Bobcat 873, 873 Turbo, 883, 883 Turbo Loaders Factory Service & Shop Manual
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Model:
Complete workshop repair service manual with electrical wiring diagrams for Bobcat 873, 873 Turbo, 883, 883 Turbo Loaders. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.
This Bobcat 873, 873 Turbo, 883, 883 Turbo Loaders service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.
6724280 (7-10) - 873 Service Manual.pdf
6724280 (9-96) - 873 Service Manual.pdf
6900369 (10-98) - 873 Operation & Maintenance Manual.pdf
6900382 (7-10) - 873 Service Manual.pdf
6900382 (7-97) - 873 Service Manual.pdf
6900791 (9-00) - 873 Operation & Maintenance Manual.pdf
6900847 (2-06) - 873 Turbo, 883 Turbo (G Series) [include High Flow] Service Manual .pdf
6900847 (7-10) - 873 Turbo, 883 Turbo (G Series) Service Manual.pdf
6900927 (3-03) - 873, 873 High Flow Operation & Maintenance Manual.pdf
6900927 (9-10) - 873, 873 High Flow Operation & Maintenance Manual.pdf
6901274 (6-01) - 883, 883 High Flow Operation & Maintenance Manual.pdf
EXCERPT:
CONTENTS
FOREWORD . . . . . . ii
SAFETY INSTRUCTIONS . . . . . . . v
SERIAL NUMBER LOCATIONS . . . . . . . vii
DELIVERY REPORT . . . . vii
BOBCAT LOADER IDENTIFICATION . . viii
PREVENTIVE MAINTENANCE . . . . . . 1–1
HYDRAULIC SYSTEM . . 2–1
HYDROSTATIC SYSTEM . . . . . 3–1
DRIVE SYSTEM . . . . . . . 4–1
MAIN FRAME . . . 5–1
ELECTRICAL SYSTEM . . . . . . . 6–1
ENGINE SERVICE . . . . . 7–1
SYSTEM ANALYSIS . . . . 8–1
SPECIFICATIONS . . . . . . 9–1
…
Disassembly
Disassemble the alternator (See Parts Identification) [A].
Remove the regulator cover and regulator.
Remove the four bolts holding halves together.
Pry the halves apart.
Use a soft jaw vise to hold rotor while removing pulley nut.
Remove front case half from the rotor using a plastic hammer.
Unsolder the stator leads from the rectifier. Remove the stator.
Stator Continuity Test
Use an ohmmeter to test the stator.
Touch the probes to two of the bare stator wires [B].
Move one of the probes to the third wire.
The readings should be the same.
If there is no continuity, replace the stator.
Stator Ground Test
Touch one probe to a bare stator lead and the other probe to the bare metal surface of the stator [C].
There should be no continuity.
Replace the stator if there is continuity.
…
6724280 (7-10) - 873 Service Manual..2
MAINTENANCE SAFETY..4
ALPHABETICAL INDEX..6
CONTENTS..8
FOREWORD..9
SAFETY INSTRUCTIONS..12
SERIAL NUMBER LOCATIONS..14
LOADER SERIAL NUMBER..14
ENGINE SERIAL NUMBER..14
DELIVERY REPORT..14
BOBCAT LOADER IDENTIFICATION..15
OPTIONS AND ACCESSORIES..16
PREVENTIVE MAINTENANCE..18
SERVICE SCHEDULE..20
LIFTING AND BLOCKING THE LOADER..21
Procedure..21
TRANSPORTING THE LOADER..22
Procedure..22
TOWING THE LOADER..22
Procedure..22
STOPPING THE BOBCAT LOADER..22
Procedure..22
LIFT ARM SUPPORT DEVICE..23
To Install The Lift Arm Support Device..23
To Remove The Lift Arm Support Device..23
OPERATOR CAB..24
Description..24
Raising The Operator Cab..24
Lowering The Operator Cab..25
Emergency Exit..26
SEAT BAR RESTRAINT SYSTEM..27
Description..27
Seat Bar Inspection..27
Seat Bar Maintenance..27
AIR CLEANER SERVICE..28
Replacing Filter Element..28
FUEL SYSTEM..30
Fuel Specifications..30
Filling The Fuel Tank..30
Fuel Filter..30
Removing Air From The Fuel System..30
ENGINE LUBRICATION SYSTEM..31
Checking Engine Oil..31
Replacing Oil And Filter..31
ENGINE COOLING SYSTEM..32
Cleaning Cooling System (S/N 514111516 – 514114999)..32
Cleaning The Cooling System (S/N 514111515 & Below)..33
ALTERNATOR BELT..34
Adjusting The Alternator Belt..34
HYDRAULIC/HYDROSTATIC SYSTEM..35
Checking And Adding Fluid..35
Hydraulic/Hydrostatic Filter Replacement..35
Replacing Hydraulic Fluid..36
TIRE MAINTENANCE..37
Wheel Nuts..37
Tire Rotation..37
Tire Mounting..37
FINAL DRIVE TRANSMISSION (CHAINCASE)..38
Checking And Adding Oil..38
FAN GEARBOX..38
Checking And Maintaining..38
LUBRICATING THE LOADER..39
Procedure..39
REMOTE START SWITCH..42
Procedure..42
HYDRAULIC SYSTEM..44
HYDRAULIC / HYDROSTATIC SCHEMATICS..47
TROUBLESHOOTING..50
HYDRAULIC SYSTEM INFORMATION..51
Flare Connections..51
O–ring Face Seal Connection..51
Straight Thread O–ring Fitting..51
Tubelines And Hoses..51
LIFT CYLINDER(S)..52
Checking The Lift Cylinder(s)..52
Removal And Installation..52
TILT CYLINDER(S)..54
Checking The Tilt Cylinder(s)..54
Removal And Installation..55
HYDRAULIC CYLINDER..57
Lift Cylinder Identification..57
Tilt Cylinder Identification..58
Disassembly..59
Assembly..61
MAIN RELIEF VALVE..64
Checking The Main Relief Valve..64
Checking The Main Relief Valve Without Auxiliaries..65
Removal And Installation..66
HYDRAULIC CONTROL VALVE..67
Removal And Installation..67
Identification Chart..69
Disassembly And Assembly..70
Load Check Valve..70
Main Relief Valve..71
Port Relief Valve..71
Anti–Cavitation Valve..72
Rubber Boot..73
Lift Spool And Detent..74
Tilt Spool And Centering Spring..79
Auxiliary Spool..80
Auxiliary Electric Solenoid..81
H Port – Auxiliary Section..82
Base End Restrictor..82
Inspection..82
Spool Seal Installation..83
HYDRAULIC PUMP..84
Checking The Output Of The Pump..84
Removal And Installation..85
Parts Identification..86
Disassembly..87
Inspection..89
Assembly..90
HYDRAULIC FLUID RESERVOIR..92
Draining The Fluid Reservoir..92
Removal And Installation..92
HYDROSTATIC FILTER HOUSING..95
Removal And Installation..95
HYDRAULIC FILTER HOUSING..96
Removal And Installation..96
HYDRAULIC/HYDROSTATIC FILTER HOUSING BRACKET..97
Removal And Installation..97
CONTROL PEDALS..99
Removal And Installation..99
Pedal Adjustment..99
PEDAL INTERLOCK LINKAGE..100
Removal And Installation..100
Pedal Interlock Linkage Adjustment..101
FRONT SIDE PANEL..101
Removal And Installation..101
REAR AUXILIARY DIVERTER..102
Disassembly..102
Inspection..102
Solenoid Testing..102
Assembly..102
HYDROSTATIC SYSTEM..104
TROUBLESHOOTING..106
HYDROSTATIC SYSTEM INFORMATION..107
Replenishing Valve Function..107
FRONT PANEL..108
Removal And Installation..108
STEERING LEVERS..110
Disassembly And Assembly..110
Pre–Adjustment Checks..112
Adjusting Lever Freeplay..113
Adjusting The Wheel RPM Forward Compared To Reverse Travel..114
Adjusting The Steering Neutral Setting..116
Adjusting The Wheel RPM Left Compared To Right Side..117
HYDROSTATIC MOTOR..118
Removal And Installation..118
Parts Identification..120
Disassembly..121
Inspection..122
Assembly..123
MOTOR CARRIER..125
Removal And Installation..125
Parts Identification..127
Disassembly..128
Assembly..130
HYDROSTATIC PUMP..132
Removal And Installation..132
Replenishing/High Pressure Relief Valve..134
Parts Identification..135
Hydraulic Pump Removal..139
Hydrostatic Pump Separation..139
Charge Pump Disassembly..140
Disassembly..141
Inspection..150
Assembly..152
Charge Pump Assembly..161
Hydrostatic Pump Connection..162
Hydraulic Pump Installation..163
Hydrostatic Pump Neutral Adjustment..164
DRIVE BELT SHIELD..166
Removal And Installation..166
DRIVE BELT..167
Adjusting The Drive Belt..167
Replacing The Drive Belt..167
DRIVE BELT TENSIONER PULLEY..168
Removal And Installation..168
Tension Spring..170
OIL COOLER..171
Removal And Installation (*S/N 514111516 – 514114999) (*Also S/N 514111504)..171
Removal And Installation (S/N 514111515 & Below)..172
DRIVE SYSTEM..174
BRAKE PEDAL..176
Removal And Installation..176
Disassembly And Assembly..177
BRAKE DISC..178
Removal And Installation..178
Removal And Installation (New Style Disc)..179
Removal And Installation (Old Style Disc)..181
FRONT CHAINCASE COVER..182
Removal And Installation..182
REAR CHAINCASE COVER..182
Removal And Installation..182
AXLE SEAL..183
Removal And Installation..183
AXLE, BEARINGS AND SPROCKET..185
Removal And Installation..185
DRIVE CHAIN..189
Removal And Installation..189
Removing The Fluid From The Chaincase..190
MAIN FRAME..192
SEAT BAR (W/GAS SPRING)..194
Removal And Installation..194
Assembly..196
Compressing The Gas Cylinder..197
SEAT BAR (W/COMPRESSION SPRING)..199
Removal And Installation..199
Assembling Components..202
Compression Spring Disassembly And Assembly..202
OPERATOR CAB GAS CYLINDER..203
Removal And Installation..203
Disassembly And Assembly..204
OPERATOR CAB..205
Removal And Installation..205
OPERATOR SEAT..208
Removal And Installation..208
BOB–TACH..209
Removal And Installation..209
Bob–Tach Lever And Wedge..210
Pivot Pin Bushing And Seal Replacement..211
LIFT ARM STABILIZER BAR..212
Removal And Installation..212
LIFT ARM LINK..213
Removal And Installation..213
LIFT ARMS..215
Removal And Installation..215
REAR GRILL..218
Removal And Installation..218
REAR DOOR..219
Removal And Installation..219
Hood Removal And Installation..220
Bumper Removal And Installation..220
Door Latch Removal And Installation..220
Door Latch And Catch Adjustment..220
FUEL TANK..221
Removal And Installation..221
Fuel Level Sender..223
Inlet Screen..223
ELECTRICAL SYSTEM..224
ELECTRICAL SCHEMATICS..226
TROUBLESHOOTING..298
ELECTRICAL SYSTEM INFORMATION..299
Description..299
Fuse Location..299
BATTERY..300
Removal and Installation..300
Servicing the Electrical System..302
Using A Booster Battery (Jump Starting)..303
ALTERNATOR..304
Alternator Output Test..304
Rectifier (Diode) Test..304
Alternator Regulator Test..305
Removal and Installation..306
Disassembly..307
Stator Continuity Test..307
Stator Ground Test..307
Rotor Continuity Test..308
Rotor Ground Test..308
Rectifier Continuity (Diode) Test..308
Assembly..309
STARTER..310
Removal and Installation..310
Parts Identification..311
Disassembly and Assembly..312
External Pinion..316
Inspection and Repair..317
Magnetic Switch Test..320
No Load Test..320
STANDARD INSTRUMENT PANEL..321
Removal and Installation..321
FRONT LIGHTS..322
Removal and Installation..322
RELAY SWITCHES..323
Location..323
ENGINE SERVICE..324
TROUBLESHOOTING..326
ENGINE SPEED CONTROL..327
Removal And Installation..327
Speed Control Cable..328
Speed Control Linkage..328
ENGINE MUFFLER..329
Removal And Installation..329
AIR CLEANER HOUSING..330
Removal And Installation..330
BLOWER HOUSING/FAN GEARBOX..332
Removal And Installation..332
FAN DRIVE TENSION PULLEY..334
Removal And Installation..334
BLOWER FAN..336
Removal And Installation..336
FAN GEARBOX..337
Parts Identification..337
Disassembly..338
Assembly..343
Checking Backlash..348
ENGINE/HYDROSTATIC PUMP ASSEMBLY..350
Removal And Installation..350
ENGINE MOUNTS..356
Replacement..356
ENGINE..357
Removal And Installation..357
FLYWHEEL..359
Removal And Installation..359
FLYWHEEL HOUSING..359
Removal And Installation..359
GLOW PLUG..360
Checking The Glow Plug..360
VALVE CLEARANCE..361
Adjustment..361
FUEL INJECTION PUMP..362
Description..362
Removal..362
Installation..364
FUEL INJECTOR..366
Removal And Installation..366
Checking..367
Disassembly..368
Assembly..369
TIMING BELT..371
Inspection..371
Removal..371
Installation..372
Belt Replacement In Loader..375
VALVE TIMING..380
Checking..380
DEUTZ ENGINE TOOLS..381
Identification Chart..381
RECONDITIONING THE ENGINE..382
Disassembly..382
Assembly..386
CYLINDER LINERS..401
Checking The Cylinder Liners..401
CAMSHAFT BEARINGS..402
Checking..402
Removal And Installation..402
CONTROL ROD GUIDE BUSHING..404
Removal..404
Installation..406
REAR COVER SEAL..410
Removal And Installation..410
CRANKSHAFT..411
Checking The Crankshaft..411
CONNECTING ROD..412
Checking The Connecting Rod..412
PISTON AND PISTON PIN..415
Checking The Piston..415
Checking Piston Pin..416
Installing Piston Rings..416
CYLINDER HEAD..417
Disassembly..417
Checking The Valves..417
Checking Valve Seats..418
Valve Spring..418
Assembly..418
ROCKER ARM AND BRACKET..420
Checking..420
FRONT COVER..421
Disassembly..421
Assembly..426
TURBOCHARGER..436
Removal And Installation..436
Disassembly..437
Inspection..441
Assembly..442
POSITIVE CRANKCASE VENTILATION SYSTEM..447
Description..447
Inspection..447
Module Removal And Installation..448
OIL COOLER..449
Removal and Installation..449
CRANKSHAFT GEAR MOUNTING BOLT..450
Torque Procedure..450
SYSTEMS ANALYSIS..452
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..454
Inspecting The BICS™ Controller (Engine STOPPED– Key ON)..454
nspecting Deactivation Of The Auxiliary HydraulicsSystem (Engine STOPPED – Key ON)..454
Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)..454
Inspecting The Traction Lock (Engine RUNNING)..454
Inspecting The Lift Arm By–Pass Control..454
Maintenance..454
Troubleshooting Chart..455
Troubleshooting Guide..456
BICS SYSTEM CONTROLLER..456
TRACTION LOCK..457
SEAT SENSOR..458
SEAT BAR SENSOR..459
LIFT LOCK BY–PASS VALVE..460
BICS™ SYSTEM CONTROLLER..461
Removal And Installation..461
Controller Test..462
SEAT BAR SENSOR..463
Removal And Installation..463
Seat Bar Sensor Test..464
SEAT SENSOR..465
Removal And Installation..465
Seat Sensor Test..466
TRACTION LOCK..467
Removal And Installation..467
LIFT LOCK BY–PASS VALVE..468
Removal And Installation..468
Disassembly And Assembly..469
TILT LOCK VALVE..470
Removal And Installation (S/N 514111092 & Below)..470
Removal And Installation (S/N 514111093 – 514114999)..470
Disassembly And Assembly..471
BOSS® DIAGNOSTIC TOOL..472
Procedure..472
SENDER AND SENSOR..472
Service Checks..472
Components..472
RPM SENSOR..472
Adjustment..472
MONITOR SERVICE CODES..473
TROUBLESHOOTING THE BOSS® & LCD DISPLAY..476
OPERATION SENSING SYSTEM UNIT..477
Removal And Installation..477
BOSS® INSTRUMENT PANEL..478
Removal And Installation..478
PWM MODULE(*S/N 514111443 –514114999) (*Except S/N 514111445)..479
Description..479
PWM TROUBLESHOOTING..480
Conditions..480
Chart..481
PWM CONTROL HANDLE..482
Handle Testing..482
PWM ELECTRIC SOLENOID..482
Solenoid Coil Testing..482
TRACTION LOCK CONTROL SYSTEM..483
Description..483
Inspection..483
Maintenance..483
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE..484
Controls Identification Chart..484
SPECIFICATIONS..486
LOADER SPECIFICATIONS..488
PERFORMANCE..488
CONTROLS..488
ENGINE..488
HYDRAULIC SYSTEM..489
ELECTRICAL..489
DRIVE SYSTEM..489
CAPACITIES..489
TIRES..489
FLOOR PRESSURE..489
ENGINE SPECIFICATIONS..490
General..490
Fuel System..490
Valve and Valve Guide & Seat Insert..490
Piston, Rings and Connecting Rod..490
Cylinder Head..491
Crankshaft and Main Bearings..491
Camshaft and Bearings..491
Oil Pump..491
Engine Torque Specifications..492
Torque for General Metric Bolts..493
TORQUE SPECIFICATIONS FOR LOADER..494
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS..495
STANDARD TORQUE SPECIFICATIONS FOR BOLTS..496
DECIMAL AND MILLIMETER EQUIVALENTS..497
U.S. TO METRIC CONVERSION..497
SERVICE MANUAL REVISIONS..498
873–001..498
873–002..500
873–003..502
873–004..504
873–005..506
873-6..508
6724280 (9-96) - 873 Service Manual..510
6900369 (10-98) - 873 Operation & Maintenance Manual..989
OPERATOR SAFETY WARNINGS..991
CONTENTS..993
MELROE COMPANY IS ISO 9001 CERTFIED..994
REGULAR MAINTENANCE ITEMS..994
FOREWORD..995
SERIAL NUMBER INFORMATION..996
SERIAL NUMBER LOCATIONS..997
LOADER SERIAL NUMBER..997
DELIVERY REPORT..997
BOBCAT LOADER IDENTIFICATION..998
OPTIONS AND ACCESSORIES..999
SAFETY..1001
SAFETY INSTRUCTIONS..1003
SAFETY IS THE OPERATOR’S RESPONSIBILITY..1003
BEFORE OPERATING THE BOBCAT LOADER..1004
SAFE OPERATION NEEDS A QUALIFIED OPERATOR*..1004
FIRE PREVENTION..1005
MACHINE SIGNS (DECALS)..1006
OPERATING INSTRUCTIONS..1009
INSTRUMENT PANEL..1011
Early Models – Front Panel – Without BOSS™..1011
Early Models – Front Panel – With BOSS™..1012
Later Models–Front Panel–Without BOSS™..1013
Without BOSS (Side Console•)..1013
Later Models–Front Panel–With BOSS™..1014
With BOSS (Side Console•) ..1014
BOSS Option Display Panel..1015
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..1016
Lift Arm By–Pass Control..1016
Traction Lock Override..1016
Seat Sensor Override (If Equipped)..1017
Auxiliary Hydraulic System..1017
TRACTION LOCK CONTROL SYSTEM..1017
ENGINE SPEED CONTROL..1018
PARKING BRAKE..1018
STEERING LEVERS..1019
STOPPING THE BOBCAT LOADER..1019
SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)..1020
SEAT BAR RESTRAINT SYSTEM (MECHANICALHAND CONTROLS)..1021
SEAT BAR RESTRAINT SYSTEM (ADVANCED HANDCONTROLS)..1022
HYDRAULIC CONTROLS..1023
Foot Pedals..1023
Lift Arm Operation..1023
Lift Arm Float Position..1023
Tilt Operation..1023
Bucket Position Valve Operation (If Equipped)..1023
Hand Controls..1024
Lift Arm Operation..1024
Lift Arm Float Position..1024
Tilt Operation..1024
Bucket Position Valve Operation (If Equipped)..1024
Auxiliary Hydraulics (If Equipped)..1025
Quick Couplers (Flush Face)..1025
Auxiliary Hydraulics Switch..1026
FRONT Auxiliary Hydraulics Operation ..1026
FRONT Auxiliary Hydraulics Continuous Operation..1026
REAR Auxiliary Hydraulics Operation..1026
Attachment Functions Control..1027
Relieving Hydraulic Pressure..1027
DAILY INSPECTION..1028
GETTING READY FOR OPERATION..1028
STARTING THE ENGINE..1030
Normal Starting (Without BOSS®)..1030
Normal Starting (With BOSS®)..1031
Cold Temperature Starting (With BOSS®)..1032
Warming The Hydraulic/Hydrostatic System..1032
STOPPING THE ENGINE..1032
ATTACHMENTS AND BUCKETS..1033
Installing The Bucket Or Attachment..1034
Removing The Bucket Or Attachment..1035
OPERATING PROCEDURE..1036
Filling The Bucket..1037
Emptying The Bucket..1037
Digging Into The Ground..1038
Backfilling..1039
PARKING THE BOBCAT LOADER..1039
OPERATING PROCEDURE (HAND CONTROLS) ..1040
Filling The Bucket..1040
Emptying The Bucket..1040
Digging Into The Ground..1041
Leveling The Ground (Using Lift Arms In Float Position)..1041
Backfilling..1042
PARKING THE BOBCAT LOADER..1042
TRANSPORTING THE BOBCAT LOADER..1043
TOWING THE LOADER..1043
LIFTING THE LOADER..1044
Four Point Lift..1044
PREVENTIVE MAINTENANCE..1045
MAINTENANCE SAFETY..1047
SERVICE SCHEDULE..1049
LIFT ARM SUPPORT DEVICE..1050
Installing The Lift Arm Support Device..1050
Removing The Lift Arm Support Device..1050
OPERATOR CAB..1051
Raising The Operator Cab..1051
Lowering The Operator Cab..1052
Emergency Exit..1053
SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)..1054
Inspecting The Seat Bar..1054
Maintaining The Seat Bar..1054
SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS)..1055
Inspecting The Seat Bar..1055
Maintaining The Seat Bar..1055
SEAT BAR RESTRAINT SYSTEM (ADVANCED HANDCONTROLS)..1056
Inspecting The Seat Bar..1056
Maintaining The Seat Bar..1056
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..1057
Inspecting The BICS™ System Controller ..1057
Inspecting The Seat And Seat Bar Sensors..1057
Inspecting The Traction Lock (Engine RUNNING)..1057
Inspecting The Lift Arm By–Pass Control..1057
Inspecting the BICS™Lock Valve (Advanced Hand Control Only)..1057
Maintenance..1058
TRACTION LOCK CONTROL SYSTEM..1058
Inspecting The Traction Lock Control System..1058
Maintenance..1059
REAR DOOR..1060
Opening And Closing The Rear Door..1060
Adjusting The Rear Door..1060
REAR GRILL..1060
AIR CLEANER SERVICE..1061
FUEL SYSTEM..1063
Fuel Specifications..1063
Filling The Fuel Tank..1063
Fuel Filter..1063
Removing Air From The Fuel System..1063
ENGINE LUBRICATION SYSTEM..1064
Checking Engine Oil..1064
Replacing The Oil And Filter..1064
ENGINE COOLING SYSTEM..1065
Cleaning The Cooling System..1065
ALTERNATOR BELT..1066
Adjusting The Alternator Belt..1066
TIMING BELT..1067
ELECTRICAL SYSTEM..1067
Description..1067
Electrical System Maintenance..1067
Fuse Location..1068
Using A Booster Battery (Jump Starting)..1069
Removing And Installing The Battery..1070
HYDRAULIC/HYDROSTATIC SYSTEM..1072
Checking And Adding Fluid..1072
Replacing Hydraulic/Hydrostatic Filters..1072
Replacing Hydraulic Fluid..1073
TIRE MAINTENANCE..1074
Wheel Nuts..1074
Tire Rotation..1074
Tire Mounting..1074
FINAL DRIVE TRANSMISSION (CHAINCASE)..1075
Checking And Adding Oil..1075
FAN GEARBOX..1076
Checking And Maintaining..1076
DRIVE BELT..1076
Adjusting The Drive Belt..1076
Replacing The Drive Belt..1077
LUBRICATING THE BOBCAT LOADER..1078
BOB–TACH..1081
Inspection And Maintenance..1081
SYSTEMS ANALYSIS..1083
MONITOR SERVICE CODES..1084
SERVICE CODES..1085
AUXILIARY HYDRAULICS OPERATION..1086
Troubleshooting Chart..1086
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..1087
Troubleshooting Chart..1087
ADVANCED HAND CONTROLS (AHC)..1087
Troubleshooting Chart..1087
MACHINE SIGN TRANSLATIONS..1089
IMPORTANT - 6708937..1091
WARNING - 6579511..1092
WARNING - 6579510..1093
WARNING - 6703726..1094
SERVICE SCHEDULE - 6715563..1095
WARNING - 6579528..1097
WARNING - 6708941..1097
WARNING - 6577754..1097
DANGER - 6579639..1097
DANGER - 6579509..1097
SPECIFICATIONS..1099
PERFORMANCE..1101
CONTROLS..1101
ENGINE..1101
HYDRAULIC SYSTEM..1102
ELECTRICAL..1102
DRIVE SYSTEM..1102
CAPACITIES..1102
TIRES..1102
FLOOR PRESSURE..1102
MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES..1103
ADDITIONAL PUBLICATIONS..1106
WARRANTY..1107
6900382 (10-12) - 873 Service Manual..1109
MAINTENANCE SAFETY..1111
ALPHABETICAL INDEX..1113
CONTENTS..1115
FOREWORD..1116
SAFETY INSTRUCTIONS..1119
SERIAL NUMBER LOCATIONS..1121
LOADER SERIAL NUMBER..1121
ENGINE SERIAL NUMBER..1121
DELIVERY REPORT..1121
BOBCAT LOADER IDENTIFICATION..1122
OPTIONS AND ACCESSORIES..1123
PREVENTIVE MAINTENANCE..1125
SERVICE SCHEDULE..1127
LIFTING AND BLOCKING THE LOADER..1128
Procedure..1128
TRANSPORTING THE LOADER..1129
Procedure..1129
TOWING THE LOADER..1129
Procedure..1129
STOPPING THE BOBCAT LOADER..1129
Procedure..1129
LIFT ARM SUPPORT DEVICE..1130
To Install The Lift Arm Support Device..1130
To Remove The Lift Arm Support Device..1130
OPERATOR CAB..1131
Raising The Operator Cab..1131
Lowering The Operator Cab..1132
Emergency Exit..1133
SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)..1134
Seat Bar Inspection..1134
Seat Bar Maintenance..1134
SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS)..1135
Seat Bar Inspection..1135
Seat Bar Maintenance..1135
SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)..1136
Inspecting The Seat Bar..1136
Maintaining The Seat Bar..1136
AIR CLEANER SERVICE..1137
Replacing Filter Element..1137
FUEL SYSTEM..1139
Fuel Specifications..1139
Filling The Fuel Tank..1139
Fuel Filter..1139
Removing Air From The Fuel System..1139
ENGINE LUBRICATION SYSTEM..1140
Checking Engine Oil..1140
Replacing Oil And Filter..1140
ENGINE COOLING SYSTEM..1141
Cleaning Cooling System..1141
ALTERNATOR BELT..1142
Adjusting The Alternator Belt..1142
HYDRAULIC/HYDROSTATIC SYSTEM..1143
Checking And Adding Fluid..1143
Hydraulic/Hydrostatic Filter Replacement..1143
Replacing Hydraulic Fluid..1144
Later Model loaders..1144
Early Model Loaders..1145
TIRE MAINTENANCE..1146
Wheel Nuts..1146
Tire Rotation..1146
Tire Mounting..1146
FINAL DRIVE TRANSMISSION (CHAINCASE)..1147
Checking And Adding Oil..1147
FAN GEARBOX..1147
Checking And Maintaining..1147
LUBRICATING THE LOADER..1148
Procedure..1148
REMOTE START SWITCH..1151
Procedure..1151
HYDRAULIC SYSTEM..1153
HYDRAULIC / HYDROSTATIC SCHEMATICS..1158
GLOSSARY OF HYDRAULIC / HYDROSTATIC SYMBOLS..1169
TROUBLESHOOTING..1173
HYDRAULIC SYSTEM INFORMATION..1174
Tighten Procedures..1174
LIFT CYLINDER(S)..1175
Checking The Lift Cylinder(s)..1175
Removal And Installation..1175
TILT CYLINDER(S)..1177
Checking The Tilt Cylinder(s)..1177
Removal And Installation..1177
HYDRAULIC CYLINDER..1179
Lift Cylinder Identification..1179
Tilt Cylinder Identification..1180
Disassembly..1181
Assembly..1183
MAIN RELIEF VALVE..1186
Checking The Main Relief Valve With Auxiliaries..1186
Checking The Main Relief Valve Without Auxiliaries..1187
MAIN RELIEF VALVE (S/N 514122001 & Above; 514222001 & Above)..1188
Removal and Installation..1188
Adjustment..1188
MAIN RELIEF VALVE (S/N 514119999 & Below; 514219999 & Below)..1189
Adjustment..1189
Removal And Installation..1189
BICS™ VALVE ASSEMBLY (S/N 514122001 & Above; 514222001 & Above)..1190
Lift Arm By–Pass Orifice..1190
Check Valve..1191
Lock Valve..1192
BICS™ Valve Solenoid..1193
Removal and Installation..1194
HYDRAULIC CONTROL VALVE (S/N 514122001 & Above; 514222001 & Above)..1195
Removal and Installation..1195
Identification Chart..1198
Disassembly and Assembly..1199
Load Check Valve..1199
Lift Base End Restrictor..1199
Main Relief Valve..1200
Port Relief Valve..1201
Anti–Cavitation/Port Relief Valve..1201
Rubber Boot..1203
Lift Spool and Detent..1204
Auxiliary Spool..1209
Auxiliary Electric Solenoid..1210
H Port – Auxiliary Section..1211
Inspection..1211
Spool Seal Installation..1212
HYDRAULIC CONTROL VALVE (S/N 514119999 & Below; 514219999 & Below)..1213
Removal And Installation..1213
Identification Chart..1215
Disassembly And Assembly..1216
Load Check Valve..1216
Main Relief Valve..1217
Port Relief Valve..1217
Anti–Cavitation Valve..1218
Rubber Boot..1219
Lift Spool And Detent..1220
Tilt Spool And Centering Spring..1225
Auxiliary Spool..1226
Auxiliary Electric Solenoid..1227
H Port – Auxiliary Section..1228
Base End Restrictor..1228
Inspection..1228
Spool Seal Installation..1229
HYDRAULIC PUMP (Double Gear)..1230
Checking The Output Of The Pump..1230
Removal And Installation..1231
Parts Identification..1232
Disassembly..1233
Inspection..1237
Assembly..1238
HYDRAULIC PUMP (Single Gear)..1241
Checking The Output Of The Pump..1241
Removal And Installation..1242
Parts Identification..1243
Disassembly..1244
Inspection..1246
Assembly..1247
HYDRAULIC FLUID RESERVOIR..1249
Draining The Fluid Reservoir..1249
Removal And Installation..1249
Hydraulic Fluid Screen Removal And Installation..1252
LIFT ARM BY–PASS CONTROL VALVE (S/N 514122001 & Above; 514222001 & Above)..1253
Removal and Installation..1253
Disassembly and Assembly..1254
LIFT LOCK BY–PASS VALVE (S/N 514119999 &Below; 514219999 & Below)..1255
Removal And Installation..1255
Disassembly And Assembly..1256
TILT LOCK VALVE (S/N 514119999 & Below; 514219999 & Below) ..1257
Removal And Installation..1257
Disassembly And Assembly..1258
HYDRAULIC/HYDROSTATIC FILTER HOUSING..1259
Removal And Installation..1259
HYDROSTATIC FILTER HOUSING..1260
Removal And Installation ..1260
S/N 514122001 thru 514122813; 514222001 thru 514222027..1260
S/N 514119999 & Below; 514219999 & Below..1261
All S/N Loaders..1262
S/N 514122001 thru 514122813; 514222001 thru 514222027..1263
S/N 514119999 & Below; 514219999 & Below..1264
HYDRAULIC/HYDROSTATIC FILTER HOUSING BRACKET..1265
Removal And Installation..1265
S/N 514122814 & Above; 514222028 & Above..1265
S/N 514122001 thru 514122813; 514222001 thru 514222027..1266
S/N 514119999 & Below; 514219999 & Below..1267
All S/N Loaders..1268
CONTROL PEDALS..1269
Removal And Installation..1269
Pedal Adjustment..1269
PEDAL INTERLOCK LINKAGE..1270
Removal And Installation..1270
Adjustment..1271
FRONT SIDE PANEL..1271
Removal And Installation..1271
REAR AUXILIARY DIVERTER..1272
Disassembly..1272
Inspection..1272
Solenoid Testing..1272
Assembly..1272
HYDROSTATIC SYSTEM..1273
TROUBLESHOOTING..1275
HYDROSTATIC SYSTEM INFORMATION..1276
Replenishing Valve Function..1276
FRONT PANEL..1277
Removal And Installation..1277
STEERING LEVERS (514122814 & Above; 514222028 & Above)..1279
Removal And Installation..1279
Disassembly And Assembly..1279
STEERING LINKAGE (S/N 514122814 & Above; 514222028 & Above)..1281
Removal And Installation..1281
Steering Linkage Adjustment..1285
STEERING LEVERS (514122814 & Below; 514222028 & Below)..1290
Removal And Installation..1290
Disassembly And Assembly..1290
STEERING LINKAGE (514122814 & Below; 514222028 & Below)..1292
Removal And Installation..1292
Steering Linkage Adjustment..1296
HYDROSTATIC MOTOR (S/N 514122306 & Above; 514223902 & Above)..1301
Removal And Installation..1301
Parts Identification..1302
Disassembly..1303
Inspection..1305
Assembly..1306
HYDROSTATIC MOTOR (S/N 514122305 & Below; 514223901 & Below)..1310
Removal and Installation..1310
Parts Identification..1312
Disassembly..1313
Inspection..1314
Assembly..1315
MOTOR CARRIER..1317
Removal and Installation..1317
Parts Identification..1319
Disassembly..1320
Assembly..1322
HYDROSTATIC PUMP..1324
Removal And Installation..1324
Parts Identification (Right Half)..1326
Parts Identification (Left Half)..1328
HYDROSTATIC PUMP (S/N 514122814 & Above; 514222028 & Above)..1330
Replenishing/High Pressure Relief Valve..1330
Charge Pressure Relief Valve..1331
Hydraulic Pump Removal..1332
Hydraulic Pump Separation..1333
Charge Pump Disassembly..1333
Disassembly..1335
Assembly..1341
HYDROSTATIC PUMP (S/N 514122813 & Below;514222027 & Below)..1349
Replenishing/High Pressure Relief Valve..1349
Parts Identification..1350
Disassembly..1352
Inspection..1358
Assembly..1361
DRIVE BELT SHIELD..1368
Removal And Installation..1368
DRIVE BELT..1369
Adjusting The Drive Belt..1369
Replacing The Drive Belt..1369
DRIVE BELT TENSIONER PULLEY..1370
Removal And Installation..1370
Tension Spring..1372
OIL COOLER..1373
Removal And Installation..1373
DRIVE SYSTEM..1375
PARKING BRAKE PEDAL..1377
Removal And Installation..1377
Disassembly And Assembly..1378
BRAKE DISC..1379
Removal And Installation..1379
FRONT CHAINCASE COVER..1381
Removal and Installation..1381
AXLE SEAL..1382
Removal and Installation..1382
Later Model Loaders..1382
Early Model Loaders..1384
AXLE, SPROCKET AND BEARINGS..1386
Removal and Installation..1386
Later Model Loaders..1386
Early Model Loaders..1388
All Model Loaders..1390
DRIVE CHAIN..1393
Removal And Installation..1393
CHAINCASE FLUID..1394
Removing The Fluid From The Chaincase..1394
MAIN FRAME..1395
SEAT BAR..1397
Removal And Installation..1397
Assembling Components..1400
Compression Spring Disassembly And Assembly..1400
OPERATOR CAB GAS CYLINDER..1401
Removal And Installation..1401
Disassembly And Assembly..1402
OPERATOR CAB..1403
Removal And Installation..1403
OPERATOR SEAT..1406
Removal And Installation..1406
BOB–TACH..1407
Removal And Installation..1407
Bob–Tach Lever And Wedge..1408
Pivot Pin Bushing And Seal Replacement..1409
Bob–Tach Stop..1409
LIFT ARM STABILIZER BAR (S/N 514122465 & Above; 514222015 & Above)..1410
Removal And Installation..1410
LIFT ARM STABILIZER BAR (S/N 514122464 & Below; 514222014 & Below)..1411
Removal And Installation..1411
LIFT ARM LINK..1413
Removal And Installation..1413
LIFT ARMS..1415
Removal And Installation..1415
REAR GRILL..1418
Removal And Installation..1418
REAR DOOR (ONE PIECE)..1419
Removal And Installation..1419
Door Latch and Catch Adjustment..1420
REAR DOOR..1421
Removal And Installation..1421
Hood Removal And Installation..1422
Bumper Removal And Installation..1422
Door Latch Removal And Installation..1422
Door Latch And Catch Adjustment..1422
FUEL TANK..1423
Removal And Installation..1423
Fuel Level Sender..1425
Inlet Screen..1425
ELECTRICAL SYSTEM..1427
ELECTRICAL SCHEMATICS..1429
TROUBLESHOOTING..1439
ELECTRICAL SYSTEM INFORMATION..1440
Description..1440
Fuse Location..1440
BATTERY..1441
Removal And Installation..1441
Servicing the Electrical System..1443
Using A Booster Battery (Jump Starting)..1444
ALTERNATOR..1445
Alternator Output Test..1445
Alternator Regulator Test..1446
Removal And Installation..1447
Disassembly..1448
Stator Continuity Test..1448
Stator Ground Test..1448
Rotor Continuity Test..1449
Rotor Ground Test..1449
Rectifier Continuity (Diode) Test..1449
Assembly..1450
STARTER..1451
Removal And Installation..1451
Parts Identification..1452
Disassembly And Assembly..1453
External Pinion..1457
Inspection And Repair..1458
Magnetic Switch Test..1461
No Load Test..1461
STANDARD INSTRUMENT PANEL..1462
Removal And Installation..1462
FRONT LIGHTS..1463
Removal And Installation..1463
RELAY SWITCHES..1464
Location..1464
ENGINE SERVICE..1465
TROUBLESHOOTING..1467
ENGINE SPEED CONTROL..1468
Removal And Installation..1468
Speed Control Cable..1469
Speed Control Linkage..1469
ENGINE MUFFLER..1470
Removal And Installation..1470
AIR CLEANER HOUSING..1471
Removal And Installation..1471
BLOWER HOUSING/FAN GEARBOX..1473
Removal And Installation..1473
FAN DRIVE TENSION PULLEY..1474
Removal And Installation..1474
BLOWER FAN..1476
Removal And Installation..1476
FAN GEARBOX..1477
Parts Identification..1477
Disassembly..1478
Assembly..1483
Long Housing..1483
Short Housing..1485
Checking Backlash..1488
OIL COOLER..1490
Removal And Installation..1490
ENGINE/HYDROSTATIC PUMP ASSEMBLY..1491
Removal And Installation..1491
ENGINE MOUNTS..1497
Replacement..1497
ENGINE..1498
Removal And Installation..1498
FLYWHEEL..1500
Removal And Installation..1500
Flywheel Ring Gear..1500
FLYWHEEL HOUSING..1500
Removal And Installation..1500
GLOW PLUG..1501
Checking The Glow Plug..1501
VALVE CLEARANCE..1502
Adjustment..1502
FUEL INJECTION PUMP..1503
Description..1503
Removal..1503
Injection Pump Timing..1504
Installation..1505
FUEL INJECTOR..1507
Removal And Installation..1507
Checking..1508
Disassembly..1509
Assembly..1510
TIMING BELT..1512
Inspection..1512
Removal..1512
Installation..1513
Belt Replacement In Loader..1516
VALVE TIMING..1521
Checking..1521
DEUTZ ENGINE TOOLS..1522
Identification Chart..1522
RECONDITIONING THE ENGINE..1523
Disassembly..1523
Assembly..1527
CYLINDER LINERS..1542
Checking The Cylinder Liners..1542
CAMSHAFT BEARINGS..1543
Checking..1543
Removal And Installation..1543
CONTROL ROD GUIDE BUSHING..1545
Removal..1545
Installation..1547
REAR COVER SEAL..1551
Removal And Installation..1551
CRANKSHAFT..1552
Checking The Crankshaft..1552
CONNECTING ROD..1553
Checking The Connecting Rod..1553
PISTON AND PISTON PIN..1556
Checking The Piston..1556
Checking Piston Pin..1557
Installing Piston Rings..1557
CYLINDER HEAD..1558
Disassembly..1558
Checking The Valves..1558
Checking Valve Seats..1559
Valve Spring..1559
Assembly..1559
ROCKER ARM AND BRACKET..1561
Checking..1561
FRONT COVER..1562
Disassembly..1562
Assembly..1567
TURBOCHARGER..1577
Removal And Installation..1577
Disassembly..1578
Inspection..1582
Assembly..1583
POSITIVE CRANKCASE VENTILATION SYSTEM (S/N 514115365 & Below; 514213009 & Below)..1588
Description..1588
Inspection..1588
Module Removal And Installation..1589
CRANKSHAFT GEAR MOUNTING BOLT..1590
Torque Procedure..1590
SYSTEMS ANALYSIS..1591
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..1593
(S/N 514123810 & Above; 514222300 & Above)..1593
Inspecting The BICS™ Controller (Engine STOPPED– Key ON)..1593
Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)..1593
Inspecting The Seat Bar Sensor (Engine RUNNING)..1593
Inspecting The Traction Lock (Engine RUNNING)..1593
Inspecting The Lift Arm By–Pass Control..1593
Additional Inspection For Loaders With Advanced Hand Controls..1593
Troubleshooting Chart..1593
(S/N 514123809 & Below; 514222299 & Below)..1595
Inspecting The BICS™ System Controller (Engine STOPPED – Key ON)..1595
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)..1595
Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)..1595
Inspecting The Traction Lock (Engine RUNNING)..1595
Inspecting The Lift Arm By–Pass Control..1595
Maintenance..1595
Troubleshooting Chart..1596
TROUBLESHOOTING GUIDE..1597
BICS SYSTEM CONTROLLER..1597
TRACTION LOCK..1598
SEAT SENSOR..1599
SEAT BAR SENSOR..1600
SEAT SENSOR..1601
Seat Sensor Test..1601
Removal And Installation..1602
BICS™ Controller Seat Sensor Circuit Test..1603
BICS™ SYSTEM CONTROLLER..1604
Removal And Installation..1604
SEAT BAR SENSOR..1605
Seat Bar Sensor Test..1605
Removal And Installation..1606
BICS™ Controller Seat Bar Sensor Circuit Test..1607
TRACTION LOCK..1608
Removal And Installation..1608
BOSS® DIAGNOSTIC TOOL..1609
Procedure..1609
SENDER AND SENSOR..1609
Service Checks..1609
Components..1609
RPM SENSOR..1609
Adjustment..1609
MONITOR SERVICE CODES..1610
TROUBLESHOOTING THE BOSS® & LCD DISPLAY..1613
OPERATION SENSING SYSTEM UNIT..1614
Removal and Installation..1614
BOSS® INSTRUMENT PANEL..1615
Removal And Installation..1615
PWM MODULE..1616
Description..1616
PWM TROUBLESHOOTING..1617
Conditions..1617
Chart..1618
PWM CONTROL HANDLE..1619
Handle Testing..1619
PWM ELECTRIC SOLENOID..1619
Solenoid Coil Testing..1619
TRACTION LOCK CONTROL SYSTEM..1620
(S/N 514123810 & Above; 514222300 & Above)..1620
Inspecting The Traction Lock Control System..1620
Maintenance..1620
(S/N 514123809 & Below; 514222299 & Below)..1620
Description..1620
Inspection..1620
Maintenance..1620
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE..1621
Controls Identification Chart..1621
SPECIFICATIONS..1623
LOADER SPECIFICATIONS..1625
Performance..1625
Controls..1625
Engine..1625
Hydraulic System..1626
Electrical..1626
Drive System..1626
Capacities..1627
Tires..1627
ENGINE SPECIFICATIONS (BF4M1011)..1628
General..1628
Fuel System..1628
Valve and Valve Guide and Seat Insert..1628
Piston and Rings..1629
Connecting Rod..1629
Cylinder Head and Block..1629
Crankshaft and Main Bearings..1630
Camshaft and Bearings..1630
Oil Pump..1630
ENGINE SPECIFICATIONS (BF4M1011F)..1631
General..1631
Fuel System..1631
Valve and Valve Guide and Seat Insert..1631
Piston and Rings..1632
Connecting Rod..1632
Crankshaft and Main Bearings..1633
Camshaft and Bearings..1633
Oil Pump..1633
ENGINE TORQUE..1634
TORQUE SPECIFICATIONS FOR LOADER..1636
TORQUE SPECIFICATIONS FOR BOLTS..1637
Torque for General SAE Bolts..1637
Torque For General Metric Bolts..1638
HYDRAULIC CONNECTION SPECIFICATIONS..1639
O–Ring Face Seal Connection..1639
Straight Thread O–Ring Fitting..1639
Tubelines And Hoses..1639
Flare Fitting..1639
O–Ring Flare Fitting..1640
Port Seal Fitting..1642
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS..1643
DECIMAL AND MILLIMETER EQUIVALENTS..1644
U.S. TO METRIC CONVERSION..1644
ADVANCE HAND CONTROL SYSTEM (A.H.C)..1645
ADVANCED HAND CONTROL ELECTRICAL SCHEMATICS..1647
A.H.C. COMPONENTS..1653
Identification..1653
TROUBLESHOOTING (A.H.C.)..1654
Chart..1654
ACTUATOR VOLTAGE TEST..1656
Procedure..1656
HANDLE CONTROL UNIT TEST..1659
Procedure..1659
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..1662
Troubleshooting Chart..1662
SEAT SENSOR OVERRIDE ONLY..1662
ADVANCED HAND CONTROLS (AHC)..1662
A.H.C./PWM CONTROLLER..1663
Removal and Installation..1663
Description..1664
Conditions..1665
Troubleshooting Chart..1665
Handle Testing..1666
Solenoid Coil Testing..1666
HANDLE CONTROL UNIT..1667
Removal And Installation..1667
Control Unit Connector..1670
SWITCH HANDLE..1671
Removal And Installation..1671
A. H. C. HANDLE..1674
Removal And Installation..1674
Disassembly And Assembly..1675
A.H.C. STEERING LEVER..1676
Removal And Installation..1676
Steering Lever Boot..1676
ACTUATORS..1677
Removal And Installation..1677
Disassembly And Assembly..1678
Mounting Plate..1679
BICS™ VALVE..1680
Lift Arm By–Pass Orifice..1680
Check Valve..1681
Lock Valve..1681
BICS™ Valve Solenoid..1682
Removal And Installation..1683
HYDRAULIC CONTROL VALVE..1684
Removal And Installation..1684
Identification Chart..1687
Disassembly And Assembly..1688
Load Check Valve..1688
Lift Base End Restrictor..1688
Main Relief Valve..1689
Port Relief Valve (Lift)..1690
Anti–Cavitation/Port Relief Valve..1690
Port Relief Valve (Tilt)..1691
Anti–Cavitation Valve..1691
Rubber Boot..1692
Lift And Tilt Spool..1693
Inspection..1695
Auxiliary Spool..1696
Auxiliary Electrical Solenoid..1697
Spool Seal Installation..1698
H–Port Auxiliary Section..1699
SERVICE MANUAL REVISIONS..1701
873–001..1701
873–002..1703
873–003..1705
873–004..1707
873-005..1709
873-006..1711
6900382 (7-10) - 873 Service Manual..1713
MAINTENANCE SAFETY..1715
ALPHABETICAL INDEX..1717
CONTENTS..1719
FOREWORD..1720
SAFETY INSTRUCTIONS..1723
SERIAL NUMBER LOCATIONS..1725
LOADER SERIAL NUMBER..1725
ENGINE SERIAL NUMBER..1725
DELIVERY REPORT..1725
BOBCAT LOADER IDENTIFICATION..1726
OPTIONS AND ACCESSORIES..1727
PREVENTIVE MAINTENANCE..1729
SERVICE SCHEDULE..1731
LIFTING AND BLOCKING THE LOADER..1732
Procedure..1732
TRANSPORTING THE LOADER..1733
Procedure..1733
TOWING THE LOADER..1733
Procedure..1733
STOPPING THE BOBCAT LOADER..1733
Procedure..1733
LIFT ARM SUPPORT DEVICE..1734
To Install The Lift Arm Support Device..1734
To Remove The Lift Arm Support Device..1734
OPERATOR CAB..1735
Raising The Operator Cab..1735
Lowering The Operator Cab..1736
Emergency Exit..1737
SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)..1738
Seat Bar Inspection..1738
Seat Bar Maintenance..1738
SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS)..1739
Seat Bar Inspection..1739
Seat Bar Maintenance..1739
SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)..1740
Inspecting The Seat Bar..1740
Maintaining The Seat Bar..1740
AIR CLEANER SERVICE..1741
Replacing Filter Element..1741
FUEL SYSTEM..1743
Fuel Specifications..1743
Filling The Fuel Tank..1743
Fuel Filter..1743
Removing Air From The Fuel System..1743
ENGINE LUBRICATION SYSTEM..1744
Checking Engine Oil..1744
Replacing Oil And Filter..1744
ENGINE COOLING SYSTEM..1745
Cleaning Cooling System..1745
ALTERNATOR BELT..1746
Adjusting The Alternator Belt..1746
HYDRAULIC/HYDROSTATIC SYSTEM..1747
Checking And Adding Fluid..1747
Hydraulic/Hydrostatic Filter Replacement..1747
Replacing Hydraulic Fluid..1748
Later Model loaders..1748
Early Model Loaders..1749
TIRE MAINTENANCE..1750
Wheel Nuts..1750
Tire Rotation..1750
Tire Mounting..1750
FINAL DRIVE TRANSMISSION (CHAINCASE)..1751
Checking And Adding Oil..1751
FAN GEARBOX..1751
Checking And Maintaining..1751
LUBRICATING THE LOADER..1752
Procedure..1752
REMOTE START SWITCH..1755
Procedure..1755
HYDRAULIC SYSTEM..1757
HYDRAULIC / HYDROSTATIC SCHEMATICS..1762
GLOSSARY OF HYDRAULIC / HYDROSTATIC SYMBOLS..1773
TROUBLESHOOTING..1777
HYDRAULIC SYSTEM INFORMATION..1778
Tighten Procedures..1778
LIFT CYLINDER(S)..1779
Checking The Lift Cylinder(s)..1779
Removal And Installation..1779
TILT CYLINDER(S)..1781
Checking The Tilt Cylinder(s)..1781
Removal And Installation..1781
HYDRAULIC CYLINDER..1783
Lift Cylinder Identification..1783
Tilt Cylinder Identification..1784
Disassembly..1785
Assembly..1787
MAIN RELIEF VALVE..1790
Checking The Main Relief Valve With Auxiliaries..1790
Checking The Main Relief Valve Without Auxiliaries..1791
MAIN RELIEF VALVE (S/N 514122001 & Above; 514222001 & Above)..1792
Removal and Installation..1792
Adjustment..1792
MAIN RELIEF VALVE (S/N 514119999 & Below; 514219999 & Below)..1793
Adjustment..1793
Removal And Installation..1793
BICS™ VALVE ASSEMBLY (S/N 514122001 & Above; 514222001 & Above)..1794
Lift Arm By–Pass Orifice..1794
Check Valve..1795
Lock Valve..1796
BICS™ Valve Solenoid..1797
Removal and Installation..1798
HYDRAULIC CONTROL VALVE (S/N 514122001 & Above; 514222001 & Above)..1799
Removal and Installation..1799
Identification Chart..1802
Disassembly and Assembly..1803
Load Check Valve..1803
Lift Base End Restrictor..1803
Main Relief Valve..1804
Port Relief Valve..1805
Anti–Cavitation/Port Relief Valve..1805
Rubber Boot..1807
Lift Spool and Detent..1808
Auxiliary Spool..1813
Auxiliary Electric Solenoid..1814
H Port – Auxiliary Section..1815
Inspection..1815
Spool Seal Installation..1816
HYDRAULIC CONTROL VALVE (S/N 514119999 & Below; 514219999 & Below)..1817
Removal And Installation..1817
Identification Chart..1819
Disassembly And Assembly..1820
Load Check Valve..1820
Main Relief Valve..1821
Port Relief Valve..1821
Anti–Cavitation Valve..1822
Rubber Boot..1823
Lift Spool And Detent..1824
Tilt Spool And Centering Spring..1829
Auxiliary Spool..1830
Auxiliary Electric Solenoid..1831
H Port – Auxiliary Section..1832
Base End Restrictor..1832
Inspection..1832
Spool Seal Installation..1833
HYDRAULIC PUMP (Double Gear)..1834
Checking The Output Of The Pump..1834
Removal And Installation..1835
Parts Identification..1836
Disassembly..1837
Inspection..1841
Assembly..1842
HYDRAULIC PUMP (Single Gear)..1845
Checking The Output Of The Pump..1845
Removal And Installation..1846
Parts Identification..1847
Disassembly..1848
Inspection..1850
Assembly..1851
HYDRAULIC FLUID RESERVOIR..1853
Draining The Fluid Reservoir..1853
Removal And Installation..1853
Hydraulic Fluid Screen Removal And Installation..1856
LIFT ARM BY–PASS CONTROL VALVE (S/N 514122001 & Above; 514222001 & Above)..1857
Removal and Installation..1857
Disassembly and Assembly..1858
LIFT LOCK BY–PASS VALVE (S/N 514119999 &Below; 514219999 & Below)..1859
Removal And Installation..1859
Disassembly And Assembly..1860
TILT LOCK VALVE (S/N 514119999 & Below; 514219999 & Below) ..1861
Removal And Installation..1861
Disassembly And Assembly..1862
HYDRAULIC/HYDROSTATIC FILTER HOUSING..1863
Removal And Installation..1863
HYDROSTATIC FILTER HOUSING..1864
Removal And Installation ..1864
S/N 514122001 thru 514122813; 514222001 thru 514222027..1864
S/N 514119999 & Below; 514219999 & Below..1865
All S/N Loaders..1866
S/N 514122001 thru 514122813; 514222001 thru 514222027..1867
S/N 514119999 & Below; 514219999 & Below..1868
HYDRAULIC/HYDROSTATIC FILTER HOUSING BRACKET..1869
Removal And Installation..1869
S/N 514122814 & Above; 514222028 & Above..1869
S/N 514122001 thru 514122813; 514222001 thru 514222027..1870
S/N 514119999 & Below; 514219999 & Below..1871
All S/N Loaders..1872
CONTROL PEDALS..1873
Removal And Installation..1873
Pedal Adjustment..1873
PEDAL INTERLOCK LINKAGE..1874
Removal And Installation..1874
Adjustment..1875
FRONT SIDE PANEL..1875
Removal And Installation..1875
REAR AUXILIARY DIVERTER..1876
Disassembly..1876
Inspection..1876
Solenoid Testing..1876
Assembly..1876
HYDROSTATIC SYSTEM..1877
TROUBLESHOOTING..1879
HYDROSTATIC SYSTEM INFORMATION..1880
Replenishing Valve Function..1880
FRONT PANEL..1881
Removal And Installation..1881
STEERING LEVERS (514122814 & Above; 514222028 & Above)..1883
Removal And Installation..1883
Disassembly And Assembly..1883
STEERING LINKAGE (S/N 514122814 & Above; 514222028 & Above)..1885
Removal And Installation..1885
Steering Linkage Adjustment..1889
STEERING LEVERS (514122814 & Below; 514222028 & Below)..1894
Removal And Installation..1894
Disassembly And Assembly..1894
STEERING LINKAGE (514122814 & Below; 514222028 & Below)..1896
Removal And Installation..1896
Steering Linkage Adjustment..1900
HYDROSTATIC MOTOR (S/N 514122306 & Above; 514223902 & Above)..1905
Removal And Installation..1905
Parts Identification..1906
Disassembly..1907
Inspection..1909
Assembly..1910
HYDROSTATIC MOTOR (S/N 514122305 & Below; 514223901 & Below)..1914
Removal and Installation..1914
Parts Identification..1916
Disassembly..1917
Inspection..1918
Assembly..1919
MOTOR CARRIER..1921
Removal and Installation..1921
Parts Identification..1923
Disassembly..1924
Assembly..1926
HYDROSTATIC PUMP..1928
Removal And Installation..1928
Parts Identification (Right Half)..1930
Parts Identification (Left Half)..1932
HYDROSTATIC PUMP (S/N 514122814 & Above; 514222028 & Above)..1934
Replenishing/High Pressure Relief Valve..1934
Charge Pressure Relief Valve..1935
Hydraulic Pump Removal..1936
Hydraulic Pump Separation..1937
Charge Pump Disassembly..1937
Disassembly..1939
Assembly..1945
HYDROSTATIC PUMP (S/N 514122813 & Below;514222027 & Below)..1953
Replenishing/High Pressure Relief Valve..1953
Parts Identification..1954
Disassembly..1956
Inspection..1962
Assembly..1965
DRIVE BELT SHIELD..1972
Removal And Installation..1972
DRIVE BELT..1973
Adjusting The Drive Belt..1973
Replacing The Drive Belt..1973
DRIVE BELT TENSIONER PULLEY..1974
Removal And Installation..1974
Tension Spring..1976
OIL COOLER..1977
Removal And Installation..1977
DRIVE SYSTEM..1979
PARKING BRAKE PEDAL..1981
Removal And Installation..1981
Disassembly And Assembly..1982
BRAKE DISC..1983
Removal And Installation..1983
FRONT CHAINCASE COVER..1985
Removal and Installation..1985
AXLE SEAL..1986
Removal and Installation..1986
Later Model Loaders..1986
Early Model Loaders..1988
AXLE, SPROCKET AND BEARINGS..1990
Removal and Installation..1990
Later Model Loaders..1990
Early Model Loaders..1992
All Model Loaders..1994
DRIVE CHAIN..1997
Removal And Installation..1997
CHAINCASE FLUID..1998
Removing The Fluid From The Chaincase..1998
MAIN FRAME..1999
SEAT BAR..2001
Removal And Installation..2001
Assembling Components..2004
Compression Spring Disassembly And Assembly..2004
OPERATOR CAB GAS CYLINDER..2005
Removal And Installation..2005
Disassembly And Assembly..2006
OPERATOR CAB..2007
Removal And Installation..2007
OPERATOR SEAT..2010
Removal And Installation..2010
BOB–TACH..2011
Removal And Installation..2011
Bob–Tach Lever And Wedge..2012
Pivot Pin Bushing And Seal Replacement..2013
Bob–Tach Stop..2013
LIFT ARM STABILIZER BAR (S/N 514122465 & Above; 514222015 & Above)..2014
Removal And Installation..2014
LIFT ARM STABILIZER BAR (S/N 514122464 & Below; 514222014 & Below)..2015
Removal And Installation..2015
LIFT ARM LINK..2017
Removal And Installation..2017
LIFT ARMS..2019
Removal And Installation..2019
REAR GRILL..2022
Removal And Installation..2022
REAR DOOR (ONE PIECE)..2023
Removal And Installation..2023
Door Latch and Catch Adjustment..2024
REAR DOOR..2025
Removal And Installation..2025
Hood Removal And Installation..2026
Bumper Removal And Installation..2026
Door Latch Removal And Installation..2026
Door Latch And Catch Adjustment..2026
FUEL TANK..2027
Removal And Installation..2027
Fuel Level Sender..2029
Inlet Screen..2029
ELECTRICAL SYSTEM..2031
ELECTRICAL SCHEMATICS..2033
TROUBLESHOOTING..2043
ELECTRICAL SYSTEM INFORMATION..2044
Description..2044
Fuse Location..2044
BATTERY..2045
Removal And Installation..2045
Servicing the Electrical System..2047
Using A Booster Battery (Jump Starting)..2048
ALTERNATOR..2049
Alternator Output Test..2049
Alternator Regulator Test..2050
Removal And Installation..2051
Disassembly..2052
Stator Continuity Test..2052
Stator Ground Test..2052
Rotor Continuity Test..2053
Rotor Ground Test..2053
Rectifier Continuity (Diode) Test..2053
Assembly..2054
STARTER..2055
Removal And Installation..2055
Parts Identification..2056
Disassembly And Assembly..2057
External Pinion..2061
Inspection And Repair..2062
Magnetic Switch Test..2065
No Load Test..2065
STANDARD INSTRUMENT PANEL..2066
Removal And Installation..2066
FRONT LIGHTS..2067
Removal And Installation..2067
RELAY SWITCHES..2068
Location..2068
ENGINE SERVICE..2069
TROUBLESHOOTING..2071
ENGINE SPEED CONTROL..2072
Removal And Installation..2072
Speed Control Cable..2073
Speed Control Linkage..2073
ENGINE MUFFLER..2074
Removal And Installation..2074
AIR CLEANER HOUSING..2075
Removal And Installation..2075
BLOWER HOUSING/FAN GEARBOX..2077
Removal And Installation..2077
FAN DRIVE TENSION PULLEY..2078
Removal And Installation..2078
BLOWER FAN..2080
Removal And Installation..2080
FAN GEARBOX..2081
Parts Identification..2081
Disassembly..2082
Assembly..2087
Long Housing..2087
Short Housing..2089
Checking Backlash..2092
OIL COOLER..2094
Removal And Installation..2094
ENGINE/HYDROSTATIC PUMP ASSEMBLY..2095
Removal And Installation..2095
ENGINE MOUNTS..2101
Replacement..2101
ENGINE..2102
Removal And Installation..2102
FLYWHEEL..2104
Removal And Installation..2104
Flywheel Ring Gear..2104
FLYWHEEL HOUSING..2104
Removal And Installation..2104
GLOW PLUG..2105
Checking The Glow Plug..2105
VALVE CLEARANCE..2106
Adjustment..2106
FUEL INJECTION PUMP..2107
Description..2107
Removal..2107
Injection Pump Timing..2108
Installation..2109
FUEL INJECTOR..2111
Removal And Installation..2111
Checking..2112
Disassembly..2113
Assembly..2114
TIMING BELT..2116
Inspection..2116
Removal..2116
Installation..2117
Belt Replacement In Loader..2120
VALVE TIMING..2125
Checking..2125
DEUTZ ENGINE TOOLS..2126
Identification Chart..2126
RECONDITIONING THE ENGINE..2127
Disassembly..2127
Assembly..2131
CYLINDER LINERS..2146
Checking The Cylinder Liners..2146
CAMSHAFT BEARINGS..2147
Checking..2147
Removal And Installation..2147
CONTROL ROD GUIDE BUSHING..2149
Removal..2149
Installation..2151
REAR COVER SEAL..2155
Removal And Installation..2155
CRANKSHAFT..2156
Checking The Crankshaft..2156
CONNECTING ROD..2157
Checking The Connecting Rod..2157
PISTON AND PISTON PIN..2160
Checking The Piston..2160
Checking Piston Pin..2161
Installing Piston Rings..2161
CYLINDER HEAD..2162
Disassembly..2162
Checking The Valves..2162
Checking Valve Seats..2163
Valve Spring..2163
Assembly..2163
ROCKER ARM AND BRACKET..2165
Checking..2165
FRONT COVER..2166
Disassembly..2166
Assembly..2171
TURBOCHARGER..2181
Removal And Installation..2181
Disassembly..2182
Inspection..2186
Assembly..2187
POSITIVE CRANKCASE VENTILATION SYSTEM (S/N 514115365 & Below; 514213009 & Below)..2192
Description..2192
Inspection..2192
Module Removal And Installation..2193
CRANKSHAFT GEAR MOUNTING BOLT..2194
Torque Procedure..2194
SYSTEMS ANALYSIS..2195
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..2197
(S/N 514123810 & Above; 514222300 & Above)..2197
Inspecting The BICS™ Controller (Engine STOPPED– Key ON)..2197
Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)..2197
Inspecting The Seat Bar Sensor (Engine RUNNING)..2197
Inspecting The Traction Lock (Engine RUNNING)..2197
Inspecting The Lift Arm By–Pass Control..2197
Additional Inspection For Loaders With Advanced Hand Controls..2197
Troubleshooting Chart..2197
(S/N 514123809 & Below; 514222299 & Below)..2199
Inspecting The BICS™ System Controller (Engine STOPPED – Key ON)..2199
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)..2199
Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)..2199
Inspecting The Traction Lock (Engine RUNNING)..2199
Inspecting The Lift Arm By–Pass Control..2199
Maintenance..2199
Troubleshooting Chart..2200
TROUBLESHOOTING GUIDE..2201
BICS SYSTEM CONTROLLER..2201
TRACTION LOCK..2202
SEAT SENSOR..2203
SEAT BAR SENSOR..2204
SEAT SENSOR..2205
Seat Sensor Test..2205
Removal And Installation..2206
BICS™ Controller Seat Sensor Circuit Test..2207
BICS™ SYSTEM CONTROLLER..2208
Removal And Installation..2208
SEAT BAR SENSOR..2209
Seat Bar Sensor Test..2209
Removal And Installation..2210
BICS™ Controller Seat Bar Sensor Circuit Test..2211
TRACTION LOCK..2212
Removal And Installation..2212
BOSS® DIAGNOSTIC TOOL..2213
Procedure..2213
SENDER AND SENSOR..2213
Service Checks..2213
Components..2213
RPM SENSOR..2213
Adjustment..2213
MONITOR SERVICE CODES..2214
TROUBLESHOOTING THE BOSS® & LCD DISPLAY..2217
OPERATION SENSING SYSTEM UNIT..2218
Removal and Installation..2218
BOSS® INSTRUMENT PANEL..2219
Removal And Installation..2219
PWM MODULE..2220
Description..2220
PWM TROUBLESHOOTING..2221
Conditions..2221
Chart..2222
PWM CONTROL HANDLE..2223
Handle Testing..2223
PWM ELECTRIC SOLENOID..2223
Solenoid Coil Testing..2223
TRACTION LOCK CONTROL SYSTEM..2224
(S/N 514123810 & Above; 514222300 & Above)..2224
Inspecting The Traction Lock Control System..2224
Maintenance..2224
(S/N 514123809 & Below; 514222299 & Below)..2224
Description..2224
Inspection..2224
Maintenance..2224
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE..2225
Controls Identification Chart..2225
SPECIFICATIONS..2227
LOADER SPECIFICATIONS..2229
Performance..2229
Controls..2229
Engine..2229
Hydraulic System..2230
Electrical..2230
Drive System..2230
Capacities..2231
Tires..2231
ENGINE SPECIFICATIONS (BF4M1011)..2232
General..2232
Fuel System..2232
Valve and Valve Guide and Seat Insert..2232
Piston and Rings..2233
Connecting Rod..2233
Cylinder Head and Block..2233
Crankshaft and Main Bearings..2234
Camshaft and Bearings..2234
Oil Pump..2234
ENGINE SPECIFICATIONS (BF4M1011F)..2235
General..2235
Fuel System..2235
Valve and Valve Guide and Seat Insert..2235
Piston and Rings..2236
Connecting Rod..2236
Crankshaft and Main Bearings..2237
Camshaft and Bearings..2237
Oil Pump..2237
ENGINE TORQUE..2238
TORQUE SPECIFICATIONS FOR LOADER..2240
TORQUE SPECIFICATIONS FOR BOLTS..2241
Torque for General SAE Bolts..2241
Torque For General Metric Bolts..2242
HYDRAULIC CONNECTION SPECIFICATIONS..2243
O–Ring Face Seal Connection..2243
Straight Thread O–Ring Fitting..2243
Tubelines And Hoses..2243
Flare Fitting..2243
O–Ring Flare Fitting..2244
Port Seal Fitting..2246
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS..2247
DECIMAL AND MILLIMETER EQUIVALENTS..2248
U.S. TO METRIC CONVERSION..2248
ADVANCE HAND CONTROL SYSTEM (A.H.C)..2249
ADVANCED HAND CONTROL ELECTRICAL SCHEMATICS..2251
A.H.C. COMPONENTS..2257
Identification..2257
TROUBLESHOOTING (A.H.C.)..2258
Chart..2258
ACTUATOR VOLTAGE TEST..2260
Procedure..2260
HANDLE CONTROL UNIT TEST..2263
Procedure..2263
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..2266
Troubleshooting Chart..2266
SEAT SENSOR OVERRIDE ONLY..2266
ADVANCED HAND CONTROLS (AHC)..2266
A.H.C./PWM CONTROLLER..2267
Removal and Installation..2267
Description..2268
Conditions..2269
Troubleshooting Chart..2269
Handle Testing..2270
Solenoid Coil Testing..2270
HANDLE CONTROL UNIT..2271
Removal And Installation..2271
Control Unit Connector..2274
SWITCH HANDLE..2275
Removal And Installation..2275
A. H. C. HANDLE..2278
Removal And Installation..2278
Disassembly And Assembly..2279
A.H.C. STEERING LEVER..2280
Removal And Installation..2280
Steering Lever Boot..2280
ACTUATORS..2281
Removal And Installation..2281
Disassembly And Assembly..2282
Mounting Plate..2283
BICS™ VALVE..2284
Lift Arm By–Pass Orifice..2284
Check Valve..2285
Lock Valve..2285
BICS™ Valve Solenoid..2286
Removal And Installation..2287
HYDRAULIC CONTROL VALVE..2288
Removal And Installation..2288
Identification Chart..2291
Disassembly And Assembly..2292
Load Check Valve..2292
Lift Base End Restrictor..2292
Main Relief Valve..2293
Port Relief Valve (Lift)..2294
Anti–Cavitation/Port Relief Valve..2294
Port Relief Valve (Tilt)..2295
Anti–Cavitation Valve..2295
Rubber Boot..2296
Lift And Tilt Spool..2297
Inspection..2299
Auxiliary Spool..2300
Auxiliary Electrical Solenoid..2301
Spool Seal Installation..2302
H–Port Auxiliary Section..2303
SERVICE MANUAL REVISIONS..2305
873–001..2305
873–002..2307
873–003..2309
873–004..2311
873-5..2313
6900382 (7-97) - 873 Service Manual..2315
6900791 (9-00) - 873 Operation & Maintenance Manual..2907
OPERATOR SAFETY WARNINGS..2909
CONTENTS..2911
REFERENCE INFORMATION..2911
BOBCAT COMPANY IS ISO 9001 CERTIFIED..2912
REGULAR MAINTENANCE ITEMS..2912
FOREWORD..2913
SERIAL NUMBER LOCATIONS..2915
LOADER SERIAL NUMBER..2915
ENGINE SERIAL NUMBER..2915
DELIVERY REPORT..2915
BOBCAT LOADER IDENTIFICATION..2916
OPTIONS AND ACCESSORIES..2917
SAFETY..2919
SAFETY INSTRUCTIONS FOR BOBCAT SKID–STEER LOADERS AND ATTACHMENTS..2921
SAFETY IS THE OPERATOR’S RESPONSIBILITY..2921
BEFORE OPERATING THE BOBCAT LOADER..2922
SAFE OPERATION NEEDS A QUALIFIED OPERATOR *..2922
FIRE PREVENTION..2923
MACHINE SIGNS (DECALS)..2924
OPERATING INSTRUCTIONS..2927
INSTRUMENT PANEL..2929
Without BOSS® (Front Panel)..2929
Without BOSS (Side Console•)..2929
With BOSS® (Front Panel)..2930
With BOSS (Side Console•) ..2930
BOSS Option Display Panel ..2931
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..2932
Lift Arm By–Pass Control..2932
Traction Lock Override..2932
Auxiliary Hydraulic System..2933
TRACTION LOCK CONTROL SYSTEM..2933
ENGINE SPEED CONTROL..2934
PARKING BRAKE..2934
STEERING LEVERS..2935
STOPPING THE BOBCAT LOADER..2935
SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)..2936
SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS)..2937
SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)..2938
HYDRAULIC CONTROLS..2939
Foot Pedals..2939
Lift Arm Operation..2939
Lift Arm Float Position..2939
Tilt Operation..2939
Bucket Position Valve Operation (If Equipped)..2939
Hand Controls..2940
Lift Arm Operation..2940
Lift Arm Float Position..2940
Tilt Operation..2940
Bucket Position Valve Operation (If Equipped)..2940
Advanced Hand Controls (AHC) (If Equipped)..2940
Auxiliary Hydraulics (If Equipped)..2941
Quick Couplers (Flush Face)..2941
Auxiliary Hydraulics Switch..2942
FRONT Auxiliary Hydraulics Operation..2942
FRONT Auxiliary Hydraulics Continuous Operation..2942
REAR Auxiliary Hydraulics Operation..2942
Attachment Functions Control (If Equipped)..2943
Relieving Hydraulic Pressure..2943
DAILY INSPECTION..2944
Daily Inspection and Maintenance..2944
GETTING READY FOR OPERATION..2944
STARTING THE ENGINE..2946
Normal Starting (Without BOSS®)..2946
Cold Temperature Starting (Without BOSS®)..2946
Normal Starting (With BOSS®)..2947
Cold Temperature Starting (With BOSS®)..2948
Warming The Hydraulic/Hydrostatic System..2948
STOPPING THE ENGINE..2948
ATTACHMENTS AND BUCKETS..2949
Installing The Bucket Or Attachment..2950
Removing The Bucket Or Attachment ..2951
OPERATING PROCEDURE..2952
Filling The Bucket..2953
Emptying The Bucket..2953
Digging Into The Ground..2954
Leveling The Ground (Using Lift Arms In Float Position)..2954
Backfilling..2955
PARKING THE BOBCAT LOADER..2955
OPERATING PROCEDURE (HAND CONTROLS) ..2956
Filling The Bucket..2956
Emptying The Bucket..2956
Digging Into The Ground..2957
Leveling The Ground (Using Lift Arms In Float Position)..2957
Backfilling..2958
PARKING THE BOBCAT LOADER..2958
TRANSPORTING THE BOBCAT LOADER..2959
TOWING THE LOADER..2959
LIFTING THE LOADER..2960
Four Point Lift..2960
PREVENTIVE MAINTENANCE..2961
MAINTENANCE SAFETY..2963
SERVICE SCHEDULE..2965
LIFT ARM SUPPORT DEVICE..2966
Installing The Lift Arm Support Device..2966
Removing The Lift Arm Support Device..2966
OPERATOR CAB..2967
Raising The Operator Cab..2968
Lowering The Operator Cab..2969
Emergency Exit..2970
SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)..2971
Inspecting The Seat Bar..2971
Maintaining The Seat Bar..2971
SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS)..2972
Inspecting The Seat Bar..2972
Maintaining The Seat Bar..2972
SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)..2973
Inspecting The Seat Bar..2973
Maintaining The Seat Bar..2973
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..2974
Inspecting The BICS™ Controller (Engine STOPPED– Key ON)..2974
Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)..2974
Inspecting The Seat Bar Sensor (Engine RUNNING)..2974
Inspecting The Traction Lock (Engine RUNNING)..2974
Inspecting The Lift Arm By–Pass Control..2974
Additional Inspection For Loaders With Advanced Hand Controls..2974
TRACTION LOCK CONTROL SYSTEM..2975
Inspecting The Traction Lock Control System..2975
Maintenance..2975
REAR DOOR..2976
Opening And Closing The Rear Door..2976
Adjusting The Rear Door..2976
REAR GRILL..2977
AIR CLEANER SERVICE..2978
FUEL SYSTEM..2980
Fuel Specifications..2980
Filling The Fuel Tank..2980
Fuel Filter..2980
Removing Air From The Fuel System..2980
ENGINE LUBRICATION SYSTEM..2981
Checking Engine Oil..2981
Replacing The Oil And Filter..2981
ENGINE COOLING SYSTEM..2982
Cleaning Cooling System..2982
ALTERNATOR BELT..2983
Adjusting The Alternator Belt..2983
TIMING BELT..2984
ELECTRICAL SYSTEM..2984
Description..2984
Electrical System Maintenance..2984
Fuse Location..2985
Using A Booster Battery (Jump Starting)..2986
Removing And Installing The Battery..2987
HYDRAULIC/HYDROSTATIC SYSTEM..2988
Checking And Adding Fluid..2988
Replacing Hydraulic Fluid..2989
Replacing Hydraulic/Hydrostatic Filter..2990
TIRE MAINTENANCE..2991
Wheel Nuts..2991
Tire Rotation..2991
Tire Mounting..2991
FINAL DRIVE TRANSMISSION (CHAINCASE)..2992
Checking And Adding Oil..2992
Removing Oil From The Chaincase..2992
FAN GEARBOX..2993
Checking And Maintaining..2993
DRIVE BELT..2993
Adjusting The Drive Belt..2993
Replacing The Drive Belt..2994
LUBRICATING THE BOBCAT LOADER..2995
BOB–TACH..2998
Inspection And Maintenance..2998
SYSTEMS ANALYSIS..2999
SERVICE CODES..3001
AUXILIARY HYDRAULICS OPERATION..3002
Troubleshooting Chart..3002
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..3003
Troubleshooting Chart..3003
ADVANCED HAND CONTROLS (AHC)..3003
Troubleshooting Chart..3003
MACHINE SIGN TRANSLATIONS..3005
IMPORTANT - 6708937..3007
WARNING - 6579510..3008
WARNING - 6703725..3009
WARNING - 6715563..3010
WARNING - 6579528 ..3012
WARNING - 6708941..3012
WARNING - 6577754..3012
DANGER - 6579639..3012
DANGER - 6579509..3012
DANGER - 6717343..3013
WARNING - 6715944..3013
SPECIFICATIONS..3015
PERFORMANCE..3017
CONTROLS..3017
ENGINE..3017
HYDRAULIC SYSTEM..3018
ELECTRICAL..3018
DRIVE SYSTEM..3018
CAPACITIES..3018
TIRES..3018
FLOOR PRESSURE..3018
BOBCAT COMPANY APPROVED ATTACHMENTS & ACCESSORIES..3019
ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS..3021
WARRANTY..3023
6900847 (10-12) - 873 Turbo, 883 Turbo (G Series) Service Manual..3025
MAINTENANCE SAFETY..3027
ALPHABETICAL INDEX..3029
CONTENTS..3031
FOREWORD..3032
SAFETY INSTRUCTIONS..3035
FIRE PREVENTION..3037
Maintenance..3037
Operation..3037
Electrical..3037
Hydraulic System..3037
Fueling..3037
Starting..3037
Spark Arrestor Exhaust System..3037
Welding And Grinding..3038
Fire Extinguishers..3038
SERIAL NUMBER LOCATION..3039
Loader Serial Number..3039
Engine Serial Number..3039
DELIVERY REPORT..3040
BOBCAT LOADER IDENTIFICATION..3041
SAFETY & MAINTENANCE..3043
LIFTING AND BLOCKING THE LOADER..3045
Procedure..3045
LIFT ARM SUPPORT DEVICE..3047
Installing The Lift Arm Support Device..3047
Removing Lift Arm Support Device..3048
OPERATOR CAB..3049
Description..3049
Raising The Operator Cab..3049
Lowering The Operator Cab..3050
Emergency Exit..3051
TRANSPORTING THE BOBCAT LOADER..3053
Procedure..3053
TOWING THE LOADER..3055
Procedure For Non-Two-Speeds..3055
Procedure For Two-Speeds..3056
REMOTE START..3057
Procedure for Loader Without Attachments Control Harness..3057
Procedure for Loader With Attachments Control Harness..3058
Procedure..3060
SERVICE SCHEDULE..3061
Chart..3061
AIR CLEANER SERVICE..3063
Replacing Filter Element..3063
ENGINE COOLING SYSTEM..3065
Cleaning The Cooling System..3065
FUEL SYSTEM..3067
Fuel Specifications..3067
Filling The Fuel Tank..3067
Fuel Filter..3068
Removing Air From The Fuel System..3068
Fuel Lift Pump Strainer..3068
ENGINE LUBRICATION SYSTEM..3069
Checking Engine Oil..3069
Replacing Oil And Filter..3069
HYDRAULIC / HYDROSTATIC SYSTEM..3071
Checking And Adding Fluid..3071
Hydraulic / Hydrostatic Filter Replacement..3071
Replacing Hydraulic Fluid..3072
FINAL DRIVE TRANSMISSION (CHAINCASE)..3075
Checking And Adding Oil..3075
Replacing The Oil..3075
FAN GEARBOX..3077
Checking And Adding Oil..3077
BOB-TACH..3079
Inspection And Maintenance..3079
POWER BOB-TACH (OPTION)..3081
Inspection And Maintenance..3081
LUBRICATION OF THE BOBCAT LOADER..3083
Procedure..3083
TIRE MAINTENANCE..3087
Wheel Nuts..3087
Tire Rotation..3087
Tire Mounting..3087
HYDRAULIC SYSTEM..3089
HYDRAULIC / HYDROSTATIC SCHEMATICS..3095
HYDRAULIC SYSTEM INFORMATION..3115
Troubleshooting..3119
Tighten Procedures..3120
CYLINDER (LIFT)..3121
Checking..3121
Removal And Installation..3121
Parts Identification..3123
Disassembly..3124
Assembly..3126
CYLINDER (TILT)..3129
Checking..3129
Removal And Installation..3129
Parts Identification..3131
Disassembly..3132
CYLINDER (POWER BOB-TACH)..3133
Checking..3133
Removal And Installation..3134
Parts Identification..3135
Disassembly..3136
Assembly..3137
MAIN RELIEF VALVE (FOOT CONTROL)..3141
Checking The Main Relief Valve At Front Auxiliary Hydraulics..3141
Checking The Main Relief Valve Without Front Auxiliaries..3142
Removal and Installation..3144
Adjustment..3145
MAIN RELIEF VALVE (AHC)..3147
Checking The Main Relief Valve At Front Auxiliary Hydraulics..3147
Checking The Main Relief Valve Without Front Auxiliaries..3148
Removal and Installation..3149
Adjustment..3150
HYDRAULIC CONTROL VALVE (FOOT CONTROL)..3151
Removal And Installation..3151
BICS™ Valve, Removal And Installation..3155
BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation..3156
BICS™ Valve, Check Valve Removal And Installation..3157
BICS™ Valve, Lock Valve Removal And Installation..3158
BICS™ Valve, Solenoid Removal And Installation..3159
BICS™ Valve, Solenoid Testing..3160
Identification Chart..3161
Load Check Valve..3161
Main Relief Valve..3163
Port Relief Valve, Tilt Spool (Linkage End)..3163
Port Relief Valve, Lift Spool (Bonnet End)..3164
Anti-Cavitation Valve / Port Relief Valve, Tilt Spool (Bonnet End)..3164
Anti-Cavitation Valve, Lift Spool (Linkage End)..3165
Rubber Boot..3165
Lift And Tilt Lock Block..3166
Lift Spool and Detent Removal..3167
Lift Spool And Detent Disassembly..3169
Lift Spool and Detent Assembly..3171
Lift Spool And Detent Installation..3175
Tilt Spool Removal And Installation..3176
Tilt Spool Disassembly And Assembly..3177
Auxiliary Spool Removal And Installation (Bonnet End)..3178
Auxiliary Spool Removal And Installation (Linkage End)..3179
Auxiliary Plug Removal And Installation..3180
Auxiliary Electric Solenoid Disassembly..3181
Port-Auxiliary Section Removal And Installation..3182
Cleaning And Inspection..3182
HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS) (AHC)..3183
Description..3183
Actuator Removal And Installation (In Loader)..3183
Removal And Installation..3185
BICS™ Valve Removal And Installation..3189
BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation..3191
BICS™ Valve Check Valve Removal And Installation..3192
BICS™ Valve Lock Valve Removal And Installation..3193
BICS™ Valve Solenoid Removal And Installation..3194
BICS™ Valve Solenoid Testing..3195
Actuator Removal And Installation..3196
Identification Chart..3197
Lift Base End Restrictor..3197
Load Check Valve..3198
Main Relief Valve..3199
Port Relief Valve..3200
Anti-Cavitation Valve / Port Relief Valve..3201
Anti-Cavitation Valve..3202
Lift Spool Removal..3203
Tilt Spool Removal And Installation..3204
Lift and Tilt Spool Disassembly And Assembly..3205
Auxiliary Spool Removal And Installation..3206
Auxiliary Electric Solenoid Disassembly..3207
Port-Auxiliary Section Disassembly..3208
Cleaning And Inspection..3208
LIFT ARM BYPASS CONTROL VALVE..3209
Inspecting..3209
Additional Inspection For Loaders With Advanced Hand Controls..3209
Removal And Installation..3209
Disassembly And Assembly..3210
HYDRAULIC PUMP (ALUMINUM)..3211
Check The Output Of The Pump..3211
Removal And Installation..3212
Identification..3213
Disassembly..3214
Inspection..3216
Assembly..3217
HYDRAULIC PUMP (ALUMINUM HIGH FLOW)..3219
Check The Output Of The Pump..3219
Removal And Installation..3220
Identification..3222
Disassembly..3223
Inspection..3227
Assembly..3228
HYDRAULIC PUMP (CAST IRON)..3233
Check The Output Of The Hydraulic Pump Without Power Bob-Tach..3233
Check The Output Of The Hydraulic Pump With Power Bob-Tach...3235
Removal And Installation..3236
Identification..3238
Disassembly And Assembly..3239
HYDRAULIC PUMP (CAST IRON HIGH FLOW)..3243
Check The Output Of The Hydraulic Pump Without Power Bob-Tach..3243
Check The Output Of The Hydraulic Pump With Power Bob-Tach...3244
Removal And Installation..3246
Identification..3248
Disassembly And Assembly..3249
HYDRAULIC / HYDROSTATIC FILTER..3257
Housing Removal And Installation..3257
Mount Removal And Installation..3258
HYDRAULIC FLUID RESERVOIR..3259
Draining The Fluid Reservoir..3259
Removal And Installation..3260
Hydraulic Fluid Screen..3263
BUCKET POSITION VALVE (873 - S/N 514147758 & BELOW)..3265
Solenoid Removal And Installation..3265
Solenoid Testing..3265
Removal And Installation..3266
BUCKET POSITION VALVE (873 - S/N 514147759 & Above & 883)..3269
Solenoid Removal And Installation..3269
Solenoid Testing..3269
Removal And Installation..3270
Disassembly And Assembly..3271
SELECT VALVE..3273
Checking The High Flow Pump Relief Valve..3273
Removal And Installation..3275
Disassembly And Assembly..3277
Solenoid Testing..3282
REAR AUXILIARY DIVERTER VALVE (SINGLE SHUTTLE)..3283
Removal And Installation..3283
Disassembly..3284
Inspection..3285
Solenoid Testing..3285
Assembly..3285
POWER BOB-TACH BLOCK (6674305 ALUMINUM)..3287
Removal And Installation..3287
Disassembly And Assembly..3289
POWER BOB-TACH BLOCK (6676547 ALUMINUM)..3295
Removal And Installation..3295
Disassembly And Assembly..3297
POWER BOB-TACH BLOCK (6677646-CAST IRON)..3303
Removal And Installation..3303
Disassembly And Assembly..3304
POWER BOB-TACH BLOCK (6678206-CAST IRON)..3311
Removal And Installation..3311
Disassembly And Assembly..3312
POWER BOB-TACH BLOCK (6678554-CAST IRON)..3321
Removal And Installation..3321
Disassembly And Assembly..3322
AUXILIARY PRESSURE RELEASE (ACCUMULATOR)..3331
Removal and Installation..3331
Disassembly And Assembly..3333
HYDROSTATIC SYSTEM..3335
HYDROSTATIC SYSTEM INFORMATION..3337
Troubleshooting Chart..3337
Replenishing Valve Function..3338
HYDROSTATIC MOTOR..3339
Removal And Installation..3339
Parts Identification..3341
Disassembly..3342
Inspection..3345
Assembly..3346
HYDROSTATIC MOTOR (TWO-SPEED)..3349
Removal And Installation..3349
Parts Identification..3352
Disassembly..3354
Inspection..3361
Assembly..3363
HYDROSTATIC MOTOR CARRIER..3369
Removal and Installation..3369
Parts Identification..3371
Disassembly..3372
Assembly..3374
CHARGE PRESSURE..3377
Sender Removal And Installation..3377
HYDROSTATIC PUMP..3379
Replenishing / High Pressure Relief Valve..3379
Charge Pressure Relief Valve..3380
Removal And Installation..3381
Parts Identification (Right Half)..3384
Parts Identification (Left Half)..3386
Hydraulic Pump Removal..3388
Disassembly..3389
Assembly..3397
DRIVE BELT..3405
Shield Removal And Installation..3405
Adjustment..3406
Replacement..3406
Tensioner Pulley Removal And Installation..3407
Tensioner Pulley Tension Spring..3409
OIL COOLER..3411
Hydraulic Oil Cooler Removal and Installation..3411
OIL COOLER (SEAL TO CONNECT) (STC)..3415
Hydraulic Oil Cooler Removal and Installation..3415
DRIVE SYSTEM..3417
BRAKE..3419
Pedal Removal And Installation..3419
Pedal Disassembly And Assembly..3420
Switch Operated Parking Brake..3420
Disc Removal And Installation..3421
BRAKE (TWO-SPEED)..3425
Block Removal And Installation..3425
Block Disassembly And Assembly..3427
DRIVE COMPONENTS..3433
Axle Seal Removal And Installation..3433
Axle, Sprocket And Bearings Removal And Installation..3435
Drive Chain Removal And Installation..3440
CHAINCASE..3441
Front Chaincase Cover Removal And Installation..3441
Rear Chaincase Cover Removal And Installation..3441
MAINFRAME..3443
SEAT BAR..3447
Removal And Installation..3447
Assembling Components..3449
Compression Spring Disassembly And Assembly..3451
OPERATOR CAB..3453
Gas Cylinder Removal And Installation..3453
Gas Cylinder Bracket Disassembly And Assembly..3455
Removal And Installation..3456
OPERATOR SEAT..3459
Removal And Installation..3459
Seat Belt Removal And Installation..3459
OPERATOR SEAT (SUSPENSION)..3461
Removal And Installation..3461
Slide Rail Removal And Installation..3462
Cushion Removal And Installation..3462
Back Removal And Installation..3463
Shock Removal And Installation..3464
BOB-TACH..3465
Removal And Installation..3465
Bob-Tach Lever And Wedge..3466
Pivot Pin Bushing And Seal Replacement..3467
POWER BOB-TACH (883)..3469
Removal And Installation..3469
Power Bob-Tach Lever And Wedge..3470
Pivot Pin Bushing And Seal Replacement..3471
LIFT ARMS..3473
Stabilizer Bar Removal And Installation..3473
Link Removal And Installation..3474
Removal And Installation..3476
REAR GRILL..3479
Removal And Installation..3479
REAR DOOR..3481
Removal And Installation..3481
Adjusting The Rear Door Latch..3482
FUEL TANK..3483
Removal And Installation..3483
Fuel Level Sender..3484
CONTROL PEDALS..3485
Removal And Installation..3485
Pedal Adjustment..3485
CONTROL PEDALS (ACS)..3487
Foot Sensor Removal And Installation..3487
Foot Pedal Removal And Installation..3488
Foot Pedal Linkage Disassembly And Assembly..3489
CONTROL PANEL..3491
Removal and Installation..3491
Steering Lever Boot..3493
CONTROL HANDLE..3495
Shock Removal And Installation..3495
Shaft Removal And Installation..3495
Shaft Disassembly And Assembly..3495
Lever Removal And Installation..3497
Steering Lever Boot..3497
Linkage Removal And Installation..3498
Linkage Neutral Adjustment..3502
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC)..3509
Components Identification..3509
Handle Control Unit Removal And Installation..3510
Control Handle Removal and Installation..3513
Control Handle Disassembly and Assembly..3513
Control Lever Removal and Installation..3514
Control Lever Boot..3514
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/ PUSH BUTTON FLOAT)..3515
Components Identification..3515
Handle Sensor Removal And Installation..3516
Control Handle Removal and Installation..3518
Control Handle Disassembly and Assembly..3519
Control Lever Removal and Installation..3519
Control Lever Boot..3520
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) ADVANCED HAND CONTROL..3521
Components Identification..3521
Handle Sensor Removal And Installation..3522
Control Handle Removal and Installation..3525
Control Handle Disassembly and Assembly..3526
Control Lever Removal and Installation..3526
Control Lever Boot..3527
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL..3529
Components Identification..3529
Handle Sensor Removal And Installation..3530
Control Handle Removal and Installation..3533
Control Handle Disassembly and Assembly..3534
Control Lever Removal and Installation..3534
Control Lever Boot..3535
ELECTRICAL SYSTEM & ANALYSIS..3537
ELECTRICAL SCHEMATICS..3541
ELECTRICAL SYSTEM INFORMATION..3551
Troubleshooting Chart..3553
Description..3554
Fuse Location..3556
Relay Switch Location..3556
Solenoid Test..3557
BATTERY..3559
Removal And Installation..3559
Servicing The Electrical System..3561
Using A Booster Battery (Jump Starting)..3562
ALTERNATOR (55 AMP)..3563
Adjusting The Alternator Belt..3563
Alternator Output Test..3563
Rectifier (Diode) Test..3564
Alternator Regulator Test..3565
Removal And Installation..3566
Disassembly..3567
Stator Continuity Test..3567
Stator Ground Test..3567
Rotor Continuity Test..3568
Rotor Ground Test..3568
Rectifier Continuity (Diode) Test..3568
Assembly..3569
ALTERNATOR (90 AMP)..3571
Adjusting The Alternator Belt..3571
Alternator Identification..3571
Charging System Check..3572
Alternator Voltage Test..3573
Low Voltage Test..3573
High Voltage Test..3574
Removal And Installation..3575
Rectifier Continuity (Diode) Test..3576
Alternator Regulator Test..3577
Disassembly..3577
Stator Continuity Test..3578
Stator Ground Test..3578
Rotor Continuity Test..3578
Rotor Ground Test..3578
Assembly..3579
STARTER..3581
Removal And Installation..3581
Parts Identification..3582
Disassembly And Assembly..3583
External Pinion..3587
Inspection And Repair..3588
Magnetic Switch Test..3591
No Load Test..3592
INSTRUMENT PANEL..3593
Left Panel..3593
Right Panel - Standard Instrument Panel (With Key Switch) [Figure 60-50-2]..3594
Right Panel - (Deluxe) (With Keyless Start) [Figure 60- 50-3]..3595
Right Panel Setup Display Options (Deluxe)..3597
Passwords..3598
Option and Field Accessory Panels..3599
Standard Panel Removal And Installation (Right Side)..3600
Deluxe Panel Removal And Installation (Right Side)..3601
Standard & Deluxe Panel Removal And Installation (Left Side)..3602
Front Accessory Panel Removal And Installation..3603
LIGHTS..3605
Front Removal And Installation..3605
Rear Removal And Installation..3606
BOBCAT CONTROLLER..3607
Identification Chart..3607
Removal And Installation..3608
DIAGNOSTICS..3609
Service Codes..3609
BICS™ SYSTEM..3611
Inspecting The BICS™ Controller (Engine STOPPED - Key ON)..3611
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)..3611
Inspecting The Seat Bar Sensor (Engine RUNNING)..3611
Inspecting The Traction Lock (Engine RUNNING)..3611
Inspecting The Lift Arm Bypass Control..3612
Additional Inspection For Loaders With Advanced Hand Controls (AHC)..3612
Troubleshooting Chart..3613
Troubleshooting Guide..3614
SEAT BAR SENSOR..3615
Troubleshooting Chart..3615
Test..3616
Removal And Installation..3617
BICS™ Circuit Test..3618
TRACTION LOCK..3621
Troubleshooting Chart..3621
Removal And Installation (Single Speed)..3622
Description Of The Control System (Single Speed)..3624
Inspecting The Control System (Single Speed)..3624
ADVANCED HAND CONTROL (AHC) SYSTEM..3625
Components Identification..3625
Troubleshooting Guide..3626
Parts Identification..3627
AHC Controller Removal And Installation..3628
Handle Control Unit Connector..3629
Switch Handle Removal And Installation..3630
Actuators Disassembly and Assembly..3633
ADVANCED HAND CONTROL (AHC) SYSTEM (W/ PUSH BUTTON FLOAT)..3635
Components Identification..3635
Troubleshooting Guide..3636
Controller, Connector And Wire Identification..3637
AHC Controller Removal And Installation..3638
Handle Control Unit Removal And Installation..3640
Handle Control Unit Connector..3642
Switch Handle Removal And Installation..3643
Actuators Disassembly and Assembly..3646
ADVANCED CONTROL SYSTEM (ACS)..3649
Components Identification..3649
Troubleshooting Guide..3651
Controller, Connector And Wire Identification..3652
ACS Controller Removal And Installation..3653
Handle Sensor Connector..3654
Switch Handle Removal..3655
Switch Handle Installation..3657
Actuators Disassembly and Assembly..3660
Handle Lock Solenoid Removal And Installation..3662
Handle Lock Solenoid Disassembly And Assembly..3662
Handle Lock Solenoid Connector..3663
Calibration Of The ACS System..3664
Switchable Hand / Foot Controls Calibration Procedure..3664
Hand Controls Only Calibration Procedure..3665
Foot Sensor Disassembly And Assembly..3667
Foot Sensor Connector..3667
Foot Lock Solenoid Removal And Installation..3668
Foot Lock Solenoid Connector..3669
ELECTRICAL / HYDRAULIC CONTROLS REFERENCE..3671
Controls Identification Chart..3671
ENGINE SERVICE..3673
TROUBLESHOOTING..3675
Chart..3675
ENGINE SPEED CONTROL..3677
Removal And Installation..3677
Speed Control Cable..3679
Speed Control Linkage..3679
MUFFLER..3681
Removal And Installation..3681
AIR CLEANER..3683
Housing Removal And Installation..3683
RADIATOR..3685
Removal And Installation..3685
COOLING FAN..3687
Drive Tension Pulley Removal And Installation..3687
Gearbox/Blower Housing Removal And Installation..3688
Blower Removal And Installation..3691
Gearbox Parts Identification..3692
Gearbox Disassembly..3693
Gearbox Assembly..3698
Gearbox, Checking Backlash..3703
ENGINE COMPONENTS AND TESTS..3707
Engine Compression, Checking..3707
Glow Plug, Checking..3708
Fuel Shut-Off Solenoid, Checking..3709
Fuel Shut-Off Solenoid Removal And Installation..3710
Fuel Injection Pump Removal..3711
Fuel Injection Pump Timing..3713
Fuel Injection Pump Installation..3714
Fuel Injector Removal And Installation..3716
Fuel Injector, Checking..3717
Fuel Injector Disassembly..3718
Fuel Injector Assembly..3719
Timing Belt Inspection..3721
Timing Belt Removal..3722
Timing Belt Installation..3723
Timing Belt, Replacement In the Loader..3727
Valve Clearance Adjustment..3732
Valve Timing, Checking..3733
Valve Timing, Checking (Cont’d)..3734
Thermostat, Oil Pressure Control Valves & Heater Connections..3735
ENGINE..3739
Removal And Installation..3739
Mount Replacement..3745
FLYWHEEL AND HOUSING..3747
Flywheel Removal And Installation..3747
Ring Gear Removal And Installation..3747
Flywheel Housing Removal And Installation..3747
RPM SENSOR..3749
Adjustment..3749
RECONDITIONING THE ENGINE..3751
Deutz Engine Tools Identification Chart..3751
Disassembly..3752
Assembly..3757
Cylinder, Checking..3772
Camshaft Bearing, Checking..3773
Camshaft Bearing, Removal And Installation..3774
Control Rod Guide Bushing Removal..3775
Control Rod Guide Bushing Installation..3777
Rear Cover Seal Removal And Installation..3781
Crankshaft, Checking..3782
Connecting Rod, Checking..3783
Piston, Checking..3786
Piston Pin, Checking..3787
Piston Rings Installation..3787
Piston Installation On The Connecting Rod..3788
Cylinder Head Disassembly..3789
Valves, Checking..3790
Valve Seats, Checking..3791
Valve Spring, Checking..3791
Cylinder Head Assembly..3791
Rocker Arm And Bracket, Checking..3793
Front Cover Disassembly..3794
Front Cover Assembly..3799
Turbo Charger Removal And Installation..3809
Crankshaft Gear Mounting Bolt Torque Procedure..3811
HEATING, VENTILATION, AIR CONDITIONING..3813
AIR CONDITIONING SYSTEM FLOW..3816
Principals..3816
Chart..3817
COMPONENTS..3819
Identification..3819
SAFETY..3823
Safety Equipment..3823
REGULAR MAINTENANCE..3825
Filter Elements Removal And Installation..3825
Compressor Drive Belt Inspection..3826
Cleaning The Condenser..3827
BASIC TROUBLESHOOTING..3829
Poor A/C Performance..3829
Cleaning The A/C Evaporator Coil & Heater Coil..3830
Receiver/Drier Sight Glass Inspection..3832
Compressor Drive Belt Inspection..3833
Checking The Electrical System..3834
Engine Coolant Bypassing The Heater Valve..3842
Heater Valve Not Opening Or Closing..3843
GENERAL AIR CONDITIONING SERVICE GUIDELINES..3845
Compressor Oil..3845
Compressor Oil Check..3846
Component Replacement And Refrigeration Leaks..3847
SYSTEM TROUBLESHOOTING CHART..3849
TEMPERATURE/PRESSURE..3853
Chart..3853
AIR CONDITIONING SERVICE..3855
Chart..3855
SYSTEM CHARGING AND RECLAMATION..3857
Reclamation Procedure..3857
Charging Procedure With A Manifold Gauge Set..3859
Charging Procedure..3860
COMPRESSOR..3863
Removal And Installation..3863
Compressor Clutch Disassembly..3864
CONDENSER..3869
Removal And Installation..3869
RECEIVER/DRIER..3871
Removal And Installation..3871
PRESSURE RELIEF VALVE..3873
Removal And Installation..3873
PRESSURE SWITCH..3875
Removal And Installation..3875
EVAPORATOR/HEATER UNIT..3877
Removal And Installation..3877
Disassembly And Assembly..3878
THERMOSTAT..3879
Removal And Installation..3879
EXPANSION VALVE..3881
Removal And Installation..3881
EVAPORATOR..3883
Removal And Installation..3883
HEATER COIL..3885
Removal And Installation With A/C..3885
Removal And Installation Without A/C..3886
BLOWER FAN..3889
Removal And Installation..3889
Disassembly And Assembly..3890
Wire Connector Removal and Installation..3892
HEATER VALVE..3895
Removal and Installation..3895
Disassembly And Assembly..3896
SPECIFICATIONS..3899
LOADER SPECIFICATIONS (873)..3901
Machine Dimensions..3901
Performance..3902
Controls..3902
Engine..3902
Hydraulic System..3903
Electrical..3903
Drive System..3904
Capacities..3904
Tires..3904
LOADER SPECIFICATIONS (883)..3905
Machine Dimensions..3905
Performance..3906
Controls..3906
Engine..3906
Hydraulic System..3907
Electrical..3907
Drive System..3908
Capacities..3908
Tires..3908
ENGINE SPECIFICATIONS..3909
General..3909
Fuel System..3909
Valve and Valve Guide and Seat Insert..3910
Pistons and Rings..3911
Connecting Rod..3911
Cylinder Head and Block..3912
Crankshaft and Main Bearings..3912
Camshaft and Bearings..3912
Oil Pump..3912
LOADER TORQUE..3913
Specifications..3913
TORQUE SPECIFICATIONS FOR BOLTS..3917
Torque For General SAE Bolts..3917
Torque For General Metric Bolts..3918
HYDRAULIC CONNECTION SPECIFICATIONS..3919
O-ring Face Seal Connection..3919
Straight Thread O-ring Fitting..3919
Tubelines And Hoses..3919
Flare Fitting..3920
O-ring Flare Fitting..3921
Port Seal Fitting..3923
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS..3925
Specifications..3925
CONVERSIONS..3927
Decimal And Millimeter Equivalents..3927
U.S. To Metric Conversion Chart..3927
SERVICE MANUAL REVISION..3929
873/873H-1..3929
873/873H-2..3931
873/873H-3..3933
873/883-4..3937
873/883-5..3939
873/883-6..3941
873/883-7..3943
873/883-8..3945
873/883-9..3947
6900847 (2-06) - 873 Turbo, 883 Turbo (G Series) [include High Flow] Service Manual..3949
MAINTENANCE SAFETY..3951
ALPHABETICAL INDEX..3953
CONTENTS..3955
FORWORD..3956
SAFETY INSTRUCTIONS..3959
Fire Prevention..3961
SERIAL NUMBER LOCATION..3963
Loader Serial Number..3963
Engine Serial Number..3963
DELIVERY REPORT..3964
BOBCAT LOADER IDENTIFICATION..3965
SAFETY & MAINTENANCE..3967
LIFTING AND BLOCKING THE LOADER..3969
Procedure..3969
LIFT ARM SUPPORT DEVICE..3971
Installing The Lift Arm Support Device..3971
Removing Lift Arm Support Device..3972
OPERATOR CAB..3973
Description..3973
Raising The Operator Cab..3973
Lowering The Operator Cab..3974
Emergency Exit..3975
TRANSPORTING THE BOBCAT LOADER..3977
Procedure..3977
TOWING THE LOADER..3979
Procedure For Non-Two-Speeds..3979
Procedure For Two-Speeds..3980
REMOTE START..3981
Procedure for Loader Without Attachments Control Harness..3981
Procedure for Loader With Attachments Control Harness..3982
Procedure..3984
SERVICE SCHEDULE..3985
Chart..3985
AIR CLEANER SERVICE..3987
Replacing Filter Element..3987
ENGINE COOLING SYSTEM..3989
Cleaning The Cooling System..3989
FUEL SYSTEM..3991
Fuel Specifications..3991
Filling The Fuel Tank..3991
Fuel Filter..3992
Removing Air From The Fuel System..3992
Fuel Lift Pump Strainer..3992
ENGINE LUBRICATION SYSTEM..3993
Checking Engine Oil..3993
Replacing Oil And Filter..3993
HYDRAULIC/HYDROSTATIC SYSTEM..3995
Checking And Adding Fluid..3995
Hydraulic/Hydrostatic Filter Replacement..3995
Replacing Hydraulic Fluid..3996
FINAL DRIVE TRANSMISSION (CHAINCASE)..3999
Checking And Adding Oil..3999
Replacing The Oil..3999
FAN GEARBOX..4001
Checking And Adding Oil..4001
BOB-TACH..4003
Inspection And Maintenance..4003
POWER BOB-TACH (OPTION)..4005
Inspection And Maintenance..4005
LUBRICATION OF THE BOBCAT LOADER..4007
Procedure..4007
TIRE MAINTENANCE..4011
Wheel Nuts..4011
Tire Rotation..4011
Tire Mounting..4011
HYDRAULIC SYSTEM..4013
HYDRAULIC/HYDROSTATIC SCHEMATICS..4019
HYDRAULIC SYSTEM INFORMATION..4039
Troubleshooting..4043
Tighten Procedures..4044
CYLINDER (LIFT)..4045
Checking..4045
Removal And Installation..4045
Parts Identification..4047
Disassembly..4048
Assembly..4050
CYLINDER (TILT)..4053
Checking..4053
Removal And Installation..4053
Parts Identification..4055
Disassembly..4056
CYLINDER (POWER BOB-TACH)..4057
Checking..4057
Removal And Installation..4058
Parts Identification..4059
Disassembly..4060
Assembly..4061
MAIN RELIEF VALVE (FOOT CONTROL)..4065
Checking The Main Relief Valve At Front Auxiliary Hydraulics..4065
Checking The Main Relief Valve Without Front Auxiliaries..4066
Removal and Installation..4068
Adjustment..4069
MAIN RELIEF VALVE (AHC)..4071
Checking The Main Relief Valve At Front Auxiliary Hydraulics..4071
Checking The Main Relief Valve Without Front Auxiliaries..4072
Removal and Installation..4073
Adjustment..4074
HYDRAULIC CONTROL VALVE (FOOT CONTROL)..4075
Removal And Installation..4075
BICS™ Valve, Removal And Installation..4079
BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation..4080
BICS™ Valve, Check Valve Removal And Installation..4081
BICS™ Valve, Lock Valve Removal And Installation..4082
BICS™ Valve, Solenoid Removal And Installation..4083
BICS™ Valve, Solenoid Testing..4084
Identification Chart..4085
Load Check Valve..4085
Main Relief Valve..4087
Port Relief Valve, Tilt Spool (Linkage End)..4087
Port Relief Valve, Lift Spool (Bonnet End)..4088
Anti-Cavitation Valve/Port Relief Valve, Tilt Spool (Bonnet End)..4088
Anti-Cavitation Valve, Lift Spool (Linkage End)..4089
Rubber Boot..4089
Lift And Tilt Lock Block..4090
Lift Spool and Detent Removal..4091
Lift Spool And Detent Disassembly..4093
Lift Spool and Detent Assembly..4095
Lift Spool And Detent Installation..4099
Tilt Spool Removal And Installation..4100
Tilt Spool Disassembly And Assembly..4101
Auxiliary Spool Removal And Installation (Bonnet End)..4102
Auxiliary Spool Removal And Installation (Linkage End)..4103
Auxiliary Plug Removal And Installation..4104
Auxiliary Electric Solenoid Disassembly..4105
Port-Auxiliary Section Removal And Installation..4106
Cleaning And Inspection..4106
HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS) (AHC)..4107
Description..4107
Actuator Removal And Installation (In Loader)..4107
Removal And Installation..4109
BICS™ Valve Removal And Installation..4113
BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation..4115
BICS™ Valve Check Valve Removal And Installation..4116
BICS™ Valve Lock Valve Removal And Installation..4117
BICS™ Valve Solenoid Removal And Installation..4118
BICS™ Valve Solenoid Testing..4119
Actuator Removal And Installation..4120
Identification Chart..4121
Lift Base End Restrictor..4121
Load Check Valve..4122
Main Relief Valve..4123
Port Relief Valve..4124
Anti-Cavitation Valve/Port Relief Valve..4125
Anti-Cavitation Valve..4126
Lift Spool Removal..4127
Tilt Spool Removal And Installation..4128
Lift and Tilt Spool Disassembly And Assembly..4129
Auxiliary Spool Removal And Installation..4130
Auxiliary Electric Solenoid Disassembly..4131
Port-Auxiliary Section Disassembly..4132
Cleaning And Inspection..4132
LIFT ARM BY-PASS CONTROL VALVE..4133
Inspecting..4133
Additional Inspection For Loaders With Advanced Hand Controls..4133
Removal And Installation..4133
Disassembly And Assembly..4134
HYDRAULIC PUMP (ALUMINUM)..4135
Check The Output Of The Pump..4135
Removal And Installation..4136
Identification..4137
Disassembly..4138
Inspection..4140
Assembly..4141
HYDRAULIC PUMP (ALUMINUM HIGH FLOW)..4143
Check The Output Of The Pump..4143
Removal And Installation..4144
Identification..4146
Disassembly..4147
Inspection..4151
Assembly..4152
HYDRAULIC PUMP (CAST IRON)..4157
Check The Output Of The Hydraulic Pump Without Power Bob-Tach..4157
Check The Output Of The Hydraulic Pump With Power Bob-Tach...4159
Removal And Installation..4160
Identification..4162
Disassembly And Assembly..4163
HYDRAULIC PUMP (CAST IRON HIGH FLOW)..4167
Check The Output Of The Hydraulic Pump Without Power Bob-Tach..4167
Check The Output Of The Hydraulic Pump With Power Bob-Tach...4168
Removal And Installation..4170
Identification..4172
Disassembly And Assembly..4173
HYDRAULIC/HYDROSTATIC FILTER..4181
Housing Removal And Installation..4181
Mount Removal And Installation..4182
HYDRAULIC FLUID RESERVOIR..4183
Draining The Fluid Reservoir..4183
Removal And Installation..4184
Hydraulic Fluid Screen..4187
BUCKET POSITION VALVE (873 - S/N 514147758 & BELOW)..4189
Solenoid Removal And Installation..4189
Solenoid Testing..4189
Removal And Installation..4190
BUCKET POSITION VALVE (873 - S/N 514147759 & Above & 883)..4193
Solenoid Removal And Installation..4193
Solenoid Testing..4193
Removal And Installation..4194
Disassembly And Assembly..4195
SELECT VALVE..4197
Checking The High Flow Pump Relief Valve..4197
Removal And Installation..4199
Disassembly And Assembly..4201
Solenoid Testing..4206
REAR AUXILIARY DIVERTER VALVE (SINGLE SHUTTLE)..4207
Removal And Installation..4207
Disassembly..4208
Inspection..4209
Solenoid Testing..4209
Assembly..4209
POWER BOB-TACH BLOCK (6674305 ALUMINUM)..4211
Removal And Installation..4211
Disassembly And Assembly..4212
POWER BOB-TACH BLOCK (6676547 ALUMINUM)..4219
Removal And Installation..4219
Disassembly And Assembly..4220
POWER BOB-TACH BLOCK (6677646-CAST IRON)..4227
Removal And Installation..4227
Disassembly And Assembly..4228
POWER BOB-TACH BLOCK (6678206-CAST IRON)..4235
Removal And Installation..4235
Disassembly And Assembly..4236
POWER BOB-TACH BLOCK (6678554-CAST IRON)..4245
Removal And Installation..4245
Disassembly And Assembly..4246
AUXILIARY PRESSURE RELEASE (ACCUMULATOR)..4255
Removal and Installation..4255
Disassembly And Assembly..4256
HYDROSTATIC SYSTEM..4257
HYDROSTATIC SYSTEM INFORMATION..4259
Troubleshooting Chart..4259
Replenishing Valve Function..4260
HYDROSTATIC MOTOR..4261
Removal And Installation..4261
Parts Identification..4262
Disassembly..4263
Inspection..4266
Assembly..4267
HYDROSTATIC MOTOR (TWO-SPEED)..4271
Removal And Installation..4271
Parts Identification..4273
Disassembly..4275
Inspection..4282
Assembly..4284
HYDROSTATIC MOTOR CARRIER..4291
Removal and Installation..4291
Parts Identification..4293
Disassembly..4294
Assembly..4296
CHARGE PRESSURE..4299
Sender Removal And Installation..4299
HYDROSTATIC PUMP..4301
Replenishing/High Pressure Relief Valve..4301
Charge Pressure Relief Valve..4302
Removal And Installation..4303
Parts Identification (Right Half)..4306
Parts Identification (Left Half)..4308
Hydraulic Pump Removal..4310
Disassembly..4311
Assembly..4319
DRIVE BELT..4327
Shield Removal And Installation..4327
Adjustment..4328
Replacement..4328
Tensioner Pulley Removal And Installation..4329
Tensioner Pulley Tension Spring..4331
OIL COOLER..4333
Hydraulic Oil Cooler Removal and Installation..4333
OIL COOLER (SEAL TO CONNECT) (STC)..4335
Hydraulic Oil Cooler Removal and Installation..4335
DRIVE SYSTEM..4337
BRAKE..4339
Pedal Removal And Installation..4339
Pedal Disassembly And Assembly..4340
Switch Operated Parking Brake..4340
Disc Removal And Installation..4341
BRAKE (TWO-SPEED)..4345
Block Removal And Installation..4345
Block Disassembly And Assembly..4347
DRIVE COMPONENTS..4353
Axle Seal Removal And Installation..4353
Axle, Sprocket And Bearings Removal And Installation..4355
Drive Chain Removal And Installation..4360
CHAINCASE..4361
Front Chaincase Cover Removal And Installation..4361
Rear Chaincase Cover Removal And Installation..4361
MAIN FRAME..4363
SEAT BAR..4367
Removal And Installation..4367
Assembling Components..4369
Compression Spring Disassembly And Assembly..4371
OPERATOR CAB..4373
Gas Cylinder Removal And Installation..4373
Gas Cylinder Bracket Dissassembly And Assembly..4375
Removal And Installation..4376
OPERATOR SEAT..4379
Removal And Installation..4379
Seat Belt Removal And Installation..4379
OPERATOR SEAT (SUSPENSION)..4381
Removal And Installation..4381
Slide Rail Removal And Installation..4382
Cushion Removal And Installation..4382
Back Removal And Installation..4383
Shock Removal And Installation..4384
BOB-TACH..4385
Removal And Installation..4385
Bob-Tach Lever And Wedge..4386
Pivot Pin Bushing And Seal Replacement..4387
POWER BOB-TACH (883)..4389
Removal And Installation..4389
Power Bob-Tach Lever And Wedge..4390
Pivot Pin Bushing And Seal Replacement..4391
LIFT ARMS..4393
Stabilizer Bar Removal And Installation..4393
Link Removal And Installation..4394
Removal And Installation..4396
REAR GRILL..4399
Removal And Installation..4399
REAR DOOR..4401
Removal And Installation..4401
Adjusting The Rear Door Latch..4402
FUEL TANK..4403
Removal And Installation..4403
Fuel Level Sender..4404
CONTROL PEDALS..4405
Removal And Installation..4405
Pedal Adjustment..4405
CONTROL PEDALS (ACS)..4407
Foot Sensor Removal And Installation..4407
Foot Pedal Removal And Installation..4408
Foot Pedal Linkage Disassembly And Assembly..4409
CONTROL PANEL..4411
Removal and Installation..4411
Steering Lever Boot..4413
CONTROL HANDLE..4415
Shock Removal And Installation..4415
Shaft Removal And Installation..4415
Shaft Disassembly And Assembly..4415
Lever Removal And Installation..4417
Steering Lever Boot..4417
Linkage Removal And Installation..4418
Linkage Neutral Adjustment..4422
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC)..4429
Components Identification..4429
Handle Control Unit Removal And Installation..4430
Control Handle Removal and Installation..4433
Control Handle Disassembly and Assembly..4433
Control Lever Removal and Installation..4434
Control Lever Boot..4434
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/PUSH BUTTON FLOAT)..4435
Components Identification..4435
Handle Sensor Removal And Installation..4436
Control Handle Removal and Installation..4438
Control Handle Disassembly and Assembly..4439
Control Lever Removal and Installation..4439
Control Lever Boot..4440
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) ADVANCED HAND CONTROL..4441
Components Identification..4441
Handle Sensor Removal And Installation..4442
Control Handle Removal and Installation..4445
Control Handle Disassembly and Assembly..4446
Control Lever Removal and Installation..4446
Control Lever Boot..4447
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL..4449
Components Identification..4449
Handle Sensor Removal And Installation..4450
Control Handle Removal and Installation..4453
Control Handle Disassembly and Assembly..4454
Control Lever Removal and Installation..4454
Control Lever Boot..4455
ELECTRICAL SYSTEM & ANALYSIS..4457
ELECTRICAL SCHEMATICS..4463
ELECTRICAL SYSTEM INFORMATION..4461
Troubleshooting Chart..4472
Description..4473
Fuse Location..4475
Relay Switch Location..4475
Solenoid Test..4476
BATTERY..4478
Removal And Installation..4478
Servicing The Electrical System..4480
Using A Booster Battery (Jump Starting)..4481
ALTERNATOR (55 AMP)..4482
Adjusting The Alternator Belt..4482
Alternator Output Test..4482
Rectifier (Diode) Test..4483
Alternator Regulator Test..4484
Removal And Installation..4485
Disassembly..4486
Stator Continuity Test..4486
Stator Ground Test..4486
Rotor Continuity Test..4487
Rotor Ground Test..4487
Rectifier Continuity (Diode) Test..4487
Assembly..4488
ALTERNATOR (90 AMP)..4490
Adjusting The Alternator Belt..4490
Alternator Identification..4490
Charging System Check..4491
Alternator Voltage Test..4492
Low Voltage Test..4492
High Voltage Test..4493
Removal And Installation..4494
Rectifier Continuity (Diode) Test..4495
Alternator Regulator Test..4496
Disassembly..4496
Stator Continuity Test..4497
Stator Ground Test..4497
Rotor Continuity Test..4497
Rotor Ground Test..4497
Assembly..4498
STARTER..4500
Removal And Installation..4500
Parts Identification..4501
Disassembly And Assembly..4502
External Pinion..4506
Inspection And Repair..4507
Magnetic Switch Test..4510
No Load Test..4511
INSTRUMENT PANEL..4512
Left Panel..4512
Right Panel - Standard Instrument Panel (With Key Switch) [Figure 60-50-2]..4513
Right Panel - (Deluxe) (With Keyless Start) [Figure 60- 50-3]..4514
Right Panel Setup Display Options (Deluxe)..4516
Passwords..4517
Option and Field Accessory Panels..4518
Standard Panel Removal And Installation (Right Side)..4519
Deluxe Panel Removal And Installation (Right Side)..4520
Standard & Deluxe Panel Removal And Installation (Left Side)..4521
Front Accessory Panel Removal And Installation..4522
LIGHTS..4524
Front Removal And Installation..4524
Rear Removal And Installation..4525
BOBCAT CONTROLLER..4526
Identification Chart..4526
Removal And Installation..4527
DIAGNOSTICS..4528
Service Codes..4528
BICS™ SYSTEM..4530
Inspecting The BICS™ Controller (Engine STOPPED - Key ON)..4530
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)..4530
Inspecting The Seat Bar Sensor (Engine RUNNING)..4530
Inspecting The Traction Lock (Engine RUNNING)..4530
Inspecting The Lift Arm By-Pass Control..4531
Additional Inspection For Loaders With Advanced Hand Controls (AHC)..4531
Troubleshooting Chart..4532
Troubleshooting Guide..4533
SEAT BAR SENSOR..4534
Troubleshooting Chart..4534
Test..4535
Removal And Installation..4536
BICS™ Circuit Test..4537
TRACTION LOCK..4540
Troubleshooting Chart..4540
Removal And Installation (Single Speed)..4541
Description Of The Control System (Single Speed)..4543
Inspecting The Control System (Single Speed)..4543
ADVANCED HAND CONTROL (AHC) SYSTEM..4544
Components Identification..4544
Troubleshooting Guide..4545
Parts Identification..4546
AHC Controller Removal And Installation..4547
Handle Control Unit Connector..4548
Switch Handle Removal And Installation..4549
Actuators Disassembly and Assembly..4552
ADVANCED HAND CONTROL (AHC) SYSTEM (W/ PUSH BUTTON FLOAT)..4554
Components Identification..4554
Troubleshooting Guide..4555
Controller, Connector And Wire Identification..4556
AHC Controller Removal And Installation..4557
Handle Control Unit Removal And Installation..4559
Handle Control Unit Connector..4561
Switch Handle Removal And Installation..4562
Actuators Disassembly and Assembly..4565
ADVANCED CONTROL SYSTEM (ACS)..4568
Components Identification..4568
Troubleshooting Guide..4570
Controller, Connector And Wire Identification..4571
ACS Controller Removal And Installation..4572
Handle Sensor Connector..4573
Switch Handle Removal..4574
Switch Handle Installation..4576
Actuators Disassembly and Assembly..4579
Handle Lock Solenoid Removal And Installation..4581
Handle Lock Solenoid Disassembly And Assembly..4581
Handle Lock Solenoid Connector..4582
Calibration Of The ACS System..4583
Switchable Hand/Foot Controls Calibration Procedure..4583
Hand Controls Only Calibration Procedure..4584
Foot Sensor Disassembly And Assembly..4586
Foot Sensor Connector..4586
Foot Lock Solenoid Removal And Installation..4587
Foot Lock Solenoid Connector..4588
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE..4590
Controls Identification Chart..4590
ENGINE SERVICE..4592
TROUBLESHOOTING..4594
Chart..4594
ENGINE SPEED CONTROL..4596
Removal And Installation..4596
Speed Control Cable..4598
Speed Control Linkage..4598
MUFFLER..4600
Removal And Installation..4600
AIR CLEANER..4602
Housing Removal And Installation..4602
RADIATOR..4604
Removal And Installation..4604
COOLING FAN..4606
Drive Tension Pulley Removal And Installation..4606
Gearbox/Blower Housing Removal And Installation..4607
Blower Removal And Installation..4610
Gearbox Parts Identification..4611
Gearbox Disassembly..4612
Gearbox Assembly..4617
Gearbox, Checking Backlash..4622
ENGINE COMPONENTS AND TESTS..4626
Engine Compression, Checking..4626
Glow Plug, Checking..4627
Fuel Shut-Off Solenoid, Checking..4628
Fuel Shut-Off Solenoid Removal And Installation..4629
Fuel Injection Pump Removal..4630
Fuel Injection Pump Timing..4632
Fuel Injection Pump Installation..4633
Fuel Injector Removal And Installation..4635
Fuel Injector, Checking..4636
Fuel Injector Disassembly..4637
Fuel Injector Assembly..4638
Timing Belt Inspection..4640
Timing Belt Removal..4641
Timing Belt Installation..4642
Timing Belt, Replacement In the Loader..4646
Valve Clearance Adjustment..4651
Valve Timing, Checking..4652
Valve Timing, Checking (Cont’d)..4653
Thermostat, Oil Pressure Control Valves & Heater Connections..4654
ENGINE..4658
Removal And Installation..4658
Mount Replacement..4664
FLYWHEEL AND HOUSING..4666
Flywheel Removal And Installation..4666
Ring Gear Removal And Installation..4666
Flywheel Housing Removal And Installation..4666
RPM SENSOR..4668
Adjustment..4668
RECONDITIONING THE ENGINE..4670
Deutz Engine Tools Identification Chart..4670
Disassembly..4671
Assembly..4676
Cylinder, Checking..4691
Camshaft Bearing, Checking..4692
Camshaft Bearing, Removal And Installation..4693
Control Rod Guide Bushing Removal..4694
Control Rod Guide Bushing Installation..4696
Rear Cover Seal Removal And Installation..4700
Crankshaft, Checking..4701
Connecting Rod, Checking..4702
Piston, Checking..4705
Piston Pin, Checking..4706
Piston Rings Installation..4706
Piston Installation On The Connecting Rod..4707
Cylinder Head Disassembly..4708
Valves, Checking..4709
Valve Seats, Checking..4710
Valve Spring, Checking..4710
Cylinder Head Assembly..4710
Rocker Arm And Bracket, Checking..4712
Front Cover Disassembly..4713
Front Cover Assembly..4718
Turbo Charger Removal And Installation..4728
Crankshaft Gear Mounting Bolt Torque Procedure..4730
HEATING, VENTILATION, AIR CONDITIONING..4732
AIR CONDITIONING SYSTEM FLOW..4735
Principals..4735
Chart..4736
COMPONENTS..4738
Identification..4738
SAFETY..4742
Safety Equipment..4742
REGULAR MAINTENANCE..4744
Filter Elements Removal And Installation..4744
Compressor Drive Belt Inspection..4745
Cleaning The Condenser..4746
BASIC TROUBLESHOOTING..4748
Poor A/C Performance..4748
Cleaning The A/C Evaporator Coil & Heater Coil..4749
Receiver/Drier Sight Glass Inspection..4751
Compressor Drive Belt Inspection..4752
Checking The Electrical System..4753
Engine Coolant By-Passing The Heater Valve..4761
Heater Valve Not Opening Or Closing..4762
GENERAL AIR CONDITIONING SERVICE GUIDELINES..4764
Compressor Oil..4764
Compressor Oil Check..4765
Component Replacement And Refrigeration Leaks..4766
SYSTEM TROUBLESHOOTING CHART..4768
TEMPERATURE/PRESSURE..4772
Chart..4772
AIR CONDITIONING SERVICE..4774
Chart..4774
SYSTEM CHARGING AND RECLAMATION..4776
Reclamation Procedure..4776
Charging Procedure With A Manifold Gauge Set..4778
Charging Procedure..4779
COMPRESSOR..4782
Removal And Installation..4782
Compressor Clutch Disassembly..4783
CONDENSER..4788
Removal And Installation..4788
RECEIVER/DRIER..4790
Removal And Installation..4790
PRESSURE RELIEF VALVE..4792
Removal And Installation..4792
PRESSURE SWITCH..4794
Removal And Installation..4794
EVAPORATOR/HEATER UNIT..4796
Removal And Installation..4796
Disassembly And Assembly..4797
THERMOSTAT..4798
Removal And Installation..4798
EXPANSION VALVE..4800
Removal And Installation..4800
EVAPORATOR..4802
Removal And Installation..4802
HEATER COIL..4804
Removal And Installation With A/C..4804
Removal And Installation Without A/C..4805
BLOWER FAN..4808
Removal And Installation..4808
Disassembly And Assembly..4809
Wire Connector Removal and Installation..4811
HEATER VALVE..4814
Removal and Installation..4814
Disassembly And Assembly..4815
SPECIFICATIONS..4818
LOADER SPECIFICATIONS (873)..4820
Machine Dimensions..4820
Performance..4821
Controls..4821
Engine..4821
Hydraulic System..4822
Electrical..4822
Drive System..4823
Capacities..4823
Tires..4823
LOADER SPECIFICATIONS (883)..4824
Machine Dimensions..4824
Performance..4825
Controls..4825
Engine..4825
Hydraulic System..4826
Electrical..4826
Drive System..4827
Capacities..4827
Tires..4827
ENGINE SPECIFICATIONS..4828
General..4828
Fuel System..4828
Valve and Valve Guide and Seat Insert..4829
Pistons and Rings..4830
Connecting Rod..4830
Cylinder Head and Block..4831
Crankshaft and Main Bearings..4831
Camshaft and Bearings..4831
Oil Pump..4831
LOADER TORQUE..4832
Specifications..4832
TORQUE SPECIFICATIONS FOR BOLTS..4836
Torque For General SAE Bolts..4836
Torque For General Metric Bolts..4837
HYDRAULIC CONNECTION SPECIFICATIONS..4838
O-ring Face Seal Connection..4838
Straight Thread O-ring Fitting..4838
Tubelines And Hoses..4838
Flare Fitting..4839
O-ring Flare Fitting..4840
Port Seal Fitting..4842
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS..4844
Specifications..4844
SMR..4858
Revision No: 873/873H-1..4848
Revision No: 873/873H-2..4850
Revision No: 873/873H-3..4852
Revision No: 873/883-4..4856
Revision No: 873/883-5..4858
Revision No: 873/883-6..4860
Revision No: 873/883-7..4862
6900847 (7-10) - 873 Turbo, 883 Turbo (G Series) Service Manual..4864
MAINTENANCE SAFETY..4866
ALPHABETICAL INDEX..4868
CONTENTS..4870
FOREWORD..4871
SAFETY INSTRUCTIONS..4874
FIRE PREVENTION..4876
Maintenance..4876
Operation..4876
Electrical..4876
Hydraulic System..4876
Fueling..4876
Starting..4876
Spark Arrestor Exhaust System..4876
Welding And Grinding..4877
Fire Extinguishers..4877
SERIAL NUMBER LOCATION..4878
Loader Serial Number..4878
Engine Serial Number..4878
DELIVERY REPORT..4879
BOBCAT LOADER IDENTIFICATION..4880
SAFETY & MAINTENANCE..4882
LIFTING AND BLOCKING THE LOADER..4884
Procedure..4884
LIFT ARM SUPPORT DEVICE..4886
Installing The Lift Arm Support Device..4886
Removing Lift Arm Support Device..4887
OPERATOR CAB..4888
Description..4888
Raising The Operator Cab..4888
Lowering The Operator Cab..4889
Emergency Exit..4890
TRANSPORTING THE BOBCAT LOADER..4892
Procedure..4892
TOWING THE LOADER..4894
Procedure For Non-Two-Speeds..4894
Procedure For Two-Speeds..4895
REMOTE START..4896
Procedure for Loader Without Attachments Control Harness..4896
Procedure for Loader With Attachments Control Harness..4897
Procedure..4899
SERVICE SCHEDULE..4900
Chart..4900
AIR CLEANER SERVICE..4902
Replacing Filter Element..4902
ENGINE COOLING SYSTEM..4904
Cleaning The Cooling System..4904
FUEL SYSTEM..4906
Fuel Specifications..4906
Filling The Fuel Tank..4906
Fuel Filter..4907
Removing Air From The Fuel System..4907
Fuel Lift Pump Strainer..4907
ENGINE LUBRICATION SYSTEM..4908
Checking Engine Oil..4908
Replacing Oil And Filter..4908
HYDRAULIC / HYDROSTATIC SYSTEM..4910
Checking And Adding Fluid..4910
Hydraulic / Hydrostatic Filter Replacement..4910
Replacing Hydraulic Fluid..4911
FINAL DRIVE TRANSMISSION (CHAINCASE)..4914
Checking And Adding Oil..4914
Replacing The Oil..4914
FAN GEARBOX..4916
Checking And Adding Oil..4916
BOB-TACH..4918
Inspection And Maintenance..4918
POWER BOB-TACH (OPTION)..4920
Inspection And Maintenance..4920
LUBRICATION OF THE BOBCAT LOADER..4922
Procedure..4922
TIRE MAINTENANCE..4926
Wheel Nuts..4926
Tire Rotation..4926
Tire Mounting..4926
HYDRAULIC SYSTEM..4928
HYDRAULIC / HYDROSTATIC SCHEMATICS..4934
HYDRAULIC SYSTEM INFORMATION..4954
Troubleshooting..4958
Tighten Procedures..4959
CYLINDER (LIFT)..4960
Checking..4960
Removal And Installation..4960
Parts Identification..4962
Disassembly..4963
Assembly..4965
CYLINDER (TILT)..4968
Checking..4968
Removal And Installation..4968
Parts Identification..4970
Disassembly..4971
CYLINDER (POWER BOB-TACH)..4972
Checking..4972
Removal And Installation..4973
Parts Identification..4974
Disassembly..4975
Assembly..4976
MAIN RELIEF VALVE (FOOT CONTROL)..4980
Checking The Main Relief Valve At Front Auxiliary Hydraulics..4980
Checking The Main Relief Valve Without Front Auxiliaries..4981
Removal and Installation..4983
Adjustment..4984
MAIN RELIEF VALVE (AHC)..4986
Checking The Main Relief Valve At Front Auxiliary Hydraulics..4986
Checking The Main Relief Valve Without Front Auxiliaries..4987
Removal and Installation..4988
Adjustment..4989
HYDRAULIC CONTROL VALVE (FOOT CONTROL)..4990
Removal And Installation..4990
BICS™ Valve, Removal And Installation..4994
BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation..4995
BICS™ Valve, Check Valve Removal And Installation..4996
BICS™ Valve, Lock Valve Removal And Installation..4997
BICS™ Valve, Solenoid Removal And Installation..4998
BICS™ Valve, Solenoid Testing..4999
Identification Chart..5000
Load Check Valve..5000
Main Relief Valve..5002
Port Relief Valve, Tilt Spool (Linkage End)..5002
Port Relief Valve, Lift Spool (Bonnet End)..5003
Anti-Cavitation Valve / Port Relief Valve, Tilt Spool (Bonnet End)..5003
Anti-Cavitation Valve, Lift Spool (Linkage End)..5004
Rubber Boot..5004
Lift And Tilt Lock Block..5005
Lift Spool and Detent Removal..5006
Lift Spool And Detent Disassembly..5008
Lift Spool and Detent Assembly..5010
Lift Spool And Detent Installation..5014
Tilt Spool Removal And Installation..5015
Tilt Spool Disassembly And Assembly..5016
Auxiliary Spool Removal And Installation (Bonnet End)..5017
Auxiliary Spool Removal And Installation (Linkage End)..5018
Auxiliary Plug Removal And Installation..5019
Auxiliary Electric Solenoid Disassembly..5020
Port-Auxiliary Section Removal And Installation..5021
Cleaning And Inspection..5021
HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS) (AHC)..5022
Description..5022
Actuator Removal And Installation (In Loader)..5022
Removal And Installation..5024
BICS™ Valve Removal And Installation..5028
BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation..5030
BICS™ Valve Check Valve Removal And Installation..5031
BICS™ Valve Lock Valve Removal And Installation..5032
BICS™ Valve Solenoid Removal And Installation..5033
BICS™ Valve Solenoid Testing..5034
Actuator Removal And Installation..5035
Identification Chart..5036
Lift Base End Restrictor..5036
Load Check Valve..5037
Main Relief Valve..5038
Port Relief Valve..5039
Anti-Cavitation Valve / Port Relief Valve..5040
Anti-Cavitation Valve..5041
Lift Spool Removal..5042
Tilt Spool Removal And Installation..5043
Lift and Tilt Spool Disassembly And Assembly..5044
Auxiliary Spool Removal And Installation..5045
Auxiliary Electric Solenoid Disassembly..5046
Port-Auxiliary Section Disassembly..5047
Cleaning And Inspection..5047
LIFT ARM BYPASS CONTROL VALVE..5048
Inspecting..5048
Additional Inspection For Loaders With Advanced Hand Controls..5048
Removal And Installation..5048
Disassembly And Assembly..5049
HYDRAULIC PUMP (ALUMINUM)..5050
Check The Output Of The Pump..5050
Removal And Installation..5051
Identification..5052
Disassembly..5053
Inspection..5055
Assembly..5056
HYDRAULIC PUMP (ALUMINUM HIGH FLOW)..5058
Check The Output Of The Pump..5058
Removal And Installation..5059
Identification..5061
Disassembly..5062
Inspection..5066
Assembly..5067
HYDRAULIC PUMP (CAST IRON)..5072
Check The Output Of The Hydraulic Pump Without Power Bob-Tach..5072
Check The Output Of The Hydraulic Pump With Power Bob-Tach...5074
Removal And Installation..5075
Identification..5077
Disassembly And Assembly..5078
HYDRAULIC PUMP (CAST IRON HIGH FLOW)..5082
Check The Output Of The Hydraulic Pump Without Power Bob-Tach..5082
Check The Output Of The Hydraulic Pump With Power Bob-Tach...5083
Removal And Installation..5085
Identification..5087
Disassembly And Assembly..5088
HYDRAULIC / HYDROSTATIC FILTER..5096
Housing Removal And Installation..5096
Mount Removal And Installation..5097
HYDRAULIC FLUID RESERVOIR..5098
Draining The Fluid Reservoir..5098
Removal And Installation..5099
Hydraulic Fluid Screen..5102
BUCKET POSITION VALVE (873 - S/N 514147758 & BELOW)..5104
Solenoid Removal And Installation..5104
Solenoid Testing..5104
Removal And Installation..5105
BUCKET POSITION VALVE (873 - S/N 514147759 & Above & 883)..5108
Solenoid Removal And Installation..5108
Solenoid Testing..5108
Removal And Installation..5109
Disassembly And Assembly..5110
SELECT VALVE..5112
Checking The High Flow Pump Relief Valve..5112
Removal And Installation..5114
Disassembly And Assembly..5116
Solenoid Testing..5121
REAR AUXILIARY DIVERTER VALVE (SINGLE SHUTTLE)..5122
Removal And Installation..5122
Disassembly..5123
Inspection..5124
Solenoid Testing..5124
Assembly..5124
POWER BOB-TACH BLOCK (6674305 ALUMINUM)..5126
Removal And Installation..5126
Disassembly And Assembly..5128
POWER BOB-TACH BLOCK (6676547 ALUMINUM)..5134
Removal And Installation..5134
Disassembly And Assembly..5136
POWER BOB-TACH BLOCK (6677646-CAST IRON)..5142
Removal And Installation..5142
Disassembly And Assembly..5143
POWER BOB-TACH BLOCK (6678206-CAST IRON)..5150
Removal And Installation..5150
Disassembly And Assembly..5151
POWER BOB-TACH BLOCK (6678554-CAST IRON)..5160
Removal And Installation..5160
Disassembly And Assembly..5161
AUXILIARY PRESSURE RELEASE (ACCUMULATOR)..5170
Removal and Installation..5170
Disassembly And Assembly..5172
HYDROSTATIC SYSTEM..5174
HYDROSTATIC SYSTEM INFORMATION..5176
Troubleshooting Chart..5176
Replenishing Valve Function..5177
HYDROSTATIC MOTOR..5178
Removal And Installation..5178
Parts Identification..5180
Disassembly..5181
Inspection..5184
Assembly..5185
HYDROSTATIC MOTOR (TWO-SPEED)..5188
Removal And Installation..5188
Parts Identification..5191
Disassembly..5193
Inspection..5200
Assembly..5202
HYDROSTATIC MOTOR CARRIER..5208
Removal and Installation..5208
Parts Identification..5210
Disassembly..5211
Assembly..5213
CHARGE PRESSURE..5216
Sender Removal And Installation..5216
HYDROSTATIC PUMP..5218
Replenishing / High Pressure Relief Valve..5218
Charge Pressure Relief Valve..5219
Removal And Installation..5220
Parts Identification (Right Half)..5223
Parts Identification (Left Half)..5225
Hydraulic Pump Removal..5227
Disassembly..5228
Assembly..5236
DRIVE BELT..5244
Shield Removal And Installation..5244
Adjustment..5245
Replacement..5245
Tensioner Pulley Removal And Installation..5246
Tensioner Pulley Tension Spring..5248
OIL COOLER..5250
Hydraulic Oil Cooler Removal and Installation..5250
OIL COOLER (SEAL TO CONNECT) (STC)..5254
Hydraulic Oil Cooler Removal and Installation..5254
DRIVE SYSTEM..5256
BRAKE..5258
Pedal Removal And Installation..5258
Pedal Disassembly And Assembly..5259
Switch Operated Parking Brake..5259
Disc Removal And Installation..5260
BRAKE (TWO-SPEED)..5264
Block Removal And Installation..5264
Block Disassembly And Assembly..5266
DRIVE COMPONENTS..5272
Axle Seal Removal And Installation..5272
Axle, Sprocket And Bearings Removal And Installation..5274
Drive Chain Removal And Installation..5279
CHAINCASE..5280
Front Chaincase Cover Removal And Installation..5280
Rear Chaincase Cover Removal And Installation..5280
MAINFRAME..5282
SEAT BAR..5286
Removal And Installation..5286
Assembling Components..5288
Compression Spring Disassembly And Assembly..5290
OPERATOR CAB..5292
Gas Cylinder Removal And Installation..5292
Gas Cylinder Bracket Disassembly And Assembly..5294
Removal And Installation..5295
OPERATOR SEAT..5298
Removal And Installation..5298
Seat Belt Removal And Installation..5298
OPERATOR SEAT (SUSPENSION)..5300
Removal And Installation..5300
Slide Rail Removal And Installation..5301
Cushion Removal And Installation..5301
Back Removal And Installation..5302
Shock Removal And Installation..5303
BOB-TACH..5304
Removal And Installation..5304
Bob-Tach Lever And Wedge..5305
Pivot Pin Bushing And Seal Replacement..5306
POWER BOB-TACH (883)..5308
Removal And Installation..5308
Power Bob-Tach Lever And Wedge..5309
Pivot Pin Bushing And Seal Replacement..5310
LIFT ARMS..5312
Stabilizer Bar Removal And Installation..5312
Link Removal And Installation..5313
Removal And Installation..5315
REAR GRILL..5318
Removal And Installation..5318
REAR DOOR..5320
Removal And Installation..5320
Adjusting The Rear Door Latch..5321
FUEL TANK..5322
Removal And Installation..5322
Fuel Level Sender..5323
CONTROL PEDALS..5324
Removal And Installation..5324
Pedal Adjustment..5324
CONTROL PEDALS (ACS)..5326
Foot Sensor Removal And Installation..5326
Foot Pedal Removal And Installation..5327
Foot Pedal Linkage Disassembly And Assembly..5328
CONTROL PANEL..5330
Removal and Installation..5330
Steering Lever Boot..5332
CONTROL HANDLE..5334
Shock Removal And Installation..5334
Shaft Removal And Installation..5334
Shaft Disassembly And Assembly..5334
Lever Removal And Installation..5336
Steering Lever Boot..5336
Linkage Removal And Installation..5337
Linkage Neutral Adjustment..5341
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC)..5348
Components Identification..5348
Handle Control Unit Removal And Installation..5349
Control Handle Removal and Installation..5352
Control Handle Disassembly and Assembly..5352
Control Lever Removal and Installation..5353
Control Lever Boot..5353
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/ PUSH BUTTON FLOAT)..5354
Components Identification..5354
Handle Sensor Removal And Installation..5355
Control Handle Removal and Installation..5357
Control Handle Disassembly and Assembly..5358
Control Lever Removal and Installation..5358
Control Lever Boot..5359
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) ADVANCED HAND CONTROL..5360
Components Identification..5360
Handle Sensor Removal And Installation..5361
Control Handle Removal and Installation..5364
Control Handle Disassembly and Assembly..5365
Control Lever Removal and Installation..5365
Control Lever Boot..5366
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL..5368
Components Identification..5368
Handle Sensor Removal And Installation..5369
Control Handle Removal and Installation..5372
Control Handle Disassembly and Assembly..5373
Control Lever Removal and Installation..5373
Control Lever Boot..5374
ELECTRICAL SYSTEM & ANALYSIS..5376
ELECTRICAL SCHEMATICS..5380
ELECTRICAL SYSTEM INFORMATION..5389
Troubleshooting Chart..5391
Description..5392
Fuse Location..5394
Relay Switch Location..5394
Solenoid Test..5395
BATTERY..5397
Removal And Installation..5397
Servicing The Electrical System..5399
Using A Booster Battery (Jump Starting)..5400
ALTERNATOR (55 AMP)..5401
Adjusting The Alternator Belt..5401
Alternator Output Test..5401
Rectifier (Diode) Test..5402
Alternator Regulator Test..5403
Removal And Installation..5404
Disassembly..5405
Stator Continuity Test..5405
Stator Ground Test..5405
Rotor Continuity Test..5406
Rotor Ground Test..5406
Rectifier Continuity (Diode) Test..5406
Assembly..5407
ALTERNATOR (90 AMP)..5409
Adjusting The Alternator Belt..5409
Alternator Identification..5409
Charging System Check..5410
Alternator Voltage Test..5411
Low Voltage Test..5411
High Voltage Test..5412
Removal And Installation..5413
Rectifier Continuity (Diode) Test..5414
Alternator Regulator Test..5415
Disassembly..5415
Stator Continuity Test..5416
Stator Ground Test..5416
Rotor Continuity Test..5416
Rotor Ground Test..5416
Assembly..5417
STARTER..5419
Removal And Installation..5419
Parts Identification..5420
Disassembly And Assembly..5421
External Pinion..5425
Inspection And Repair..5426
Magnetic Switch Test..5429
No Load Test..5430
INSTRUMENT PANEL..5431
Left Panel..5431
Right Panel - Standard Instrument Panel (With Key Switch) [Figure 60-50-2]..5432
Right Panel - (Deluxe) (With Keyless Start) [Figure 60- 50-3]..5433
Right Panel Setup Display Options (Deluxe)..5435
Passwords..5436
Option and Field Accessory Panels..5437
Standard Panel Removal And Installation (Right Side)..5438
Deluxe Panel Removal And Installation (Right Side)..5439
Standard & Deluxe Panel Removal And Installation (Left Side)..5440
Front Accessory Panel Removal And Installation..5441
LIGHTS..5443
Front Removal And Installation..5443
Rear Removal And Installation..5444
BOBCAT CONTROLLER..5445
Identification Chart..5445
Removal And Installation..5446
DIAGNOSTICS..5447
Service Codes..5447
BICS™ SYSTEM..5449
Inspecting The BICS™ Controller (Engine STOPPED - Key ON)..5449
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)..5449
Inspecting The Seat Bar Sensor (Engine RUNNING)..5449
Inspecting The Traction Lock (Engine RUNNING)..5449
Inspecting The Lift Arm Bypass Control..5450
Additional Inspection For Loaders With Advanced Hand Controls (AHC)..5450
Troubleshooting Chart..5451
Troubleshooting Guide..5452
SEAT BAR SENSOR..5453
Troubleshooting Chart..5453
Test..5454
Removal And Installation..5455
BICS™ Circuit Test..5456
TRACTION LOCK..5459
Troubleshooting Chart..5459
Removal And Installation (Single Speed)..5460
Description Of The Control System (Single Speed)..5462
Inspecting The Control System (Single Speed)..5462
ADVANCED HAND CONTROL (AHC) SYSTEM..5463
Components Identification..5463
Troubleshooting Guide..5464
Parts Identification..5465
AHC Controller Removal And Installation..5466
Handle Control Unit Connector..5467
Switch Handle Removal And Installation..5468
Actuators Disassembly and Assembly..5471
ADVANCED HAND CONTROL (AHC) SYSTEM (W/ PUSH BUTTON FLOAT)..5473
Components Identification..5473
Troubleshooting Guide..5474
Controller, Connector And Wire Identification..5475
AHC Controller Removal And Installation..5476
Handle Control Unit Removal And Installation..5478
Handle Control Unit Connector..5480
Switch Handle Removal And Installation..5481
Actuators Disassembly and Assembly..5484
ADVANCED CONTROL SYSTEM (ACS)..5487
Components Identification..5487
Troubleshooting Guide..5489
Controller, Connector And Wire Identification..5490
ACS Controller Removal And Installation..5491
Handle Sensor Connector..5492
Switch Handle Removal..5493
Switch Handle Installation..5495
Actuators Disassembly and Assembly..5498
Handle Lock Solenoid Removal And Installation..5500
Handle Lock Solenoid Disassembly And Assembly..5500
Handle Lock Solenoid Connector..5501
Calibration Of The ACS System..5502
Switchable Hand / Foot Controls Calibration Procedure..5502
Hand Controls Only Calibration Procedure..5503
Foot Sensor Disassembly And Assembly..5505
Foot Sensor Connector..5505
Foot Lock Solenoid Removal And Installation..5506
Foot Lock Solenoid Connector..5507
ELECTRICAL / HYDRAULIC CONTROLS REFERENCE..5509
Controls Identification Chart..5509
ENGINE SERVICE..5511
TROUBLESHOOTING..5513
Chart..5513
ENGINE SPEED CONTROL..5515
Removal And Installation..5515
Speed Control Cable..5517
Speed Control Linkage..5517
MUFFLER..5519
Removal And Installation..5519
AIR CLEANER..5521
Housing Removal And Installation..5521
RADIATOR..5523
Removal And Installation..5523
COOLING FAN..5525
Drive Tension Pulley Removal And Installation..5525
Gearbox/Blower Housing Removal And Installation..5526
Blower Removal And Installation..5529
Gearbox Parts Identification..5530
Gearbox Disassembly..5531
Gearbox Assembly..5536
Gearbox, Checking Backlash..5541
ENGINE COMPONENTS AND TESTS..5545
Engine Compression, Checking..5545
Glow Plug, Checking..5546
Fuel Shut-Off Solenoid, Checking..5547
Fuel Shut-Off Solenoid Removal And Installation..5548
Fuel Injection Pump Removal..5549
Fuel Injection Pump Timing..5551
Fuel Injection Pump Installation..5552
Fuel Injector Removal And Installation..5554
Fuel Injector, Checking..5555
Fuel Injector Disassembly..5556
Fuel Injector Assembly..5557
Timing Belt Inspection..5559
Timing Belt Removal..5560
Timing Belt Installation..5561
Timing Belt, Replacement In the Loader..5565
Valve Clearance Adjustment..5570
Valve Timing, Checking..5571
Valve Timing, Checking (Cont’d)..5572
Thermostat, Oil Pressure Control Valves & Heater Connections..5573
ENGINE..5577
Removal And Installation..5577
Mount Replacement..5583
FLYWHEEL AND HOUSING..5585
Flywheel Removal And Installation..5585
Ring Gear Removal And Installation..5585
Flywheel Housing Removal And Installation..5585
RPM SENSOR..5587
Adjustment..5587
RECONDITIONING THE ENGINE..5589
Deutz Engine Tools Identification Chart..5589
Disassembly..5590
Assembly..5595
Cylinder, Checking..5610
Camshaft Bearing, Checking..5611
Camshaft Bearing, Removal And Installation..5612
Control Rod Guide Bushing Removal..5613
Control Rod Guide Bushing Installation..5615
Rear Cover Seal Removal And Installation..5619
Crankshaft, Checking..5620
Connecting Rod, Checking..5621
Piston, Checking..5624
Piston Pin, Checking..5625
Piston Rings Installation..5625
Piston Installation On The Connecting Rod..5626
Cylinder Head Disassembly..5627
Valves, Checking..5628
Valve Seats, Checking..5629
Valve Spring, Checking..5629
Cylinder Head Assembly..5629
Rocker Arm And Bracket, Checking..5631
Front Cover Disassembly..5632
Front Cover Assembly..5637
Turbo Charger Removal And Installation..5647
Crankshaft Gear Mounting Bolt Torque Procedure..5649
HEATING, VENTILATION, AIR CONDITIONING..5651
AIR CONDITIONING SYSTEM FLOW..5654
Principals..5654
Chart..5655
COMPONENTS..5657
Identification..5657
SAFETY..5661
Safety Equipment..5661
REGULAR MAINTENANCE..5663
Filter Elements Removal And Installation..5663
Compressor Drive Belt Inspection..5664
Cleaning The Condenser..5665
BASIC TROUBLESHOOTING..5667
Poor A/C Performance..5667
Cleaning The A/C Evaporator Coil & Heater Coil..5668
Receiver/Drier Sight Glass Inspection..5670
Compressor Drive Belt Inspection..5671
Checking The Electrical System..5672
Engine Coolant Bypassing The Heater Valve..5680
Heater Valve Not Opening Or Closing..5681
GENERAL AIR CONDITIONING SERVICE GUIDELINES..5683
Compressor Oil..5683
Compressor Oil Check..5684
Component Replacement And Refrigeration Leaks..5685
SYSTEM TROUBLESHOOTING CHART..5687
TEMPERATURE/PRESSURE..5691
Chart..5691
AIR CONDITIONING SERVICE..5693
Chart..5693
SYSTEM CHARGING AND RECLAMATION..5695
Reclamation Procedure..5695
Charging Procedure With A Manifold Gauge Set..5697
Charging Procedure..5698
COMPRESSOR..5701
Removal And Installation..5701
Compressor Clutch Disassembly..5702
CONDENSER..5707
Removal And Installation..5707
RECEIVER/DRIER..5709
Removal And Installation..5709
PRESSURE RELIEF VALVE..5711
Removal And Installation..5711
PRESSURE SWITCH..5713
Removal And Installation..5713
EVAPORATOR/HEATER UNIT..5715
Removal And Installation..5715
Disassembly And Assembly..5716
THERMOSTAT..5717
Removal And Installation..5717
EXPANSION VALVE..5719
Removal And Installation..5719
EVAPORATOR..5721
Removal And Installation..5721
HEATER COIL..5723
Removal And Installation With A/C..5723
Removal And Installation Without A/C..5724
BLOWER FAN..5727
Removal And Installation..5727
Disassembly And Assembly..5728
Wire Connector Removal and Installation..5730
HEATER VALVE..5733
Removal and Installation..5733
Disassembly And Assembly..5734
SPECIFICATIONS..5737
LOADER SPECIFICATIONS (873)..5739
Machine Dimensions..5739
Performance..5740
Controls..5740
Engine..5740
Hydraulic System..5741
Electrical..5741
Drive System..5742
Capacities..5742
Tires..5742
LOADER SPECIFICATIONS (883)..5743
Machine Dimensions..5743
Performance..5744
Controls..5744
Engine..5744
Hydraulic System..5745
Electrical..5745
Drive System..5746
Capacities..5746
Tires..5746
ENGINE SPECIFICATIONS..5747
General..5747
Fuel System..5747
Valve and Valve Guide and Seat Insert..5748
Pistons and Rings..5749
Connecting Rod..5749
Cylinder Head and Block..5750
Crankshaft and Main Bearings..5750
Camshaft and Bearings..5750
Oil Pump..5750
LOADER TORQUE..5751
Specifications..5751
TORQUE SPECIFICATIONS FOR BOLTS..5755
Torque For General SAE Bolts..5755
Torque For General Metric Bolts..5756
HYDRAULIC CONNECTION SPECIFICATIONS..5757
O-ring Face Seal Connection..5757
Straight Thread O-ring Fitting..5757
Tubelines And Hoses..5757
Flare Fitting..5758
O-ring Flare Fitting..5759
Port Seal Fitting..5761
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS..5763
Specifications..5763
CONVERSIONS..5765
Decimal And Millimeter Equivalents..5765
U.S. To Metric Conversion Chart..5765
SERVICE MANUAL REVISION..5767
873/873H-1..5767
873/873H-2..5769
873/873H-3..5771
873/883-4..5775
873/883-5..5777
873/883-6..5779
873/883-7..5781
873/883-8..5783
6900927 (3-03) - 873, 873 High Flow Operation & Maintenance Manual..5785
OPERATOR SAFETY WARNINGS..5787
CONTENTS..5789
REFERENCE INFORMATION..5789
BOBCAT COMPANY IS ISO 9001 CERTIFIED..5790
REGULAR MAINTENANCE ITEMS..5790
FOREWORD..5791
SERIAL NUMBER LOCATIONS..5793
LOADER SERIAL NUMBER..5793
ENGINE SERIAL NUMBER..5793
DELIVERY REPORT..5793
BOBCAT LOADER IDENTIFICATION..5794
FEATURES AND ACCESSORIES..5795
SAFETY..5797
SAFETY INSTRUCTIONS..5799
SAFETY IS THE OPERATOR’S RESPONSIBILITY..5799
BEFORE OPERATING THE BOBCAT LOADER..5800
SAFE OPERATION NEEDS A QUALIFIED OPERATOR *..5800
FIRE PREVENTION..5801
MACHINE SIGNS (DECALS)..5802
OPERATING INSTRUCTIONS..5805
INSTRUMENT PANEL IDENTIFICATION..5807
Left Panel – Standard and Deluxe Instrument Panels..5807
Right Panel – Standard Instrument Panel (With KeySwitch)..5808
Right Panel – Deluxe Instrument Panel (With Keyless Start) ..5809
Option and Field Accessory Panels (If Equipped)..5810
Cab Light..5811
LIFT ARM BY–PASS CONTROL..5811
TRACTION LOCK OVERRIDE..5811
ENGINE SPEED CONTROL..5812
TWO–SPEED CONTROL..5812
PARKING BRAKE (Early Models)..5812
PARKING BRAKE (Later Models)..5812
STEERING LEVERS..5813
SEAT BAR RESTRAINT SYSTEM..5814
HYDRAULIC CONTROLS..5815
Foot Pedals..5815
Lift Arm Operation..5815
Lift Arm Float Position..5815
Tilt Operation..5815
Hand Controls (If Equipped)..5815
Lift Arm Operation ..5815
Lift Arm Float Position..5815
Tilt Operation..5815
Quick Couplers..5816
Releasing Hydraulic Pressure (Loader and Attachment)..5816
Attachment Auxiliary Hydraulic Controls (If Equipped)..5817
Auxiliary Hydraulics Button..5817
FRONT Auxiliary Hydraulics Operation..5817
REAR Auxiliary Hydraulics Operation..5817
High–Flow Hydraulics Operation (If Equipped)..5818
Secondary Front Auxiliary Hydraulics (If Equipped)..5818
Attachment Control Device (ACD) (If Equipped)..5819
Bucket Position Valve Operation (If Equipped)..5819
DAILY INSPECTION..5820
Daily Inspection and Maintenance..5820
PRE–STARTING PROCEDURE..5821
STARTING THE ENGINE..5823
Standard Instrument Panel (With Key Switch)..5823
Deluxe Instrument Panel (With Keyless Start)..5824
Cold Temperature Starting..5825
Warming the Hydraulic/Hydrostatic System..5825
STOPPING THE ENGINE..5825
MONITORING THE DISPLAY PANEL..5826
ATTACHMENTS AND BUCKETS..5827
Hand Lever Bob–Tach..5828
Installing The Bucket Or Attachment..5828
Removing The Bucket Or Attatchment..5829
Power Bob–Tach..5830
Installing The Bucket Or Attachment..5830
Removing The Bucket Or Attachment..5831
OPERATING PROCEDURE..5832
Filling the Bucket (Foot Pedals)..5833
Filling the Bucket (Hand Controls)..5833
Emptying the Bucket (Foot Pedals)..5834
Emptying the Bucket (Hand Controls)..5834
Leveling the Ground (Using Lift Arms in Float Position) (Foot Pedals)..5834
Leveling the Ground (Using Lift Arms in Float Position) (Hand Controls)..5834
Digging Into the Ground (Foot Pedals)..5835
Digging Into the Ground (Hand Controls)..5835
Backfilling (Foot Pedals)..5835
Backfilling (Hand Controls)..5835
PARKING THE BOBCAT LOADER..5836
TRANSPORTING THE BOBCAT LOADER..5837
TOWING THE LOADER..5837
LIFTING THE LOADER..5838
Four Point Lift..5838
PREVENTIVE MAINTENANCE..5839
MAINTENANCE SAFETY..5841
SERVICE SCHEDULE..5843
LIFT ARM SUPPORT DEVICE..5844
Installing The Lift Arm Support Device..5844
Removing The Lift Arm Support Device..5844
OPERATOR CAB..5845
Raising The Operator Cab..5845
Lowering The Operator Cab..5846
Emergency Exit..5847
SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)..5848
Inspecting the Seat Bar..5848
Maintaining the Seat Bar..5848
SEAT BAR RESTRAINT SYSTEM ADVANCED CONTROL SYSTEM (ACS) and ADVANCED HAND CONTROLS (AHC)..5849
Inspecting the Seat Bar..5849
Maintaining the Seat Bar..5849
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..5850
Inspecting The BICS™ Controller..5850
Inspecting Deactivation Of The Auxiliary HydraulicsSystem (Engine STOPPED – Key ON)..5850
Inspecting The Seat Bar Sensor (Engine RUNNING)..5850
Inspecting The Traction Lock (Engine RUNNING)..5850
Inspecting The Lift Arm By–Pass Control..5850
Inspecting Deactivation of Lift And Tilt Functions (AHC & ACS)..5850
REAR DOOR..5851
Opening And Closing The Rear Door..5851
Adjusting The Rear Door..5851
REAR GRILL..5852
HEATER AND AIR CONDITIONING SYSTEM..5852
Cleaning and Maintenance..5852
AIR CLEANER SERVICE..5853
Replacing Filter Element..5853
FUEL SYSTEM..5855
Fuel Specifications..5855
Filling the Fuel Tank..5855
Fuel Filter..5855
Fuel Lift Pump Strainer..5856
Removing Air From The Fuel System..5856
ENGINE LUBRICATION SYSTEM..5857
Checking Engine Oil..5857
Replacing The Oil And Filter..5857
ENGINE COOLING SYSTEM..5858
Cleaning The Cooling System..5858
ELECTRICAL SYSTEM..5859
Description..5859
Cleaning Battery And Terminals..5859
Fuse Location..5859
Using A Booster Battery (Jump Starting)..5860
Removing And Installing The Battery..5861
HYDRAULIC/HYDROSTATIC SYSTEM..5863
Checking And Adding Fluid..5863
Replacing Hydraulic/Hydrostatic Filter..5863
Replacing Hydraulic Fluid And Case Drain Filters..5864
Breather Cap..5865
TIRE MAINTENANCE..5866
Wheel Nuts..5866
Rotating..5866
Mounting..5866
FINAL DRIVE TRANSMISSION (CHAINCASE)..5867
Checking And Adding Oil..5867
Removing Oil From The Chaincase..5867
FAN GEARBOX..5868
Checking And Maintaining..5868
DRIVE BELT..5868
Adjusting The Drive Belt..5868
Replacing The Drive Belt..5869
ALTERNATOR BELT..5870
Adjusting the Alternator Belt..5870
TIMING BELT..5870
LUBRICATING THE BOBCAT LOADER..5871
PIVOT PINS..5873
BOB–TACH..5874
Inspection And Maintenance..5874
POWER BOB–TACH (OPTION)..5875
Inspection and Maintenance..5875
SYSTEM SETUP AND ANALYSIS..5877
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..5879
Troubleshooting Chart..5879
DELUXE INSTRUMENTATION SERVICE CODES..5880
Number Codes List..5880
DELUXE INSTRUMENTATION PANEL SETUP..5882
Deluxe Panel Upgrade..5882
Icon Identification..5882
Deluxe Panel Setup..5882
Passwords..5883
Changing the Password..5883
MACHINE SIGN TRANSLATIONS..5885
IMPORTANT - 6708937..5887
SERVICE SCHEDULE - 6718398..5888
WARNING - 6718698..5890
WARNING - 6718699..5891
WARNING - 6579528..5892
WARNING - 6708941 ..5892
WARNING - 6577754..5892
DANGER - 6579639..5892
DANGER - 6579509 ..5892
DANGER - 6717343..5893
WARNING - 6715944 ..5893
SPECIFICATIONS..5895
SKID STEER LOADER SPECIFICATIONS..5897
Performance Specifications..5897
Engine..5897
Loader Controls..5897
Drive System..5897
Hydraulic System..5897
Electrical System..5897
Standard Instrumental Panel..5897
Optional Deluxe Instrumentation..5897
BOBCAT COMPANY APPROVED ATTACHMENTS & ACCESSORIES..5898
ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS..5901
WARRANTY..5903
6900927 (9-10) - 873, 873 High Flow Operation & Maintenance Manual..5905
OPERATOR SAFETY WARNINGS..5907
CONTENTS..5909
REFERENCE INFORMATION..5909
BOBCAT COMPANY IS ISO 9001 CERTIFIED..5910
REGULAR MAINTENANCE ITEMS..5910
FOREWORD..5911
SERIAL NUMBER LOCATIONS..5913
LOADER SERIAL NUMBER..5913
ENGINE SERIAL NUMBER..5913
DELIVERY REPORT..5913
BOBCAT LOADER IDENTIFICATION..5914
FEATURES AND ACCESSORIES..5915
SAFETY..5917
SAFETY INSTRUCTIONS..5919
SAFETY IS THE OPERATOR’S RESPONSIBILITY..5919
BEFORE OPERATING THE BOBCAT LOADER..5920
SAFE OPERATION NEEDS A QUALIFIED OPERATOR *..5920
FIRE PREVENTION..5921
MACHINE SIGNS (DECALS)..5922
OPERATING INSTRUCTIONS..5925
INSTRUMENT PANEL IDENTIFICATION..5927
Left Panel – Standard and Deluxe Instrument Panels..5927
Right Panel – Standard Instrument Panel (With KeySwitch)..5928
Right Panel – Deluxe Instrument Panel (With Keyless Start) ..5929
Option and Field Accessory Panels (If Equipped)..5930
Cab Light..5931
LIFT ARM BY–PASS CONTROL..5931
TRACTION LOCK OVERRIDE..5931
ENGINE SPEED CONTROL..5932
TWO–SPEED CONTROL..5932
PARKING BRAKE (Early Models)..5932
PARKING BRAKE (Later Models)..5932
STEERING LEVERS..5933
SEAT BAR RESTRAINT SYSTEM..5934
HYDRAULIC CONTROLS..5935
Foot Pedals..5935
Lift Arm Operation..5935
Lift Arm Float Position..5935
Tilt Operation..5935
Hand Controls (If Equipped)..5935
Lift Arm Operation ..5935
Lift Arm Float Position..5935
Tilt Operation..5935
Quick Couplers..5936
Releasing Hydraulic Pressure (Loader and Attachment)..5936
Attachment Auxiliary Hydraulic Controls (If Equipped)..5937
Auxiliary Hydraulics Button..5937
FRONT Auxiliary Hydraulics Operation..5937
REAR Auxiliary Hydraulics Operation..5937
High–Flow Hydraulics Operation (If Equipped)..5938
Secondary Front Auxiliary Hydraulics (If Equipped)..5938
Attachment Control Device (ACD) (If Equipped)..5939
Bucket Position Valve Operation (If Equipped)..5939
DAILY INSPECTION..5940
Daily Inspection and Maintenance..5940
PRE–STARTING PROCEDURE..5941
STARTING THE ENGINE..5943
Standard Instrument Panel (With Key Switch)..5943
Deluxe Instrument Panel (With Keyless Start)..5944
Cold Temperature Starting..5945
Warming the Hydraulic/Hydrostatic System..5945
STOPPING THE ENGINE..5945
MONITORING THE DISPLAY PANEL..5946
ATTACHMENTS AND BUCKETS..5947
Hand Lever Bob–Tach..5948
Installing The Bucket Or Attachment..5948
Removing The Bucket Or Attatchment..5949
Power Bob–Tach..5950
Installing The Bucket Or Attachment..5950
Removing The Bucket Or Attachment..5951
OPERATING PROCEDURE..5952
Filling the Bucket (Foot Pedals)..5953
Filling the Bucket (Hand Controls)..5953
Emptying the Bucket (Foot Pedals)..5954
Emptying the Bucket (Hand Controls)..5954
Leveling the Ground (Using Lift Arms in Float Position) (Foot Pedals)..5954
Leveling the Ground (Using Lift Arms in Float Position) (Hand Controls)..5954
Digging Into the Ground (Foot Pedals)..5955
Digging Into the Ground (Hand Controls)..5955
Backfilling (Foot Pedals)..5955
Backfilling (Hand Controls)..5955
PARKING THE BOBCAT LOADER..5956
TRANSPORTING THE BOBCAT LOADER..5957
TOWING THE LOADER..5957
LIFTING THE LOADER..5958
Four Point Lift..5958
PREVENTIVE MAINTENANCE..5959
MAINTENANCE SAFETY..5961
SERVICE SCHEDULE..5963
LIFT ARM SUPPORT DEVICE..5964
Installing The Lift Arm Support Device..5964
Removing The Lift Arm Support Device..5964
OPERATOR CAB..5965
Raising The Operator Cab..5965
Lowering The Operator Cab..5966
Emergency Exit..5967
SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)..5968
Inspecting the Seat Bar..5968
Maintaining the Seat Bar..5968
SEAT BAR RESTRAINT SYSTEM ADVANCED CONTROL SYSTEM (ACS) and ADVANCED HAND CONTROLS (AHC)..5969
Inspecting the Seat Bar..5969
Maintaining the Seat Bar..5969
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..5970
Inspecting The BICS™ Controller..5970
Inspecting Deactivation Of The Auxiliary HydraulicsSystem (Engine STOPPED – Key ON)..5970
Inspecting The Seat Bar Sensor (Engine RUNNING)..5970
Inspecting The Traction Lock (Engine RUNNING)..5970
Inspecting The Lift Arm By–Pass Control..5970
Inspecting Deactivation of Lift And Tilt Functions (AHC & ACS)..5970
REAR DOOR..5971
Opening And Closing The Rear Door..5971
Adjusting The Rear Door..5971
REAR GRILL..5972
HEATER AND AIR CONDITIONING SYSTEM..5972
Cleaning and Maintenance..5972
AIR CLEANER SERVICE..5973
Replacing Filter Element..5973
FUEL SYSTEM..5975
Fuel Specifications..5975
Filling the Fuel Tank..5975
Fuel Filter..5975
Fuel Lift Pump Strainer..5976
Removing Air From The Fuel System..5976
ENGINE LUBRICATION SYSTEM..5977
Checking Engine Oil..5977
Replacing The Oil And Filter..5977
ENGINE COOLING SYSTEM..5978
Cleaning The Cooling System..5978
ELECTRICAL SYSTEM..5979
Description..5979
Cleaning Battery And Terminals..5979
Fuse Location..5979
Using A Booster Battery (Jump Starting)..5980
Removing And Installing The Battery..5981
HYDRAULIC/HYDROSTATIC SYSTEM..5983
Checking And Adding Fluid..5983
Replacing Hydraulic/Hydrostatic Filter..5983
Replacing Hydraulic Fluid And Case Drain Filters..5984
Breather Cap..5985
TIRE MAINTENANCE..5986
Wheel Nuts..5986
Rotating..5986
Mounting..5986
FINAL DRIVE TRANSMISSION (CHAINCASE)..5987
Checking And Adding Oil..5987
Removing Oil From The Chaincase..5987
FAN GEARBOX..5988
Checking And Maintaining..5988
DRIVE BELT..5988
Adjusting The Drive Belt..5988
Replacing The Drive Belt..5989
ALTERNATOR BELT..5990
Adjusting the Alternator Belt..5990
TIMING BELT..5990
LUBRICATING THE BOBCAT LOADER..5991
PIVOT PINS..5993
BOB–TACH..5994
Inspection And Maintenance..5994
POWER BOB–TACH (OPTION)..5995
Inspection and Maintenance..5995
SYSTEM SETUP AND ANALYSIS..5997
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..5999
Troubleshooting Chart..5999
DELUXE INSTRUMENTATION SERVICE CODES..6000
Number Codes List..6000
DELUXE INSTRUMENTATION PANEL SETUP..6002
Deluxe Panel Upgrade..6002
Icon Identification..6002
Deluxe Panel Setup..6002
Passwords..6003
Changing the Password..6003
MACHINE SIGN TRANSLATIONS..6005
IMPORTANT - 6708937..6007
SERVICE SCHEDULE - 6718398..6008
WARNING - 6718698..6010
WARNING - 6718699..6011
WARNING - 6579528..6012
WARNING - 6708941 ..6012
WARNING - 6577754..6012
DANGER - 6579639..6012
DANGER - 6579509 ..6012
DANGER - 6717343..6013
WARNING - 6715944 ..6013
SPECIFICATIONS..6015
SKID STEER LOADER SPECIFICATIONS..6017
Performance Specifications..6017
Engine..6017
Loader Controls..6017
Drive System..6017
Hydraulic System..6017
Electrical System..6017
Standard Instrumental Panel..6017
Optional Deluxe Instrumentation..6017
BOBCAT COMPANY APPROVED ATTACHMENTS & ACCESSORIES..6018
ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS..6021
WARRANTY..6023
6901274 (6-01) - 883, 883 High Flow Operation & Maintenance Manual..6025
OPERATOR SAFETY WARNINGS..6027
CONTENTS..6029
REFERENCE INFORMATION..6029
BOBCAT COMPANY IS ISO 9001 CERTIFIED..6030
REGULAR MAINTENANCE ITEMS..6030
FOREWORD..6031
SERIAL NUMBER LOCATIONS..6033
LOADER SERIAL NUMBER..6033
ENGINE SERIAL NUMBER..6033
DELIVERY REPORT..6033
BOBCAT LOADER IDENTIFICATION..6034
FEATURES AND ACCESSORIES..6035
SAFETY..6037
SAFETY INSTRUCTIONS FOR BOBCAT SKID–STEER LOADERS AND ATTACHMENTS..6039
SAFETY IS THE OPERATOR’S RESPONSIBILITY..6039
BEFORE OPERATING THE BOBCAT LOADER..6040
SAFE OPERATION NEEDS A QUALIFIED OPERATOR *..6040
FIRE PREVENTION..6041
MACHINE SIGNS (DECALS)..6042
OPERATING INSTRUCTIONS..6045
INSTRUMENT PANEL IDENTIFICATION..6047
Left Panel – Standard and Deluxe Instrument Panels..6047
Right Panel – Standard Instrument Panel (With KeySwitch)..6048
Right Panel – Deluxe Instrument Panel (With Keyless Start) ..6049
Option and Field Accessory Panels (If Equipped)..6050
Cab Light..6051
LIFT ARM BY–PASS CONTROL..6051
TRACTION LOCK OVERRIDE..6051
ENGINE SPEED CONTROL..6052
TWO–SPEED CONTROL..6052
PARKING BRAKE..6052
STEERING LEVERS..6053
STOPPING THE BOBCAT LOADER..6053
SEAT BAR RESTRAINT SYSTEM..6054
HYDRAULIC CONTROLS..6055
Foot Pedals..6055
Hand Controls (If Equipped)..6055
Quick Couplers..6056
Releasing Hydraulic Pressure (Loader and Attachment)..6056
Attachment Auxiliary Hydraulic Controls (If Equipped)..6057
FRONT Auxiliary Hydraulics Operation..6057
Auxiliary Hydraulics Button..6057
REAR Auxiliary Hydraulics Operation ..6057
High–Flow Hydraulics Operation (If Equipped)..6058
Secondary Front Auxiliary Hydraulics (If Equipped)..6058
Attachment Control Device (ACD) (If Equipped)..6059
Bucket Position Valve Operation (If Equipped)..6059
DAILY INSPECTION..6060
Daily Inspection and Maintenance:..6060
PRE–STARTING PROCEDURE..6061
STARTING THE ENGINE..6063
Standard Instrument Panel (With Key Switch)..6063
Deluxe Instrument Panel (With Keyless Start)..6064
Cold Temperature Starting..6065
Warming the Hydraulic/Hydrostatic System..6065
STOPPING THE ENGINE..6065
MONITORING THE DISPLAY PANEL..6066
ATTACHMENTS AND BUCKETS..6067
Hand Lever Bob–Tach..6068
Installing The Bucket Or Attachment..6068
Removing The Bucket Or Attatchment..6069
Power Bob–Tach..6070
Installing The Bucket Or Attachment..6070
Removing The Bucket Or Attachment ..6071
OPERATING PROCEDURE..6072
Filling the Bucket (Foot Pedals)..6073
Filling the Bucket (Hand Controls)..6073
Emptying the Bucket (Foot Pedals)..6074
Emptying the Bucket (Hand Controls)..6074
Leveling the Ground (Using Lift Arms in Float Position) (Foot Pedals)..6074
Leveling the Ground (Using Lift Arms in Float Position) (Hand Controls)..6074
Digging Into the Ground (Foot Pedals)..6075
Digging Into the Ground (Hand Controls)..6075
Backfilling (Foot Pedals)..6075
Backfilling (Hand Controls)..6075
PARKING THE BOBCAT LOADER..6076
TRANSPORTING THE BOBCAT LOADER..6077
TOWING THE LOADER..6077
LIFTING THE LOADER..6078
Four Point Lift..6078
PREVENTIVE MAINTENANCE..6079
MAINTENANCE SAFETY..6081
SERVICE SCHEDULE..6083
LIFT ARM SUPPORT DEVICE..6084
Installing The Lift Arm Support Device..6084
Removing The Lift Arm Support Device..6084
OPERATOR CAB..6085
Raising The Operator Cab..6085
Lowering The Operator Cab..6086
Emergency Exit..6087
SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)..6088
Inspecting the Seat Bar..6088
Maintaining the Seat Bar..6088
SEAT BAR RESTRAINT SYSTEM ADVANCED CONTROL SYSTEM (ACS) and HAND CONTROLS..6089
Inspecting the Seat Bar..6089
Maintaining the Seat Bar..6089
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..6090
Inspecting The BICS™ Controller..6090
Inspecting Deactivation Of The Auxiliary HydraulicsSystem (Engine STOPPED – Key ON)..6090
Inspecting The Seat Bar Sensor (Engine RUNNING)..6090
Inspecting The Traction Lock (Engine RUNNING)..6090
Inspecting The Lift Arm By–Pass Control..6090
Inspecting Deactivation Of The Lift And Tilt Functions..6090
REAR DOOR..6091
Opening And Closing The Rear Door..6091
Adjusting The Rear Door..6091
REAR GRILL..6092
HEATER AND AIR CONDITIONING SYSTEM..6092
Cleaning and Maintenance..6092
AIR CLEANER SERVICE..6093
Replacing Filter Element..6093
FUEL SYSTEM..6095
Fuel Specifications..6095
Filling the Fuel Tank..6095
Fuel Filter..6095
Fuel Lift Pump Strainer..6096
Removing Air From The Fuel System..6096
ENGINE LUBRICATION SYSTEM..6097
Checking Engine Oil..6097
Replacing The Oil And Filter..6097
Cleaning The Cooling System..6098
ELECTRICAL SYSTEM..6099
Description..6099
Cleaning Battery And Terminals..6099
Fuse Location..6099
Using A Booster Battery (Jump Starting)..6100
Removing And Installing The Battery..6101
HYDRAULIC/HYDROSTATIC SYSTEM..6103
Checking And Adding Fluid..6103
Replacing Hydraulic/Hydrostatic Filter..6103
Replacing Hydraulic Fluid And Case Drain Filters..6104
Breather Cap..6105
TIRE MAINTENANCE..6106
Wheel Nuts..6106
Rotating..6106
Mounting..6106
FINAL DRIVE TRANSMISSION (CHAINCASE)..6107
Checking And Adding Oil..6107
Removing Oil From The Chaincase..6107
FAN GEARBOX..6108
Checking And Maintaining..6108
DRIVE BELT..6108
Adjusting The Drive Belt..6108
for the correct serviceinterval...6109
ALTERNATOR BELT..6110
Adjusting the Alternator Belt..6110
TIMING BELT..6110
LUBRICATING THE BOBCAT LOADER..6111
PIVOT PINS..6113
POWER BOB–TACH..6114
Inspection and Maintenance..6114
SYSTEM SETUP AND ANALYSIS..6115
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..6117
Troubleshooting Chart..6117
DELUXE INSTRUMENTATION SERVICE CODES..6118
Deluxe Panel Upgrade..6119
Icon Identification..6119
Deluxe Panel Setup..6119
Passwords..6120
Changing the Password..6120
MACHINE SIGN TRANSLATIONS..6121
IMPORTANT - 6708937..6123
WARNING - 6718398..6124
WARNING - 6728327..6126
WARNING - 6728328..6127
WARNING - 6579628..6128
DANGER - 6579639 ..6128
WARNING - 6708941..6128
DANGER - 6579509..6128
WARNING - 6577754..6128
DANGER - 6717343..6129
WARNING - 6715944..6129
SPECIFICATIONS..6131
SKID STEER LOADER SPECIFICATIONS..6133
Performance Specifications..6133
Engine..6133
Loader Controls..6133
Drive System..6133
Hydraulic System..6133
Electrical System..6133
Standard Instrument Panel..6133
Optional Deluxe Instrumentation..6133
BOBCAT COMPANY APPROVED ATTACHMENTS & ACCESSORIES..6134
ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS..6137
WARRANTY..6139
