANAGER 0
SERVICE MANAGER [].I
Model 963 SALES MANAGER 0
Manual No. 6724545(11-97}
NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.
Take out the pages shown and put in the revised and/or added pages as follows:
NOTE: Put the new Section 10 for Advanced Hand Control System and Wiring Schematics in the Service Manual
after Specifications Section (Nine).
ADVANCED HAND CONTROL SYSTEM (A.H .C.)
10-1 thru 10-48
963
MELROE
INGERSOLL-RAND ~
., bobcat®
963-4
Revision Number
19 March 1999
SERVICE MANUAL
Date
REVISION
ROUTE TO
ATTENTION
AFFECTING:
Product BOBCAT LOADER
PARTS MANAGER D
SERVICE MANAGER [XJ
Model 963 SALES MANAGER D
Manual No. 6724545 (11-97)
NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.
Take out the pages shown and put in the revised and/or added pages as follows:
TAKE OUT
PUT IN
ALPHABETICAL INDEX
ALPHABETICAL INDEX
i thru x
i thru viii
1-1 th ru 1--6
1-1 thru 1--6
Glossary of Hydraulic/Hxdrostatic