Complete repair service manual for Bobcat Loaders 863, 863 High Flow, 863 Turbo, 863 Turbo High Flow, 864, 864 High Flow, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Bobcat Loaders 863, 863 High Flow, 863 Turbo, 863 Turbo High Flow, 864, 864 High Flow workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

6724799 (4-96) - 863, 863 High Flow Service Manual.pdf
6724799 (7-10) - 863, 863 High Flow Service Manual.pdf
6724799 (10-12) - 863, 863 High Flow Service Manual.pdf
6900373 (6-00) - 863, 863 High Flow Operation & Maintenance Manual.pdf
6900626 (9-00) - 864, 864 High Flow Operation & Maintenance Manual.pdf
6900627 (7-10) - 864, 864 High Flow Service Manual.pdf
6900627 (7-99) - 864, 864 High Flow Service Manual.pdf
6900627 (10-12) - 864, 864 High Flow Service Manual.pdf
6900648 (7-10) - 863, 863 High Flow Service Manual.pdf
6900648 (10-12) - 863, 863 High Flow Service Manual.pdf
6900648 (10-98) - 863, 863 High Flow Service Manual.pdf
6900790 (9-00) - 863, 863 High Flow Operation & Maintenance Manual.pdf
6900937 (12-06) - 863 Turbo, 863 Turbo High Flow Operation & Maintenance Manual.pdf
6900942 (2-06) - 863 Turbo, 863 Turbo High Flow Service Manual.pdf
6900942 (7-10) - 863 Turbo, 863 Turbo High Flow Service Manual.pdf
6900942 (10-12) - 863 Turbo, 863 Turbo High Flow Service Manual.pdf
6900945 (3-06) - 864, 864 High Flow Service Manual.pdf
6900945 (7-10)  - 864, 864 High Flow Service Manual.pdf
6900945 (10-12)  - 864, 864 High Flow Service Manual.pdf
6900953 (12-06) - 864, 864 High Flow Operation & Maintenance Manual.pdf

Total Pages: 10,323 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
6724799 (10-12) - 863, 863 High Flow Service Manual...1
  MAINTENANCE SAFET...3
  CONTENTS...5
    FOREWORD...6
    SAFETY INSTRUCTIONS...9
    SERIAL NUMBER LOCATIONS...11
    LOADER SERIAL NUMBER...11
    DELIVERY REPORT...11
    BOBCAT LOADER IDENTIFICATION...12
    OPTIONS AND ACCESSORIES...13
  PREVENTIVE MAINTENANCE...15
    SERVICE SCHEDULE...17
    LIFTING AND BLOCKING THE LOADER...18
      Procedure...18
    TRANSPORTING THE BOBCAT LOADER...19
      Procedure...19
    TOWING THE LOADER...19
    LIFT ARM SUPPORT DEVICE...20
      To Install The Lift Arm Support Device...20
      To Remove The Lift Arm Support Device...21
    OPERATOR CAB...22
      Description...22
      Raising The Operator Cab...22
      Lowering The Operator Cab...23
      Emergency Exit...23
    SEAT BAR RESTRAINT SYSTEM...24
      Description...24
      Seat Bar Inspection...24
      Seat Bar Maintenance...24
    AIR CLEANER SERVICE...25
      Replacing Filter Element...25
    FUEL SYSTEM...27
      Fuel Specifications...27
      Filling The Fuel Tank...27
      Fuel Filter...27
      Removing Air From The Fuel System...27
    ENGINE LUBRICATION SYSTEM...28
      Checking Engine Oil...28
      Replacement Of Oil And Filter...28
    COOLING SYSTEM...29
      Cleaning The Cooling System...29
    ALTERNATOR BELT...30
      Adjusting The Alternator Belt...30
    HYDRAULIC/HYDROSTATIC SYSTEM...31
      Checking And Adding Fluid...31
      Replacing The Hydraulic/Hydrostatic Filter...31
      Replacing The Hydraulic Fluid...32
    TIRE MAINTENANCE...33
      Wheel Nuts...33
      Tire Rotation...33
      Tire Mounting...33
    FINAL DRIVE TRANSMISSION (CHAINCASE)...34
      Checking And Adding Oil...34
      Removing Oil From The Chaincase...34
    LUBRICATION OF THE BOBCAT LOADER...35
      Procedure...35
    FAN GEARBOX...36
      Checking And Maintaining...36
    REMOTE START SWITCH...37
      Procedure...37
  HYDRAULIC SYSTEM...39
    HYDRAULIC / HYDROSTATIC SCHEMATICS...41
    TROUBLESHOOTING...53
    HYDRAULIC SYSTEM INFORMATION...54
      Tighten Procedures...54
    LIFT CYLINDER(S)...55
      Checking The Lift Cylinder(s)...55
      Removal And Installation...55
    TILT CYLINDER...57
      Checking The Tilt Cylinder...57
      Removal And Installation...57
      Rod End Seal...58
    HYDRAULIC CYLINDER...59
      Lift Cylinder Identification...59
      Tilt Cylinder Identification...60
      Disassembly...61
      Assembly...63
    MAIN RELIEF VALVE...66
      Checking The Main Relief Valve...66
      Checking The Main Relief Valve Without Auxiliaries...67
      Removal And Installation...68
      Adjustment...68
    SELECT VALVE 863H...69
      Checking The High Flow Pump Relief Valve...69
      Removal And Installation...70
      Disassembly And Assembly...71
      Solenoid Testing...72
    LIFT ARM BY–PASS CONTROL VALVE...73
      Removal And Installation...73
      Disassembly And Assembly...74
    BICS™ CONTROL VALVE...75
      Removal And Installation...75
    BICS™ VALVE ASSEMBLY...78
      Lift Arm By–Pass Orifice...78
      Check Valve...79
      Lock Valve...80
      BICS™ Valve Solenoid...81
    HYDRAULIC CONTROL VALVE...82
      Removal And Installation...82
      Identification Chart...86
      Disassembly And Assembly...87
      Load Check Valve...87
      Lift Base End Restrictor...87
      Main Relief Valve...88
      Port Relief Valve...89
      Anti–Cavitation/Port Relief Valve...89
      Rubber Boot...91
      Lift Spool And Detent...92
      Tilt Spool And Centering Spring...96
      Auxiliary Spool...97
      Auxiliary Electric Solenoid...98
      H Port – Auxiliary Section...99
      Inspection...99
      Spool Seal Installation...100
    HYDRAULIC PUMP...101
      Checking The Output Of The Pump...101
      Removal And Installation...102
      Parts Identification...103
      Disassembly...104
      Inspection...106
      Assembly...107
    HYDRAULIC PUMP (Double Gear) 863H...109
      Checking The Output Of The High Flow Pump...109
      Removal And Installation...110
      Parts Identification...112
      Disassembly...113
      Inspection...117
      Assembly...118
    HYDRAULIC FLUID RESERVOIR...121
      Removal And Installation...121
    HYDROSTATIC FILTER HOUSING...122
      Removal And Installation...122
      Hydrostatic Charge Pressure Sender...122
    HYDRAULIC FILTER HOUSING...123
      Removal And Installation...123
    CONTROL PEDALS...124
      Removal And Installation...124
      Pedal Adjustment...124
    PEDAL INTERLOCK LINKAGE...125
      Removal And Installation...125
      Pedal Interlock Linkage Adjustment...126
    REAR AUXILIARY DIVERTER...127
      Disassembly...127
      Inspection...127
      Solenoid Testing...127
      Assembly...127
  HYDROSTATIC SYSTEM...129
    TROUBLESHOOTING...131
    HYDROSTATIC SYSTEM INFORMATION...132
      Replenishing Valve Function...132
    FRONT PANEL (SOLID STEERING LINKAGE)...133
      Removal And Installation...133
    FRONT PANEL (CABLE STEERING LINKAGE)...135
      Removal And Installation...135
    STEERING LEVERS...137
      Disassembly And Assembly...137
    CONTROL TOWER (SOLID STEERING LINKAGE)...139
      Removal And Installation...139
      Disassembly And Assembly...140
    SOLID STEERING LINKAGE NEUTRAL ADJUSTMENT...142
      Procedure...142
    CABLE STEERING LINKAGE NEUTRAL ADJUSTMENT...145
      Pre–Adjustment Checks...145
      Adjusting Lever Freeplay...146
      Adjusting The Wheel RPM Forward Compared to Reverse Travel...147
      Adjusting The Steering Neutral Setting...149
      Adjusting The Wheel RPM Left Compared To Right Side...150
    HYDROSTATIC MOTOR...151
      Removal And Installation...151
      Parts Identification...153
      Disassembly...154
      Inspection...157
      Assembly...158
    HYDROSTATIC PUMP...162
      Removal And Installation...162
      Replenishing/High Pressure Relief Valve...164
      Parts Identification...166
      Hydraulic Pump Removal...170
      Hydrostatic Pump Separation...170
      Charge Pump Disassembly...171
      Disassembly...172
      Inspection...181
      Assembly...183
      Charge Pump Assembly...192
      Hydrostatic Pump Connection...193
      Hydraulic Pump Installation...194
      Swashplate Neutral Adjustment...195
      Displacement Control Servo (Solid Linkage)...196
      Displacement Control Servo (Cable Linkage)...197
    DRIVE BELT SHIELD...199
      Removal And Installation...199
    DRIVE BELT...200
      Adjusting The Drive Belt...200
      Replacing The Drive Belt...200
    DRIVE BELT TENSIONER PULLEY...201
      Removal And Installation...201
      Tension Spring...203
    OIL COOLER...204
      Removal And Installation...204
  DRIVE SYSTEM...205
    PARKING BRAKE PEDAL...207
      Removal And Installation...207
      Disassembly And Assembly...208
    PARKING BRAKE DISC...209
      Removal And Installation...209
    FRONT CHAINCASE COVER...212
      Removal And Installation...212
    REAR CHAINCASE COVER...212
      Removal And Installation...212
    AXLE SEAL...213
      Removal And Installation...213
    AXLE, SPROCKET AND BEARINGS...215
      Removal And Installation...215
    MOTOR CARRIER...219
      Shaft Seal Replacement...219
      Removal And Installation...220
      Parts Identification...222
      Disassembly...223
      Assembly...225
    DRIVE CHAIN...229
      Removal And Installation...229
    CHAINCASE FLUID...230
      Removing The Fluid From The Chaincase...230
  MAIN FRAME...231
    SEAT BAR (W/GAS SPRING)...233
      Removal And Installation...233
      Seat Bar Pivot Assembly...235
      Compressing The Gas Cylinder...236
      Assembly...237
    SEAT BAR (W/COMPRESSION SPRING)...238
      Removal And Installation...238
      Assembling Components...241
      Compression Spring Disassembly And Assembly...241
    OPERATOR CAB GAS CYLINDER...242
      Removal And Installation...242
      Disassembly And Assembly...243
    OPERATOR CAB...244
      Removal And Installation...244
    OPERATOR SEAT...246
      Removal And Installation...246
    BOB–TACH...247
      Bob–Tach Lever And Wedge...247
      Bob–Tach Stops...248
      Removal And Installation...249
      Pivot Pin Bushing And Seal Replacement...251
    LIFT ARMS...252
      Removal And Installation...252
    REAR GRILL...255
      Removal And Installation...255
    REAR DOOR (ONE PIECE)...256
      Removal And Installation...256
      Door Latch And Catch Adjustment...257
    REAR DOOR...258
      Removal And Installation...258
      Hood Removal And Installation...259
      Bumper Removal And Installation...259
      Door Latch Removal And Installation...259
      Door Latch And Catch Adjustment...259
    FUEL TANK...260
      Removal And Installation...260
      Fuel Level Sender...261
      Fuel Pick–Up Screen/Check Valve...261
      Inlet Screen...262
  ELECTRICAL SYSTEM...263
    ELECTRICAL SCHEMATICS...265
    TROUBLESHOOTING...289
    ELECTRICAL SYSTEM INFORMATION...290
      Description...290
      Fuse Location...290
    BATTERY...291
      Removal And Installation...291
      Servicing The Battery...292
      Using A Booster Battery...293
    ALTERNATOR...294
      Alternator Output Test...294
      Rectifier (Diode) Test...294
      Alternator Regulator Test...295
      Removal And Installation...296
      Disassembly...297
      Stator Continuity Test...297
      Stator Ground Test...297
      Rotor Continuity Test...298
      Rotor Ground Test...298
      Rectifier Continuity (Diode) Test...298
      Assembly...299
    STARTER...299
      Removal And Installation...299
      Parts Identification...300
      Disassembly And Assembly...301
      External Pinion...305
      Inspection And Repair...306
      Magnetic Switch Test...309
      No Load Test...309
    STANDARD INSTRUMENT PANEL...310
      Removal And Installation...310
    FRONT LIGHTS...311
      Removal And Installation...311
    RELAY SWITCHES...312
      Location...312
  ENGINE SERVICE...313
    TROUBLESHOOTING...315
    ENGINE SPEED CONTROL...316
      Removal And Installation...316
      Speed Control Cable...317
      Speed Control Linkage...317
    ENGINE MUFFLER...318
      Removal And Installation...318
    AIR CLEANER HOUSING...319
      Removal And Installation...319
    BLOWER HOUSING/FAN GEARBOX...320
      Removal And Installation...320
    FAN DRIVE TENSION PULLEY...322
      Removal And Installation...322
    BLOWER FAN...323
      Removal And Installation...323
    FAN GEARBOX...324
      Parts Identification...324
      Disassembly...325
      Assembly...330
      Checking Backlash...335
    ENGINE...338
      Removal And Installation...338
    ENGINE MOUNTS...344
      Replacement...344
    FLYWHEEL...345
      Removal And Installation...345
      Flywheel Ring Gear...345
    FLYWHEEL HOUSING...345
      Removal And Installation...345
    GLOW PLUG...346
      Checking The Glow Plug...346
    VALVE CLEARANCE...347
      Adjustment...347
    FUEL INJECTION PUMP...348
      Description...348
      Removal...348
      Installation...350
    FUEL INJECTOR...352
      Removal And Installation...352
      Checking...353
      Disassembly...354
      Assembly...355
    TIMING BELT...357
      Inspection...357
      Removal...357
      Installation...358
      Belt Replacement In Loader...361
    VALVE TIMING...366
      Checking...366
    DEUTZ ENGINE TOOLS...367
      Identification Chart...367
    RECONDITIONING THE ENGINE...368
      Disassembly...368
      Assembly...372
    CYLINDER LINERS...387
      Checking The Cylinder Liners...387
    CAMSHAFT BEARINGS...388
      Checking...388
      Removal And Installation...388
    CONTROL ROD GUIDE BUSHING...390
      Removal...390
      Installation...392
    REAR COVER SEAL...396
      Removal And Installation...396
    CRANKSHAFT...397
      Checking The Crankshaft...397
    CONNECTING ROD...398
      Checking The Connecting Rod...398
    PISTON AND PISTON PIN...401
      Checking The Piston...401
      Checking Piston Pin...402
      Installing Piston Rings...402
    CYLINDER HEAD...403
      Disassembly...403
      Checking The Valves...403
      Checking Valve Seats...404
      Valve Spring...404
      Assembly...404
    ROCKER ARM AND BRACKET...406
      Checking...406
    FRONT COVER...407
      Disassembly...407
      Assembly...412
    TURBOCHARGER...422
      Removal And Installation...422
      Disassembly...423
      Inspection...427
      Assembly...428
    POSITIVE CRANKCASE VENTILATION SYSTEM(S/N 514415609, 514611152, 514511106 & Below)...433
      Description...433
      Inspection...433
      Module Removal And Installation...434
    OIL COOLER...435
      Removal And Installation...435
    CRANKSHAFT GEAR MOUNTING BOLT...436
      Torque Procedure...436
  SYSTEMS ANALYSIS...437
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...439
      Inspecting The BICS™ Controller (Engine STOPPED – Key ON)...439
      Inspecting Deactivation Of The Auxiliary HydraulicsSystem (Engine STOPPED – Key ON)...439
      Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)...439
      Inspecting The Traction Lock (Engine RUNNING)...439
      Inspecting The Lift Arm By–Pass Control...439
      Maintenance...439
      Troubleshooting Chart...440
      SEAT SENSOR OVERRIDE ONLY (If Equipped)...440
      Troubleshooting Guide...441
        BICS SYSTEM CONTROLLER...441
        TRACTION LOCK...442
        SEAT SENSOR...443
        SEAT BAR SENSOR...444
        LIFT ARM BY–PASS VALVE...445
    BICS™ SYSTEM CONTROLLER...446
      Removal And Installation...446
      Controller Test...447
    SEAT BAR SENSOR...448
      Removal And Installation...448
      Seat Bar Sensor Test...449
    SEAT SENSOR...450
      Removal And Installation...450
      Seat Sensor Test...451
    TRACTION LOCK...452
      Removal And Installation...452
    BOSS® DIAGNOSTIC TOOL...453
      Procedure...453
    SENDER AND SENSOR...453
      Service Checks...453
      Components...453
    RPM SENSOR...453
      Adjustment...453
    MONITOR SERVICE CODES...454
    TROUBLESHOOTING THE BOSS® & LCD DISPLAY...457
    OPERATION SENSING SYSTEM UNIT...458
      Removal And Installation...458
    BOSS® INSTRUMENT PANEL...459
      Removal And Installation...459
    PWM MODULE...460
      Description...460
      Troubleshooting Chart...462
    PWM CONTROL HANDLE...463
      Handle Testing...463
    PWM ELECTRIC SOLENOID...463
      Solenoid Coil Testing...463
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE...464
      Controls Identification Chart...464
  SPECIFICATIONS...465
    LOADER SPECIFICATIONS...467
      LOADER DIMENSIONS...467
      PERFORMANCE...467
      CONTROLS...467
      ENGINE...467
      HYDRAULIC SYSTEM...468
      ELECTRICAL...468
      DRIVE SYSTEM...468
      CAPACITIES...469
      TIRES...469
    ENGINE SPECIFICATIONS (BF4M1011)...470
      General...470
      Fuel System...470
      Valve And Valve Guide And Seat Insert...470
      Piston And Rings...471
      Connecting Rod...471
      Cylinder Head And Block...471
      Crankshaft And Main Bearings...472
      Camshaft And Bearings...472
      Oil Pump...472
    ENGINE SPECIFICATIONS (BF4M1011F)...473
      General...473
      Fuel System...473
      Valve And Valve Guide And Seat Insert...473
      Piston And Rings...474
      Connecting Rod...474
      Crankshaft And Main Bearings...475
      Camshaft And Bearings...475
      Oil Pump...475
    ENGINE TORQUE...476
      Specifications...476
      Torque For General Metric Bolts...477
    TORQUE SPECIFICATIONS FOR LOADER...478
    HYDRAULIC CONNECTION SPECIFICATIONS...479
      O–ring Face Seal Connection...479
      Straight Thread O–ring Fitting...479
      Tubelines And Hoses...479
      Flare Fitting...479
      O–ring Flare Fitting...480
      Port Seal Fitting...482
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...483
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...484
    DECIMAL AND MILLIMETER EQUIVALENTS...485
    U.S. TO METRIC CONVERSION...485
  SERVICE MANUAL REVISIONS...487
    863–001...487
    863–002...489
    863–003...491
    863–004...493
    863–005...495
    863–006...497
    863–007...499
    863–008...501
    863–009...503
    863-010...505
    863-011...507
6724799 (4-96) - 863, 863 High Flow Service Manual...509
6724799 (7-10) - 863, 863 High Flow Service Manual...1009
  MAINTENANCE SAFET...1011
  CONTENTS...1013
    FOREWORD...1014
    SAFETY INSTRUCTIONS...1017
    SERIAL NUMBER LOCATIONS...1019
    LOADER SERIAL NUMBER...1019
    DELIVERY REPORT...1019
    BOBCAT LOADER IDENTIFICATION...1020
    OPTIONS AND ACCESSORIES...1021
  PREVENTIVE MAINTENANCE...1023
    SERVICE SCHEDULE...1025
    LIFTING AND BLOCKING THE LOADER...1026
      Procedure...1026
    TRANSPORTING THE BOBCAT LOADER...1027
      Procedure...1027
    TOWING THE LOADER...1027
    LIFT ARM SUPPORT DEVICE...1028
      To Install The Lift Arm Support Device...1028
      To Remove The Lift Arm Support Device...1029
    OPERATOR CAB...1030
      Description...1030
      Raising The Operator Cab...1030
      Lowering The Operator Cab...1031
      Emergency Exit...1031
    SEAT BAR RESTRAINT SYSTEM...1032
      Description...1032
      Seat Bar Inspection...1032
      Seat Bar Maintenance...1032
    AIR CLEANER SERVICE...1033
      Replacing Filter Element...1033
    FUEL SYSTEM...1035
      Fuel Specifications...1035
      Filling The Fuel Tank...1035
      Fuel Filter...1035
      Removing Air From The Fuel System...1035
    ENGINE LUBRICATION SYSTEM...1036
      Checking Engine Oil...1036
      Replacement Of Oil And Filter...1036
    COOLING SYSTEM...1037
      Cleaning The Cooling System...1037
    ALTERNATOR BELT...1038
      Adjusting The Alternator Belt...1038
    HYDRAULIC/HYDROSTATIC SYSTEM...1039
      Checking And Adding Fluid...1039
      Replacing The Hydraulic/Hydrostatic Filter...1039
      Replacing The Hydraulic Fluid...1040
    TIRE MAINTENANCE...1041
      Wheel Nuts...1041
      Tire Rotation...1041
      Tire Mounting...1041
    FINAL DRIVE TRANSMISSION (CHAINCASE)...1042
      Checking And Adding Oil...1042
      Removing Oil From The Chaincase...1042
    LUBRICATION OF THE BOBCAT LOADER...1043
      Procedure...1043
    FAN GEARBOX...1044
      Checking And Maintaining...1044
    REMOTE START SWITCH...1045
      Procedure...1045
  HYDRAULIC SYSTEM...1047
    HYDRAULIC / HYDROSTATIC SCHEMATICS...1049
    TROUBLESHOOTING...1061
    HYDRAULIC SYSTEM INFORMATION...1062
      Tighten Procedures...1062
    LIFT CYLINDER(S)...1063
      Checking The Lift Cylinder(s)...1063
      Removal And Installation...1063
    TILT CYLINDER...1065
      Checking The Tilt Cylinder...1065
      Removal And Installation...1065
      Rod End Seal...1066
    HYDRAULIC CYLINDER...1067
      Lift Cylinder Identification...1067
      Tilt Cylinder Identification...1068
      Disassembly...1069
      Assembly...1071
    MAIN RELIEF VALVE...1074
      Checking The Main Relief Valve...1074
      Checking The Main Relief Valve Without Auxiliaries...1075
      Removal And Installation...1076
      Adjustment...1076
    SELECT VALVE 863H...1077
      Checking The High Flow Pump Relief Valve...1077
      Removal And Installation...1078
      Disassembly And Assembly...1079
      Solenoid Testing...1080
    LIFT ARM BY–PASS CONTROL VALVE...1081
      Removal And Installation...1081
      Disassembly And Assembly...1082
    BICS™ CONTROL VALVE...1083
      Removal And Installation...1083
    BICS™ VALVE ASSEMBLY...1086
      Lift Arm By–Pass Orifice...1086
      Check Valve...1087
      Lock Valve...1088
      BICS™ Valve Solenoid...1089
    HYDRAULIC CONTROL VALVE...1090
      Removal And Installation...1090
      Identification Chart...1094
      Disassembly And Assembly...1095
      Load Check Valve...1095
      Lift Base End Restrictor...1095
      Main Relief Valve...1096
      Port Relief Valve...1097
      Anti–Cavitation/Port Relief Valve...1097
      Rubber Boot...1099
      Lift Spool And Detent...1100
      Tilt Spool And Centering Spring...1104
      Auxiliary Spool...1105
      Auxiliary Electric Solenoid...1106
      H Port – Auxiliary Section...1107
      Inspection...1107
      Spool Seal Installation...1108
    HYDRAULIC PUMP...1109
      Checking The Output Of The Pump...1109
      Removal And Installation...1110
      Parts Identification...1111
      Disassembly...1112
      Inspection...1114
      Assembly...1115
    HYDRAULIC PUMP (Double Gear) 863H...1117
      Checking The Output Of The High Flow Pump...1117
      Removal And Installation...1118
      Parts Identification...1120
      Disassembly...1121
      Inspection...1125
      Assembly...1126
    HYDRAULIC FLUID RESERVOIR...1129
      Removal And Installation...1129
    HYDROSTATIC FILTER HOUSING...1130
      Removal And Installation...1130
      Hydrostatic Charge Pressure Sender...1130
    HYDRAULIC FILTER HOUSING...1131
      Removal And Installation...1131
    CONTROL PEDALS...1132
      Removal And Installation...1132
      Pedal Adjustment...1132
    PEDAL INTERLOCK LINKAGE...1133
      Removal And Installation...1133
      Pedal Interlock Linkage Adjustment...1134
    REAR AUXILIARY DIVERTER...1135
      Disassembly...1135
      Inspection...1135
      Solenoid Testing...1135
      Assembly...1135
  HYDROSTATIC SYSTEM...1137
    TROUBLESHOOTING...1139
    HYDROSTATIC SYSTEM INFORMATION...1140
      Replenishing Valve Function...1140
    FRONT PANEL (SOLID STEERING LINKAGE)...1141
      Removal And Installation...1141
    FRONT PANEL (CABLE STEERING LINKAGE)...1143
      Removal And Installation...1143
    STEERING LEVERS...1145
      Disassembly And Assembly...1145
    CONTROL TOWER (SOLID STEERING LINKAGE)...1147
      Removal And Installation...1147
      Disassembly And Assembly...1148
    SOLID STEERING LINKAGE NEUTRAL ADJUSTMENT...1150
      Procedure...1150
    CABLE STEERING LINKAGE NEUTRAL ADJUSTMENT...1153
      Pre–Adjustment Checks...1153
      Adjusting Lever Freeplay...1154
      Adjusting The Wheel RPM Forward Compared to Reverse Travel...1155
      Adjusting The Steering Neutral Setting...1157
      Adjusting The Wheel RPM Left Compared To Right Side...1158
    HYDROSTATIC MOTOR...1159
      Removal And Installation...1159
      Parts Identification...1161
      Disassembly...1162
      Inspection...1165
      Assembly...1166
    HYDROSTATIC PUMP...1170
      Removal And Installation...1170
      Replenishing/High Pressure Relief Valve...1172
      Parts Identification...1174
      Hydraulic Pump Removal...1178
      Hydrostatic Pump Separation...1178
      Charge Pump Disassembly...1179
      Disassembly...1180
      Inspection...1189
      Assembly...1191
      Charge Pump Assembly...1200
      Hydrostatic Pump Connection...1201
      Hydraulic Pump Installation...1202
      Swashplate Neutral Adjustment...1203
      Displacement Control Servo (Solid Linkage)...1204
      Displacement Control Servo (Cable Linkage)...1205
    DRIVE BELT SHIELD...1207
      Removal And Installation...1207
    DRIVE BELT...1208
      Adjusting The Drive Belt...1208
      Replacing The Drive Belt...1208
    DRIVE BELT TENSIONER PULLEY...1209
      Removal And Installation...1209
      Tension Spring...1211
    OIL COOLER...1212
      Removal And Installation...1212
  DRIVE SYSTEM...1213
    PARKING BRAKE PEDAL...1215
      Removal And Installation...1215
      Disassembly And Assembly...1216
    PARKING BRAKE DISC...1217
      Removal And Installation...1217
    FRONT CHAINCASE COVER...1220
      Removal And Installation...1220
    REAR CHAINCASE COVER...1220
      Removal And Installation...1220
    AXLE SEAL...1221
      Removal And Installation...1221
    AXLE, SPROCKET AND BEARINGS...1223
      Removal And Installation...1223
    MOTOR CARRIER...1227
      Shaft Seal Replacement...1227
      Removal And Installation...1228
      Parts Identification...1230
      Disassembly...1231
      Assembly...1233
    DRIVE CHAIN...1237
      Removal And Installation...1237
    CHAINCASE FLUID...1238
      Removing The Fluid From The Chaincase...1238
  MAIN FRAME...1239
    SEAT BAR (W/GAS SPRING)...1241
      Removal And Installation...1241
      Seat Bar Pivot Assembly...1243
      Compressing The Gas Cylinder...1244
      Assembly...1245
    SEAT BAR (W/COMPRESSION SPRING)...1246
      Removal And Installation...1246
      Assembling Components...1249
      Compression Spring Disassembly And Assembly...1249
    OPERATOR CAB GAS CYLINDER...1250
      Removal And Installation...1250
      Disassembly And Assembly...1251
    OPERATOR CAB...1252
      Removal And Installation...1252
    OPERATOR SEAT...1254
      Removal And Installation...1254
    BOB–TACH...1255
      Bob–Tach Lever And Wedge...1255
      Bob–Tach Stops...1256
      Removal And Installation...1257
      Pivot Pin Bushing And Seal Replacement...1259
    LIFT ARMS...1260
      Removal And Installation...1260
    REAR GRILL...1263
      Removal And Installation...1263
    REAR DOOR (ONE PIECE)...1264
      Removal And Installation...1264
      Door Latch And Catch Adjustment...1265
    REAR DOOR...1266
      Removal And Installation...1266
      Hood Removal And Installation...1267
      Bumper Removal And Installation...1267
      Door Latch Removal And Installation...1267
      Door Latch And Catch Adjustment...1267
    FUEL TANK...1268
      Removal And Installation...1268
      Fuel Level Sender...1269
      Fuel Pick–Up Screen/Check Valve...1269
      Inlet Screen...1270
  ELECTRICAL SYSTEM...1271
    ELECTRICAL SCHEMATICS...1273
    TROUBLESHOOTING...1297
    ELECTRICAL SYSTEM INFORMATION...1298
      Description...1298
      Fuse Location...1298
    BATTERY...1299
      Removal And Installation...1299
      Servicing The Battery...1300
      Using A Booster Battery...1301
    ALTERNATOR...1302
      Alternator Output Test...1302
      Rectifier (Diode) Test...1302
      Alternator Regulator Test...1303
      Removal And Installation...1304
      Disassembly...1305
      Stator Continuity Test...1305
      Stator Ground Test...1305
      Rotor Continuity Test...1306
      Rotor Ground Test...1306
      Rectifier Continuity (Diode) Test...1306
      Assembly...1307
    STARTER...1307
      Removal And Installation...1307
      Parts Identification...1308
      Disassembly And Assembly...1309
      External Pinion...1313
      Inspection And Repair...1314
      Magnetic Switch Test...1317
      No Load Test...1317
    STANDARD INSTRUMENT PANEL...1318
      Removal And Installation...1318
    FRONT LIGHTS...1319
      Removal And Installation...1319
    RELAY SWITCHES...1320
      Location...1320
  ENGINE SERVICE...1321
    TROUBLESHOOTING...1323
    ENGINE SPEED CONTROL...1324
      Removal And Installation...1324
      Speed Control Cable...1325
      Speed Control Linkage...1325
    ENGINE MUFFLER...1326
      Removal And Installation...1326
    AIR CLEANER HOUSING...1327
      Removal And Installation...1327
    BLOWER HOUSING/FAN GEARBOX...1328
      Removal And Installation...1328
    FAN DRIVE TENSION PULLEY...1330
      Removal And Installation...1330
    BLOWER FAN...1331
      Removal And Installation...1331
    FAN GEARBOX...1332
      Parts Identification...1332
      Disassembly...1333
      Assembly...1338
      Checking Backlash...1343
    ENGINE...1346
      Removal And Installation...1346
    ENGINE MOUNTS...1352
      Replacement...1352
    FLYWHEEL...1353
      Removal And Installation...1353
      Flywheel Ring Gear...1353
    FLYWHEEL HOUSING...1353
      Removal And Installation...1353
    GLOW PLUG...1354
      Checking The Glow Plug...1354
    VALVE CLEARANCE...1355
      Adjustment...1355
    FUEL INJECTION PUMP...1356
      Description...1356
      Removal...1356
      Installation...1358
    FUEL INJECTOR...1360
      Removal And Installation...1360
      Checking...1361
      Disassembly...1362
      Assembly...1363
    TIMING BELT...1365
      Inspection...1365
      Removal...1365
      Installation...1366
      Belt Replacement In Loader...1369
    VALVE TIMING...1374
      Checking...1374
    DEUTZ ENGINE TOOLS...1375
      Identification Chart...1375
    RECONDITIONING THE ENGINE...1376
      Disassembly...1376
      Assembly...1380
    CYLINDER LINERS...1395
      Checking The Cylinder Liners...1395
    CAMSHAFT BEARINGS...1396
      Checking...1396
      Removal And Installation...1396
    CONTROL ROD GUIDE BUSHING...1398
      Removal...1398
      Installation...1400
    REAR COVER SEAL...1404
      Removal And Installation...1404
    CRANKSHAFT...1405
      Checking The Crankshaft...1405
    CONNECTING ROD...1406
      Checking The Connecting Rod...1406
    PISTON AND PISTON PIN...1409
      Checking The Piston...1409
      Checking Piston Pin...1410
      Installing Piston Rings...1410
    CYLINDER HEAD...1411
      Disassembly...1411
      Checking The Valves...1411
      Checking Valve Seats...1412
      Valve Spring...1412
      Assembly...1412
    ROCKER ARM AND BRACKET...1414
      Checking...1414
    FRONT COVER...1415
      Disassembly...1415
      Assembly...1420
    TURBOCHARGER...1430
      Removal And Installation...1430
      Disassembly...1431
      Inspection...1435
      Assembly...1436
    POSITIVE CRANKCASE VENTILATION SYSTEM(S/N 514415609, 514611152, 514511106 & Below)...1441
      Description...1441
      Inspection...1441
      Module Removal And Installation...1442
    OIL COOLER...1443
      Removal And Installation...1443
    CRANKSHAFT GEAR MOUNTING BOLT...1444
      Torque Procedure...1444
  SYSTEMS ANALYSIS...1445
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...1447
      Inspecting The BICS™ Controller (Engine STOPPED – Key ON)...1447
      Inspecting Deactivation Of The Auxiliary HydraulicsSystem (Engine STOPPED – Key ON)...1447
      Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)...1447
      Inspecting The Traction Lock (Engine RUNNING)...1447
      Inspecting The Lift Arm By–Pass Control...1447
      Maintenance...1447
      Troubleshooting Chart...1448
      SEAT SENSOR OVERRIDE ONLY (If Equipped)...1448
      Troubleshooting Guide...1449
        BICS SYSTEM CONTROLLER...1449
        TRACTION LOCK...1450
        SEAT SENSOR...1451
        SEAT BAR SENSOR...1452
        LIFT ARM BY–PASS VALVE...1453
    BICS™ SYSTEM CONTROLLER...1454
      Removal And Installation...1454
      Controller Test...1455
    SEAT BAR SENSOR...1456
      Removal And Installation...1456
      Seat Bar Sensor Test...1457
    SEAT SENSOR...1458
      Removal And Installation...1458
      Seat Sensor Test...1459
    TRACTION LOCK...1460
      Removal And Installation...1460
    BOSS® DIAGNOSTIC TOOL...1461
      Procedure...1461
    SENDER AND SENSOR...1461
      Service Checks...1461
      Components...1461
    RPM SENSOR...1461
      Adjustment...1461
    MONITOR SERVICE CODES...1462
    TROUBLESHOOTING THE BOSS® & LCD DISPLAY...1465
    OPERATION SENSING SYSTEM UNIT...1466
      Removal And Installation...1466
    BOSS® INSTRUMENT PANEL...1467
      Removal And Installation...1467
    PWM MODULE...1468
      Description...1468
      Troubleshooting Chart...1470
    PWM CONTROL HANDLE...1471
      Handle Testing...1471
    PWM ELECTRIC SOLENOID...1471
      Solenoid Coil Testing...1471
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE...1472
      Controls Identification Chart...1472
  SPECIFICATIONS...1473
    LOADER SPECIFICATIONS...1475
      LOADER DIMENSIONS...1475
      PERFORMANCE...1475
      CONTROLS...1475
      ENGINE...1475
      HYDRAULIC SYSTEM...1476
      ELECTRICAL...1476
      DRIVE SYSTEM...1476
      CAPACITIES...1477
      TIRES...1477
    ENGINE SPECIFICATIONS (BF4M1011)...1478
      General...1478
      Fuel System...1478
      Valve And Valve Guide And Seat Insert...1478
      Piston And Rings...1479
      Connecting Rod...1479
      Cylinder Head And Block...1479
      Crankshaft And Main Bearings...1480
      Camshaft And Bearings...1480
      Oil Pump...1480
    ENGINE SPECIFICATIONS (BF4M1011F)...1481
      General...1481
      Fuel System...1481
      Valve And Valve Guide And Seat Insert...1481
      Piston And Rings...1482
      Connecting Rod...1482
      Crankshaft And Main Bearings...1483
      Camshaft And Bearings...1483
      Oil Pump...1483
    ENGINE TORQUE...1484
      Specifications...1484
      Torque For General Metric Bolts...1485
    TORQUE SPECIFICATIONS FOR LOADER...1486
    HYDRAULIC CONNECTION SPECIFICATIONS...1487
      O–ring Face Seal Connection...1487
      Straight Thread O–ring Fitting...1487
      Tubelines And Hoses...1487
      Flare Fitting...1487
      O–ring Flare Fitting...1488
      Port Seal Fitting...1490
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...1491
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...1492
    DECIMAL AND MILLIMETER EQUIVALENTS...1493
    U.S. TO METRIC CONVERSION...1493
  SERVICE MANUAL REVISIONS...1495
    863–001...1495
    863–002...1497
    863–003...1499
    863–004...1501
    863–005...1503
    863–006...1505
    863–007...1507
    863–008...1509
    863–009...1511
    863-10...1513
6900373 (6-00) - 863, 863 High Flow Operation & Maintenance Manual...1515
  OPERATOR SAFETY WARNINGS...1517
  CONTENTS...1519
    REFERENCE INFORMATION...1519
    BOBCAT COMPANY IS ISO 9001 CERTIFIED...1520
    REGULAR MAINTENANCE ITEMS...1520
  FOREWORD...1521
    SERIAL NUMBER INFORMATION...1522
    SERIAL NUMBER LOCATIONS...1523
    LOADER SERIAL NUMBER...1523
    ENGINE SERIAL NUMBER...1523
    DELIVERY REPORT...1523
    BOBCAT LOADER IDENTIFICATION...1524
    OPTIONS AND ACCESSORIES...1525
  SAFETY...1527
    SAFETY INSTRUCTIONS...1529
      SAFETY IS THE OPERATOR’S RESPONSIBILITY...1529
      BEFORE OPERATING THE BOBCAT LOADER...1530
      SAFE OPERATION NEEDS A QUALIFIED OPERATOR *...1530
    FIRE PREVENTION...1531
    MACHINE SIGNS (DECALS)...1532
  OPERATING INSTRUCTIONS...1535
    INSTRUMENT PANEL...1537
      Without BOSS® (Front Panel) ...1537
      Without BOSS (Side Console•) ...1537
      With BOSS® (Front Panel)...1538
      With BOSS (Side Console•)...1538
      BOSS® OPTION PANEL...1539
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...1540
      Lift Arm By–Pass Control...1541
      Traction Lock Override...1541
      Seat Sensor Override (If Equipped)...1541
      Auxiliary Hydraulic System (If Equipped)...1541
    TRACTION LOCK CONTROL SYSTEM...1541
    ENGINE SPEED CONTROL...1542
    PARKING BRAKE...1542
    STEERING LEVERS...1543
    STOPPING THE BOBCAT LOADER...1543
    SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)...1544
    SEAT BAR RESTRAINT SYSTEM (MACHANICAL HAND CONTROLS)...1545
    SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)...1546
    HYDRAULIC CONTROLS...1547
      Foot Pedals...1547
        Lift Arm Operation...1547
        Lift Arm Float Position...1547
        Tilt Operation (Bucket)...1547
        Bucket Position Valve Operation (If Equipped)...1547
      Hand Controls (Mechanical and Advanced Hand Controls)...1548
        Lift Arm Operation...1548
        Lift Arm Float Position...1548
        Tilt Operation (Bucket)...1548
        Bucket Position Valve Operation (If Equipped)...1548
      Advanced Hand Controls (AHC) (If Equipped)...1548
      Auxiliary Hydraulics (If Equipped)...1549
        Quick Couplers (Flush Face)...1549
        Relieving Hydraulic Pressure...1549
        Auxiliary Hydraulics Switch...1550
        FRONT Auxiliary Hydraulics Operation...1550
        FRONT Auxiliary Hydraulics Continuous Operation...1550
        REAR Auxiliary Hydraulics Operation...1550
        High–Flow Hydraulics Operation (If Equipped)...1551
        Secondary Front Auxiliary Hydraulics (If Equipped)...1551
      Attachment Functions Control (If Equipped)...1552
    DAILY INSPECTION...1552
      Daily Inspection and Maintenance...1552
    GETTING READY FOR OPERATION...1553
    STARTING THE ENGINE...1555
      Normal Starting (Without BOSS®)...1555
      Cold Temperature Starting (Without BOSS®)...1556
      Warming The Hydraulic/Hydrostatic System...1556
    STOPPING THE ENGINE...1556
    STARTING THE ENGINE...1557
      Normal Starting (With BOSS®)...1557
      Cold Temperature Starting (With BOSS®)...1558
      Warming The Hydraulic/Hydrostatic System...1558
    STOPPING THE ENGINE...1558
    ATTACHMENTS AND BUCKETS...1559
      Installing The Bucket Or Attachment...1560
      Removing The Bucket Or Attachment ...1561
    OPERATING PROCEDURE...1562
      Filling The Bucket...1563
      Emptying The Bucket...1563
      Digging Into The Ground...1564
      Leveling The Ground (Using Lift Arms In Float Position)...1564
      Backfilling...1565
    PARKING THE BOBCAT LOADER...1565
    OPERATING PROCEDURE (HAND CONTROLS)...1566
      Filling The Bucket...1566
      Emptying The Bucket...1566
      Digging Into The Ground...1567
      Leveling The Ground (Using Lift Arms In FloatPosition)...1567
      Backfilling...1568
    PARKING THE BOBCAT LOADER...1568
    TRANSPORTING THE BOBCAT LOADER...1569
    TOWING THE LOADER...1569
    STOPPING THE BOBCAT LOADER...1569
    LIFTING THE LOADER...1570
      Four Point Lift...1570
      Single Point Lift...1570
  PREVENTIVE MAINTENANCE...1571
    MAINTENANCE SAFETY...1573
    SERVICE SCHEDULE...1575
    OPERATOR CAB...1576
      Raising The Operator Cab...1576
      Lowering the Operator Cab...1577
      Emergency Exit...1578
    SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)...1579
      Inspecting The Seat Bar...1579
      Maintaining The Seat Bar...1579
    SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS)...1580
      Inspecting The Seat Bar...1580
      Maintaining The Seat Bar...1580
    SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)...1581
      Inspecting The Seat Bar...1581
      Maintaining The Seat Bar...1581
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...1582
      Inspecting The BICS™ Controller (Engine STOPPED– Key ON)...1582
      Inspecting The Seat And Seat Bar Sensors (EngineRUNNING)...1582
      Inspecting The Traction Lock (Engine RUNNING)...1582
      Inspecting The Lift Arm By–Pass Control...1582
      Maintenance...1583
    TRACTION LOCK CONTROL SYSTEM...1583
      Inspecting The Traction Lock Control System...1583
      Maintenance...1583
    PIVOT PINS...1584
    TIRE MAINTENANCE...1584
      Wheel Nuts...1584
      Tire Rotation...1584
      Tire Mounting...1584
    LIFT ARM SUPPORT DEVICE...1585
      Engaging The Lift Arm Support Device...1585
      Disengaging The Lift Arm Support Device...1586
    BOB–TACH...1587
      Inspection And Maintenance...1587
    REAR DOOR...1588
      Adjusting the Rear Door...1588
    REAR GRILL...1588
    AIR CLEANER SERVICE...1589
    FUEL SYSTEM...1591
      Fuel Specifications...1591
      Filling The Fuel Tank...1591
      Fuel Filter...1592
      Removing Air From The Fuel System...1592
    ENGINE LUBRICATION...1593
      Checking...1593
      Oil Chart...1593
      Replacing The Oil And Filter...1593
    ENGINE COOLING SYSTEM...1595
      Cleaning The Cooling System...1595
    ALTERNATOR BELT...1596
      Adjusting The Alternator Belt...1596
    TIMING BELT...1597
    DRIVE BELT...1597
      Adjusting The Drive Belt...1597
      Replacing The Drive Belt...1598
    ELECTRICAL SYSTEM...1599
      Description...1599
      Servicing The Electrical System...1599
      Fuse Location...1599
      Using A Booster Battery (Jump Starting)...1600
      Removing And Installing The Battery...1601
    FAN GEARBOX...1602
      Checking And Maintaining...1602
    FINAL DRIVE TRANSMISSION (CHAINCASE)...1603
      Checking And Adding Oil...1603
    HYDRAULIC/HYDROSTATIC SYSTEM...1604
      Checking And Adding Fluid...1604
      Replacing the Hydraulic/Hydrostatic Filter...1604
      Replacing The Hydraulic Fluid...1605
      Hydraulic Reservoir Breather Cap...1606
    LUBRICATION OF THE BOBCAT LOADER...1607
  SYSTEMS ANALYSIS...1609
    SERVICE CODES...1611
    AUXILIARY HYDRAULICS OPERATION...1612
      Troubleshooting Chart...1612
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...1613
      Troubleshooting Chart...1613
    ADVANCED HAND CONTROLS (AHC)...1613
      Troubleshooting Chart...1613
  MACHINE SIGN TRANSLATIONS...1615
    IMPORTANT - 6710456...1617
    SERVICE SCHEDULE - 6718398...1618
    WARNING - 6579510...1620
    WARNING - 6703725...1621
    WARNING - 6579528...1622
    WARNING - 6577754...1622
    DANGER - 6702302...1622
    DANGER - 6702301...1622
  SPECIFICATIONS...1623
    SPECIFICATIONS...1625
    PERFORMANCE...1625
    CONTROLS...1625
    ENGINE...1625
    HYDRAULIC SYSTEM...1626
    ELECTRICAL...1626
    DRIVE SYSTEM...1626
    CAPACITIES...1626
    TIRES...1626
    FLOOR PRESSURE...1626
    BOBCAT COMPANY APPROVED ATTACHMENTS & ACCESSORIES...1627
    ADDITIONAL PUBLICATIONS...1630
  WARRANTY...1631
6900626 (9-00) - 864, 864 High Flow Operation & Maintenance Manual...1633
  OPERATOR SAFETY WARNINGS...1635
  CONTENTS...1637
    REFERENCE INFORMATION...1637
    BOBCAT COMPANY IS ISO 9001 CERTIFIED...1638
    REGULAR MAINTENANCE ITEMS...1638
  FOREWORD...1639
    SERIAL NUMBER LOCATIONS...1641
    LOADER SERIAL NUMBER...1641
    ENGINE SERIAL NUMBER...1641
    DELIVERY REPORT...1641
    BOBCAT LOADER IDENTIFICATION...1642
    OPTIONS AND ACCESSORIES...1643
  SAFETY...1645
    SAFETY INSTRUCTIONS FOR BOBCAT SKID–STEER LOADERS AND ATTACHMENTS...1647
      SAFETY IS THE OPERATOR’S RESPONSIBILITY...1647
      BEFORE OPERATING THE BOBCAT LOADER...1648
      SAFE OPERATION NEEDS A QUALIFIED OPERATOR *...1648
    FIRE PREVENTION...1649
    MACHINE SIGNS (DECALS)...1650
  OPERATING INSTRUCTIONS...1653
    INSTRUMENT PANEL...1655
      Without BOSS® (Front Panel) ...1655
      Without BOSS (Side Console*)...1655
      With BOSS® (Front Panel) ...1656
      With BOSS (Side Console*) ...1656
    BOSS® OPTION PANEL...1657
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...1658
      Lift Arm By–Pass Control...1659
      Traction Lock Override...1659
      Auxiliary Hydraulic System (If Equipped)...1659
    TRACTION LOCK CONTROL SYSTEM...1659
    ENGINE SPEED CONTROL...1660
    PARKING BRAKE...1660
    STEERING LEVERS...1661
    STOPPING THE BOBCAT LOADER...1661
    SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)...1662
    SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)...1663
    HYDRAULIC CONTROLS...1664
      Foot Pedals...1664
        Lift Arm Operation...1664
        Lift Arm Float Position...1664
        Tilt Operation...1664
        Bucket Position Valve Operation (If Equipped)...1664
      Advanced Hand Controls...1665
        Lift Arm Operation...1665
        Lift Arm Float Position...1665
        Tilt Operation...1665
        Bucket Position Valve Operation (If Equipped)...1665
      Auxiliary Hydraulics...1666
        Relieving Hydraulic Pressure...1666
        Auxiliary Hydraulics Switch...1667
        FRONT Auxiliary Hydraulics Operation...1667
        FRONT Auxiliary Hydraulics Continuous Operation...1667
        REAR Auxiliary Hydraulics Operation ...1667
        High–Flow Hydraulics Operation (If Equipped)...1668
        Secondary Front Auxiliary Hydraulics (If Equipped)...1668
        Attachment Functions Control (If Equipped)...1669
    DAILY INSPECTION...1669
      Daily Inspection and Maintenance...1669
    PRE–STARTING PROCEDURE...1670
    STARTING THE ENGINE (Without BOSS®)...1672
    STOPPING THE ENGINE...1673
    STARTING THE ENGINE (With BOSS™)...1674
    STOPPING THE ENGINE...1675
    ATTACHMENTS AND BUCKETS...1676
      Installing The Bucket Or Attachment...1677
      Removing The Bucket Or Attachment...1679
    OPERATING PROCEDURE...1680
    COMPACT TRACK LOADER OPERATING TIPS...1681
    OPERATING PROCEDURE (FOOT PEDALS)...1682
      Filling The Bucket...1682
      Emptying The Bucket...1682
      Digging Into The Ground...1683
      Leveling The Ground (Using Lift Arms In Float Position)...1683
      Backfilling...1684
    PARKING THE BOBCAT LOADER...1684
    OPERATING PROCEDURE (HAND CONTROLS)...1685
      Filling The Bucket...1685
      Emptying The Bucket...1685
      Digging Into The Ground...1686
      Leveling The Ground (Using Lift Arms In Float Position)...1686
      Backfilling...1687
    PARKING THE BOBCAT LOADER...1687
    TRANSPORTING THE BOBCAT LOADER...1688
    TOWING THE LOADER...1689
    LIFTING THE LOADER...1690
      Four Point Lift...1690
      Single Point Lift...1690
  PREVENTIVE MAINTENANCE...1691
    MAINTENANCE SAFETY...1693
    SERVICE SCHEDULE...1695
    OPERATOR CAB...1696
      Raising The Operator Cab...1696
      Lowering the Operator Cab...1697
      Emergency Exit...1698
    SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)...1699
      Inspecting The Seat Bar...1699
      Maintaining The Seat Bar...1699
    SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)...1700
      Inspecting The Seat Bar...1700
      Maintaining The Seat Bar...1700
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...1701
      Inspecting The BICS™ Controller (Engine STOPPED– Key ON)...1701
      Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)...1701
      Inspecting The Seat Bar Sensor (Engine RUNNING)...1701
      Inspecting The Traction Lock (Engine RUNNING)...1701
      Inspecting The Lift Arm By–Pass Control...1701
      Additional Inspection For Loaders With Advanced Hand Controls...1701
    TRACTION LOCK CONTROL SYSTEM...1702
      Inspecting The Traction Lock Control System...1702
      Maintenance...1702
    PIVOT PINS...1702
    TRACK TENSION...1703
      Adjusting...1703
    LIFT ARM SUPPORT DEVICE...1704
      Engaging The Lift Arm Support Device...1704
      Disengaging The Lift Arm Support Device...1705
    BOB–TACH...1706
      Inspection And Maintenance...1706
    REAR DOOR...1707
      Adjusting the Rear Door...1707
    REAR GRILL...1707
    AIR CLEANER SERVICE...1708
    FUEL SYSTEM...1710
      Fuel Specifications...1710
      Filling The Fuel Tank...1710
      Fuel Filter...1711
      Removing Air From The Fuel System...1711
      Removing Fuel From The Fuel Tank...1712
    ENGINE LUBRICATION...1713
      Checking...1713
      Oil Chart...1713
      Replacing The Oil And Filter...1713
    ENGINE COOLING SYSTEM...1715
      Cleaning The Cooling System...1715
    ALTERNATOR BELT...1716
      Adjusting The Alternator Belt...1716
    TIMING BELT...1717
    DRIVE BELT...1717
      Adjusting The Drive Belt...1717
      Replacing The Drive Belt...1718
    ELECTRICAL SYSTEM...1719
      Description...1719
      Servicing The Electrical System...1719
      Fuse Location...1719
      Using A Booster Battery (Jump Starting)...1720
      Removing And Installing The Battery...1721
    FAN GEARBOX...1722
      Checking And Maintaining...1722
    HYDRAULIC/HYDROSTATIC SYSTEM...1723
      Checking And Adding Fluid...1723
      Replacing the Hydraulic/Hydrostatic Filter...1723
      Replacing The Hydraulic Fluid...1724
      Hydraulic Reservoir Breather Cap...1725
    HYDROSTATIC MOTOR CARRIER OIL...1726
      Removing And Replacing Oil...1726
    TRACK ROLLER AND IDLER LUBRICATION...1726
      Removing And Replacing Oil...1726
    LUBRICATION OF THE BOBCAT LOADER...1727
  SYSTEMS ANALYSIS...1729
    SERVICE CODES...1731
    AUXILIARY HYDRAULICS OPERATION...1732
      Troubleshooting Chart...1732
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...1733
      Troubleshooting Chart...1733
    ADVANCED HAND CONTROLS (AHC)...1734
      Troubleshooting Chart...1734
  MACHINE SIGN TRANSLATIONS...1735
    IMPORTANT - 6710456...1737
    SERVICE SCHEDULE -6715563 ...1738
    WARNING - 6579510 ...1740
    WARNING - 6703725...1741
    WARNING - 6579528 ...1742
    WARNING - 6577754...1742
    DANGER - 6702302...1742
    DANGER - 6702301...1742
    DANGER - 6717343...1743
    WARNING - 6715944...1743
  SPECIFICATIONS...1745
    864/864H COMPACT TRACK LOADER SPECIFICATIONS...1747
      Performance Specifications...1747
      Engine...1747
      Loader Controls...1747
      Drive System...1747
      Hydraulic System...1747
      Electrical System...1747
      Capacities...1747
    BOBCAT COMPANY APPROVED ATTACHMENTS & ACCESSORIES...1748
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS...1750
  WARRANTY...1751
6900627 (10-12) - 864, 864 High Flow Service Manual...1753
  MAINTENANCE SAFETY...1755
  ALPHABETICAL INDEX...1757
  CONTENTS...1759
    FOREWORD...1760
    SAFETY INSTRUCTIONS...1763
    FIRE PREVENTION...1764
    SERIAL NUMBER LOCATIONS...1765
    LOADER SERIAL NUMBER...1765
    ENGINE SERIAL NUMBER...1765
    DELIVERY REPORT...1765
    BOBCAT LOADER IDENTIFICATION...1766
  PREVENTIVE MAINTENANCE...1767
    SERVICE SCHEDULE...1769
    LIFTING AND BLOCKING THE LOADER...1770
      Procedure...1770
    TRANSPORTING THE BOBCAT LOADER...1771
      Procedure...1771
    TOWING THE LOADER...1772
      Procedure (Without Coupler)...1772
      Procedure (With Coupler)...1773
    LIFT ARM SUPPORT DEVICE...1774
      Engaging The Lift Arm Support Device...1774
      Disengaging The Lift Arm Support Device...1775
    REMOTE START SWITCH...1776
      Procedure...1776
    OPERATOR CAB...1778
      Description...1778
      Raising The Operator Cab...1778
      Lowering The Operator Cab...1779
      Emergency Exit...1779
    SEAT BAR RESTRAINT SYSTEM...1780
      Description...1780
      Inspecting The Seat Bar...1780
      Maintaining The Seat Bar...1780
    SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)...1781
      Description...1781
    FUEL SYSTEM...1782
      Fuel Specifications...1782
      Filling the Fuel Tank...1782
      Fuel Filter...1782
      Removing Air From The Fuel System...1782
    ENGINE LUBRICATION SYSTEM...1783
      Checking Engine Oil...1783
      Replacing The Oil And Filter...1783
    ENGINE COOLING SYSTEM...1784
      Cleaning The Cooling System...1784
    HYDRAULIC/HYDROSTATIC SYSTEM...1785
      Checking And Adding Fluid...1785
      Hydraulic/Hydrostatic Filter Replacement...1785
      Replacing The Hydraulic Fluid...1786
    LUBRICATING THE LOADER...1787
      Procedure...1787
  HYDRAULIC SYSTEM...1789
    HYDRAULIC / HYDROSTATIC SCHEMATICS...1794
    HYDRAULIC SYSTEM INFORMATION...1797
    TROUBLESHOOTING...1801
    LIFT CYLINDER...1802
      Checking The Lift Cylinder(s)...1802
      Removal And Installation...1802
    TILT CYLINDER...1804
      Checking The Tilt Cylinder(s)...1804
      Removal And Installation...1804
      Rod End Seal...1805
    HYDRAULIC CYLINDER...1806
      Lift Cylinder Identification...1806
      Tilt Cylinder Identification...1807
      Disassembly...1808
      Assembly...1810
    MAIN RELIEF VALVE...1813
      Checking The Main Relief Valve At The Front Auxiliary Hydraulics...1813
      Checking The Main Relief Valve Without Auxiliaries...1814
      Removal And Installation...1815
      Adjustment...1815
    BICS™ VALVE...1816
      Lift Arm By–Pass Orifice...1816
      Check Valve...1817
      Lock Valve...1818
      BICS™ Valve Solenoid...1819
      Removal And Installation...1820
    HYDRAULIC CONTROL VALVE...1824
      Auxiliary Pressure Relief Block (864H)...1824
      Removal And Installation...1825
      Identification Chart...1829
      Disassembly and Assembly...1830
      Load Check Valve...1830
      Lift Base End Restrictor...1830
      Main Relief Valve...1831
      Port Relief Valve...1832
      Anti–Cavitation Valve/Port Relief Valve...1832
      Anti–Cavitation Valve...1833
      Rubber Boot...1834
      Lift Spool and Detent...1835
      Tilt Spool and Centering Spring...1839
      Auxiliary Spool...1840
      Auxiliary Electric Solenoid...1841
      H Port – Auxiliary Section...1842
      Inspection...1842
      Spool Seal Installation...1843
    LIFT ARM BY–PASS CONTROL VALVE...1844
      Removal And Installation...1844
    LIFT ARM BY–PASS CONTROL VALVE MOUNT BRACKET...1845
      Removal And Installation...1845
      Disassembly And Assembly...1845
    HYDRAULIC PUMP...1846
      Checking The Output Of The Pump...1846
      Removal and Installation...1847
      Parts Identification...1848
      Disassembly...1849
      Inspection...1851
      Assembly...1852
    HYDRAULIC PUMP (Double Gear)...1854
      Checking The Output Of The High Flow Pump...1854
      Removal and Installation...1855
      Disassembly...1858
      Parts Identification...1857
      Inspection...1862
      Assembly...1863
    HYDRAULIC/HYDROSTATIC FILTER HOUSING...1866
      Removal and Installation...1866
    HYDRAULIC FLUID RESERVOIR...1867
      Draining The Hydraulic Fluid Reservoir...1867
      Removal And Installation...1867
    CONTROL PEDALS...1868
      Pedal Adjustment...1868
      Removal and Installation...1868
    PEDAL INTERLOCK LINKAGE...1869
      Pedal Interlock Linkage Adjustment...1869
      Removal and Installation...1869
    CROSSBAR LINKAGE...1871
      Removal And Installation...1871
      Inspection...1871
    REAR AUXILIARY DIVERTER–864 STANDARD FLOW...1873
      Disassembly...1873
      Inspection...1873
      Solenoid Testing...1873
      Assembly...1873
    SELECT VALVE (864H)...1874
      Checking The High Flow Pump Relief Valve...1874
      Removal And Installation...1875
      Disassembly And Assembly...1876
      Solenoid Testing...1880
    BUCKET POSITION VALVE...1881
      Solenoid Removal And Installation...1881
      Solenoid Testing...1881
      Removal And Installation...1882
      Disassembly And Assembly...1883
  HYDROSTATIC SYSTEM...1885
    TROUBLESHOOTING...1887
    HYDROSTATIC SYSTEM INFORMATION...1888
      Replenishing Valve Function...1888
    CHARGE PRESSURE...1888
      Charge Pressure Sender...1888
    CONTROL PANEL...1889
      Removal and Installation...1889
    STEERING LEVERS...1891
      Removal And Installation...1891
      Disassembly And Assembly...1891
    STEERING LINKAGE...1893
      Removal And Installation...1893
      Neutral Adjustment...1896
    HYDROSTATIC MOTOR...1901
      Removal And Installation...1901
      Parts Identification...1904
      Disassembly...1906
      Inspection...1915
      Assembly...1916
    HYDROSTATIC PUMP...1925
      Removal And Installation...1925
      Replenishing/High Pressure Relief Valve...1927
      Charge Pressure Relief Valve...1928
      Parts Identification (Right Half)...1930
      Parts Identification (Left Half)...1932
      Hydraulic Pump Removal...1934
      Disassembly...1935
      Assembly...1943
    DRIVE BELT SHIELD...1951
      Removal And Installation...1951
    DRIVE BELT...1952
      Adjusting The Drive Belt...1952
      Replacing The Drive Belt...1952
    DRIVE BELT TENSIONER PULLEY...1953
      Removal And Installation...1953
      Disassembly And Assembly...1954
      Tension Spring...1955
    OIL COOLER...1956
      Removal and Installation...1956
  DRIVE SYSTEM...1957
    PARKING BRAKE PEDAL...1959
      Removal And Installation...1959
      Disassembly And Assembly...1960
    BRAKE BLOCK...1961
      Removal And Installation...1961
      Disassembly And Assembly...1962
      Traction Lock By–Pass Knob...1962
    TRACK...1963
      Checking Track Tension...1963
      Adjusting Track Tension...1964
      Removal And Installation...1965
    TRACK IDLER (Front)...1968
      Removal And Installation...1968
      Parts Identification...1970
      Disassembly...1971
      Assembly...1972
    TRACK IDLER (Rear)...1975
      Removal And Installation...1975
      Parts Identification...1975
      Disassembly...1976
      Assembly...1977
    TRACK ROLLER...1979
      Removal And Installation...1979
      Parts Identification...1979
      Disassembly...1980
      Assembly...1981
    TRACK HOUSING...1984
      Removal And Installation...1984
    TRACK DAMAGE IDENTIFICATION...1985
      Cutting Of Steel Cords...1985
      Abrasion Of Embedded Metals...1986
      Separation Of Embedded Metals...1987
      Cuts On The Lug Side Rubber...1989
      Separation Of Embedded Metals Due To Corrosion...1988
      Lug Abrasion...1991
      Cracks And Cuts On The Lug Side Rubber...1991
      Cracks On The Lug Side Rubber Due To Fatigue...1990
      Abrasion Of The Track Roller Side...1992
      Cuts On The Edges Of Track Roller Side...1993
  MAIN FRAME...1995
    SEAT BAR...1997
      Removal And Installation...1997
      Assembling Components...2000
      Compression Spring Disassembly And Assembly...2000
    OPERATOR CAB GAS CYLINDER...2001
      Removal And Installation...2001
      Disassembly And Assembly...2002
    OPERATOR CAB...2003
      Removal And Installation...2003
    OPERATOR SEAT...2005
      Removal And Installation...2005
    BOB–TACH...2006
      Inspection And Maintenance...2006
      Bob–Tach Lever And Wedge...2007
      Removal And Installation...2009
      Pivot Pin Bushing And Seal Replacement...2011
    LIFT ARMS...2012
      Removal And Installation...2012
    REAR GRILL...2015
      Removal And Installation...2015
    REAR DOOR...2016
      Removal And Installation...2016
      Adjusting The Rear Door Latch...2017
    FUEL TANK...2018
      Removal And Installation...2018
      Fuel Level Sender...2021
      Fuel Pick–up Screen/Check Valve...2021
  ELECTRICAL SYSTEM...2023
    ELECTRICAL SCHEMATICS...2025
    TROUBLESHOOTING...2033
    ELECTRICAL SYSTEM INFORMATION...2034
      Description...2034
      Fuse Location...2034
      Solenoid Testing...2034
    BATTERY...2035
      Removal And Installation...2035
      Servicing The Battery...2036
      Using A Booster Battery...2037
    ALTERNATOR BELT...2038
      Adjusting The Alternator Belt...2038
    ALTERNATOR...2039
      Alternator Output Test...2039
      Rectifier (Diode) Test...2039
      Alternator Regulator Test...2040
      Removal And Installation...2041
      Disassembly...2042
      Stator Continuity Test...2042
      Stator Ground Test...2042
      Rotor Continuity Test...2043
      Rotor Ground Test...2043
      Rectifier Continuity (Diode) Test...2043
      Assembly...2044
    STARTER...2044
      Removal And Installation...2044
      Parts Identification...2045
      Disassembly And Assembly...2046
      External Pinion...2050
      Inspection And Repair...2051
      Magnetic Switch Test...2054
      No Load Test...2054
    STANDARD INSTRUMENT PANEL...2055
      Removal And Installation...2055
    FRONT LIGHTS...2056
      Removal And Installation...2056
    RELAY SWITCHES...2057
      Location...2057
  ENGINE SERVICE...2059
    TROUBLESHOOTING...2061
    ENGINE SPEED CONTROL...2062
      Removal And Installation...2062
      Speed Control Linkage...2063
      Speed Control Cable...2063
    ENGINE MUFFLER...2064
      Removal And Installation...2064
    AIR CLEANER...2065
      Replacing Filter Element...2065
    AIR CLEANER...2067
      Housing, Removal And Installation...2067
    RADIATOR...2068
      Oil Cooler, Removal And Installation...2068
    COOLING FAN...2069
      Drive Tension Pulley, Removal And Installation...2069
      Gearbox/Blower Housing, Removal And Installation...2070
      Blower, Removal And Installation...2072
      Gearbox, Checking And Maintaining...2073
      Gearbox, Parts Identification...2074
      Gearbox, Disassembly...2075
      Gearbox, Assembly...2080
      Gearbox, Checking Backlash...2085
    ENGINE COMPONENTS AND TESTS...2088
      Engine Compression, Checking...2088
      Glow Plug, Checking...2090
      Fuel Shut–Off Solenoid, Checking...2091
      Fuel Shut–Off Solenoid Removal and Installation...2092
      Fuel Injection Pump, Removal...2093
      Fuel Injection Pump Timing...2094
      Fuel Injection Pump Installation...2095
      Fuel Injector Removal and Installation...2097
      Fuel Injector Checking...2098
      Fuel Injector Disassembly...2099
      Fuel Injector Assembly...2100
      Timing Belt, Inspection...2102
      Timing Belt, Removal...2102
      Timing Belt, Installation...2103
      Timing Belt, Replacement In the Loader...2107
      Valve Clearance Adjustment...2112
      Valve Timing, Checking...2113
      Thermostat, Oil Pressure Control Valves & Heater Connections...2114
    ENGINE AND ENGINE MOUNTS...2117
      Removal And Installation...2117
      Engine Mount Replacement...2123
    FLYWHEEL AND HOUSING...2124
      Flywheel Removal And Installation...2124
      Ring Gear Removal And Installation...2124
      Flywheel Housing Removal And Installation...2124
    RECONDITIONING THE ENGINE...2125
      Deutz Engine Tools Identification Chart...2125
      Disassembly...2126
      Assembly...2130
       Cylinder, Checking...2145
      Camshaft Bearing, Checking...2146
      Camshaft Bearing, Removal And Installation...2146
      Control Rod Guide Bushing, Removal...2148
      Control Rod Guide Bushing, Installation...2150
      Rear Cover Seal, Removal And Installation...2154
      Crankshaft, Checking...2155
      Connecting Rod, Checking...2156
      Piston, Checking...2158
      Piston Pin, Checking...2159
      Piston Rings, Installation...2159
      Piston Installation On the Connecting Rod...2160
      Cylinder Head, Disassembly...2162
      Valves, Checking...2162
       Valve Seats, Checking...2163
      Valve Spring, Checking...2163
      Cylinder Head, Assembly...2163
      Rocker Arm and Bracket, Checking...2165
      Front Cover, Disassembly...2166
      Front Cover, Assembly...2171
      Turbo Charger, Removal and Installation...2181
      Crankshaft Gear Mounting Bolt Torque Procedure...2182
  SYSTEMS ANALYSIS...2185
    BICS™...2187
      Inspecting The BICS™ Controller (Engine STOPPED – Key ON)...2187
      Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)...2187
      Inspecting The Seat Bar Sensor (Engine RUNNING)...2187
      Inspecting The Traction Lock (Engine RUNNING)...2187
      Inspecting The Lift Arm By–Pass Control...2187
      Additional Inspection For Loaders With Advanced Hand Controls...2187
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...2188
      Troubleshooting Chart...2188
    BICS SYSTEM CONTROLLER...2189
      Troubleshooting Guide...2189
      Removal And Installation...2190
    SEAT BAR SENSOR...2191
      Troubleshooting Guide...2191
      Seat Bar Sensor Test...2192
      Removal And Installation...2193
      BICS™ Controller Seat Bar Sensor Circuit Test...2194
    TRACTION LOCK...2195
      Troubleshooting Guide...2195
      Removal And Installation...2196
    BOSS® DIAGNOSTIC TOOL...2197
      Procedure...2197
    SENDER AND SENSOR...2197
      Service Checks...2197
      Components...2197
    RPM SENSOR...2197
      Adjustment...2197
    MONITOR SERVICE CODES...2198
    TROUBLESHOOTING THE BOSS® & LCD DISPLAY...2200
    BOSS®UNIT...2201
      Removal And Installation...2201
    BOSS® INSTRUMENT PANEL...2202
      Removal And Installation...2202
    PWM MODULE...2203
      Description...2203
    PWM TROUBLESHOOTING...2204
      Conditions...2204
      Chart...2205
    PWM CONTROL HANDLE...2206
      Handle Testing...2206
    PWM ELECTRIC SOLENOID...2206
      Solenoid Coil Testing...2206
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE...2207
      Controls Identification Chart...2207
  SPECIFICATIONS...2209
    LOADER SPECIFICATIONS...2211
      LOADER DIMENSIONS...2211
      PERFORMANCE...2211
      CONTROLS...2211
      ENGINE...2211
      HYDRAULIC SYSTEM...2212
      ELECTRICAL...2212
      DRIVE SYSTEM...2212
      CAPACITIES...2212
      TRACKS...2212
      GROUND PRESSURE...2212
    ENGINE SPECIFICATIONS (BF4M1011)...2213
      General...2213
      Fuel System...2213
      Valve And Valve Guide And Seat Insert...2213
      Piston And Rings...2214
      Connecting Rod...2214
      Cylinder Head And Block...2214
      Crankshaft And Main Bearings...2215
      Camshaft And Bearings...2215
      Oil Pump...2215
    ENGINE SPECIFICATIONS (BF4M1011F)...2216
      General...2216
      Fuel System...2216
      Valve And Valve Guide And Seat Insert...2216
      Piston And Rings...2217
      Connecting Rod...2217
      Cylinder Head And Block...2217
      Crankshaft And Main Bearings...2218
      Camshaft And Bearings...2218
      Oil Pump...2218
    ENGINE TORQUE...2219
    TORQUE SPECIFICATIONS FOR LOADER...2221
    HYDRAULIC CONNECTION SPECIFICATIONS...2222
      O–ring Face Seal Connection...2222
      Straight Thread O–ring Fitting...2222
      Tubelines And Hoses...2222
      Flare Fitting...2222
      O–ring Flare Fitting...2223
      Port Seal Fitting...2225
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...2226
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...2227
    DECIMAL AND MILLIMETER EQUIVALENTS...2228
    U.S. TO METRIC CONVERSION...2228
  ADVANCE HAND CONTROL SYSTEM (A.H.C)...2229
    ADVANCE HAND CONTROL ELECTRICAL SCHEMATICS...2231
    A.H.C. COMPONENTS...2237
      Identification...2237
    TROUBLESHOOTING (A.H.C.)...2238
    ACTUATOR VOLTAGE TEST...2240
      Procedure...2240
    HANDLE CONTROL UNIT TEST...2243
      Procedure...2243
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...2246
      Troubleshooting Chart...2246
    A.H.C./PWM CONTROLLER...2247
      Removal And Installation...2247
      Test...2248
      Description...2249
      Conditions...2250
      Troubleshooting Chart...2250
      Handle Testing...2251
      Solenoid Coil Testing...2251
    HANDLE CONTROL UNIT...2252
      Removal And Installation...2252
      Control Unit Connector...2255
    SWITCH HANDLE...2256
      Removal And Installation...2256
    A. H. C. HANDLE...2259
      Removal And Installation...2259
        Disassembly And Assembly...2260
    A.H.C. STEERING LEVER...2261
      Removal And Installation...2261
      Steering Lever Boot...2261
    ACTUATORS...2262
      Removal And Installation...2262
      Disassembly And Assembly...2263
      Mounting Plate...2264
    BICS™ VALVE...2265
      Lift Arm By–Pass Orifice...2265
      Check Valve...2266
      Lock Valve...2266
      BICS™ Valve Solenoid...2267
      Removal And Installation...2268
    HYDRAULIC CONTROL VALVE...2269
      Removal And Installation...2269
      Identification Chart...2272
      Disassembly And Assembly...2273
      Load Check Valve...2273
      Lift Base End Restrictor...2273
      Main Relief Valve...2274
      Port Relief Valve (Lift)...2275
      Anti–Cavitation/Port Relief Valve...2275
      Port Relief Valve (Tilt)...2276
      Anti–Cavitation Valve...2276
      Rubber Boot...2277
      Lift And Tilt Spool...2278
      Inspection...2280
      Auxiliary Spool...2281
      Auxiliary Electrical Solenoid...2282
      Spool Seal Installation...2283
      H–Port Auxiliary Section...2284
  SERVICE MANUAL REVISION...2285
    864-1...2285
    864-2...2287
6900627 (7-10) - 864, 864 High Flow Service Manual...2289
  MAINTENANCE SAFETY...2291
  ALPHABETICAL INDEX...2293
  CONTENTS...2295
    FOREWORD...2296
    SAFETY INSTRUCTIONS...2299
    FIRE PREVENTION...2300
    SERIAL NUMBER LOCATIONS...2301
    LOADER SERIAL NUMBER...2301
    ENGINE SERIAL NUMBER...2301
    DELIVERY REPORT...2301
    BOBCAT LOADER IDENTIFICATION...2302
  PREVENTIVE MAINTENANCE...2303
    SERVICE SCHEDULE...2305
    LIFTING AND BLOCKING THE LOADER...2306
      Procedure...2306
    TRANSPORTING THE BOBCAT LOADER...2307
      Procedure...2307
    TOWING THE LOADER...2308
      Procedure (Without Coupler)...2308
      Procedure (With Coupler)...2309
    LIFT ARM SUPPORT DEVICE...2310
      Engaging The Lift Arm Support Device...2310
      Disengaging The Lift Arm Support Device...2311
    REMOTE START SWITCH...2312
      Procedure...2312
    OPERATOR CAB...2314
      Description...2314
      Raising The Operator Cab...2314
      Lowering The Operator Cab...2315
      Emergency Exit...2315
    SEAT BAR RESTRAINT SYSTEM...2316
      Description...2316
      Inspecting The Seat Bar...2316
      Maintaining The Seat Bar...2316
    SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)...2317
      Description...2317
    FUEL SYSTEM...2318
      Fuel Specifications...2318
      Filling the Fuel Tank...2318
      Fuel Filter...2318
      Removing Air From The Fuel System...2318
    ENGINE LUBRICATION SYSTEM...2319
      Checking Engine Oil...2319
      Replacing The Oil And Filter...2319
    ENGINE COOLING SYSTEM...2320
      Cleaning The Cooling System...2320
    HYDRAULIC/HYDROSTATIC SYSTEM...2321
      Checking And Adding Fluid...2321
      Hydraulic/Hydrostatic Filter Replacement...2321
      Replacing The Hydraulic Fluid...2322
    LUBRICATING THE LOADER...2323
      Procedure...2323
  HYDRAULIC SYSTEM...2325
    HYDRAULIC / HYDROSTATIC SCHEMATICS...2330
    HYDRAULIC SYSTEM INFORMATION...2333
    TROUBLESHOOTING...2337
    LIFT CYLINDER...2338
      Checking The Lift Cylinder(s)...2338
      Removal And Installation...2338
    TILT CYLINDER...2340
      Checking The Tilt Cylinder(s)...2340
      Removal And Installation...2340
      Rod End Seal...2341
    HYDRAULIC CYLINDER...2342
      Lift Cylinder Identification...2342
      Tilt Cylinder Identification...2343
      Disassembly...2344
      Assembly...2346
    MAIN RELIEF VALVE...2349
      Checking The Main Relief Valve At The Front Auxiliary Hydraulics...2349
      Checking The Main Relief Valve Without Auxiliaries...2350
      Removal And Installation...2351
      Adjustment...2351
    BICS™ VALVE...2352
      Lift Arm By–Pass Orifice...2352
      Check Valve...2353
      Lock Valve...2354
      BICS™ Valve Solenoid...2355
      Removal And Installation...2356
    HYDRAULIC CONTROL VALVE...2360
      Auxiliary Pressure Relief Block (864H)...2360
      Removal And Installation...2361
      Identification Chart...2365
      Disassembly and Assembly...2366
      Load Check Valve...2366
      Lift Base End Restrictor...2366
      Main Relief Valve...2367
      Port Relief Valve...2368
      Anti–Cavitation Valve/Port Relief Valve...2368
      Anti–Cavitation Valve...2369
      Rubber Boot...2370
      Lift Spool and Detent...2371
      Tilt Spool and Centering Spring...2375
      Auxiliary Spool...2376
      Auxiliary Electric Solenoid...2377
      H Port – Auxiliary Section...2378
      Inspection...2378
      Spool Seal Installation...2379
    LIFT ARM BY–PASS CONTROL VALVE...2380
      Removal And Installation...2380
    LIFT ARM BY–PASS CONTROL VALVE MOUNT BRACKET...2381
      Removal And Installation...2381
      Disassembly And Assembly...2381
    HYDRAULIC PUMP...2382
      Checking The Output Of The Pump...2382
      Removal and Installation...2383
      Parts Identification...2384
      Disassembly...2385
      Inspection...2387
      Assembly...2388
    HYDRAULIC PUMP (Double Gear)...2390
      Checking The Output Of The High Flow Pump...2390
      Removal and Installation...2391
      Disassembly...2394
      Parts Identification...2393
      Inspection...2398
      Assembly...2399
    HYDRAULIC/HYDROSTATIC FILTER HOUSING...2402
      Removal and Installation...2402
    HYDRAULIC FLUID RESERVOIR...2403
      Draining The Hydraulic Fluid Reservoir...2403
      Removal And Installation...2403
    CONTROL PEDALS...2404
      Pedal Adjustment...2404
      Removal and Installation...2404
    PEDAL INTERLOCK LINKAGE...2405
      Pedal Interlock Linkage Adjustment...2405
      Removal and Installation...2405
    CROSSBAR LINKAGE...2407
      Removal And Installation...2407
      Inspection...2407
    REAR AUXILIARY DIVERTER–864 STANDARD FLOW...2409
      Disassembly...2409
      Inspection...2409
      Solenoid Testing...2409
      Assembly...2409
    SELECT VALVE (864H)...2410
      Checking The High Flow Pump Relief Valve...2410
      Removal And Installation...2411
      Disassembly And Assembly...2412
      Solenoid Testing...2416
    BUCKET POSITION VALVE...2417
      Solenoid Removal And Installation...2417
      Solenoid Testing...2417
      Removal And Installation...2418
      Disassembly And Assembly...2419
  HYDROSTATIC SYSTEM...2421
    TROUBLESHOOTING...2423
    HYDROSTATIC SYSTEM INFORMATION...2424
      Replenishing Valve Function...2424
    CHARGE PRESSURE...2424
      Charge Pressure Sender...2424
    CONTROL PANEL...2425
      Removal and Installation...2425
    STEERING LEVERS...2427
      Removal And Installation...2427
      Disassembly And Assembly...2427
    STEERING LINKAGE...2429
      Removal And Installation...2429
      Neutral Adjustment...2432
    HYDROSTATIC MOTOR...2437
      Removal And Installation...2437
      Parts Identification...2440
      Disassembly...2442
      Inspection...2451
      Assembly...2452
    HYDROSTATIC PUMP...2461
      Removal And Installation...2461
      Replenishing/High Pressure Relief Valve...2463
      Charge Pressure Relief Valve...2464
      Parts Identification (Right Half)...2466
      Parts Identification (Left Half)...2468
      Hydraulic Pump Removal...2470
      Disassembly...2471
      Assembly...2479
    DRIVE BELT SHIELD...2487
      Removal And Installation...2487
    DRIVE BELT...2488
      Adjusting The Drive Belt...2488
      Replacing The Drive Belt...2488
    DRIVE BELT TENSIONER PULLEY...2489
      Removal And Installation...2489
      Disassembly And Assembly...2490
      Tension Spring...2491
    OIL COOLER...2492
      Removal and Installation...2492
  DRIVE SYSTEM...2493
    PARKING BRAKE PEDAL...2495
      Removal And Installation...2495
      Disassembly And Assembly...2496
    BRAKE BLOCK...2497
      Removal And Installation...2497
      Disassembly And Assembly...2498
      Traction Lock By–Pass Knob...2498
    TRACK...2499
      Checking Track Tension...2499
      Adjusting Track Tension...2500
      Removal And Installation...2501
    TRACK IDLER (Front)...2504
      Removal And Installation...2504
      Parts Identification...2506
      Disassembly...2507
      Assembly...2508
    TRACK IDLER (Rear)...2511
      Removal And Installation...2511
      Parts Identification...2511
      Disassembly...2512
      Assembly...2513
    TRACK ROLLER...2515
      Removal And Installation...2515
      Parts Identification...2515
      Disassembly...2516
      Assembly...2517
    TRACK HOUSING...2520
      Removal And Installation...2520
    TRACK DAMAGE IDENTIFICATION...2521
      Cutting Of Steel Cords...2521
      Abrasion Of Embedded Metals...2522
      Separation Of Embedded Metals...2523
      Cuts On The Lug Side Rubber...2525
      Separation Of Embedded Metals Due To Corrosion...2524
      Lug Abrasion...2527
      Cracks And Cuts On The Lug Side Rubber...2527
      Cracks On The Lug Side Rubber Due To Fatigue...2526
      Abrasion Of The Track Roller Side...2528
      Cuts On The Edges Of Track Roller Side...2529
  MAIN FRAME...2531
    SEAT BAR...2533
      Removal And Installation...2533
      Assembling Components...2536
      Compression Spring Disassembly And Assembly...2536
    OPERATOR CAB GAS CYLINDER...2537
      Removal And Installation...2537
      Disassembly And Assembly...2538
    OPERATOR CAB...2539
      Removal And Installation...2539
    OPERATOR SEAT...2541
      Removal And Installation...2541
    BOB–TACH...2542
      Inspection And Maintenance...2542
      Bob–Tach Lever And Wedge...2543
      Removal And Installation...2545
      Pivot Pin Bushing And Seal Replacement...2547
    LIFT ARMS...2548
      Removal And Installation...2548
    REAR GRILL...2551
      Removal And Installation...2551
    REAR DOOR...2552
      Removal And Installation...2552
      Adjusting The Rear Door Latch...2553
    FUEL TANK...2554
      Removal And Installation...2554
      Fuel Level Sender...2557
      Fuel Pick–up Screen/Check Valve...2557
  ELECTRICAL SYSTEM...2559
    ELECTRICAL SCHEMATICS...2561
    TROUBLESHOOTING...2569
    ELECTRICAL SYSTEM INFORMATION...2570
      Description...2570
      Fuse Location...2570
      Solenoid Testing...2570
    BATTERY...2571
      Removal And Installation...2571
      Servicing The Battery...2572
      Using A Booster Battery...2573
    ALTERNATOR BELT...2574
      Adjusting The Alternator Belt...2574
    ALTERNATOR...2575
      Alternator Output Test...2575
      Rectifier (Diode) Test...2575
      Alternator Regulator Test...2576
      Removal And Installation...2577
      Disassembly...2578
      Stator Continuity Test...2578
      Stator Ground Test...2578
      Rotor Continuity Test...2579
      Rotor Ground Test...2579
      Rectifier Continuity (Diode) Test...2579
      Assembly...2580
    STARTER...2580
      Removal And Installation...2580
      Parts Identification...2581
      Disassembly And Assembly...2582
      External Pinion...2586
      Inspection And Repair...2587
      Magnetic Switch Test...2590
      No Load Test...2590
    STANDARD INSTRUMENT PANEL...2591
      Removal And Installation...2591
    FRONT LIGHTS...2592
      Removal And Installation...2592
    RELAY SWITCHES...2593
      Location...2593
  ENGINE SERVICE...2595
    TROUBLESHOOTING...2597
    ENGINE SPEED CONTROL...2598
      Removal And Installation...2598
      Speed Control Linkage...2599
      Speed Control Cable...2599
    ENGINE MUFFLER...2600
      Removal And Installation...2600
    AIR CLEANER...2601
      Replacing Filter Element...2601
    AIR CLEANER...2603
      Housing, Removal And Installation...2603
    RADIATOR...2604
      Oil Cooler, Removal And Installation...2604
    COOLING FAN...2605
      Drive Tension Pulley, Removal And Installation...2605
      Gearbox/Blower Housing, Removal And Installation...2606
      Blower, Removal And Installation...2608
      Gearbox, Checking And Maintaining...2609
      Gearbox, Parts Identification...2610
      Gearbox, Disassembly...2611
      Gearbox, Assembly...2616
      Gearbox, Checking Backlash...2621
    ENGINE COMPONENTS AND TESTS...2624
      Engine Compression, Checking...2624
      Glow Plug, Checking...2626
      Fuel Shut–Off Solenoid, Checking...2627
      Fuel Shut–Off Solenoid Removal and Installation...2628
      Fuel Injection Pump, Removal...2629
      Fuel Injection Pump Timing...2630
      Fuel Injection Pump Installation...2631
      Fuel Injector Removal and Installation...2633
      Fuel Injector Checking...2634
      Fuel Injector Disassembly...2635
      Fuel Injector Assembly...2636
      Timing Belt, Inspection...2638
      Timing Belt, Removal...2638
      Timing Belt, Installation...2639
      Timing Belt, Replacement In the Loader...2643
      Valve Clearance Adjustment...2648
      Valve Timing, Checking...2649
      Thermostat, Oil Pressure Control Valves & Heater Connections...2650
    ENGINE AND ENGINE MOUNTS...2653
      Removal And Installation...2653
      Engine Mount Replacement...2659
    FLYWHEEL AND HOUSING...2660
      Flywheel Removal And Installation...2660
      Ring Gear Removal And Installation...2660
      Flywheel Housing Removal And Installation...2660
    RECONDITIONING THE ENGINE...2661
      Deutz Engine Tools Identification Chart...2661
      Disassembly...2662
      Assembly...2666
       Cylinder, Checking...2681
      Camshaft Bearing, Checking...2682
      Camshaft Bearing, Removal And Installation...2682
      Control Rod Guide Bushing, Removal...2684
      Control Rod Guide Bushing, Installation...2686
      Rear Cover Seal, Removal And Installation...2690
      Crankshaft, Checking...2691
      Connecting Rod, Checking...2692
      Piston, Checking...2694
      Piston Pin, Checking...2695
      Piston Rings, Installation...2695
      Piston Installation On the Connecting Rod...2696
      Cylinder Head, Disassembly...2698
      Valves, Checking...2698
       Valve Seats, Checking...2699
      Valve Spring, Checking...2699
      Cylinder Head, Assembly...2699
      Rocker Arm and Bracket, Checking...2701
      Front Cover, Disassembly...2702
      Front Cover, Assembly...2707
      Turbo Charger, Removal and Installation...2717
      Crankshaft Gear Mounting Bolt Torque Procedure...2718
  SYSTEMS ANALYSIS...2721
    BICS™...2723
      Inspecting The BICS™ Controller (Engine STOPPED – Key ON)...2723
      Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)...2723
      Inspecting The Seat Bar Sensor (Engine RUNNING)...2723
      Inspecting The Traction Lock (Engine RUNNING)...2723
      Inspecting The Lift Arm By–Pass Control...2723
      Additional Inspection For Loaders With Advanced Hand Controls...2723
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...2724
      Troubleshooting Chart...2724
    BICS SYSTEM CONTROLLER...2725
      Troubleshooting Guide...2725
      Removal And Installation...2726
    SEAT BAR SENSOR...2727
      Troubleshooting Guide...2727
      Seat Bar Sensor Test...2728
      Removal And Installation...2729
      BICS™ Controller Seat Bar Sensor Circuit Test...2730
    TRACTION LOCK...2731
      Troubleshooting Guide...2731
      Removal And Installation...2732
    BOSS® DIAGNOSTIC TOOL...2733
      Procedure...2733
    SENDER AND SENSOR...2733
      Service Checks...2733
      Components...2733
    RPM SENSOR...2733
      Adjustment...2733
    MONITOR SERVICE CODES...2734
    TROUBLESHOOTING THE BOSS® & LCD DISPLAY...2736
    BOSS®UNIT...2737
      Removal And Installation...2737
    BOSS® INSTRUMENT PANEL...2738
      Removal And Installation...2738
    PWM MODULE...2739
      Description...2739
    PWM TROUBLESHOOTING...2740
      Conditions...2740
      Chart...2741
    PWM CONTROL HANDLE...2742
      Handle Testing...2742
    PWM ELECTRIC SOLENOID...2742
      Solenoid Coil Testing...2742
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE...2743
      Controls Identification Chart...2743
  SPECIFICATIONS...2745
    LOADER SPECIFICATIONS...2747
      LOADER DIMENSIONS...2747
      PERFORMANCE...2747
      CONTROLS...2747
      ENGINE...2747
      HYDRAULIC SYSTEM...2748
      ELECTRICAL...2748
      DRIVE SYSTEM...2748
      CAPACITIES...2748
      TRACKS...2748
      GROUND PRESSURE...2748
    ENGINE SPECIFICATIONS (BF4M1011)...2749
      General...2749
      Fuel System...2749
      Valve And Valve Guide And Seat Insert...2749
      Piston And Rings...2750
      Connecting Rod...2750
      Cylinder Head And Block...2750
      Crankshaft And Main Bearings...2751
      Camshaft And Bearings...2751
      Oil Pump...2751
    ENGINE SPECIFICATIONS (BF4M1011F)...2752
      General...2752
      Fuel System...2752
      Valve And Valve Guide And Seat Insert...2752
      Piston And Rings...2753
      Connecting Rod...2753
      Cylinder Head And Block...2753
      Crankshaft And Main Bearings...2754
      Camshaft And Bearings...2754
      Oil Pump...2754
    ENGINE TORQUE...2755
    TORQUE SPECIFICATIONS FOR LOADER...2757
    HYDRAULIC CONNECTION SPECIFICATIONS...2758
      O–ring Face Seal Connection...2758
      Straight Thread O–ring Fitting...2758
      Tubelines And Hoses...2758
      Flare Fitting...2758
      O–ring Flare Fitting...2759
      Port Seal Fitting...2761
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...2762
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...2763
    DECIMAL AND MILLIMETER EQUIVALENTS...2764
    U.S. TO METRIC CONVERSION...2764
  ADVANCE HAND CONTROL SYSTEM (A.H.C)...2765
    ADVANCE HAND CONTROL ELECTRICAL SCHEMATICS...2767
    A.H.C. COMPONENTS...2773
      Identification...2773
    TROUBLESHOOTING (A.H.C.)...2774
    ACTUATOR VOLTAGE TEST...2776
      Procedure...2776
    HANDLE CONTROL UNIT TEST...2779
      Procedure...2779
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...2782
      Troubleshooting Chart...2782
    A.H.C./PWM CONTROLLER...2783
      Removal And Installation...2783
      Test...2784
      Description...2785
      Conditions...2786
      Troubleshooting Chart...2786
      Handle Testing...2787
      Solenoid Coil Testing...2787
    HANDLE CONTROL UNIT...2788
      Removal And Installation...2788
      Control Unit Connector...2791
    SWITCH HANDLE...2792
      Removal And Installation...2792
    A. H. C. HANDLE...2795
      Removal And Installation...2795
        Disassembly And Assembly...2796
    A.H.C. STEERING LEVER...2797
      Removal And Installation...2797
      Steering Lever Boot...2797
    ACTUATORS...2798
      Removal And Installation...2798
      Disassembly And Assembly...2799
      Mounting Plate...2800
    BICS™ VALVE...2801
      Lift Arm By–Pass Orifice...2801
      Check Valve...2802
      Lock Valve...2802
      BICS™ Valve Solenoid...2803
      Removal And Installation...2804
    HYDRAULIC CONTROL VALVE...2805
      Removal And Installation...2805
      Identification Chart...2808
      Disassembly And Assembly...2809
      Load Check Valve...2809
      Lift Base End Restrictor...2809
      Main Relief Valve...2810
      Port Relief Valve (Lift)...2811
      Anti–Cavitation/Port Relief Valve...2811
      Port Relief Valve (Tilt)...2812
      Anti–Cavitation Valve...2812
      Rubber Boot...2813
      Lift And Tilt Spool...2814
      Inspection...2816
      Auxiliary Spool...2817
      Auxiliary Electrical Solenoid...2818
      Spool Seal Installation...2819
      H–Port Auxiliary Section...2820
  SERVICE MANUAL REVISION...2821
    864-1...2821
6900627 (7-99) - 864, 864 High Flow Service Manual...2823
6900648 (10-12) - 863, 863 High Flow Service Manual...3353
  MAINTENANCE SAFETY...3355
  ALPHABETICAL INDEX...3357
  CONTENTS...3359
    FOREWORD...3360
    SAFETY INSTRUCTIONS...3363
    SERIAL NUMBER LOCATIONS...3365
    LOADER SERIAL NUMBER...3365
    ENGINE SERIAL NUMBER...3365
    DELIVERY REPORT...3365
    BOBCAT LOADER IDENTIFICATION...3366
  PREVENTIVE MAINTENANCE...3367
    SERVICE SCHEDULE...3369
    LIFTING AND BLOCKING THE LOADER...3370
      Procedure...3370
    TRANSPORTING THE BOBCAT LOADER...3371
      Procedure...3371
    TOWING THE LOADER...3371
    LIFT ARM SUPPORT DEVICE...3372
      To Install The Lift Arm Support Device...3372
      To Remove The Lift Arm Support Device...3373
    OPERATOR CAB...3374
      Raising The Operator Cab...3374
      Lowering The Operator Cab...3375
      Emergency Exit...3376
    SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)...3377
      Description...3377
      Seat Bar Inspection...3377
      Seat Bar Maintenance...3377
    SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS)...3378
      Description...3378
      Seat Bar Inspection...3378
      Seat Bar Maintenance...3378
    SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)...3379
      Description...3379
      Seat Bar Maintenance...3379
      Seat Bar Inspection...3379
    AIR CLEANER SERVICE...3380
      Replacing Filter Element...3380
    FUEL SYSTEM...3382
      Fuel Specifications...3382
      Filling The Fuel Tank...3382
      Fuel Filter...3382
      Removing Air From The Fuel System...3382
    ENGINE LUBRICATION SYSTEM...3383
      Checking Engine Oil...3383
      Replacement Of Oil And Filter...3383
    COOLING SYSTEM...3384
      Cleaning The Cooling System...3384
    ALTERNATOR BELT...3385
      Adjusting The Alternator Belt...3385
    HYDRAULIC/HYDROSTATIC SYSTEM...3386
      Replacing The Hydraulic/Hydrostatic Filter...3386
      Checking And Adding Fluid...3386
      Replacing The Hydraulic Fluid...3387
    TIRE MAINTENANCE...3388
      Wheel Nuts...3388
      Tire Rotation...3388
      Tire Mounting...3388
    FINAL DRIVE TRANSMISSION (CHAINCASE)...3389
      Checking And Adding Oil...3389
      Removing Oil From The Chaincase...3389
    LUBRICATION OF THE BOBCAT LOADER...3390
      Procedure...3390
    FAN GEARBOX...3392
      Checking And Maintaining...3392
    BOB–TACH...3393
      Inspection And Maintenance...3393
    REMOTE START SWITCH...3394
      Procedure...3394
  HYDRAULIC SYSTEM...3397
    HYDRAULIC/HYDROSTATIC SCHEMATICS...3400
    TROUBLESHOOTING...3415
    HYDRAULIC SYSTEM INFORMATION...3416
      Tighten Procedures...3416
    LIFT CYLINDER(S)...3417
      Checking The Lift Cylinder(s)...3417
      Removal And Installation...3417
    TILT CYLINDER...3419
      Checking The Tilt Cylinder...3419
      Removal And Installation...3419
      Rod End Seal...3420
    HYDRAULIC CYLINDER...3421
      Lift Cylinder Identification...3421
      Tilt Cylinder Identification...3422
      Disassembly...3423
      Assembly...3425
    MAIN RELIEF VALVE...3428
      Checking The Main Relief Valve...3428
      Checking The Main Relief Valve Without Auxiliaries...3429
      Removal And Installation...3430
      Adjustment...3430
    MAIN RELIEF VALVE (Advanced Hand Control)...3431
      Adjustment...3431
    SELECT VALVE 863H...3432
      Checking The High Flow Pump Relief Valve...3432
      Removal And Installation...3433
      Disassembly And Assembly...3434
      Solenoid Testing...3435
    LIFT ARM BY–PASS CONTROL VALVE...3436
      Removal And Installation...3436
      Disassembly And Assembly...3437
    BICS™ CONTROL VALVE...3438
      Removal And Installation...3438
    BICS™ VALVE ASSEMBLY...3441
      Lift Arm By–Pass Orifice...3441
      Check Valve...3442
      Lock Valve...3443
      BICS™ Valve Solenoid...3444
    HYDRAULIC CONTROL VALVE...3445
      Removal And Installation...3445
      Identification Chart...3448
      Disassembly And Assembly...3449
      Load Check Valve...3449
      Lift Base End Restrictor...3449
      Main Relief Valve...3450
      Port Relief Valve...3451
      Anti–Cavitation/Port Relief Valve...3451
      Rubber Boot...3453
      Lift Spool And Detent...3454
      Tilt Spool And Centering Spring...3458
      Auxiliary Spool...3459
      Auxiliary Electric Solenoid...3460
      H Port – Auxiliary Section...3461
      Inspection...3461
      Spool Seal Installation...3462
    HYDRAULIC PUMP...3463
      Checking The Output Of The Pump...3463
      Removal And Installation...3464
      Parts Identification...3465
      Disassembly...3466
      Inspection...3468
      Assembly...3469
    HYDRAULIC PUMP (Double Gear) 863H...3471
      Checking The Output Of The High Flow Pump...3471
      Removal And Installation...3472
      Parts Identification...3474
      Disassembly...3475
      Inspection...3479
      Assembly...3480
    HYDRAULIC FLUID RESERVOIR...3483
      Removal And Installation...3483
    HYDROSTATIC FILTER HOUSING...3484
      Removal And Installation...3484
      Hydrostatic Charge Pressure Sender...3484
    CONTROL PEDALS...3485
      Removal And Installation...3485
      Pedal Adjustment...3485
    PEDAL INTERLOCK LINKAGE...3486
      Removal And Installation...3486
      Pedal Interlock Linkage Adjustment...3487
    REAR AUXILIARY DIVERTER...3488
      Disassembly...3488
      Inspection...3488
      Solenoid Testing...3488
      Assembly...3488
  HYDROSTATIC SYSTEM...3489
    TROUBLESHOOTING...3491
    HYDROSTATIC SYSTEM INFORMATION...3492
      Replenishing Valve Function...3492
    FRONT PANEL (M46 Pump & AHC)...3493
      Removal And Installation...3493
    FRONT PANEL (M44 Hydraulic Pump)...3495
      Removal And Installation...3495
    STEERING LEVERS (M46 Pumps & AHC)...3497
      Disassembly And Assembly...3497
    STEERING LEVERS (M44 Pumps)...3499
      Removal And Installation...3499
      Disassembly And Assembly...3499
    CONTROL TOWER (M46 Pump & AHC)...3501
      Removal And Installation...3501
      Disassembly And Assembly...3502
    SOLID STEERING LINKAGE NEUTRAL ADJUSTMENT (M46 Pump)...3504
      Procedure...3504
    STEERING LINKAGE (M44 Pump)...3507
      Removal And Installation...3507
      Steering Linkage Adjustment...3510
    HYDROSTATIC MOTOR (S/N 514427762 & Above; 514525304 & Above; 514625302 & Above)...3515
      Removal And Installation...3515
      Parts Identification...3516
      Disassembly...3517
      Inspection...3519
      Assembly...3520
    HYDROSTATIC MOTOR (S/N 514427761 & Below; 514525303 & Below; 514625301 & Below)...3524
      Removal And Installation...3524
      Parts Identification...3526
      Disassembly...3527
      Inspection...3528
      Assembly...3529
    MOTOR CARRIER...3531
      Removal And Installation...3531
      Parts Identification...3532
      Disassembly...3533
      Assembly...3535
    HYDROSTATIC PUMP (M46)...3537
      Removal And Installation...3537
      Replenishing/High Pressure Relief Valve...3539
      Charge Pressure Relief Valve...3539
      Parts Identification (Right Half)...3540
      Parts Identification (Left Half) ...3542
      Hydraulic Pump Removal...3544
      Hydrostatic Pump Separation...3544
      Charge Pump Disassembly...3545
      Disassembly...3546
      Inspection...3555
      Assembly...3558
      Charge Pump Assembly...3567
      Hydrostatic Pump Connection...3568
      Hydraulic Pump Installation...3568
      Swashplate Neutral Adjustment...3569
      Displacement Control Servo (Solid Linkage)...3570
    HYDROSTATIC PUMP (M44)...3572
      Parts Identification (Right Half)...3572
      Parts Identification (Left Half)...3574
      Replenishing/High Pressure Relief Valve...3576
      Charge Pressure Relief Valve...3577
      Hydraulic Pump Removal...3578
      Hydraulic Pump Separation...3579
      Charge Pump Disassembly...3579
      Disassembly...3581
      Assembly...3587
    CHARGE PUMP (M44)...3592
      Assembly...3592
    DRIVE BELT SHIELD...3595
      Removal And Installation...3595
    DRIVE BELT...3596
      Adjusting The Drive Belt...3596
      Replacing The Drive Belt...3596
    DRIVE BELT TENSIONER PULLEY...3597
      Removal And Installation...3597
      Tension Spring...3599
    HYDRAULIC/HYDROSTATIC OIL COOLER...3600
      Removal And Installation...3600
  DRIVE SYSTEM...3601
    PARKING BRAKE PEDAL...3603
      Removal And Installation...3603
      Disassembly And Assembly...3604
    PARKING BRAKE DISC...3605
      Removal And Installation...3605
    FRONT CHAINCASE COVER...3608
      Removal And Installation...3608
    REAR CHAINCASE COVER...3608
      Removal And Installation...3608
    AXLE SEAL...3609
      Removal And Installation...3609
    AXLE, SPROCKET AND BEARINGS...3611
      Removal And Installation...3611
    DRIVE CHAIN...3616
      Removal And Installation...3616
    CHAINCASE FLUID...3617
      Removing The Fluid From The Chaincase...3617
  MAIN FRAME...3619
    SEAT BAR...3621
      Removal And Installation...3621
      Assembling Components...3624
      Compression Spring Disassembly And Assembly...3624
    OPERATOR CAB GAS CYLINDER...3625
      Removal And Installation...3625
      Disassembly And Assembly...3626
    OPERATOR CAB...3627
      Removal And Installation...3627
    OPERATOR SEAT...3629
      Removal And Installation...3629
    BOB–TACH...3630
      Bob–Tach Lever And Wedge...3630
      Bob–Tach Stops...3631
      Removal And Installation...3632
      Pivot Pin Bushing And Seal Replacement...3634
    LIFT ARMS...3635
      Removal And Installation...3635
    REAR GRILL...3638
      Removal And Installation...3638
    REAR DOOR...3639
      Removal And Installation...3639
      Door Latch And Catch Adjustment...3640
    FUEL TANK...3641
      Removal And Installation...3641
      Fuel Level Sender...3642
      Fuel Pick–Up Screen/Check Valve...3642
      Inlet Screen...3643
  ELECTRICAL SYSTEM...3645
    ELECTRICAL SCHEMATICS...3647
    TROUBLESHOOTING...3661
    ELECTRICAL SYSTEM INFORMATION...3662
      Description...3662
      Fuse Location...3662
    BATTERY...3663
      Removal And Installation...3663
      Servicing The Battery...3664
      Using A Booster Battery...3665
    ALTERNATOR...3666
      Alternator Output Test...3666
      Rectifier (Diode) Test...3666
      Alternator Regulator Test...3667
      Removal And Installation...3668
      Disassembly...3669
      Stator Continuity Test...3669
      Stator Ground Test...3669
      Rotor Continuity Test...3670
      Rotor Ground Test...3670
      Rectifier Continuity (Diode) Test...3670
      Assembly...3671
    STARTER...3671
      Removal And Installation...3671
      Parts Identification...3672
      Disassembly And Assembly...3673
      External Pinion...3677
      Inspection And Repair...3678
      Magnetic Switch Test...3681
      No Load Test...3681
    STANDARD INSTRUMENT PANEL...3682
      Removal And Installation...3682
    FRONT LIGHTS...3683
      Removal And Installation...3683
    RELAY SWITCHES...3684
      Location...3684
  ENGINE SERVICE...3685
    TROUBLESHOOTING...3687
    ENGINE SPEED CONTROL...3688
      Removal And Installation...3688
      Speed Control Cable...3689
      Speed Control Linkage...3689
    ENGINE MUFFLER...3690
      Removal And Installation...3690
    AIR CLEANER HOUSING...3691
      Removal And Installation...3691
    BLOWER HOUSING/FAN GEARBOX...3692
      Removal And Installation...3692
    FAN DRIVE TENSION PULLEY...3694
      Removal And Installation...3694
    BLOWER FAN...3695
      Removal And Installation...3695
    FAN GEARBOX...3696
      Parts Identification...3696
      Disassembly...3697
      Assembly...3702
      Checking Backlash...3707
    ENGINE...3710
      Removal And Installation...3710
      Replacement...3716
    FLYWHEEL...3717
      Removal And Installation...3717
      Flywheel Ring Gear...3717
    FLYWHEEL HOUSING...3717
      Removal And Installation...3717
    GLOW PLUG...3718
      Checking The Glow Plug...3718
    VALVE CLEARANCE...3719
      Adjustment...3719
    FUEL INJECTION PUMP...3720
      Description...3720
      Removal...3720
      Injection Pump Timing...3721
      Installation...3722
    FUEL INJECTOR...3724
      Removal and Installation...3724
      Checking...3725
      Disassembly...3726
      Assembly...3727
    TIMING BELT...3729
      Inspection...3729
      Removal...3729
      Installation...3730
      Belt Replacement In Loader...3733
    VALVE TIMING...3738
      Checking...3738
    DEUTZ ENGINE TOOLS...3739
      Identification Chart...3739
    RECONDITIONING THE ENGINE...3740
      Disassembly...3740
      Assembly...3744
    CYLINDER LINERS...3759
      Checking The Cylinder Liners...3759
    CAMSHAFT BEARINGS...3760
      Checking...3760
      Removal And Installation...3760
    CONTROL ROD GUIDE BUSHING...3762
      Removal...3762
      Installation...3764
    REAR COVER SEAL...3768
      Removal And Installation...3768
    CRANKSHAFT...3769
      Checking The Crankshaft...3769
    CONNECTING ROD...3770
      Checking The Connecting Rod...3770
    PISTON AND PISTON PIN...3773
      Checking the Piston...3773
      Installing Piston Rings...3774
    CYLINDER HEAD...3775
      Disassembly...3775
      Checking The Valves...3775
      Checking Valve Seats...3776
      Valve Spring...3776
      Assembly...3776
    ROCKER ARM AND BRACKET...3778
      Checking...3778
    FRONT COVER...3779
      Disassembly...3779
      Assembly...3784
    TURBOCHARGER...3794
      Removal and Installation...3794
      Disassembly...3795
      Inspection...3799
      Assembly...3800
    ENGINE OIL COOLER...3805
      Removal And Installation...3805
    CRANKSHAFT GEAR MOUNTING BOLT...3806
      Torque Procedure...3806
  SYSTEMS ANALYSIS...3807
    BICS™ (With Press To Operate Button)...3809
      Inspecting The BICS™ Controller (Engine STOPPED– Key ON)...3809
      Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)...3809
      Inspecting The Seat Bar Sensor (Engine RUNNING)...3809
      Inspecting The Traction Lock (Engine RUNNING)...3809
      Inspecting The Lift Arm By–Pass Control...3809
      Additional Inspection For Loaders With Advanced Hand Controls...3809
      Troubleshooting Chart...3810
    BICS™ (Without Press To Operate Button)...3811
      Inspecting The BICS™ Controller (Engine STOPPED– Key ON)...3811
      Inspecting Deactivation of the Auxiliary HydraulicsSystem (Engine STOPPED – Key ON)...3811
      Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)...3811
      Inspecting The Traction Lock (Engine RUNNING)...3811
      Inspecting The Lift Arm By–Pass Control...3811
      Maintenance...3811
      Troubleshooting Chart...3812
    SEAT SENSOR OVERRIDE ONLY (If Equipped)...3812
    BICS SYSTEM CONTROLLER...3813
      Removal And Installation...3814
    SEAT BAR SENSOR...3815
      Troubleshooting Guide...3815
      Seat Bar Sensor Test...3816
      Removal And Installation...3817
      BICS™ Controller Seat Bar Sensor Circuit Test...3818
    SEAT SENSOR...3819
      Troubleshooting Guide...3819
      Seat Sensor Test...3820
      Removal And Installation...3821
      BICS™ Controller Seat Sensor Circuit Test...3822
    TRACTION LOCK...3823
      Troubleshooting Guide...3823
      Removal And Installation...3824
    TRACTION LOCK CONTROL SYSTEM (S/N 514427600 & Above; 514525300 & Above; 514625300 & Above)...3825
      Inspecting The Traction Lock Control System...3825
      Maintenance...3825
    TRACTION LOCK CONTROL SYSTEM (S/N 514123809 & Below; 514222299 & Below)...3825
      Description...3825
      Inspection...3825
      Maintenance...3825
    BOSS® DIAGNOSTIC TOOL...3826
      Procedure...3826
    SENDER AND SENSOR...3826
      Service Checks...3826
    RPM SENSOR...3826
      Adjustment...3826
    MONITOR SERVICE CODES...3827
    TROUBLESHOOTING THE BOSS® & LCD DISPLAY...3829
    BOSS® UNIT...3830
      Removal And Installation...3830
    BOSS® INSTRUMENT PANEL...3831
      Removal And Installation...3831
    PWM MODULE...3832
      Description...3832
    PWM TROUBLESHOOTING...3833
      Chart...3834
    PWM CONTROL HANDLE...3835
      Handle Testing...3835
    PWM ELECTRIC SOLENOID...3835
      Solenoid Coil Testing...3835
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE...3836
  SPECIFICATIONS...3837
    LOADER SPECIFICATIONS...3839
      LOADER DIMENSIONS...3839
      PERFORMANCE...3839
      CONTROLS...3839
      ENGINE...3839
      HYDRAULIC SYSTEM...3840
      ELECTRICAL...3840
      DRIVE SYSTEM...3840
      CAPACITIES...3841
      TIRES...3841
    ENGINE SPECIFICATIONS (BF4M1011)...3842
      General...3842
      Fuel System...3842
      Valve And Valve Guide And Seat Insert...3842
      Piston And Rings...3843
      Connecting Rod...3843
      Cylinder Head And Block...3843
      Crankshaft And Main Bearings...3844
      Camshaft And Bearings...3844
      Oil Pump...3844
    ENGINE SPECIFICATIONS (BF4M1011F)...3845
      General...3845
      Fuel System...3845
      Valve And Valve Guide And Seat Insert...3845
      Piston And Rings...3846
      Connecting Rod...3846
      Cylinder Head And Block...3846
      Crankshaft And Main Bearings...3847
      Camshaft And Bearings...3847
      Oil Pump...3847
    ENGINE TORQUE...3848
      Specifications...3848
      Torque For General Metric Bolts...3849
    TORQUE SPECIFICATIONS FOR LOADER...3850
    HYDRAULIC CONNECTION SPECIFICATIONS...3851
      O–ring Face Seal Connection...3851
      Straight Thread O–ring Fitting...3851
      Tubelines And Hoses...3851
      Flare Fitting...3851
      O–ring Flare Fitting...3852
      Port Seal Fitting...3854
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...3855
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...3856
    DECIMAL AND MILLIMETER EQUIVALENTS...3857
    U.S. TO METRIC CONVERSION...3857
  ADVANCE HAND CONTROL SYSTEM (A.H.C)...3859
    ADVANCE HAND CONTROL ELECTRICAL SCHEMATICS...3861
    A.H.C. COMPONENTS...3871
      Identification...3871
    TROUBLESHOOTING (A.H.C.)...3872
    ACTUATOR VOLTAGE TEST...3874
      Procedure...3874
    HANDLE CONTROL UNIT TEST...3877
      Procedure...3877
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...3880
      Troubleshooting Chart...3880
    A.H.C./PWM CONTROLLER...3881
      Removal and Installation...3881
      Test...3881
      Description...3882
      Conditions...3883
      Troubleshooting Chart...3883
      Handle Testing...3884
      Solenoid Coil Testing...3884
    HANDLE CONTROL UNIT...3885
      Removal And Installation...3885
      Control Unit Connector...3888
    SWITCH HANDLE...3889
      Removal And Installation...3889
    A. H. C. HANDLE...3892
      Removal And Installation...3892
      Disassembly And Assembly...3893
    A.H.C. STEERING LEVER...3894
      Removal And Installation...3894
      Steering Lever Boot...3894
    ACTUATORS...3895
      Removal And Installation...3895
      Disassembly And Assembly...3896
      Mounting Plate...3897
    BICS™ VALVE...3898
      Lift Arm By–Pass Orifice...3898
      Check Valve...3899
      Lock Valve...3899
      BICS™ Valve Solenoid...3900
      Removal And Installation...3901
    HYDRAULIC CONTROL VALVE...3902
      Removal And Installation...3902
      Identification Chart...3905
      Disassembly And Assembly...3906
      Load Check Valve...3906
      Lift Base End Restrictor...3906
      Main Relief Valve...3907
      Port Relief Valve (Lift)...3908
      Anti–Cavitation/Port Relief Valve...3908
      Port Relief Valve (Tilt)...3909
      Anti–Cavitation Valve...3909
      Rubber Boot...3910
      Lift And Tilt Spool...3911
      Inspection...3913
      Auxiliary Spool...3914
      Auxiliary Electrical Solenoid...3915
      Spool Seal Installation...3916
      H–Port Auxiliary Section...3917
  SERVICE MANUAL REVISIONS...3919
    863/863H–1...3919
    863/863H-2...3921
    863/863H-3...3923
6900648 (10-98) - 863, 863 High Flow Service Manual...3925
6900648 (7-10) - 863, 863 High Flow Service Manual...4475
  MAINTENANCE SAFETY...4477
  ALPHABETICAL INDEX...4479
  CONTENTS...4481
    FOREWORD...4482
    SAFETY INSTRUCTIONS...4485
    SERIAL NUMBER LOCATIONS...4487
    LOADER SERIAL NUMBER...4487
    ENGINE SERIAL NUMBER...4487
    DELIVERY REPORT...4487
    BOBCAT LOADER IDENTIFICATION...4488
  PREVENTIVE MAINTENANCE...4489
    SERVICE SCHEDULE...4491
    LIFTING AND BLOCKING THE LOADER...4492
      Procedure...4492
    TRANSPORTING THE BOBCAT LOADER...4493
      Procedure...4493
    TOWING THE LOADER...4493
    LIFT ARM SUPPORT DEVICE...4494
      To Install The Lift Arm Support Device...4494
      To Remove The Lift Arm Support Device...4495
    OPERATOR CAB...4496
      Raising The Operator Cab...4496
      Lowering The Operator Cab...4497
      Emergency Exit...4498
    SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)...4499
      Description...4499
      Seat Bar Inspection...4499
      Seat Bar Maintenance...4499
    SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS)...4500
      Description...4500
      Seat Bar Inspection...4500
      Seat Bar Maintenance...4500
    SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)...4501
      Description...4501
      Seat Bar Maintenance...4501
      Seat Bar Inspection...4501
    AIR CLEANER SERVICE...4502
      Replacing Filter Element...4502
    FUEL SYSTEM...4504
      Fuel Specifications...4504
      Filling The Fuel Tank...4504
      Fuel Filter...4504
      Removing Air From The Fuel System...4504
    ENGINE LUBRICATION SYSTEM...4505
      Checking Engine Oil...4505
      Replacement Of Oil And Filter...4505
    COOLING SYSTEM...4506
      Cleaning The Cooling System...4506
    ALTERNATOR BELT...4507
      Adjusting The Alternator Belt...4507
    HYDRAULIC/HYDROSTATIC SYSTEM...4508
      Replacing The Hydraulic/Hydrostatic Filter...4508
      Checking And Adding Fluid...4508
      Replacing The Hydraulic Fluid...4509
    TIRE MAINTENANCE...4510
      Wheel Nuts...4510
      Tire Rotation...4510
      Tire Mounting...4510
    FINAL DRIVE TRANSMISSION (CHAINCASE)...4511
      Checking And Adding Oil...4511
      Removing Oil From The Chaincase...4511
    LUBRICATION OF THE BOBCAT LOADER...4512
      Procedure...4512
    FAN GEARBOX...4514
      Checking And Maintaining...4514
    BOB–TACH...4515
      Inspection And Maintenance...4515
    REMOTE START SWITCH...4516
      Procedure...4516
  HYDRAULIC SYSTEM...4519
    HYDRAULIC/HYDROSTATIC SCHEMATICS...4522
    TROUBLESHOOTING...4537
    HYDRAULIC SYSTEM INFORMATION...4538
      Tighten Procedures...4538
    LIFT CYLINDER(S)...4539
      Checking The Lift Cylinder(s)...4539
      Removal And Installation...4539
    TILT CYLINDER...4541
      Checking The Tilt Cylinder...4541
      Removal And Installation...4541
      Rod End Seal...4542
    HYDRAULIC CYLINDER...4543
      Lift Cylinder Identification...4543
      Tilt Cylinder Identification...4544
      Disassembly...4545
      Assembly...4547
    MAIN RELIEF VALVE...4550
      Checking The Main Relief Valve...4550
      Checking The Main Relief Valve Without Auxiliaries...4551
      Removal And Installation...4552
      Adjustment...4552
    MAIN RELIEF VALVE (Advanced Hand Control)...4553
      Adjustment...4553
    SELECT VALVE 863H...4554
      Checking The High Flow Pump Relief Valve...4554
      Removal And Installation...4555
      Disassembly And Assembly...4556
      Solenoid Testing...4557
    LIFT ARM BY–PASS CONTROL VALVE...4558
      Removal And Installation...4558
      Disassembly And Assembly...4559
    BICS™ CONTROL VALVE...4560
      Removal And Installation...4560
    BICS™ VALVE ASSEMBLY...4563
      Lift Arm By–Pass Orifice...4563
      Check Valve...4564
      Lock Valve...4565
      BICS™ Valve Solenoid...4566
    HYDRAULIC CONTROL VALVE...4567
      Removal And Installation...4567
      Identification Chart...4570
      Disassembly And Assembly...4571
      Load Check Valve...4571
      Lift Base End Restrictor...4571
      Main Relief Valve...4572
      Port Relief Valve...4573
      Anti–Cavitation/Port Relief Valve...4573
      Rubber Boot...4575
      Lift Spool And Detent...4576
      Tilt Spool And Centering Spring...4580
      Auxiliary Spool...4581
      Auxiliary Electric Solenoid...4582
      H Port – Auxiliary Section...4583
      Inspection...4583
      Spool Seal Installation...4584
    HYDRAULIC PUMP...4585
      Checking The Output Of The Pump...4585
      Removal And Installation...4586
      Parts Identification...4587
      Disassembly...4588
      Inspection...4590
      Assembly...4591
    HYDRAULIC PUMP (Double Gear) 863H...4593
      Checking The Output Of The High Flow Pump...4593
      Removal And Installation...4594
      Parts Identification...4596
      Disassembly...4597
      Inspection...4601
      Assembly...4602
    HYDRAULIC FLUID RESERVOIR...4605
      Removal And Installation...4605
    HYDROSTATIC FILTER HOUSING...4606
      Removal And Installation...4606
      Hydrostatic Charge Pressure Sender...4606
    CONTROL PEDALS...4607
      Removal And Installation...4607
      Pedal Adjustment...4607
    PEDAL INTERLOCK LINKAGE...4608
      Removal And Installation...4608
      Pedal Interlock Linkage Adjustment...4609
    REAR AUXILIARY DIVERTER...4610
      Disassembly...4610
      Inspection...4610
      Solenoid Testing...4610
      Assembly...4610
  HYDROSTATIC SYSTEM...4611
    TROUBLESHOOTING...4613
    HYDROSTATIC SYSTEM INFORMATION...4614
      Replenishing Valve Function...4614
    FRONT PANEL (M46 Pump & AHC)...4615
      Removal And Installation...4615
    FRONT PANEL (M44 Hydraulic Pump)...4617
      Removal And Installation...4617
    STEERING LEVERS (M46 Pumps & AHC)...4619
      Disassembly And Assembly...4619
    STEERING LEVERS (M44 Pumps)...4621
      Removal And Installation...4621
      Disassembly And Assembly...4621
    CONTROL TOWER (M46 Pump & AHC)...4623
      Removal And Installation...4623
      Disassembly And Assembly...4624
    SOLID STEERING LINKAGE NEUTRAL ADJUSTMENT (M46 Pump)...4626
      Procedure...4626
    STEERING LINKAGE (M44 Pump)...4629
      Removal And Installation...4629
      Steering Linkage Adjustment...4632
    HYDROSTATIC MOTOR (S/N 514427762 & Above; 514525304 & Above; 514625302 & Above)...4637
      Removal And Installation...4637
      Parts Identification...4638
      Disassembly...4639
      Inspection...4641
      Assembly...4642
    HYDROSTATIC MOTOR (S/N 514427761 & Below; 514525303 & Below; 514625301 & Below)...4646
      Removal And Installation...4646
      Parts Identification...4648
      Disassembly...4649
      Inspection...4650
      Assembly...4651
    MOTOR CARRIER...4653
      Removal And Installation...4653
      Parts Identification...4654
      Disassembly...4655
      Assembly...4657
    HYDROSTATIC PUMP (M46)...4659
      Removal And Installation...4659
      Replenishing/High Pressure Relief Valve...4661
      Charge Pressure Relief Valve...4661
      Parts Identification (Right Half)...4662
      Parts Identification (Left Half) ...4664
      Hydraulic Pump Removal...4666
      Hydrostatic Pump Separation...4666
      Charge Pump Disassembly...4667
      Disassembly...4668
      Inspection...4677
      Assembly...4680
      Charge Pump Assembly...4689
      Hydrostatic Pump Connection...4690
      Hydraulic Pump Installation...4690
      Swashplate Neutral Adjustment...4691
      Displacement Control Servo (Solid Linkage)...4692
    HYDROSTATIC PUMP (M44)...4694
      Parts Identification (Right Half)...4694
      Parts Identification (Left Half)...4696
      Replenishing/High Pressure Relief Valve...4698
      Charge Pressure Relief Valve...4699
      Hydraulic Pump Removal...4700
      Hydraulic Pump Separation...4701
      Charge Pump Disassembly...4701
      Disassembly...4703
      Assembly...4709
    CHARGE PUMP (M44)...4714
      Assembly...4714
    DRIVE BELT SHIELD...4717
      Removal And Installation...4717
    DRIVE BELT...4718
      Adjusting The Drive Belt...4718
      Replacing The Drive Belt...4718
    DRIVE BELT TENSIONER PULLEY...4719
      Removal And Installation...4719
      Tension Spring...4721
    HYDRAULIC/HYDROSTATIC OIL COOLER...4722
      Removal And Installation...4722
  DRIVE SYSTEM...4723
    PARKING BRAKE PEDAL...4725
      Removal And Installation...4725
      Disassembly And Assembly...4726
    PARKING BRAKE DISC...4727
      Removal And Installation...4727
    FRONT CHAINCASE COVER...4730
      Removal And Installation...4730
    REAR CHAINCASE COVER...4730
      Removal And Installation...4730
    AXLE SEAL...4731
      Removal And Installation...4731
    AXLE, SPROCKET AND BEARINGS...4733
      Removal And Installation...4733
    DRIVE CHAIN...4738
      Removal And Installation...4738
    CHAINCASE FLUID...4739
      Removing The Fluid From The Chaincase...4739
  MAIN FRAME...4741
    SEAT BAR...4743
      Removal And Installation...4743
      Assembling Components...4746
      Compression Spring Disassembly And Assembly...4746
    OPERATOR CAB GAS CYLINDER...4747
      Removal And Installation...4747
      Disassembly And Assembly...4748
    OPERATOR CAB...4749
      Removal And Installation...4749
    OPERATOR SEAT...4751
      Removal And Installation...4751
    BOB–TACH...4752
      Bob–Tach Lever And Wedge...4752
      Bob–Tach Stops...4753
      Removal And Installation...4754
      Pivot Pin Bushing And Seal Replacement...4756
    LIFT ARMS...4757
      Removal And Installation...4757
    REAR GRILL...4760
      Removal And Installation...4760
    REAR DOOR...4761
      Removal And Installation...4761
      Door Latch And Catch Adjustment...4762
    FUEL TANK...4763
      Removal And Installation...4763
      Fuel Level Sender...4764
      Fuel Pick–Up Screen/Check Valve...4764
      Inlet Screen...4765
  ELECTRICAL SYSTEM...4767
    ELECTRICAL SCHEMATICS...4769
    TROUBLESHOOTING...4783
    ELECTRICAL SYSTEM INFORMATION...4784
      Description...4784
      Fuse Location...4784
    BATTERY...4785
      Removal And Installation...4785
      Servicing The Battery...4786
      Using A Booster Battery...4787
    ALTERNATOR...4788
      Alternator Output Test...4788
      Rectifier (Diode) Test...4788
      Alternator Regulator Test...4789
      Removal And Installation...4790
      Disassembly...4791
      Stator Continuity Test...4791
      Stator Ground Test...4791
      Rotor Continuity Test...4792
      Rotor Ground Test...4792
      Rectifier Continuity (Diode) Test...4792
      Assembly...4793
    STARTER...4793
      Removal And Installation...4793
      Parts Identification...4794
      Disassembly And Assembly...4795
      External Pinion...4799
      Inspection And Repair...4800
      Magnetic Switch Test...4803
      No Load Test...4803
    STANDARD INSTRUMENT PANEL...4804
      Removal And Installation...4804
    FRONT LIGHTS...4805
      Removal And Installation...4805
    RELAY SWITCHES...4806
      Location...4806
  ENGINE SERVICE...4807
    TROUBLESHOOTING...4809
    ENGINE SPEED CONTROL...4810
      Removal And Installation...4810
      Speed Control Cable...4811
      Speed Control Linkage...4811
    ENGINE MUFFLER...4812
      Removal And Installation...4812
    AIR CLEANER HOUSING...4813
      Removal And Installation...4813
    BLOWER HOUSING/FAN GEARBOX...4814
      Removal And Installation...4814
    FAN DRIVE TENSION PULLEY...4816
      Removal And Installation...4816
    BLOWER FAN...4817
      Removal And Installation...4817
    FAN GEARBOX...4818
      Parts Identification...4818
      Disassembly...4819
      Assembly...4824
      Checking Backlash...4829
    ENGINE...4832
      Removal And Installation...4832
      Replacement...4838
    FLYWHEEL...4839
      Removal And Installation...4839
      Flywheel Ring Gear...4839
    FLYWHEEL HOUSING...4839
      Removal And Installation...4839
    GLOW PLUG...4840
      Checking The Glow Plug...4840
    VALVE CLEARANCE...4841
      Adjustment...4841
    FUEL INJECTION PUMP...4842
      Description...4842
      Removal...4842
      Injection Pump Timing...4843
      Installation...4844
    FUEL INJECTOR...4846
      Removal and Installation...4846
      Checking...4847
      Disassembly...4848
      Assembly...4849
    TIMING BELT...4851
      Inspection...4851
      Removal...4851
      Installation...4852
      Belt Replacement In Loader...4855
    VALVE TIMING...4860
      Checking...4860
    DEUTZ ENGINE TOOLS...4861
      Identification Chart...4861
    RECONDITIONING THE ENGINE...4862
      Disassembly...4862
      Assembly...4866
    CYLINDER LINERS...4881
      Checking The Cylinder Liners...4881
    CAMSHAFT BEARINGS...4882
      Checking...4882
      Removal And Installation...4882
    CONTROL ROD GUIDE BUSHING...4884
      Removal...4884
      Installation...4886
    REAR COVER SEAL...4890
      Removal And Installation...4890
    CRANKSHAFT...4891
      Checking The Crankshaft...4891
    CONNECTING ROD...4892
      Checking The Connecting Rod...4892
    PISTON AND PISTON PIN...4895
      Checking the Piston...4895
      Installing Piston Rings...4896
    CYLINDER HEAD...4897
      Disassembly...4897
      Checking The Valves...4897
      Checking Valve Seats...4898
      Valve Spring...4898
      Assembly...4898
    ROCKER ARM AND BRACKET...4900
      Checking...4900
    FRONT COVER...4901
      Disassembly...4901
      Assembly...4906
    TURBOCHARGER...4916
      Removal and Installation...4916
      Disassembly...4917
      Inspection...4921
      Assembly...4922
    ENGINE OIL COOLER...4927
      Removal And Installation...4927
    CRANKSHAFT GEAR MOUNTING BOLT...4928
      Torque Procedure...4928
  SYSTEMS ANALYSIS...4929
    BICS™ (With Press To Operate Button)...4931
      Inspecting The BICS™ Controller (Engine STOPPED– Key ON)...4931
      Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)...4931
      Inspecting The Seat Bar Sensor (Engine RUNNING)...4931
      Inspecting The Traction Lock (Engine RUNNING)...4931
      Inspecting The Lift Arm By–Pass Control...4931
      Additional Inspection For Loaders With Advanced Hand Controls...4931
      Troubleshooting Chart...4932
    BICS™ (Without Press To Operate Button)...4933
      Inspecting The BICS™ Controller (Engine STOPPED– Key ON)...4933
      Inspecting Deactivation of the Auxiliary HydraulicsSystem (Engine STOPPED – Key ON)...4933
      Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)...4933
      Inspecting The Traction Lock (Engine RUNNING)...4933
      Inspecting The Lift Arm By–Pass Control...4933
      Maintenance...4933
      Troubleshooting Chart...4934
    SEAT SENSOR OVERRIDE ONLY (If Equipped)...4934
    BICS SYSTEM CONTROLLER...4935
      Removal And Installation...4936
    SEAT BAR SENSOR...4937
      Troubleshooting Guide...4937
      Seat Bar Sensor Test...4938
      Removal And Installation...4939
      BICS™ Controller Seat Bar Sensor Circuit Test...4940
    SEAT SENSOR...4941
      Troubleshooting Guide...4941
      Seat Sensor Test...4942
      Removal And Installation...4943
      BICS™ Controller Seat Sensor Circuit Test...4944
    TRACTION LOCK...4945
      Troubleshooting Guide...4945
      Removal And Installation...4946
    TRACTION LOCK CONTROL SYSTEM (S/N 514427600 & Above; 514525300 & Above; 514625300 & Above)...4947
      Inspecting The Traction Lock Control System...4947
      Maintenance...4947
    TRACTION LOCK CONTROL SYSTEM (S/N 514123809 & Below; 514222299 & Below)...4947
      Description...4947
      Inspection...4947
      Maintenance...4947
    BOSS® DIAGNOSTIC TOOL...4948
      Procedure...4948
    SENDER AND SENSOR...4948
      Service Checks...4948
    RPM SENSOR...4948
      Adjustment...4948
    MONITOR SERVICE CODES...4949
    TROUBLESHOOTING THE BOSS® & LCD DISPLAY...4951
    BOSS® UNIT...4952
      Removal And Installation...4952
    BOSS® INSTRUMENT PANEL...4953
      Removal And Installation...4953
    PWM MODULE...4954
      Description...4954
    PWM TROUBLESHOOTING...4955
      Chart...4956
    PWM CONTROL HANDLE...4957
      Handle Testing...4957
    PWM ELECTRIC SOLENOID...4957
      Solenoid Coil Testing...4957
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE...4958
  SPECIFICATIONS...4959
    LOADER SPECIFICATIONS...4961
      LOADER DIMENSIONS...4961
      PERFORMANCE...4961
      CONTROLS...4961
      ENGINE...4961
      HYDRAULIC SYSTEM...4962
      ELECTRICAL...4962
      DRIVE SYSTEM...4962
      CAPACITIES...4963
      TIRES...4963
    ENGINE SPECIFICATIONS (BF4M1011)...4964
      General...4964
      Fuel System...4964
      Valve And Valve Guide And Seat Insert...4964
      Piston And Rings...4965
      Connecting Rod...4965
      Cylinder Head And Block...4965
      Crankshaft And Main Bearings...4966
      Camshaft And Bearings...4966
      Oil Pump...4966
    ENGINE SPECIFICATIONS (BF4M1011F)...4967
      General...4967
      Fuel System...4967
      Valve And Valve Guide And Seat Insert...4967
      Piston And Rings...4968
      Connecting Rod...4968
      Cylinder Head And Block...4968
      Crankshaft And Main Bearings...4969
      Camshaft And Bearings...4969
      Oil Pump...4969
    ENGINE TORQUE...4970
      Specifications...4970
      Torque For General Metric Bolts...4971
    TORQUE SPECIFICATIONS FOR LOADER...4972
    HYDRAULIC CONNECTION SPECIFICATIONS...4973
      O–ring Face Seal Connection...4973
      Straight Thread O–ring Fitting...4973
      Tubelines And Hoses...4973
      Flare Fitting...4973
      O–ring Flare Fitting...4974
      Port Seal Fitting...4976
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...4977
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...4978
    DECIMAL AND MILLIMETER EQUIVALENTS...4979
    U.S. TO METRIC CONVERSION...4979
  ADVANCE HAND CONTROL SYSTEM (A.H.C)...4981
    ADVANCE HAND CONTROL ELECTRICAL SCHEMATICS...4983
    A.H.C. COMPONENTS...4993
      Identification...4993
    TROUBLESHOOTING (A.H.C.)...4994
    ACTUATOR VOLTAGE TEST...4996
      Procedure...4996
    HANDLE CONTROL UNIT TEST...4999
      Procedure...4999
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...5002
      Troubleshooting Chart...5002
    A.H.C./PWM CONTROLLER...5003
      Removal and Installation...5003
      Test...5003
      Description...5004
      Conditions...5005
      Troubleshooting Chart...5005
      Handle Testing...5006
      Solenoid Coil Testing...5006
    HANDLE CONTROL UNIT...5007
      Removal And Installation...5007
      Control Unit Connector...5010
    SWITCH HANDLE...5011
      Removal And Installation...5011
    A. H. C. HANDLE...5014
      Removal And Installation...5014
      Disassembly And Assembly...5015
    A.H.C. STEERING LEVER...5016
      Removal And Installation...5016
      Steering Lever Boot...5016
    ACTUATORS...5017
      Removal And Installation...5017
      Disassembly And Assembly...5018
      Mounting Plate...5019
    BICS™ VALVE...5020
      Lift Arm By–Pass Orifice...5020
      Check Valve...5021
      Lock Valve...5021
      BICS™ Valve Solenoid...5022
      Removal And Installation...5023
    HYDRAULIC CONTROL VALVE...5024
      Removal And Installation...5024
      Identification Chart...5027
      Disassembly And Assembly...5028
      Load Check Valve...5028
      Lift Base End Restrictor...5028
      Main Relief Valve...5029
      Port Relief Valve (Lift)...5030
      Anti–Cavitation/Port Relief Valve...5030
      Port Relief Valve (Tilt)...5031
      Anti–Cavitation Valve...5031
      Rubber Boot...5032
      Lift And Tilt Spool...5033
      Inspection...5035
      Auxiliary Spool...5036
      Auxiliary Electrical Solenoid...5037
      Spool Seal Installation...5038
      H–Port Auxiliary Section...5039
  SERVICE MANUAL REVISIONS...5041
    863/863H–1...5041
    863-2...5043
6900790 (9-00) - 863, 863 High Flow Operation & Maintenance Manual...5045
  OPERATOR SAFETY WARNINGS...5047
  CONTENTS...5049
    REFERENCE INFORMATION...5049
    BOBCAT COMPANY IS ISO 9001 CERTIFIED...5050
    REGULAR MAINTENANCE ITEMS...5050
  FOREWORD...5051
    SERIAL NUMBER LOCATIONS...5053
    LOADER SERIAL NUMBER...5053
    ENGINE SERIAL NUMBER...5053
    DELIVERY REPORT...5053
    BOBCAT LOADER IDENTIFICATION...5054
    OPTIONS AND ACCESSORIES...5055
  SAFETY...5057
    SAFETY INSTRUCTIONS...5059
      SAFETY IS THE OPERATOR’S RESPONSIBILITY...5059
      BEFORE OPERATING THE BOBCAT LOADER...5060
      SAFE OPERATION NEEDS A QUALIFIED OPERATOR *...5060
    FIRE PREVENTION...5061
    MACHINE SIGNS (DECALS)...5062
  OPERATING INSTRUCTIONS...5065
    INSTRUMENT PANEL...5067
      Without BOSS® (Front Panel)...5067
      Without BOSS (Side Console•)...5067
      With BOSS® (Front Panel)...5068
      With BOSS (Side Console•)...5068
    BOSS® OPTION PANEL...5069
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...5070
      Lift Arm By–Pass Control...5071
      Traction Lock Override...5071
      Auxiliary Hydraulic System (If Equipped)...5071
    TRACTION LOCK CONTROL SYSTEM...5071
    ENGINE SPEED CONTROL...5072
    PARKING BRAKE...5072
    STEERING LEVERS...5073
    STOPPING THE BOBCAT LOADER...5073
    SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)...5074
    SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS)...5075
    SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)...5076
    HYDRAULIC CONTROLS...5077
      Foot Pedals...5077
        Lift Arm Operation...5077
        Lift Arm Float Position...5077
        Tilt Operation...5077
        Bucket Position Valve Operation (If Equipped)...5077
      Hand Controls (Mechanical and Advanced Hand Controls)...5078
        Lift Arm Operation...5078
        Lift Arm Float Position...5078
        Tilt Operation...5078
        Bucket Position Valve Operation (If Equipped)...5078
      Advanced Hand Controls (AHC) (If Equipped)...5078
      Auxiliary Hydraulics (If Equipped)...5079
        Quick Couplers...5079
        Relieving Hydraulic Pressure...5079
        Auxiliary Hydraulics Switch...5080
        FRONT Auxiliary Hydraulics Operation ...5080
        FRONT Auxiliary Hydraulics Continuous Operation...5080
        REAR Auxiliary Hydraulics Operation ...5080
        High–Flow Hydraulics Operation (If Equipped)...5081
        Secondary Front Auxiliary Hydraulics (If Equipped)...5081
      Attachment Functions Control (If Equipped)...5082
    DAILY INSPECTION...5082
      Daily Inspection and Maintenance...5082
    GETTING READY FOR OPERATION...5083
    STARTING THE ENGINE...5084
      Normal Starting (Without BOSS®)...5085
      Cold Temperature Starting (Without BOSS®)...5086
      Warming The Hydraulic/Hydrostatic System...5086
    STOPPING THE ENGINE...5086
    STARTING THE ENGINE...5086
      Normal Starting (With BOSS®)...5086
      Cold Temperature Starting (With BOSS®)...5088
      Warming The Hydraulic/Hydrostatic System...5088
    STOPPING THE ENGINE...5088
    ATTACHMENTS AND BUCKETS...5089
      Installing The Bucket Or Attachment...5090
      Removing The Bucket Or Attachment ...5091
    OPERATING PROCEDURE...5092
      Filling The Bucket...5093
      Emptying The Bucket...5093
      Digging Into The Ground...5094
      Leveling The Ground (Using Lift Arms In Float Position)...5094
      Backfilling...5095
      PARKING THE BOBCAT LOADER...5095
    OPERATING PROCEDURE (HAND CONTROLS)...5096
      Filling The Bucket...5096
      Emptying The Bucket...5096
      Digging Into The Ground...5097
      Leveling The Ground (Using Lift Arms In Float Position)...5097
      Backfilling...5098
      PARKING THE BOBCAT LOADER...5098
    TRANSPORTING THE BOBCAT LOADER...5099
    TOWING THE LOADER...5099
    STOPPING THE BOBCAT LOADER...5099
    LIFTING THE LOADER...5100
      Four Point Lift...5100
      Single Point Lift...5100
  PREVENTIVE MAINTENANCE...5101
    MAINTENANCE SAFETY...5103
    SERVICE SCHEDULE...5105
    OPERATOR CAB...5106
      Raising The Operator Cab...5106
      Lowering the Operator Cab...5107
      Emergency Exit...5108
    SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)...5109
      Inspecting The Seat Bar...5109
      Maintaining The Seat Bar...5109
    SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS)...5110
      Inspecting The Seat Bar...5110
      Maintaining The Seat Bar...5110
    SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)...5111
      Inspecting The Seat Bar...5111
      Maintaining The Seat Bar...5111
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...5112
      Inspecting The BICS™ Controller (Engine STOPPED– Key ON)...5112
      Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)...5112
      Inspecting The Seat Bar Sensor (Engine RUNNING)...5112
      Inspecting The Traction Lock (Engine RUNNING)...5112
      Inspecting The Lift Arm By–Pass Control...5112
      Additional Inspection For Loaders With Advanced Hand Controls...5112
    TRACTION LOCK CONTROL SYSTEM...5113
      Inspecting The Traction Lock Control System...5113
      Maintenance...5113
    PIVOT PINS...5114
    TIRE MAINTENANCE...5114
      Wheel Nuts...5114
      Tire Rotation...5114
      Tire Mounting...5114
    LIFT ARM SUPPORT DEVICE...5115
      Engaging The Lift Arm Support Device...5115
      Disengaging The Lift Arm Support Device...5116
    BOB–TACH...5117
      Inspection And Maintenance...5117
    REAR DOOR...5118
      Adjusting the Rear Door...5118
    REAR GRILL...5118
    AIR CLEANER SERVICE...5119
    FUEL SYSTEM...5121
      Fuel Specifications...5121
      Filling The Fuel Tank...5121
      Fuel Filter...5122
      Removing Air From The Fuel System...5122
    ENGINE LUBRICATION...5123
      Checking...5123
      Oil Chart...5123
      Replacing The Oil And Filter...5123
    ENGINE COOLING SYSTEM...5125
      Cleaning The Cooling System...5125
    ALTERNATOR BELT...5126
      Adjusting The Alternator Belt...5126
    TIMING BELT...5127
    DRIVE BELT...5127
      Adjusting The Drive Belt...5127
      Replacing The Drive Belt...5128
    ELECTRICAL SYSTEM...5129
      Description...5129
      Servicing The Electrical System...5129
      Fuse Location...5129
      Using A Booster Battery (Jump Starting)...5130
      Removing And Installing The Battery...5131
    FAN GEARBOX...5132
      Checking And Maintaining...5132
    FINAL DRIVE TRANSMISSION (CHAINCASE)...5133
      Checking And Adding Oil...5133
      Removing Oil From The Chaincase...5133
    HYDRAULIC/HYDROSTATIC SYSTEM...5134
      Checking And Adding Fluid...5134
      Replacing the Hydraulic/Hydrostatic Filter...5134
      Replacing The Hydraulic Fluid...5135
      Hydraulic Reservoir Breather Cap...5136
    LUBRICATION OF THE BOBCAT LOADER...5137
  SYSTEMS ANALYSIS...5139
    SERVICE CODES...5141
    AUXILIARY HYDRAULICS OPERATION...5142
      Troubleshooting Chart...5142
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...5143
      Troubleshooting Chart...5143
    ADVANCED HAND CONTROLS (AHC)...5143
      Troubleshooting Chart...5143
  MACHINE SIGN TRANSLATIONS...5145
    IMPORTANT - 6710456...5147
    SERVICE SCHEDULE - 6715563...5148
    WARNING - 6579510...5150
    WARNING - 6703725...5151
    WARNING - 6579528...5152
    WARNING - 6577754...5152
    DANGER - 6702302...5152
    DANGER - 6702301...5152
    DANGER - 6717343...5153
    WARNING - 6575944...5153
  SPECIFICATIONS...5155
    PERFORMANCE...5157
    CONTROLS...5157
    ENGINE...5157
    HYDRAULIC SYSTEM...5158
    ELECTRICAL...5158
    DRIVE SYSTEM...5158
    CAPACITIES...5158
    TIRES...5158
    BOBCAT COMPANY APPROVED ATTACHMENTS & ACCESSORIES...5159
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS...5161
  WARRANTY...5163
6900937 (12-06) - 863 Turbo, 863 Turbo High Flow Operation & Maintenance Manual...5165
  OPERATOR SAFETY WARNINGS...5167
  CONTENTS...5169
  FOREWORD...5171
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...5173
    REGULAR MAINTENANCE ITEMS...5173
    MOTOR OIL...5173
    SERIAL NUMBER LOCATIONS...5174
      Loader Serial Number...5174
      Engine Serial Number...5174
    DELIVERY REPORT...5174
    BOBCAT LOADER IDENTIFICATION...5175
    FEATURES AND ACCESSORIES...5176
  SAFETY...5177
    SAFETY INSTRUCTIONS...5179
      Before Operation...5179
      Safe Operation Is The Operator’s Responsibility...5180
      Safe Operation Needs A Qualified Operator...5180
      Fire Prevention...5181
    MACHINE SIGNS (DECALS)...5182
  OPERATING INSTRUCTIONS...5185
    INSTRUMENT PANEL IDENTIFICATION...5187
      Left Panel - Standard and Deluxe Instrument Panels...5187
      Right Panel - Standard Instrument Panel (With Key Switch)...5188
      Right Panel - Deluxe Instrument Panel (With Keyless Start)...5189
      Option and Field Accessory Panels (If Equipped)...5191
      Side Accessory Panel...5191
      Front Accessory Panel...5191
      Cab Light...5192
    LIFT ARM BY-PASS CONTROL...5192
    TRACTION LOCK OVERRIDE...5192
    ENGINE SPEED CONTROL...5193
    TWO-SPEED CONTROL...5193
    PARKING BRAKE (Early Models)...5193
    PARKING BRAKE (Later Models)...5194
    STEERING LEVERS...5195
    STOPPING THE BOBCAT LOADER...5195
    SEAT BAR RESTRAINT SYSTEM...5196
    HYDRAULIC CONTROLS...5197
      Foot Pedals...5197
      Hand Controls (If Equipped)...5198
      Quick Couplers...5198
      Releasing Hydraulic Pressure (Loader and Attachment)...5199
      Attachment Auxiliary Hydraulic Controls (If Equipped)...5199
      Auxiliary Hydraulics Button...5199
      FRONT Auxiliary Hydraulics Operation...5200
      REAR Auxiliary Hydraulics Operation...5200
      High-Flow Hydraulics Operation (If Equipped)...5201
      Secondary Front Auxiliary Hydraulics (If Equipped)...5202
      Attachment Control Device (ACD) (If Equipped)...5203
      Bucket Position Valve Operation (If Equipped)...5203
    DAILY INSPECTION...5204
    PRE-STARTING PROCEDURE...5205
    STARTING THE ENGINE...5208
      Standard Instrument Panel (With Key Switch)...5208
      Deluxe Instrument Panel (With Keyless Start)...5209
      Cold Temperature Starting...5210
      Warming the Hydraulic/Hydrostatic System...5210
    STOPPING THE ENGINE...5211
    MONITORING THE DISPLAY PANEL...5212
    ATTACHMENTS AND BUCKETS...5213
      Hand Lever Bob-Tach...5214
      Power Bob-Tach...5217
    OPERATING PROCEDURE...5219
      Filling the Bucket (Foot Pedals)...5220
      Filling the Bucket (Hand Controls)...5220
      Emptying the Bucket (Foot Pedals)...5221
      Emptying the Bucket (Hand Controls)...5221
      Leveling the Ground (Using Lift Arms in Float Position) (Foot Pedals)...5221
      Leveling the Ground (Using Lift Arms in Float Position) (Hand Controls)...5222
      Digging Into the Ground (Foot Pedals)...5222
      Digging Into the Ground (Hand Controls)...5223
      Backfilling (Foot Pedals)...5223
      Backfilling (Hand Controls)...5223
    PARKING THE BOBCAT LOADER...5224
    TRANSPORTING THE BOBCAT LOADER...5225
    TOWING THE LOADER...5226
      Procedure For Single Speed...5226
      Procedure For Two Speeds...5226
    LIFTING THE LOADER...5228
      Single Point Lift...5228
      Four Point Lift...5228
  PREVENTIVE MAINTENANCE...5231
    MAINTENANCE SAFETY...5235
    SERVICE SCHEDULE...5237
    LIFT ARM SUPPORT DEVICE...5238
      Engaging The Lift Arm Support Device...5238
      Disengaging The Lift Arm Support Device...5239
    HEATER AND AIR CONDITIONING...5240
      Cleaning and Maintenance...5240
    OPERATOR CAB...5241
      Raising The Operator Cab...5241
      Lowering The Operator Cab...5242
      Cab Door Sensor (If Equipped)...5243
      Emergency Exit...5243
    SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)...5245
      Inspecting the Seat Bar...5245
      Maintaining the Seat Bar...5245
    SEAT BAR RESTRAINT SYSTEM ADVANCED CONTROL SYSTEM (ACS) and ADVANCED HAND CONTROLS (AHC)...5246
      Inspecting the Seat Bar...5246
      Maintaining the Seat Bar...5246
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...5247
      Inspecting The BICS Controller (Engine STOPPED - Key ON)...5247
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...5247
      Inspecting The Seat Bar Sensor (Engine RUNNING)...5247
      Inspecting The Traction Lock (Engine RUNNING)...5247
      Inspecting The Lift Arm By-Pass Control...5247
      Inspection For Deactivation Of Lift And Tilt Functions (AHC & ACS)...5247
    REAR DOOR...5248
      Opening And Closing The Rear Door...5248
      Adjusting The Rear Door...5248
    REAR GRILL...5249
    AIR CLEANER SERVICE...5249
      Replacing Filter Element...5249
    FUEL SYSTEM...5251
      Fuel Specifications...5251
      Filling the Fuel Tank...5251
      Fuel Filter...5251
      Fuel Lift Pump Strainer...5252
      Removing Air From The Fuel System...5252
    ENGINE LUBRICATION SYSTEM...5253
      Checking Engine Oil...5253
      Replacing The Oil And Filter...5253
      Oil Chart...5253
    ENGINE COOLING SYSTEM...5254
      Cleaning The Cooling System...5254
    ELECTRICAL SYSTEM...5255
      Description...5255
      Cleaning Battery And Terminals...5255
      Fuse Location...5255
      Using A Booster Battery (Jump Starting)...5256
      Removing And Installing The Battery...5257
    HYDRAULIC/HYDROSTATIC SYSTEM...5259
      Checking And Adding Fluid...5259
      Replacing Hydraulic/Hydrostatic Filter...5260
      Replacing Hydraulic Fluid And Case Drain Filters...5260
      Breather Cap...5262
    TIRE MAINTENANCE...5263
      Wheel Nuts...5263
      Rotating...5263
      Mounting...5263
    FINAL DRIVE TRANSMISSION (CHAINCASE)...5264
      Checking And Adding Oil...5264
      Removing Oil From The Chaincase...5264
    FAN GEARBOX...5265
      Checking And Maintaining...5265
    DRIVE BELT...5266
      Adjusting The Drive Belt...5266
      Replacing The Drive Belt...5266
    ALTERNATOR BELT...5267
      Adjusting The Alternator Belt...5267
    TIMING BELT...5267
    LUBRICATING THE BOBCAT LOADER...5268
    HAND LEVER BOB-TACH...5270
      Inspection And Maintenance...5270
    POWER BOB-TACH (OPTION)...5271
      Inspection And Maintenance...5271
  SYSTEM SETUP & ANALYSIS...5273
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...5275
      Troubleshooting Chart...5275
    DIAGNOSTICS SERVICE CODES...5276
      Display...5276
      Number Codes List...5277
    DELUXE INSTRUMENTATION PANEL SETUP...5280
      Deluxe Panel Upgrade...5280
      Icon Identification...5281
      Deluxe Panel Setup...5282
      Passwords...5282
      Changing the Password...5283
    SHUTDOWN FEATURE...5284
    SERVICE CLOCK RESET...5284
  MACHINE SIGN TRANSLATIONS...5285
    IMPORTANT (6560573)...5287
    WARNING (6734534)...5288
    WARNING (6728539)...5289
    WARNING (6718699)...5290
    DANGER (6702301)...5291
    WARNING (6577754)...5291
    DANGER (6702302)...5292
    WARNING (6579528)...5292
    WARNING (6710358)...5292
    WARNING (6717343)...5293
    WARNING (6705221)...5293
    WARNING (6715944)...5293
    LIFT ARM SUPPORT DEVICE (6706558)...5294
  SPECIFICATIONS...5295
    SKID STEER LOADER SPECIFICATIONS...5297
      Performance Specifications...5297
      Engine...5297
      Loader Controls...5298
      Drive System...5298
      Hydraulic System...5298
      Electrical System...5298
      Standard Instrumental Panel...5298
      Optional Deluxe Instrumentation...5298
      Capacity...5298
    BOBCAT APPROVED ATTACHMENTS & ACCESSORIES...5299
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS...5301
6900942 (10-12) - 863 Turbo, 863 Turbo High Flow Service Manual...5305
  MAINTENANCE SAFETY...5307
  ALPHABETICAL INDEX...5309
  CONTENTS...5311
    FOREWORD...5312
    SAFETY INSTRUCTIONS...5315
    FIRE PREVENTION...5317
      Maintenance...5317
      Operation...5317
      Electrical...5317
      Hydraulic System...5317
      Fueling...5317
      Starting...5317
      Spark Arrestor Exhaust System...5317
      Welding And Grinding...5318
      Fire Extinguishers...5318
    SERIAL NUMBER LOCATIONS...5319
      Loader Serial Number...5319
      Engine Serial Number...5319
    DELIVERY REPORT...5320
    BOBCAT LOADER IDENTIFICATION...5321
  SAFETY AND MAINTENANCE...5323
    LIFTING AND BLOCKING THE LOADER...5325
      Procedure...5325
    LIFT ARM SUPPORT DEVICE...5327
      Engaging The Lift Arm Support Device...5327
      Disengaging The Lift Arm Support Device...5328
    OPERATOR CAB...5329
      Raising The Operator Cab...5329
      Lowering The Operator Cab...5330
      Emergency Exit...5331
    TRANSPORTING THE LOADER...5333
      Procedure...5333
      Adjusting The Bumper...5333
    TOWING THE LOADER...5335
      Procedure For Non-Two-Speeds...5335
      Procedure For Two-Speeds (S/N 51464170, 514540172, 514449389 And Below)...5336
      Procedure (S/N 51451171, 514540173, 514449390 and Above)...5337
    REMOTE START...5339
      Procedure For Loader Without, Attachments Control Harness...5339
      Procedure For Loader With, Attachments Control Harness...5340
      Procedure...5342
    SERVICE SCHEDULE...5343
      Chart...5343
    AIR CLEANER SERVICE...5345
      Replacing Filter Element...5345
    ENGINE COOLING SYSTEM...5347
      Cleaning The Cooling System...5347
    FUEL SYSTEM...5349
      Fuel Specifications...5349
      Filling The Fuel Tank...5349
      Fuel Filter...5350
      Fuel Lift Pump Strainer...5351
      Removing Air From The Fuel System...5351
    ENGINE LUBRICATION SYSTEM...5353
      Checking Engine Oil...5353
      Replacing Oil And Filter...5353
    HYDRAULIC / HYDROSTATIC SYSTEM...5355
      Checking And Adding Fluid...5355
      Replacing The Hydraulic / Hydrostatic Fluid...5356
      Replacing Hydraulic Fluid And Case Drain Filters...5356
      Breather Cap...5358
    FINAL DRIVE TRANSMISSION (CHAINCASE)...5359
      Checking And Adding Oil...5359
      Replacing The Oil...5359
    FAN GEAR BOX...5361
      Checking And Adding Oil...5361
    BOB-TACH...5363
      Inspection And Maintenance...5363
    POWER BOB-TACH (OPTION)...5365
      Inspection And Maintenance...5365
    LUBRICATING THE LOADER...5367
      Procedure...5367
    TIRE MAINTENANCE...5369
      Wheel Nuts...5369
      Tire Rotation...5369
      Tire Mounting...5369
  HYDRAULIC SYSTEM...5371
    HYDRAULIC / HYDROSTATIC SCHEMATICS...5377
    HYDRAULIC SYSTEM INFORMATION...5417
      Tighten Procedures...5421
      Troubleshooting Chart...5421
    CYLINDER (LIFT)...5423
      Checking...5423
      Removal And Installation...5424
      Parts Identification...5426
      Disassembly...5427
      Assembly...5429
    CYLINDER (TILT)...5433
      Checking...5433
      Removal And Installation...5433
      Rod End Seal...5435
      Parts Identification...5436
      Disassembly...5437
      Assembly...5439
    CYLINDER (POWER BOB-TACH)...5443
      Checking...5443
      Removal And Installation...5444
      Parts Identification...5445
      Disassembly...5446
      Assembly...5447
    MAIN RELIEF VALVE (FOOT CONTROL)...5451
      Checking The Main Relief Valve At Front Auxiliary Hydraulics...5451
      Checking The Main Relief Valve Without Front Auxiliaries...5452
      Removal And Installation...5454
      Adjustment...5455
    HYDRAULIC CONTROL VALVE (FOOT CONTROL)...5457
      Removal And Installation (S/N 514447863 & Below)...5457
      Removal And Installation (S/N 514447864 & Above)...5460
      BICS™ Valve, Removal And Installation...5466
      BICS™ Valve, Lift arm Bypass Orifice Disassembly And Assembly...5467
      BICS™ Valve, Check Valve Disassembly And Assembly (S/N 514450007 & Below)...5468
      BICS™ Valve, Check Valve Disassembly And Assembly (514450007 & Above)...5469
      BICS™ Valve, Lock Valve Disassembly And Assembly...5470
      BICS™ Valve, Solenoid Disassembly And Assembly...5471
      BICS™ Valve, Solenoid Testing...5472
      Identification Chart...5472
      Load Check Valve...5473
      Main Relief Valve...5474
      Port Relief Valve, Tilt Spool...5475
      Port Relief Valve, Lift Spool...5475
      Anti-Cavitation Valve / Port Relief Valve, Tilt Spool...5476
      Anti-Cavitation Valve, Lift Spool...5476
      Rubber Boot...5477
      Lift And Tilt Block...5477
      Lift Spool And Detent...5478
      Tilt Spool Removal And Installation...5487
      Auxiliary Spool Removal And Installation...5489
      Auxiliary Plug Removal And Installation...5491
      Auxiliary Electric Solenoid Disassembly...5492
      Port Relief-Auxiliary Section Disassembly...5493
      Cleaning And Inspection...5494
    HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)...5495
      Description...5495
      Actuator Removal And Installation (In Loader)...5495
      Removal & Installation (S/N 514447863 & Below)...5497
      Removal And Installation (S/N 514447864 & Above)...5501
      Actuator Removal And Installation (Out Of Loader)...5506
      BICS™ Valve Removal And Installation...5507
      BICS™ Valve Lift Arm Bypass Orifice Removal And Installation...5509
      BICS™ Valve Check Valve Removal And Installation...5510
      BICS™ Valve Lock Valve Removal And Installation...5511
      BICS™ Valve Removal Solenoid And Installation...5512
      BICS™ Valve Solenoid Testing...5513
      Identification Chart...5513
      Lift Base End Restrictor...5514
      Load Check Valve...5514
      Main Relief Valve...5516
      Port Relief Valve(s)...5517
      Anti-Cavitation Valve / Port Relief Valve...5518
      Anti-Cavitation Valve...5519
      Lift Spool Removal And Installation...5520
      Tilt Spool Removal And Installation...5521
      Lift And Tilt Spool Disassembly And Assembly...5522
      Auxiliary Spool Removal And Installation...5523
      Auxiliary Electric Solenoid Disassembly And Assembly...5524
      Port-Auxiliary Section Disassembly...5525
      Cleaning And Inspection...5526
    LIFT ARM BYPASS CONTROL VALVE...5527
      Inspecting...5527
      Additional Inspection For Loaders With ACS...5527
      Removal And Installation...5527
      Disassembly And Assembly...5528
    HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 & BELOW)...5529
      Checking The Output Of The Pump...5529
      Removal And Installation...5530
      Parts Identification...5531
      Disassembly...5532
      Inspection...5534
      Assembly...5535
    HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N 514449483 & Below)...5537
      Checking The Output Of The High Flow Pump...5537
      Removal And Installation...5538
      Parts Identification...5540
      Disassembly...5541
      Inspection...5545
      Assembly...5546
    HYDRAULIC PUMP (CAST IRON) (S/N 514449260 & ABOVE)...5551
      Check The Output Of The Hydraulic Pump Without Power Bob-Tach...5551
      Check The Output Of The Hydraulic Pump With Power Bob-Tach...5553
      Removal And Installation...5554
      Identification...5556
      Disassembly And Assembly...5557
    HYDRAULIC PUMP (CAST IRON HIGH FLOW) (S/N 514449484-514450945)...5563
      Check The Output Of The Hydraulic Pump Without Power Bob-Tach...5563
      Check The Output Of The Hydraulic Pump With Power Bob-Tach...5564
      Removal And Installation...5566
      Identification...5568
      Disassembly And Assembly...5569
    HYDRAULIC PUMP (CAST IRON HI FLOW) (514450846 & aBOVE)...5579
      Hydraulic Pump Test...5579
      Inline Hydraulic Pump Test (Standard)...5580
      Inline Hydraulic Pump Test (High Flow)...5582
      High Flow Relief Adjustment Procedure...5584
      High Flow Relief Valve Removal and Installation...5586
      Removal And Installation...5588
      Identification...5590
      Disassembly And Assembly...5591
    HYDRAULIC / HYDROSTATIC FILTER...5601
      Housing Removal And Installation...5601
    HYDRAULIC FLUID RESERVOIR...5603
      Draining The Fluid Reservoir...5603
      Removal And Installation...5603
      Hydraulic Fluid Screen...5605
    BUCKET POSITION VALVE...5607
      Solenoid Removal And Installation...5607
      Solenoid Testing...5608
      Removal And Installation...5608
      Disassembly And Assembly...5610
    SELECT VALVE...5613
      Checking The High Flow Pump Relief Valve (S/N 514450945 & Below)...5613
      Removal And Installation...5614
      Disassembly And Assembly...5616
    REAR AUXILIARY DIVERTER VALVE...5619
      Disassembly...5619
      Inspection...5620
      Solenoid Testing...5620
      Assembly...5620
    POWER BOB-TACH BLOCK (6676547-ALUMINUM)...5621
      Removal And Installation...5621
      Disassembly And Assembly...5623
    POWER BOB-TACH BLOCK (6678554-CAST IRON)...5631
      Removal And Installation...5631
      Disassembly And Assembly...5632
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK...5641
      Removal And Installation (514449564 & Above)...5641
      Disassembly And Assembly (518916011 & Above)...5641
  HYDROSTATIC SYSTEM...5643
    HYDROSTATIC SYSTEM INFORMATION...5645
      Troubleshooting Chart...5645
      Replentishing The Valve Function...5646
    HYDROSTATIC MOTOR...5647
      Removal And Installation...5647
      Parts Identification...5649
      Disassembly...5650
      Inspection...5653
      Assembly...5654
      Carrier Removal And Installation...5657
      Carrier Parts Identification...5658
      Carrier Disassembly...5659
      Carrier Assembly...5660
    HYDROSTATIC MOTOR (TWO-SPEED)...5663
      Removal And Installation...5663
      Parts Identification...5666
      Disassembly...5667
      Inspection...5674
      Assembly...5675
    CHARGE PRESSURE...5683
      Hydrostatic Charge Pressure Sender Removal And Installation...5683
    HYDROSTATIC PUMP...5685
      Replenishing / High Pressure Relief Valve...5685
      Charge Pressure Relief Valve...5686
      Removal And Installation...5687
      Parts Identification (Right Half)...5689
      Parts Identification (Left Half)...5690
      Hydraulic Pump Removal & Installation...5691
      Disassembly...5692
      Assembly...5700
    DRIVE BELT...5709
      Shield Removal And Installation...5709
      Adjustment...5709
      Replacement...5710
      Tensioner Pulley Removal And Installation...5710
      Tensioner Pulley Tension Spring...5712
    OIL COOLER...5713
      Removal And Installation With STC (Seal Tight Connector)...5713
  DRIVE SYSTEM...5715
    BRAKE...5717
      Pedal Removal And Installation...5717
      Pedal Disassembly And Assembly...5718
      Disc Removal And Installation...5719
    BRAKE (TWO-SPEED) (S/N 514449389 & Below)...5723
      Block Removal And Installation...5723
      Block Disassembly And Assembly...5724
    BRAKE (TWO-SPEED) (S/N 514449390 & Above)...5729
      Block Removal And Installation...5729
      Block Disassembly And Assembly...5731
    DRIVE COMPONENTS...5735
      Axle Seal Removal And Installation...5735
      Axle, Sprocket And Bearings Removal And Installation...5737
      Drive Chain Removal And Installation...5742
    CHAINCASE...5743
      Front Chaincase Cover Removal And Installation...5743
      Rear Chaincase Cover Removal And Installation...5743
  MAINFRAME...5747
    SEAT BAR...5751
      Removal And Installation...5751
      Assembling Components...5752
      Compression Spring Assembly And Assembly...5754
    OPERATOR CAB...5755
      Gas Cylinder Removal And Installation...5755
      Gas Cylinder Bracket Disassembly And Assembly...5756
      Removal And Installation...5757
    OPERATOR SEAT...5759
      Removal And Installation...5759
      Seat Belt Removal And Installation...5759
    OPERATOR SEAT (SUSPENSION)...5761
      Removal And Installation...5761
      Slide Rail Removal And Installation...5762
      Cushion Removal And Installation...5763
      Back Removal And Installation...5764
      Shock Removal And Installation...5764
    BOB-TACH...5767
      Removal And Installation...5767
      Bob-Tach Lever And Wedge...5769
      Bob-Tach Stops...5770
      Pivot Pin Bushing And Seal Replacement...5771
    POWER BOB-TACH...5773
      Removal And Installation...5773
      Power Bob-Tach Lever And Wedge...5774
      Pivot Pin Bushing And Seal Replacement...5776
    LIFT ARMS...5777
      Removal And Installation...5777
    REAR GRILL...5781
      Removal And Installation...5781
    REAR DOOR...5783
      Removal And Installation (S/N 514449208 & Below)...5783
      Adjusting The Rear Door Latch (S/N 514449208 & Below)...5784
      Striker Removal And Installation (S/N 514449209 & Above)...5785
      Adjusting The Striker (S/N 514449209 & Above)...5785
      Latch Removal And Installation (S/N 514449209 & Above)...5786
    FUEL TANK...5787
      Removal And Installation...5787
      Fuel Level Sender...5788
    CONTROL PEDALS...5789
      Removal And Installation...5789
      Pedal Adjustment...5789
      Crossbar Linkage Removal And Installation...5790
      Lift Foot Pedal Linkage Removal And Installation...5791
      Tilt Foot Pedal Linkage Removal And Installation...5792
    CONTROL PEDALS (ACS)...5793
      Foot Sensor Removal And Installation...5793
      Foot Pedal Removal And Installation...5794
      Foot Pedal Linkage Disassembly And Assembly...5794
    CONTROL PANEL...5795
      Removal And Installation...5795
    CONTROL HANDLE...5799
      Lever Removal And Installation...5799
      Lever Disassembly And Assembly...5799
      Linkage Removal And Installation...5800
      Linkage Neutral Adjustment...5803
    CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC)...5809
      Components Identification...5809
      Trouble shooting Guide...5810
      Parts Identification...5811
      AHC Controller Removal And Installation...5812
      Handle Control Unit Connector...5813
      Control Handle Removal And Installation...5814
      Actuators Disassembly And Assembly...5817
    CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/ PUSH BUTTON FLOAT)...5819
      Components Identification...5819
      Trouble shooting Guide...5820
      Controller Connector and Wire Identification...5821
      AHC Controller Removal And Installation...5822
      Handle Sensor Removal And Installation...5823
      Handle Sensor Connector...5825
      Control Handle Removal And Installation...5826
      Actuators Disassembly And Assembly...5829
    CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) ADVANCED HAND CONTROL...5831
      Components Identification...5831
      Handle Sensor Removal And Installation...5831
      Control Handle Removal And Installation...5835
      Control Handle Disassembly and Assembly...5836
      Control Lever Removal And Installation...5837
      Control Lever Boot...5838
    CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL...5839
      Components Identification...5839
      Handle Sensor Removal And Installation...5839
      Control Handle Removal And Installation...5843
      Control Handle Disassembly and Assembly...5844
      Control Lever Removal And Installation...5844
      Control Lever Boot...5846
  ELECTRICAL SYSTEM & ANALYSIS...5847
    ELECTRICAL SCHEMATICS...5851
    ELECTRICAL SYSTEM INFORMATION...5859
      Troubleshooting Chart...5861
      Description...5863
      Fuse Location...5865
      Relay Switches Location...5865
      Solenoid Test...5866
    BATTERY...5869
      Removal And Installation...5869
      Servicing The Electrical System...5871
      Using A Booster Battery (Jump Starting)...5872
    ALTERNATOR (55 AMP)...5873
      Alternator Output Test...5873
      Rectifier (Diode) Test...5873
      Alternator Regulator Test...5874
      Removal And Installation...5875
      Disassembly...5876
      Stator Continuity Test...5876
      Stator Ground Test...5876
      Rotor Continuity Test...5877
      Rotor Ground Test...5877
      Rectifier Continuity (Diode) Test...5877
      Assembly...5878
    ALTERNATOR (90 AMP)...5879
      Adjusting The Alternator Belt...5879
      Alternator Identification...5879
      Charging System Check...5880
      Alternator Voltage Test...5881
      Low Voltage Test...5882
      High Voltage Test...5882
      Removal And Installation...5883
      Rectifier Continuity (Diode) Test...5884
      Alternator Regulator Test...5885
      Disassembly...5885
      Stator Continuity Test...5886
      Stator Ground Test...5886
      Rotor Continuity Test...5886
      Rotor Ground Test...5886
      Assembly...5887
    STARTER (NIPPONDENSO)...5889
      Removal And Installation...5889
      Parts Identification...5890
      Disassembly And Assembly...5891
      External Pinion...5894
      Inspection And Repair...5895
      No Load Test...5899
    STARTER (VALEO)...5901
      Checking...5901
      Removal And Installation...5902
      Parts Identification...5903
      Disassembly and Assembly...5904
      Inspection And Repair...5907
      No Load Test...5909
    INSTRUMENT PANEL...5911
      Left Panel...5911
      Right Panel - Standard Instrument Panel (With Key Switch)...5912
      Right Panel - (Deluxe) (With Keyless Start)...5913
      Right Panel Setup Display Options (Deluxe)...5914
      Deluxe Panel Setup...5915
      Passwords...5915
      Changing The Password...5915
      Option And Field Accessory Panels...5917
      Standard Panel Removal And Installation (Right Side)...5918
      Deluxe Panel Removal And Installation (Right Side)...5919
      Standard & Deluxe Panel Removal And Installation (Left Side)...5920
    LIGHTS...5923
      Front Removal And Installation...5923
      Rear Removal And Installation...5924
    BOBCAT CONTROLLER...5925
      Identification Chart (S/N 514450763 & Below)...5925
      Identification Chart (S/N 514450764 & Above)...5926
      Removal And Installation...5928
    DELUXE INSTRUMENTATION SERVICE CODES...5931
    BICS™ SYSTEM...5933
      Inspecting The BICS™ Controller (Engine STOPPED - Key ON)...5933
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...5933
      Inspecting The Seat Bar Sensor (Engine RUNNING)...5933
      Inspecting The Traction Lock (Engine RUNNING)...5933
      Inspecting The Lift Arm Bypass Control...5933
      Additional Inspection For Loaders With Advanced Hand Controls...5934
      Troubleshooting Chart...5935
      Troubleshooting Guide...5936
    SEAT BAR SENSOR...5937
      Troubleshooting Chart...5937
      Test...5938
      Removal And Installation...5939
      BICS™ Circuit Test...5940
    TRACTION LOCK...5941
      Troubleshooting Chart...5941
      Removal And Installation (Single Speed)...5942
      Description Of The Control System (Two-Speed)...5943
      Inspecting The Control System (Two-Speed)...5943
    ADVANCED HAND CONTROL SYSTEM (AHC)...5945
      Components Identification...5945
      Trouble shooting Guide...5946
      Parts Identification...5947
      AHC Controller Removal And Installation...5948
      Handle Control Unit Connector...5949
      Switch Handle Removal And Installation...5950
      Actuators Disassembly And Assembly...5953
    ADVANCED HAND CONTROL SYSTEM (AHC) (W/ PUSH BUTTON FLOAT)...5955
      Components Identification...5955
      Trouble shooting Guide...5956
      Controller Connector and Wire Identification...5957
      AHC Controller Removal And Installation...5958
      Handle Control Unit Removal And Installation...5959
      Handle Control Unit Connector...5961
      Switch Handle Removal And Installation...5962
      Actuators Disassembly And Assembly...5965
    ADVANCED CONTROL SYSTEM (ACS) ADVANCED HAND CONTROL...5967
      Components Identification...5967
      Troubleshooting Guide...5968
      Controller, Connector And Wire Identification...5969
      ACS Controller Removal And Installation...5970
      Handle Sensor Connector...5971
      Switch Handle Removal...5972
      Switch Handle Installation...5974
      Actuators Disassembly and Assembly...5977
    ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND / FOOT CONTROL...5979
      Components Identification...5979
      Troubleshooting Guide...5981
      Controller, Connector And Wire Identification...5982
      ACS Controller Removal And Installation...5983
      Handle Sensor Connector...5984
      Switch Handle Removal...5985
      Switch Handle Installation...5987
      Actuators Disassembly and Assembly...5990
      Handle Lock Solenoid Removal And Installation...5991
      Handle Lock Solenoid Disassembly And Assembly...5992
      Handle Lock Solenoid Connector...5992
      Calibration Of The ACS System...5993
      Switchable Hand / Foot Controls Calibration Procedure...5993
      Hand Controls Only Calibration Procedure...5995
      Foot Sensor Disassembly And Assembly...5996
      Foot Sensor Connector...5997
      Foot Lock Solenoid Removal And Installation...5998
      Foot Lock Solenoid Connector...5998
    ELECTRICAL / HYDRAULIC CONTROLS REFERENCE...6001
      Controls Identification Chart...6001
  ENGINE SERVICE...6003
    TROUBLESHOOTING...6005
      Chart...6005
    ENGINE SPEED CONTROL...6007
      Removal And Installation...6007
      Speed Control Cable...6008
      Speed Control Linkage...6009
    MUFFLER...6011
      Removal And Installation...6011
    AIR CLEANER...6013
      Housing Removal And Installation...6013
    RADIATOR...6015
      Oil Cooler Removal And Installation...6015
    COOLING FAN...6017
      Drive Tension Pulley Removal And Installation...6017
      Gearbox / Blower Housing Removal And Installation...6018
      Blower Removal And Installation...6021
      Gearbox Parts Identification...6022
      Gearbox Disassembly...6023
      Gearbox Assembly...6028
      Gearbox, Checking Backlash...6033
    ENGINE COMPONENTS AND TESTS...6037
      Engine Compression, Checking...6037
      Glow Plug, Checking...6038
      Fuel Shut-Off Solenoid, Checking...6039
      Fuel Shut-Off Solenoid Removal and Installation...6040
      Fuel Injection Pump Removal...6040
      Fuel Injection Pump Timing...6042
      Fuel Injection Pump Installation...6043
      Fuel Injector Removal and Installation...6045
      Fuel Injector, Checking...6046
      Fuel Injector Disassembly...6047
      Fuel Injector Assembly...6048
      Timing Belt Inspection...6050
      Timing Belt Removal...6050
      Timing Belt Installation...6051
      Timing Belt, Replacement In the Loader...6055
      Valve Clearance Adjustment...6060
      Valve Timing, Checking...6061
      Thermostat, Oil Pressure Control Valves And Heater Connections...6063
    ENGINE AND ENGINE MOUNTS...6067
      Removal And Installation...6067
      Engine Mount Replacement...6073
    FLYWHEEL AND HOUSING...6075
      Flywheel Removal And Installation...6075
      Ring Gear Removal And Installation...6075
      Flywheel Housing Removal And Installation...6075
    RPM SENSOR...6077
      Adjustment...6077
    RECONDITIONING THE ENGINE...6079
      Deutz Engine Tools Identification Chart...6079
      Disassembly...6080
      Assembly...6084
      Cylinder, Checking...6100
      Camshaft Bearing, Checking...6101
      Camshaft Bearing, Removal And Installation...6101
      Control Rod Guide Bushing Removal...6102
      Control Rod Guide Bushing Installation...6104
      Rear Cover Seal Removal And Installation...6108
      Crankshaft, Checking...6109
      Connecting Rod, Checking...6111
      Piston, Checking...6113
      Piston Pin, Checking...6114
      Piston Rings Installation...6114
      Piston Installation On the Connecting Rod...6115
      Cylinder Head Disassembly...6117
      Valves, Checking...6117
      Valve Seats, Checking...6118
      Valve Spring, Checking...6119
      Cylinder Head Assembly...6119
      Rocker Arm and Bracket, Checking...6120
      Front Cover Disassembly...6121
      Front Cover Assembly...6126
      Turbo Charger Removal and Installation...6135
      Crankshaft Gear Mounting Bolt Torque Procedure...6136
  HEATING, VENTILATION, AIR CONDITIONING...6139
    AIR CONDITIONING SYSTEM FLOW...6142
      Principals...6142
      Chart...6143
    COMPONENTS...6145
      Identification...6145
    SAFETY...6149
      Safety Equipment...6149
    REGULAR MAINTENANCE...6151
      Cleaning The Condenser...6151
      Compressor Drive Belt Inspection...6152
      Filter Elements Removal And Installation...6152
    BASIC TROUBLESHOOTING...6155
      Cleaning The A/C Evaporator Coil & Heater Coil...6155
      Checking The Electrical System...6157
      Compressor Drive Belt Inspection:...6165
      Engine Coolant Bypassing The Heater Valve...6165
      Heater Valve Not Opening Or Closing...6166
      Poor A/C Performance...6167
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...6169
      Compressor Oil...6169
      Compressor Oil Check...6169
      Component Replacement And Refrigeration Leaks...6171
    SYSTEM TROUBLESHOOTING CHART...6173
      Gauge Pressure Related Troubleshooting...6174
      Troubleshooting Tree...6176
    TEMPERATURE / PRESSURE...6181
      Chart...6181
    AIR CONDITIONING SERVICE...6183
      Chart...6183
    SYSTEM CHARGING AND RECLAMATION...6185
      Reclamation Procedure...6185
      Charging Procedure With A Manifold Gauge Set...6187
      Charging Procedure...6188
    COMPRESSOR...6191
      Removal And Installation...6191
      Compressor Clutch Disassembly...6192
    CONDENSER...6197
      Removal And Installation...6197
    RECEIVER / DRIER...6199
      Removal And Installation...6199
    PRESSURE RELIEF VALVE...6201
      Removal And Installation...6201
    PRESSURE SWITCH...6203
      Removal And Installation...6203
    EVAPORATOR / HEATER UNIT...6205
      Removal And Installation...6205
      Disassembly And Assembly...6206
    THERMOSTAT...6207
      Removal And Installation...6207
    EXPANSION VALVE...6209
      Removal And Installation...6209
    EVAPORATOR...6211
      Removal And Installation...6211
    HEATER COIL...6213
      Removal And Installation With A/C...6213
      Removal And Installation Without A/C...6214
    HEATER / AC FAN...6217
      Removal And Installation...6217
      Disassembly And Assembly...6218
      Wire Connector Removal And Installation...6220
    HEATER VALVE...6223
      Removal and Installation...6223
      Disassembly And Assembly...6224
  SPECIFICATIONS...6227
    LOADER SPECIFICATIONS...6229
      Loader Dimensions...6229
      Performance...6230
      Controls...6230
      Engine...6230
      Hydraulic System...6231
      Electrical...6231
      Drive System...6232
      Capacities...6232
      Tires...6232
    ENGINE SPECIFICATIONS...6233
      General...6233
      Fuel System...6233
      Valve and Valve Guide and Seat Insert...6234
      Piston and Rings...6235
      Connecting Rod...6235
      Cylinder Head and Block...6236
      Crankshaft and Main Bearings...6236
      Camshaft and Bearings...6236
      Oil Pump...6236
    LOADER TORQUE...6237
      Specifications...6237
    TORQUE SPECIFICATIONS FOR BOLTS...6241
      Torque For General SAE Bolts...6241
      Torque For General Metric Bolts...6242
    HYDRAULIC CONNECTION SPECIFICATIONS...6243
      O-ring Face Seal Connection...6243
      Straight Thread O-ring Fitting...6243
      Tubelines And Hoses...6243
      Flare Fitting...6244
      O-ring Flare Fitting...6245
      Port Seal Fitting...6247
    HYDRAULIC FLUID SPECIFICATIONS...6249
      Specifications...6249
    CONVERSIONS...6251
      Decimal And Millimeter Equivalents...6251
      U.S. To Metric Conversion...6252
  SERVICE MANUAL REVISION...6253
    863/863H-1...6253
    863/863H-2...6255
    863/863H-3...6257
    863/863H-4...6259
    863/863H-5...6261
    863/863H-6...6263
    863/863H-7...6265
    863/863H-8...6267
    863/863H-9...6269
    863/863H-10...6271
    863/863H-11...6273
6900942 (2-06) - 863 Turbo, 863 Turbo High Flow Service Manual...6275
  MAINTENANCE SAFETY...6277
  ALPHABETICAL INDEX...6279
  CONTENTS...6281
    FOREWORD...6282
    SAFETY INSTRUCTIONS...6285
      Fire Prevention...6287
    SERIAL NUMBER LOCATIONS...6289
      Loader Serial Number...6289
      Engine Serial Number...6289
    DELIVERY REPORT...6290
    BOBCAT LOADER IDENTIFICATION...6291
  SAFETY AND MAINTENANCE...6293
    LIFTING AND BLOCKING THE LOADER...6295
      Procedure...6295
    LIFT ARM SUPPORT DEVICE...6297
      Engaging The Lift Arm Support Device...6297
      Disengaging The Lift Arm Support Device...6298
    OPERATOR CAB...6299
      Raising The Operator Cab...6299
      Lowering The Operator Cab...6300
      Emergency Exit...6301
    TRANSPORTING THE LOADER...6303
      Procedure...6303
      Adjusting The Bumper...6303
    TOWING THE LOADER...6305
      Procedure For Non-Two-Speeds...6305
      Procedure For Two-Speeds (S/N 51464170, 514540172, 514449389 And Below)...6306
      Procedure (S/N 51451171, 514540173, 514449390 and Above)...6307
    REMOTE START...6309
      Procedure For Loader Without, Attachments Control Harness...6309
      Procedure For Loader With, Attachments Control Harness...6310
      Procedure...6312
    SERVICE SCHEDULE...6313
      Chart...6313
    AIR CLEANER SERVICE...6315
      Replacing Filter Element...6315
    ENGINE COOLING SYSTEM...6317
      Cleaning The Cooling System...6317
    FUEL SYSTEM...6319
      Fuel Specifications...6319
      Filling The Fuel Tank...6319
      Fuel Filter...6320
      Fuel Lift Pump Strainer...6321
      Removing Air From The Fuel System...6321
    ENGINE LUBRICATION SYSTEM...6323
      Checking Engine Oil...6323
      Replacing Oil And Filter...6323
    HYDRAULIC/HYDROSTATIC SYSTEM...6325
      Checking And Adding Fluid...6325
      Replacing The Hydraulic/Hydrostatic Fluid...6326
      Replacing Hydraulic Fluid And Case Drain Filters...6326
      Breather Cap...6328
    FINAL DRIVE TRANSMISSION (CHAINCASE)...6329
      Checking And Adding Oil...6329
      Replacing The Oil...6329
    FAN GEAR BOX...6331
      Checking And Adding Oil...6331
    BOB-TACH...6333
      Inspection And Maintenance...6333
    POWER BOB-TACH (OPTION)...6335
      Inspection And Maintenance...6335
    LUBRICATING THE LOADER...6337
      Procedure...6337
    TIRE MAINTENANCE...6339
      Wheel Nuts...6339
      Tire Rotation...6339
      Tire Mounting...6339
  HYDRAULIC SYSTEM...6341
    HYDRAULIC/HYDROSTATIC SCHEMATICS...6347
    HYDRAULIC SYSTEM INFORMATION...6387
      Tighten Procedures...6391
      Troubleshooting Chart...6391
    CYLINDER (LIFT)...6393
      Checking...6393
      Removal And Installation...6394
      Parts Identification...6396
      Disassembly...6397
      Assembly...6399
    CYLINDER (TILT)...6403
      Checking...6403
      Removal And Installation...6403
      Rod End Seal...6405
      Parts Identification...6406
      Disassembly...6407
      Assembly...6409
    CYLINDER (POWER BOB-TACH)...6413
      Checking...6413
      Removal And Installation...6414
      Parts Identification...6415
      Disassembly...6416
      Assembly...6417
    MAIN RELIEF VALVE (FOOT CONTROL)...6421
      Checking The Main Relief Valve At Front Auxiliary Hydraulics...6421
      Checking The Main Relief Valve Without Front Auxiliaries...6422
      Removal And Installation...6424
      Adjustment...6425
    HYDRAULIC CONTROL VALVE (FOOT CONTROL)...6427
      Removal And Installation (S/N 514447863 & Below)...6427
      Removal And Installation (S/N 514447864 & Above)...6430
      BICS™ Valve, Removal And Installation...6436
      BICS™ Valve, Lift arm By-Pass Orifice Disassembly And Assembly...6437
      BICS™ Valve, Check Valve Disassembly And Assembly (S/N 514450007 & Below)...6438
      BICS™ Valve, Check Valve Disassembly And Assembly (514450007 & Above)...6439
      BICS™ Valve, Lock Valve Disassembly And Assembly...6440
      BICS™ Valve, Solenoid Disassembly And Assembly...6441
      BICS™ Valve, Solenoid Testing...6442
      Identification Chart...6442
      Load Check Valve...6443
      Main Relief Valve...6444
      Port Relief Valve, Tilt Spool...6445
      Port Relief Valve, Lift Spool...6445
      Anti-Cavitation Valve/Port Relief Valve, Tilt Spool...6446
      Anti-Cavitation Valve, Lift Spool...6446
      Rubber Boot...6447
      Lift And Tilt Block...6447
      Lift Spool And Detent...6448
      Tilt Spool Removal And Installation...6457
      Auxiliary Spool Removal And Installation...6459
      Auxiliary Plug Removal And Installation...6461
      Auxiliary Electric Solenoid Disassembly...6462
      Port Relief-Auxiliary Section Disassembly...6463
      Cleaning And Inspection...6464
    HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)...6465
      Description...6465
      Actuator Removal And Installation (In Loader)...6465
      Removal & Installation (S/N 514447863 & Below)...6467
      Removal And Installation (S/N 514447864 & Above)...6471
      Actuator Removal And Installation (Out Of Loader)...6476
      BICS™ Valve Removal And Installation...6477
      BICS™ Valve Lift Arm By-Pass Orifice Removal And Installation...6479
      BICS™ Valve Check Valve Removal And Installation...6480
      BICS™ Valve Lock Valve Removal And Installation...6481
      BICS™ Valve Removal Solenoid And Installation...6482
      BICS™ Valve Solenoid Testing...6483
      Identification Chart...6483
      Lift Base End Restrictor...6484
      Load Check Valve...6484
      Main Relief Valve...6486
      Port Relief Valve(s)...6487
      Anti-Cavitation Valve/Port Relief Valve...6488
      Anti-Cavitation Valve...6489
      Lift Spool Removal And Installation...6490
      Tilt Spool Removal And Installation...6491
      Lift And Tilt Spool Disassembly And Assembly...6492
      Auxiliary Spool Removal And Installation...6493
      Auxiliary Electric Solenoid Disassembly And Assembly...6494
      Port-Auxiliary Section Disassembly...6495
      Cleaning And Inspection...6496
    LIFT ARM BY-PASS CONTROL VALVE...6497
      Inspecting...6497
      Additional Inspection For Loaders With ACS...6497
      Removal And Installation...6497
      Disassembly And Assembly...6498
    HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 & BELOW)...6499
      Checking The Output Of The Pump...6499
      Removal And Installation...6500
      Parts Identification...6501
      Disassembly...6502
      Inspection...6504
      Assembly...6505
    HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N 514449483 & Below)...6507
      Checking The Output Of The High Flow Pump...6507
      Removal And Installation...6508
      Parts Identification...6510
      Disassembly...6511
      Inspection...6515
      Assembly...6516
    HYDRAULIC PUMP (CAST IRON) (S/N 514449260 & ABOVE)...6521
      Check The Output Of The Hydraulic Pump Without Power Bob-Tach...6521
      Check The Output Of The Hydraulic Pump With Power Bob-Tach...6523
      Removal And Installation...6524
      Identification...6526
      Disassembly And Assembly...6527
    HYDRAULIC PUMP (CAST IRON HIGH FLOW) (S/N 514449484-514450945)...6533
      Check The Output Of The Hydraulic Pump Without Power Bob-Tach...6533
      Check The Output Of The Hydraulic Pump With Power Bob-Tach...6534
      Removal And Installation...6536
      Identification...6538
      Disassembly And Assembly...6539
    HYDRAULIC PUMP (CAST IRON HI FLOW) (514450846 & aBOVE)...6549
      Hydraulic Pump Test...6549
      Inline Hydraulic Pump Test (Standard)...6550
      Inline Hydraulic Pump Test (High Flow)...6552
      High Flow Relief Adjustment Procedure...6554
      High Flow Relief Valve Removal and Installation...6556
      Removal And Installation...6558
      Identification...6560
      Disassembly And Assembly...6561
    HYDRAULIC/HYDROSTATIC FILTER...6571
      Housing Removal And Installation...6571
    HYDRAULIC FLUID RESERVOIR...6573
      Draining The Fluid Reservoir...6573
      Removal And Installation...6573
      Hydraulic Fluid Screen...6575
    BUCKET POSITION VALVE...6577
      Solenoid Removal And Installation...6577
      Solenoid Testing...6578
      Removal And Installation...6578
      Disassembly And Assembly...6580
    SELECT VALVE...6583
      Checking The High Flow Pump Relief Valve (S/N 514450945 & Below)...6583
      Removal And Installation...6584
      Disassembly And Assembly...6586
    REAR AUXILIARY DIVERTER VALVE...6589
      Disassembly...6589
      Inspection...6590
      Solenoid Testing...6590
      Assembly...6590
    POWER BOB-TACH BLOCK (6676547-ALUMINUM)...6591
      Removal And Installation...6591
      Disassembly And Assembly...6593
    POWER BOB-TACH BLOCK (6678554-CAST IRON)...6601
      Removal And Installation...6601
      Disassembly And Assembly...6602
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK...6611
      Removal And Installation (514449564 & Above)...6611
      Disassembly And Assembly (518916011 & Above)...6611
  HYDROSTATIC SYSTEM...6613
    HYDROSTATIC SYSTEM INFORMATION...6615
      Troubleshooting Chart...6615
      Replentishing The Valve Function...6616
    HYDROSTATIC MOTOR...6617
      Removal And Installation...6617
      Parts Identification...6619
      Disassembly...6620
      Inspection...6623
      Assembly...6624
      Carrier Removal And Installation...6627
      Carrier Parts Identification...6628
      Carrier Disassembly...6629
      Carrier Assembly...6630
    HYDROSTATIC MOTOR (TWO-SPEED)...6633
      Removal And Installation...6633
      Parts Identification...6635
      Disassembly...6636
      Inspection...6643
      Assembly...6644
    CHARGE PRESSURE...6651
      Hydrostatic Charge Pressure Sender Removal And Installation...6651
    HYDROSTATIC PUMP...6653
      Replenishing/High Pressure Relief Valve...6653
      Charge Pressure Relief Valve...6654
      Removal And Installation...6655
      Parts Identification (Right Half)...6657
      Parts Identification (Left Half)...6658
      Hydraulic Pump Removal & Installation...6659
      Disassembly...6660
      Assembly...6668
    DRIVE BELT...6677
      Shield Removal And Installation...6677
      Adjustment...6677
      Replacement...6678
      Tensioner Pulley Removal And Installation...6678
      Tensioner Pulley Tension Spring...6680
    OIL COOLER...6681
      Removal And Installation With STC (Seal Tight Connector)...6681
  DRIVE SYSTEM...6683
    BRAKE...6685
      Pedal Removal And Installation...6685
      Pedal Disassembly And Assembly...6686
      Disc Removal And Installation...6687
    BRAKE (TWO-SPEED) (S/N 514449389 & Below)...6691
      Block Removal And Installation...6691
      Block Disassembly And Assembly...6692
    BRAKE (TWO-SPEED) (S/N 514449390 & Above)...6697
      Block Removal And Installation...6697
      Block Disassembly And Assembly...6699
    DRIVE COMPONENTS...6703
      Axle Seal Removal And Installation...6703
      Axle, Sprocket And Bearings Removal And Installation...6705
      Drive Chain Removal And Installation...6710
    CHAINCASE...6711
      Front Chaincase Cover Removal And Installation...6711
      Rear Chaincase Cover Removal And Installation...6711
  MAIN FRAME...6713
    SEAT BAR...6717
      Removal And Installation...6717
      Assembling Components...6718
      Compression Spring Assembly And Assembly...6720
    OPERATOR CAB...6721
      Gas Cylinder Removal And Installation...6721
      Gas Cylinder Bracket Disassembly And Assembly...6722
      Removal And Installation...6723
    OPERATOR SEAT...6725
      Removal And Installation...6725
      Seat Belt Removal And Installation...6725
    OPERATOR SEAT (SUSPENSION)...6727
      Removal And Installation...6727
      Slide Rail Removal And Installation...6728
      Cushion Removal And Installation...6729
      Back Removal And Installation...6730
      Shock Removal And Installation...6730
    BOB-TACH...6733
      Removal And Installation...6733
      Bob-Tach Lever And Wedge...6735
      Bob-Tach Stops...6736
      Pivot Pin Bushing And Seal Replacement...6737
    POWER BOB-TACH...6739
      Removal And Installation...6739
      Power Bob-Tach Lever And Wedge...6740
      Pivot Pin Bushing And Seal Replacement...6742
    LIFT ARMS...6743
      Removal And Installation...6743
    REAR GRILL...6747
      Removal And Installation...6747
    REAR DOOR...6749
      Removal And Installation (S/N 514449208 & Below)...6749
      Adjusting The Rear Door Latch (S/N 514449208 & Below)...6750
      Striker Removal And Installation (S/N 514449209 & Above)...6751
      Adjusting The Striker (S/N 514449209 & Above)...6751
      Latch Removal And Installation (S/N 514449209 & Above)...6752
    FUEL TANK...6753
      Removal And Installation...6753
      Fuel Level Sender...6754
    CONTROL PEDALS...6755
      Removal And Installation...6755
      Pedal Adjustment...6755
      Crossbar Linkage Removal And Installation...6756
      Lift Foot Pedal Linkage Removal And Installation...6757
      Tilt Foot Pedal Linkage Removal And Installation...6758
    CONTROL PEDALS (ACS)...6759
      Foot Sensor Removal And Installation...6759
      Foot Pedal Removal And Installation...6760
      Foot Pedal Linkage Disassembly And Assembly...6760
    CONTROL PANEL...6761
      Removal And Installation...6761
    CONTROL HANDLE...6765
      Lever Removal And Installation...6765
      Lever Disassembly And Assembly...6765
      Linkage Removal And Installation...6766
      Linkage Neutral Adjustment...6769
    CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC)...6775
      Components Identification...6775
      Trouble shooting Guide...6776
      Parts Identification...6777
      AHC Controller Removal And Installation...6778
      Handle Control Unit Connector...6779
      Control Handle Removal And Installation...6780
      Actuators Disassembly And Assembly...6783
    CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/PUSH BUTTON FLOAT)...6785
      Components Identification...6785
      Trouble shooting Guide...6786
      Controller Connector and Wire Identification...6787
      AHC Controller Removal And Installation...6788
      Handle Sensor Removal And Installation...6789
      Handle Sensor Connector...6791
      Control Handle Removal And Installation...6792
      Actuators Disassembly And Assembly...6795
    CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) ADVANCED HAND CONTROL...6797
      Components Identification...6797
      Handle Sensor Removal And Installation...6797
      Control Handle Removal And Installation...6801
      Control Handle Disassembly and Assembly...6802
      Control Lever Removal And Installation...6803
      Control Lever Boot...6804
    CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL...6805
      Components Identification...6805
      Handle Sensor Removal And Installation...6805
      Control Handle Removal And Installation...6809
      Control Handle Disassembly and Assembly...6810
      Control Lever Removal And Installation...6810
      Control Lever Boot...6812
  ELECTRICAL SYSTEM & ANALYSIS...6813
    ELECTRICAL SCHEMATICS...6817
    ELECTRICAL SYSTEM INFORMATION...6828
      Troubleshooting Chart...6830
      Description...6831
      Fuse Location...6833
      Relay Switches Location...6833
      Solenoid Test...6834
    BATTERY...6836
      Removal And Installation...6836
      Servicing The Electrical System...6838
      Using A Booster Battery (Jump Starting)...6838
    ALTERNATOR (55 AMP)...6840
      Alternator Output Test...6840
      Rectifier (Diode) Test...6840
      Alternator Regulator Test...6841
      Removal And Installation...6842
      Disassembly...6843
      Stator Continuity Test...6843
      Stator Ground Test...6843
      Rotor Continuity Test...6844
      Rotor Ground Test...6844
      Rectifier Continuity (Diode) Test...6844
      Assembly...6845
    ALTERNATOR (90 AMP)...6846
      Adjusting The Alternator Belt...6846
      Alternator Identification...6846
      Charging System Check...6847
      Alternator Voltage Test...6848
      Low Voltage Test...6849
      High Voltage Test...6849
      Removal And Installation...6850
      Rectifier Continuity (Diode) Test...6851
      Alternator Regulator Test...6852
      Disassembly...6852
      Stator Continuity Test...6853
      Stator Ground Test...6853
      Rotor Continuity Test...6853
      Rotor Ground Test...6853
      Assembly...6854
    STARTER (NIPPONDENSO)...6856
      Removal And Installation...6856
      Parts Identification...6857
      Disassembly And Assembly...6858
      External Pinion...6861
      Inspection And Repair...6862
      No Load Test...6866
    STARTER (VALEO)...6868
      Checking...6868
      Removal And Installation...6869
      Parts Identification...6870
      Disassembly and Assembly...6871
      Inspection And Repair...6874
      No Load Test...6876
    INSTRUMENT PANEL...6878
      Left Panel...6878
      Right Panel - Standard Instrument Panel (With Key Switch)...6879
      Right Panel - (Deluxe) (With Keyless Start)...6880
      Right Panel Setup Display Options (Deluxe)...6881
      Deluxe Panel Setup...6882
      Passwords...6882
      Changing The Password...6882
      Option And Field Accessory Panels...6884
      Standard Panel Removal And Installation (Right Side)...6885
      Deluxe Panel Removal And Installation (Right Side)...6886
      Standard & Deluxe Panel Removal And Installation (Left Side)...6887
    LIGHTS...6890
      Front Removal And Installation...6890
      Rear Removal And Installation...6891
    BOBCAT CONTROLLER...6892
      Identification Chart (S/N 514450763 & Below)...6892
      Identification Chart (S/N 514450764 & Above)...6893
      Removal And Installation...6895
    DELUXE INSTRUMENTATION SERVICE CODES...6898
    BICS™ SYSTEM...6900
      Inspecting The BICS™ Controller (Engine STOPPED - Key ON)...6900
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...6900
      Inspecting The Seat Bar Sensor (Engine RUNNING)...6900
      Inspecting The Traction Lock (Engine RUNNING)...6900
      Inspecting The Lift Arm By-Pass Control...6900
      Additional Inspection For Loaders With Advanced Hand Controls...6901
      Troubleshooting Chart...6902
      Troubleshooting Guide...6903
    SEAT BAR SENSOR...6904
      Troubleshooting Chart...6904
      Test...6905
      Removal And Installation...6906
      BICS™ Circuit Test...6907
    TRACTION LOCK...6908
      Troubleshooting Chart...6908
      Removal And Installation (Single Speed)...6909
      Description Of The Control System (Two-Speed)...6910
      Inspecting The Control System (Two-Speed)...6910
    ADVANCED HAND CONTROL SYSTEM (AHC)...6912
      Components Identification...6912
      Trouble shooting Guide...6913
      Parts Identification...6914
      AHC Controller Removal And Installation...6915
      Handle Control Unit Connector...6916
      Switch Handle Removal And Installation...6917
      Actuators Disassembly And Assembly...6920
    ADVANCED HAND CONTROL SYSTEM (AHC) (W/ PUSH BUTTON FLOAT)...6922
      Components Identification...6922
      Trouble shooting Guide...6923
      Controller Connector and Wire Identification...6924
      AHC Controller Removal And Installation...6925
      Handle Control Unit Removal And Installation...6926
      Handle Control Unit Connector...6928
      Switch Handle Removal And Installation...6929
      Actuators Disassembly And Assembly...6932
    ADVANCED CONTROL SYSTEM (ACS) ADVANCED HAND CONTROL...6934
      Components Identification...6934
      Troubleshooting Guide...6935
      Controller, Connector And Wire Identification...6936
      ACS Controller Removal And Installation...6937
      Handle Sensor Connector...6938
      Switch Handle Removal...6939
      Switch Handle Installation...6941
      Actuators Disassembly and Assembly...6944
    ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND/FOOT CONTROL...6946
      Components Identification...6946
      Troubleshooting Guide...6948
      Controller, Connector And Wire Identification...6949
      ACS Controller Removal And Installation...6950
      Handle Sensor Connector...6951
      Switch Handle Removal...6952
      Switch Handle Installation...6954
      Actuators Disassembly and Assembly...6957
      Handle Lock Solenoid Removal And Installation...6958
      Handle Lock Solenoid Disassembly And Assembly...6959
      Handle Lock Solenoid Connector...6959
      Calibration Of The ACS System...6960
      Switchable Hand/Foot Controls Calibration Procedure...6960
      Hand Controls Only Calibration Procedure...6962
      Foot Sensor Disassembly And Assembly...6963
      Foot Sensor Connector...6964
      Foot Lock Solenoid Removal And Installation...6965
      Foot Lock Solenoid Connector...6965
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE...6968
      Controls Identification Chart...6968
  ENGINE SERVICE...6970
    TROUBLESHOOTING...6972
      Chart...6972
    ENGINE SPEED CONTROL...6974
      Removal And Installation...6974
      Speed Control Cable...6975
      Speed Control Linkage...6976
    MUFFLER...6978
      Removal And Installation...6978
    AIR CLEANER...6980
      Housing Removal And Installation...6980
    RADIATOR...6982
      Oil Cooler Removal And Installation...6982
    COOLING FAN...6984
      Drive Tension Pulley Removal And Installation...6984
      Gearbox/Blower Housing Removal And Installation...6985
      Blower Removal And Installation...6988
      Gearbox Parts Identification...6989
      Gearbox Disassembly...6990
      Gearbox Assembly...6995
      Gearbox, Checking Backlash...7000
    ENGINE COMPONENTS AND TESTS...7004
      Engine Compression, Checking...7004
      Glow Plug, Checking...7005
      Fuel Shut-Off Solenoid, Checking...7006
      Fuel Shut-Off Solenoid Removal and Installation...7007
      Fuel Injection Pump Removal...7007
      Fuel Injection Pump Timing...7009
      Fuel Injection Pump Installation...7010
      Fuel Injector Removal and Installation...7012
      Fuel Injector, Checking...7013
      Fuel Injector Disassembly...7014
      Fuel Injector Assembly...7015
      Timing Belt Inspection...7017
      Timing Belt Removal...7017
      Timing Belt Installation...7018
      Timing Belt, Replacement In the Loader...7022
      Valve Clearance Adjustment...7027
      Valve Timing, Checking...7028
      Thermostat, Oil Pressure Control Valves And Heater Connections...7030
    ENGINE AND ENGINE MOUNTS...7034
      Removal And Installation...7034
      Engine Mount Replacement...7040
    FLYWHEEL AND HOUSING...7042
      Flywheel Removal And Installation...7042
      Ring Gear Removal And Installation...7042
      Flywheel Housing Removal And Installation...7042
    RPM SENSOR...7044
      Adjustment...7044
    RECONDITIONING THE ENGINE...7046
      Deutz Engine Tools Identification Chart...7046
      Disassembly...7047
      Assembly...7051
      Cylinder, Checking...7067
      Camshaft Bearing, Checking...7068
      Camshaft Bearing, Removal And Installation...7068
      Control Rod Guide Bushing Removal...7069
      Control Rod Guide Bushing Installation...7071
      Rear Cover Seal Removal And Installation...7075
      Crankshaft, Checking...7076
      Connecting Rod, Checking...7078
      Piston, Checking...7080
      Piston Pin, Checking...7081
      Piston Rings Installation...7081
      Piston Installation On the Connecting Rod...7082
      Cylinder Head Disassembly...7084
      Valves, Checking...7084
      Valve Seats, Checking...7085
      Valve Spring, Checking...7086
      Cylinder Head Assembly...7086
      Rocker Arm and Bracket, Checking...7087
      Front Cover Disassembly...7088
      Front Cover Assembly...7093
      Turbo Charger Removal and Installation...7102
      Crankshaft Gear Mounting Bolt Torque Procedure...7103
  HEATING, VENTILATION, AIR CONDITIONING...7106
    AIR CONDITIONING SYSTEM FLOW...7109
      Principals...7109
      Chart...7110
    COMPONENTS...7112
      Identification...7112
    SAFETY...7116
      Safety Equipment...7116
    REGULAR MAINTENANCE...7118
      Cleaning The Condenser...7118
      Compressor Drive Belt Inspection...7119
      Filter Elements Removal And Installation...7119
    BASIC TROUBLESHOOTING...7122
      Cleaning The A/C Evaporator Coil & Heater Coil...7122
      Checking The Electrical System...7124
      Compressor Drive Belt Inspection:...7132
      Engine Coolant By-Passing The Heater Valve...7132
      Heater Valve Not Opening Or Closing...7133
      Poor A/C Performance...7134
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...7136
      Compressor Oil...7136
      Compressor Oil Check...7136
      Component Replacement And Refrigeration Leaks...7138
    SYSTEM TROUBLESHOOTING CHART...7140
      Gauge Pressure Related Troubleshooting...7141
      Troubleshooting Tree...7143
    TEMPERATURE/PRESSURE...7148
      Chart...7148
    AIR CONDITIONING SERVICE...7150
      Chart...7150
    SYSTEM CHARGING AND RECLAMATION...7152
      Reclamation Procedure...7152
      Charging Procedure With A Manifold Gauge Set...7154
      Charging Procedure...7155
    COMPRESSOR...7158
      Removal And Installation...7158
      Compressor Clutch Disassembly...7159
    CONDENSER...7164
      Removal And Installation...7164
    RECEIVER/DRIER...7166
      Removal And Installation...7166
    PRESSURE RELIEF VALVE...7168
      Removal And Installation...7168
    PRESSURE SWITCH...7170
      Removal And Installation...7170
    EVAPORATOR/HEATER UNIT...7172
      Removal And Installation...7172
      Disassembly And Assembly...7173
    THERMOSTAT...7174
      Removal And Installation...7174
    EXPANSION VALVE...7176
      Removal And Installation...7176
    EVAPORATOR...7178
      Removal And Installation...7178
    HEATER COIL...7180
      Removal And Installation With A/C...7180
      Removal And Installation Without A/C...7181
    HEATER/AC FAN...7184
      Removal And Installation...7184
      Disassmbly And Assembly...7185
      Wire Connector Removal And Installation...7187
    HEATER VALVE...7190
      Removal and Installation...7190
      Disassembly And Assembly...7191
  SPECIFICATIONS...7194
    LOADER SPECIFICATIONS...7196
      Loader Dimensions...7196
      Performance...7197
      Controls...7197
      Engine...7197
      Hydraulic System...7198
      Electrical...7198
      Drive System...7199
      Capacities...7199
      Tires...7199
    ENGINE SPECIFICATIONS...7200
      General...7200
      Fuel System...7200
      Valve and Valve Guide and Seat Insert...7201
      Piston and Rings...7202
      Connecting Rod...7202
      Cylinder Head and Block...7203
      Crankshaft and Main Bearings...7203
      Camshaft and Bearings...7203
      Oil Pump...7203
    LOADER TORQUE...7204
      Specifications...7204
    TORQUE SPECIFICATIONS FOR BOLTS...7208
      Torque For General SAE Bolts...7208
      Torque For General Metric Bolts...7209
    HYDRAULIC CONNECTION SPECIFICATIONS...7210
      O-ring Face Seal Connection...7210
      Straight Thread O-ring Fitting...7210
      Tubelines And Hoses...7210
      Flare Fitting...7211
      O-ring Flare Fitting...7212
      Port Seal Fitting...7214
    HYDRAULIC FLUID SPECIFICATIONS...7216
      Specifications...7216
    CONVERSIONS...7218
  SMR...7220
    Revision No: 863/863H-1...7220
    Revision No: 863/863H-2...7222
    Revision No: 863/863H-3...7224
    Revision No: 863/863H-4...7226
    Revision No: 863-5...7228
    Revision No: 863-6...7230
    Revision No: 863-7...7232
    Revision No: 863-8...7234
    Revision No: 863-9...7236
6900942 (7-10) - 863 Turbo, 863 Turbo High Flow Service Manual...7238
  MAINTENANCE SAFETY...7240
  ALPHABETICAL INDEX...7242
  CONTENTS...7244
    FOREWORD...7245
    SAFETY INSTRUCTIONS...7248
    FIRE PREVENTION...7250
      Maintenance...7250
      Operation...7250
      Electrical...7250
      Hydraulic System...7250
      Fueling...7250
      Starting...7250
      Spark Arrestor Exhaust System...7250
      Welding And Grinding...7251
      Fire Extinguishers...7251
    SERIAL NUMBER LOCATIONS...7252
      Loader Serial Number...7252
      Engine Serial Number...7252
    DELIVERY REPORT...7253
    BOBCAT LOADER IDENTIFICATION...7254
  SAFETY AND MAINTENANCE...7256
    LIFTING AND BLOCKING THE LOADER...7258
      Procedure...7258
    LIFT ARM SUPPORT DEVICE...7260
      Engaging The Lift Arm Support Device...7260
      Disengaging The Lift Arm Support Device...7261
    OPERATOR CAB...7262
      Raising The Operator Cab...7262
      Lowering The Operator Cab...7263
      Emergency Exit...7264
    TRANSPORTING THE LOADER...7266
      Procedure...7266
      Adjusting The Bumper...7266
    TOWING THE LOADER...7268
      Procedure For Non-Two-Speeds...7268
      Procedure For Two-Speeds (S/N 51464170, 514540172, 514449389 And Below)...7269
      Procedure (S/N 51451171, 514540173, 514449390 and Above)...7270
    REMOTE START...7272
      Procedure For Loader Without, Attachments Control Harness...7272
      Procedure For Loader With, Attachments Control Harness...7273
      Procedure...7275
    SERVICE SCHEDULE...7276
      Chart...7276
    AIR CLEANER SERVICE...7278
      Replacing Filter Element...7278
    ENGINE COOLING SYSTEM...7280
      Cleaning The Cooling System...7280
    FUEL SYSTEM...7282
      Fuel Specifications...7282
      Filling The Fuel Tank...7282
      Fuel Filter...7283
      Fuel Lift Pump Strainer...7284
      Removing Air From The Fuel System...7284
    ENGINE LUBRICATION SYSTEM...7286
      Checking Engine Oil...7286
      Replacing Oil And Filter...7286
    HYDRAULIC / HYDROSTATIC SYSTEM...7288
      Checking And Adding Fluid...7288
      Replacing The Hydraulic / Hydrostatic Fluid...7289
      Replacing Hydraulic Fluid And Case Drain Filters...7289
      Breather Cap...7291
    FINAL DRIVE TRANSMISSION (CHAINCASE)...7292
      Checking And Adding Oil...7292
      Replacing The Oil...7292
    FAN GEAR BOX...7294
      Checking And Adding Oil...7294
    BOB-TACH...7296
      Inspection And Maintenance...7296
    POWER BOB-TACH (OPTION)...7298
      Inspection And Maintenance...7298
    LUBRICATING THE LOADER...7300
      Procedure...7300
    TIRE MAINTENANCE...7302
      Wheel Nuts...7302
      Tire Rotation...7302
      Tire Mounting...7302
  HYDRAULIC SYSTEM...7304
    HYDRAULIC / HYDROSTATIC SCHEMATICS...7310
    HYDRAULIC SYSTEM INFORMATION...7350
      Tighten Procedures...7354
      Troubleshooting Chart...7354
    CYLINDER (LIFT)...7356
      Checking...7356
      Removal And Installation...7357
      Parts Identification...7359
      Disassembly...7360
      Assembly...7362
    CYLINDER (TILT)...7366
      Checking...7366
      Removal And Installation...7366
      Rod End Seal...7368
      Parts Identification...7369
      Disassembly...7370
      Assembly...7372
    CYLINDER (POWER BOB-TACH)...7376
      Checking...7376
      Removal And Installation...7377
      Parts Identification...7378
      Disassembly...7379
      Assembly...7380
    MAIN RELIEF VALVE (FOOT CONTROL)...7384
      Checking The Main Relief Valve At Front Auxiliary Hydraulics...7384
      Checking The Main Relief Valve Without Front Auxiliaries...7385
      Removal And Installation...7387
      Adjustment...7388
    HYDRAULIC CONTROL VALVE (FOOT CONTROL)...7390
      Removal And Installation (S/N 514447863 & Below)...7390
      Removal And Installation (S/N 514447864 & Above)...7393
      BICS™ Valve, Removal And Installation...7399
      BICS™ Valve, Lift arm Bypass Orifice Disassembly And Assembly...7400
      BICS™ Valve, Check Valve Disassembly And Assembly (S/N 514450007 & Below)...7401
      BICS™ Valve, Check Valve Disassembly And Assembly (514450007 & Above)...7402
      BICS™ Valve, Lock Valve Disassembly And Assembly...7403
      BICS™ Valve, Solenoid Disassembly And Assembly...7404
      BICS™ Valve, Solenoid Testing...7405
      Identification Chart...7405
      Load Check Valve...7406
      Main Relief Valve...7407
      Port Relief Valve, Tilt Spool...7408
      Port Relief Valve, Lift Spool...7408
      Anti-Cavitation Valve / Port Relief Valve, Tilt Spool...7409
      Anti-Cavitation Valve, Lift Spool...7409
      Rubber Boot...7410
      Lift And Tilt Block...7410
      Lift Spool And Detent...7411
      Tilt Spool Removal And Installation...7420
      Auxiliary Spool Removal And Installation...7422
      Auxiliary Plug Removal And Installation...7424
      Auxiliary Electric Solenoid Disassembly...7425
      Port Relief-Auxiliary Section Disassembly...7426
      Cleaning And Inspection...7427
    HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)...7428
      Description...7428
      Actuator Removal And Installation (In Loader)...7428
      Removal & Installation (S/N 514447863 & Below)...7430
      Removal And Installation (S/N 514447864 & Above)...7434
      Actuator Removal And Installation (Out Of Loader)...7439
      BICS™ Valve Removal And Installation...7440
      BICS™ Valve Lift Arm Bypass Orifice Removal And Installation...7442
      BICS™ Valve Check Valve Removal And Installation...7443
      BICS™ Valve Lock Valve Removal And Installation...7444
      BICS™ Valve Removal Solenoid And Installation...7445
      BICS™ Valve Solenoid Testing...7446
      Identification Chart...7446
      Lift Base End Restrictor...7447
      Load Check Valve...7447
      Main Relief Valve...7449
      Port Relief Valve(s)...7450
      Anti-Cavitation Valve / Port Relief Valve...7451
      Anti-Cavitation Valve...7452
      Lift Spool Removal And Installation...7453
      Tilt Spool Removal And Installation...7454
      Lift And Tilt Spool Disassembly And Assembly...7455
      Auxiliary Spool Removal And Installation...7456
      Auxiliary Electric Solenoid Disassembly And Assembly...7457
      Port-Auxiliary Section Disassembly...7458
      Cleaning And Inspection...7459
    LIFT ARM BYPASS CONTROL VALVE...7460
      Inspecting...7460
      Additional Inspection For Loaders With ACS...7460
      Removal And Installation...7460
      Disassembly And Assembly...7461
    HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 & BELOW)...7462
      Checking The Output Of The Pump...7462
      Removal And Installation...7463
      Parts Identification...7464
      Disassembly...7465
      Inspection...7467
      Assembly...7468
    HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N 514449483 & Below)...7470
      Checking The Output Of The High Flow Pump...7470
      Removal And Installation...7471
      Parts Identification...7473
      Disassembly...7474
      Inspection...7478
      Assembly...7479
    HYDRAULIC PUMP (CAST IRON) (S/N 514449260 & ABOVE)...7484
      Check The Output Of The Hydraulic Pump Without Power Bob-Tach...7484
      Check The Output Of The Hydraulic Pump With Power Bob-Tach...7486
      Removal And Installation...7487
      Identification...7489
      Disassembly And Assembly...7490
    HYDRAULIC PUMP (CAST IRON HIGH FLOW) (S/N 514449484-514450945)...7496
      Check The Output Of The Hydraulic Pump Without Power Bob-Tach...7496
      Check The Output Of The Hydraulic Pump With Power Bob-Tach...7497
      Removal And Installation...7499
      Identification...7501
      Disassembly And Assembly...7502
    HYDRAULIC PUMP (CAST IRON HI FLOW) (514450846 & aBOVE)...7512
      Hydraulic Pump Test...7512
      Inline Hydraulic Pump Test (Standard)...7513
      Inline Hydraulic Pump Test (High Flow)...7515
      High Flow Relief Adjustment Procedure...7517
      High Flow Relief Valve Removal and Installation...7519
      Removal And Installation...7521
      Identification...7523
      Disassembly And Assembly...7524
    HYDRAULIC / HYDROSTATIC FILTER...7534
      Housing Removal And Installation...7534
    HYDRAULIC FLUID RESERVOIR...7536
      Draining The Fluid Reservoir...7536
      Removal And Installation...7536
      Hydraulic Fluid Screen...7538
    BUCKET POSITION VALVE...7540
      Solenoid Removal And Installation...7540
      Solenoid Testing...7541
      Removal And Installation...7541
      Disassembly And Assembly...7543
    SELECT VALVE...7546
      Checking The High Flow Pump Relief Valve (S/N 514450945 & Below)...7546
      Removal And Installation...7547
      Disassembly And Assembly...7549
    REAR AUXILIARY DIVERTER VALVE...7552
      Disassembly...7552
      Inspection...7553
      Solenoid Testing...7553
      Assembly...7553
    POWER BOB-TACH BLOCK (6676547-ALUMINUM)...7554
      Removal And Installation...7554
      Disassembly And Assembly...7556
    POWER BOB-TACH BLOCK (6678554-CAST IRON)...7564
      Removal And Installation...7564
      Disassembly And Assembly...7565
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK...7574
      Removal And Installation (514449564 & Above)...7574
      Disassembly And Assembly (518916011 & Above)...7574
  HYDROSTATIC SYSTEM...7576
    HYDROSTATIC SYSTEM INFORMATION...7578
      Troubleshooting Chart...7578
      Replentishing The Valve Function...7579
    HYDROSTATIC MOTOR...7580
      Removal And Installation...7580
      Parts Identification...7582
      Disassembly...7583
      Inspection...7586
      Assembly...7587
      Carrier Removal And Installation...7590
      Carrier Parts Identification...7591
      Carrier Disassembly...7592
      Carrier Assembly...7593
    HYDROSTATIC MOTOR (TWO-SPEED)...7596
      Removal And Installation...7596
      Parts Identification...7599
      Disassembly...7600
      Inspection...7607
      Assembly...7608
    CHARGE PRESSURE...7616
      Hydrostatic Charge Pressure Sender Removal And Installation...7616
    HYDROSTATIC PUMP...7618
      Replenishing / High Pressure Relief Valve...7618
      Charge Pressure Relief Valve...7619
      Removal And Installation...7620
      Parts Identification (Right Half)...7622
      Parts Identification (Left Half)...7623
      Hydraulic Pump Removal & Installation...7624
      Disassembly...7625
      Assembly...7633
    DRIVE BELT...7642
      Shield Removal And Installation...7642
      Adjustment...7642
      Replacement...7643
      Tensioner Pulley Removal And Installation...7643
      Tensioner Pulley Tension Spring...7645
    OIL COOLER...7646
      Removal And Installation With STC (Seal Tight Connector)...7646
  DRIVE SYSTEM...7648
    BRAKE...7650
      Pedal Removal And Installation...7650
      Pedal Disassembly And Assembly...7651
      Disc Removal And Installation...7652
    BRAKE (TWO-SPEED) (S/N 514449389 & Below)...7656
      Block Removal And Installation...7656
      Block Disassembly And Assembly...7657
    BRAKE (TWO-SPEED) (S/N 514449390 & Above)...7662
      Block Removal And Installation...7662
      Block Disassembly And Assembly...7664
    DRIVE COMPONENTS...7668
      Axle Seal Removal And Installation...7668
      Axle, Sprocket And Bearings Removal And Installation...7670
      Drive Chain Removal And Installation...7675
    CHAINCASE...7676
      Front Chaincase Cover Removal And Installation...7676
      Rear Chaincase Cover Removal And Installation...7676
  MAINFRAME...7680
    SEAT BAR...7684
      Removal And Installation...7684
      Assembling Components...7685
      Compression Spring Assembly And Assembly...7687
    OPERATOR CAB...7688
      Gas Cylinder Removal And Installation...7688
      Gas Cylinder Bracket Disassembly And Assembly...7689
      Removal And Installation...7690
    OPERATOR SEAT...7692
      Removal And Installation...7692
      Seat Belt Removal And Installation...7692
    OPERATOR SEAT (SUSPENSION)...7694
      Removal And Installation...7694
      Slide Rail Removal And Installation...7695
      Cushion Removal And Installation...7696
      Back Removal And Installation...7697
      Shock Removal And Installation...7697
    BOB-TACH...7700
      Removal And Installation...7700
      Bob-Tach Lever And Wedge...7702
      Bob-Tach Stops...7703
      Pivot Pin Bushing And Seal Replacement...7704
    POWER BOB-TACH...7706
      Removal And Installation...7706
      Power Bob-Tach Lever And Wedge...7707
      Pivot Pin Bushing And Seal Replacement...7709
    LIFT ARMS...7710
      Removal And Installation...7710
    REAR GRILL...7714
      Removal And Installation...7714
    REAR DOOR...7716
      Removal And Installation (S/N 514449208 & Below)...7716
      Adjusting The Rear Door Latch (S/N 514449208 & Below)...7717
      Striker Removal And Installation (S/N 514449209 & Above)...7718
      Adjusting The Striker (S/N 514449209 & Above)...7718
      Latch Removal And Installation (S/N 514449209 & Above)...7719
    FUEL TANK...7720
      Removal And Installation...7720
      Fuel Level Sender...7721
    CONTROL PEDALS...7722
      Removal And Installation...7722
      Pedal Adjustment...7722
      Crossbar Linkage Removal And Installation...7723
      Lift Foot Pedal Linkage Removal And Installation...7724
      Tilt Foot Pedal Linkage Removal And Installation...7725
    CONTROL PEDALS (ACS)...7726
      Foot Sensor Removal And Installation...7726
      Foot Pedal Removal And Installation...7727
      Foot Pedal Linkage Disassembly And Assembly...7727
    CONTROL PANEL...7728
      Removal And Installation...7728
    CONTROL HANDLE...7732
      Lever Removal And Installation...7732
      Lever Disassembly And Assembly...7732
      Linkage Removal And Installation...7733
      Linkage Neutral Adjustment...7736
    CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC)...7742
      Components Identification...7742
      Trouble shooting Guide...7743
      Parts Identification...7744
      AHC Controller Removal And Installation...7745
      Handle Control Unit Connector...7746
      Control Handle Removal And Installation...7747
      Actuators Disassembly And Assembly...7750
    CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/ PUSH BUTTON FLOAT)...7752
      Components Identification...7752
      Trouble shooting Guide...7753
      Controller Connector and Wire Identification...7754
      AHC Controller Removal And Installation...7755
      Handle Sensor Removal And Installation...7756
      Handle Sensor Connector...7758
      Control Handle Removal And Installation...7759
      Actuators Disassembly And Assembly...7762
    CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) ADVANCED HAND CONTROL...7764
      Components Identification...7764
      Handle Sensor Removal And Installation...7764
      Control Handle Removal And Installation...7768
      Control Handle Disassembly and Assembly...7769
      Control Lever Removal And Installation...7770
      Control Lever Boot...7771
    CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL...7772
      Components Identification...7772
      Handle Sensor Removal And Installation...7772
      Control Handle Removal And Installation...7776
      Control Handle Disassembly and Assembly...7777
      Control Lever Removal And Installation...7777
      Control Lever Boot...7779
  ELECTRICAL SYSTEM & ANALYSIS...7780
    ELECTRICAL SCHEMATICS...7784
    ELECTRICAL SYSTEM INFORMATION...7792
      Troubleshooting Chart...7794
      Description...7796
      Fuse Location...7798
      Relay Switches Location...7798
      Solenoid Test...7799
    BATTERY...7802
      Removal And Installation...7802
      Servicing The Electrical System...7804
      Using A Booster Battery (Jump Starting)...7805
    ALTERNATOR (55 AMP)...7806
      Alternator Output Test...7806
      Rectifier (Diode) Test...7806
      Alternator Regulator Test...7807
      Removal And Installation...7808
      Disassembly...7809
      Stator Continuity Test...7809
      Stator Ground Test...7809
      Rotor Continuity Test...7810
      Rotor Ground Test...7810
      Rectifier Continuity (Diode) Test...7810
      Assembly...7811
    ALTERNATOR (90 AMP)...7812
      Adjusting The Alternator Belt...7812
      Alternator Identification...7812
      Charging System Check...7813
      Alternator Voltage Test...7814
      Low Voltage Test...7815
      High Voltage Test...7815
      Removal And Installation...7816
      Rectifier Continuity (Diode) Test...7817
      Alternator Regulator Test...7818
      Disassembly...7818
      Stator Continuity Test...7819
      Stator Ground Test...7819
      Rotor Continuity Test...7819
      Rotor Ground Test...7819
      Assembly...7820
    STARTER (NIPPONDENSO)...7822
      Removal And Installation...7822
      Parts Identification...7823
      Disassembly And Assembly...7824
      External Pinion...7827
      Inspection And Repair...7828
      No Load Test...7832
    STARTER (VALEO)...7834
      Checking...7834
      Removal And Installation...7835
      Parts Identification...7836
      Disassembly and Assembly...7837
      Inspection And Repair...7840
      No Load Test...7842
    INSTRUMENT PANEL...7844
      Left Panel...7844
      Right Panel - Standard Instrument Panel (With Key Switch)...7845
      Right Panel - (Deluxe) (With Keyless Start)...7846
      Right Panel Setup Display Options (Deluxe)...7847
      Deluxe Panel Setup...7848
      Passwords...7848
      Changing The Password...7848
      Option And Field Accessory Panels...7850
      Standard Panel Removal And Installation (Right Side)...7851
      Deluxe Panel Removal And Installation (Right Side)...7852
      Standard & Deluxe Panel Removal And Installation (Left Side)...7853
    LIGHTS...7856
      Front Removal And Installation...7856
      Rear Removal And Installation...7857
    BOBCAT CONTROLLER...7858
      Identification Chart (S/N 514450763 & Below)...7858
      Identification Chart (S/N 514450764 & Above)...7859
      Removal And Installation...7861
    DELUXE INSTRUMENTATION SERVICE CODES...7864
    BICS™ SYSTEM...7866
      Inspecting The BICS™ Controller (Engine STOPPED - Key ON)...7866
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...7866
      Inspecting The Seat Bar Sensor (Engine RUNNING)...7866
      Inspecting The Traction Lock (Engine RUNNING)...7866
      Inspecting The Lift Arm Bypass Control...7866
      Additional Inspection For Loaders With Advanced Hand Controls...7867
      Troubleshooting Chart...7868
      Troubleshooting Guide...7869
    SEAT BAR SENSOR...7870
      Troubleshooting Chart...7870
      Test...7871
      Removal And Installation...7872
      BICS™ Circuit Test...7873
    TRACTION LOCK...7874
      Troubleshooting Chart...7874
      Removal And Installation (Single Speed)...7875
      Description Of The Control System (Two-Speed)...7876
      Inspecting The Control System (Two-Speed)...7876
    ADVANCED HAND CONTROL SYSTEM (AHC)...7878
      Components Identification...7878
      Trouble shooting Guide...7879
      Parts Identification...7880
      AHC Controller Removal And Installation...7881
      Handle Control Unit Connector...7882
      Switch Handle Removal And Installation...7883
      Actuators Disassembly And Assembly...7886
    ADVANCED HAND CONTROL SYSTEM (AHC) (W/ PUSH BUTTON FLOAT)...7888
      Components Identification...7888
      Trouble shooting Guide...7889
      Controller Connector and Wire Identification...7890
      AHC Controller Removal And Installation...7891
      Handle Control Unit Removal And Installation...7892
      Handle Control Unit Connector...7894
      Switch Handle Removal And Installation...7895
      Actuators Disassembly And Assembly...7898
    ADVANCED CONTROL SYSTEM (ACS) ADVANCED HAND CONTROL...7900
      Components Identification...7900
      Troubleshooting Guide...7901
      Controller, Connector And Wire Identification...7902
      ACS Controller Removal And Installation...7903
      Handle Sensor Connector...7904
      Switch Handle Removal...7905
      Switch Handle Installation...7907
      Actuators Disassembly and Assembly...7910
    ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND / FOOT CONTROL...7912
      Components Identification...7912
      Troubleshooting Guide...7914
      Controller, Connector And Wire Identification...7915
      ACS Controller Removal And Installation...7916
      Handle Sensor Connector...7917
      Switch Handle Removal...7918
      Switch Handle Installation...7920
      Actuators Disassembly and Assembly...7923
      Handle Lock Solenoid Removal And Installation...7924
      Handle Lock Solenoid Disassembly And Assembly...7925
      Handle Lock Solenoid Connector...7925
      Calibration Of The ACS System...7926
      Switchable Hand / Foot Controls Calibration Procedure...7926
      Hand Controls Only Calibration Procedure...7928
      Foot Sensor Disassembly And Assembly...7929
      Foot Sensor Connector...7930
      Foot Lock Solenoid Removal And Installation...7931
      Foot Lock Solenoid Connector...7931
    ELECTRICAL / HYDRAULIC CONTROLS REFERENCE...7934
      Controls Identification Chart...7934
  ENGINE SERVICE...7936
    TROUBLESHOOTING...7938
      Chart...7938
    ENGINE SPEED CONTROL...7940
      Removal And Installation...7940
      Speed Control Cable...7941
      Speed Control Linkage...7942
    MUFFLER...7944
      Removal And Installation...7944
    AIR CLEANER...7946
      Housing Removal And Installation...7946
    RADIATOR...7948
      Oil Cooler Removal And Installation...7948
    COOLING FAN...7950
      Drive Tension Pulley Removal And Installation...7950
      Gearbox / Blower Housing Removal And Installation...7951
      Blower Removal And Installation...7954
      Gearbox Parts Identification...7955
      Gearbox Disassembly...7956
      Gearbox Assembly...7961
      Gearbox, Checking Backlash...7966
    ENGINE COMPONENTS AND TESTS...7970
      Engine Compression, Checking...7970
      Glow Plug, Checking...7971
      Fuel Shut-Off Solenoid, Checking...7972
      Fuel Shut-Off Solenoid Removal and Installation...7973
      Fuel Injection Pump Removal...7973
      Fuel Injection Pump Timing...7975
      Fuel Injection Pump Installation...7976
      Fuel Injector Removal and Installation...7978
      Fuel Injector, Checking...7979
      Fuel Injector Disassembly...7980
      Fuel Injector Assembly...7981
      Timing Belt Inspection...7983
      Timing Belt Removal...7983
      Timing Belt Installation...7984
      Timing Belt, Replacement In the Loader...7988
      Valve Clearance Adjustment...7993
      Valve Timing, Checking...7994
      Thermostat, Oil Pressure Control Valves And Heater Connections...7996
    ENGINE AND ENGINE MOUNTS...8000
      Removal And Installation...8000
      Engine Mount Replacement...8006
    FLYWHEEL AND HOUSING...8008
      Flywheel Removal And Installation...8008
      Ring Gear Removal And Installation...8008
      Flywheel Housing Removal And Installation...8008
    RPM SENSOR...8010
      Adjustment...8010
    RECONDITIONING THE ENGINE...8012
      Deutz Engine Tools Identification Chart...8012
      Disassembly...8013
      Assembly...8017
      Cylinder, Checking...8033
      Camshaft Bearing, Checking...8034
      Camshaft Bearing, Removal And Installation...8034
      Control Rod Guide Bushing Removal...8035
      Control Rod Guide Bushing Installation...8037
      Rear Cover Seal Removal And Installation...8041
      Crankshaft, Checking...8042
      Connecting Rod, Checking...8044
      Piston, Checking...8046
      Piston Pin, Checking...8047
      Piston Rings Installation...8047
      Piston Installation On the Connecting Rod...8048
      Cylinder Head Disassembly...8050
      Valves, Checking...8050
      Valve Seats, Checking...8051
      Valve Spring, Checking...8052
      Cylinder Head Assembly...8052
      Rocker Arm and Bracket, Checking...8053
      Front Cover Disassembly...8054
      Front Cover Assembly...8059
      Turbo Charger Removal and Installation...8068
      Crankshaft Gear Mounting Bolt Torque Procedure...8069
  HEATING, VENTILATION, AIR CONDITIONING...8072
    AIR CONDITIONING SYSTEM FLOW...8075
      Principals...8075
      Chart...8076
    COMPONENTS...8078
      Identification...8078
    SAFETY...8082
      Safety Equipment...8082
    REGULAR MAINTENANCE...8084
      Cleaning The Condenser...8084
      Compressor Drive Belt Inspection...8085
      Filter Elements Removal And Installation...8085
    BASIC TROUBLESHOOTING...8088
      Cleaning The A/C Evaporator Coil & Heater Coil...8088
      Checking The Electrical System...8090
      Compressor Drive Belt Inspection:...8098
      Engine Coolant Bypassing The Heater Valve...8098
      Heater Valve Not Opening Or Closing...8099
      Poor A/C Performance...8100
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...8102
      Compressor Oil...8102
      Compressor Oil Check...8102
      Component Replacement And Refrigeration Leaks...8104
    SYSTEM TROUBLESHOOTING CHART...8106
      Gauge Pressure Related Troubleshooting...8107
      Troubleshooting Tree...8109
    TEMPERATURE / PRESSURE...8114
      Chart...8114
    AIR CONDITIONING SERVICE...8116
      Chart...8116
    SYSTEM CHARGING AND RECLAMATION...8118
      Reclamation Procedure...8118
      Charging Procedure With A Manifold Gauge Set...8120
      Charging Procedure...8121
    COMPRESSOR...8124
      Removal And Installation...8124
      Compressor Clutch Disassembly...8125
    CONDENSER...8130
      Removal And Installation...8130
    RECEIVER / DRIER...8132
      Removal And Installation...8132
    PRESSURE RELIEF VALVE...8134
      Removal And Installation...8134
    PRESSURE SWITCH...8136
      Removal And Installation...8136
    EVAPORATOR / HEATER UNIT...8138
      Removal And Installation...8138
      Disassembly And Assembly...8139
    THERMOSTAT...8140
      Removal And Installation...8140
    EXPANSION VALVE...8142
      Removal And Installation...8142
    EVAPORATOR...8144
      Removal And Installation...8144
    HEATER COIL...8146
      Removal And Installation With A/C...8146
      Removal And Installation Without A/C...8147
    HEATER / AC FAN...8150
      Removal And Installation...8150
      Disassembly And Assembly...8151
      Wire Connector Removal And Installation...8153
    HEATER VALVE...8156
      Removal and Installation...8156
      Disassembly And Assembly...8157
  SPECIFICATIONS...8160
    LOADER SPECIFICATIONS...8162
      Loader Dimensions...8162
      Performance...8163
      Controls...8163
      Engine...8163
      Hydraulic System...8164
      Electrical...8164
      Drive System...8165
      Capacities...8165
      Tires...8165
    ENGINE SPECIFICATIONS...8166
      General...8166
      Fuel System...8166
      Valve and Valve Guide and Seat Insert...8167
      Piston and Rings...8168
      Connecting Rod...8168
      Cylinder Head and Block...8169
      Crankshaft and Main Bearings...8169
      Camshaft and Bearings...8169
      Oil Pump...8169
    LOADER TORQUE...8170
      Specifications...8170
    TORQUE SPECIFICATIONS FOR BOLTS...8174
      Torque For General SAE Bolts...8174
      Torque For General Metric Bolts...8175
    HYDRAULIC CONNECTION SPECIFICATIONS...8176
      O-ring Face Seal Connection...8176
      Straight Thread O-ring Fitting...8176
      Tubelines And Hoses...8176
      Flare Fitting...8177
      O-ring Flare Fitting...8178
      Port Seal Fitting...8180
    HYDRAULIC FLUID SPECIFICATIONS...8182
      Specifications...8182
    CONVERSIONS...8184
      Decimal And Millimeter Equivalents...8184
      U.S. To Metric Conversion...8185
  SERVICE MANUAL REVISION...8186
    863/863H-1...8186
    863/863H-2...8188
    863/863H-3...8190
    863/863H-4...8192
    863-5...8194
    863-6...8196
    863-7...8198
    863-8...8200
    863-9...8202
    863-10...8204
6900945 (10-12)  - 864, 864 High Flow Service Manual...8206
  MAINTENANCE SAFETY...8208
  ALPHABETICAL INDEX...8210
  CONTENTS...8212
    FOREWORD...8213
    SAFETY INSTRUCTIONS...8216
    FIRE PREVENTION...8218
      Maintenance...8218
      Operation...8218
      Electrical...8218
      Hydraulic System...8218
      Fueling...8218
      Starting...8218
      Spark Arrestor Exhaust System...8218
      Welding And Grinding...8219
      Fire Extinguishers...8219
    SERIAL NUMBER LOCATIONS...8220
      Loader Serial Number...8220
      Engine Serial Number...8220
    DELIVERY REPORT...8220
    BOBCAT LOADER IDENTIFICATION...8221
  SAFETY AND MAINTENANCE...8222
    LIFTING AND BLOCKING THE LOADER...8224
      Procedure...8224
    LIFT ARM SUPPORT DEVICE...8226
      Engaging The Lift Arm Support Device...8226
      Disengaging The Lift Arm Support Device...8228
    OPERATOR CAB...8230
      Raising The Operator Cab...8230
      Lowering The Operator Cab...8231
      Emergency Exit...8232
    TRANSPORTING THE BOBCAT LOADER...8234
      Procedure...8234
    TOWING THE LOADER...8236
      Procedure...8236
    REMOTE START...8238
      Procedure For Loader Without Attachments Control Harness...8238
      Procedure For Loader With Attachments Control Harness...8239
    SERVICE SCHEDULE...8242
      Chart...8242
    AIR CLEANER SERVICE...8244
      Replacing Filter Element...8244
    ENGINE COOLING SYSTEM...8246
      Cleaning The Cooling System...8246
    FUEL SYSTEM...8248
      Fuel Specifications...8248
      Filling The Fuel Tank...8248
      Fuel Filter...8249
      Removing Air From The Fuel System...8249
    ENGINE LUBRICATION SYSTEM...8250
      Checking Engine Oil...8250
      Replacing Oil And Filter...8250
    HYDRAULIC/HYDROSTATIC SYSTEM...8252
      Checking And Adding Fluid...8252
      Hydraulic/Hydrostatic Filter Replacement...8252
      Replacing Hydraulic Fluid...8253
    FAN GEARBOX...8256
      Checking And Adding Oil...8256
    BOB-TACH...8258
      Inspection And Maintenance...8258
    POWER BOB-TACH (OPTION)...8260
      Inspection And Maintenance...8260
    LUBRICATING THE LOADER...8262
      Procedure...8262
  HYDRAULIC SYSTEM...8264
    HYDRAULIC / HYDROSTATIC SCHEMATICS...8268
    HYDRAULIC SYSTEM INFORMATION...8276
      Glossary Of Hydraulic/Hydrostatic Symbols For Loaders...8276
      Troubleshooting...8280
      Tighten Procedures...8281
    CYLINDER (LIFT)...8282
      Checking...8282
      Removal And Installation...8282
      Parts Identification...8284
      Disassembly...8285
      Assembly...8286
    CYLINDER (TILT)...8290
      Checking...8290
      Removal And Installation...8290
      Rod End Seal...8291
      Parts Identification...8293
      Disassembly...8294
      Assembly...8296
    CYLINDER (POWER BOB-TACH)...8300
      Checking...8300
      Removal And Installation...8301
      Parts Identification...8302
      Disassembly...8303
      Assembly...8304
    MAIN RELIEF VALVE (FOOT CONTROL)...8308
      Checking The Main Relief Valve At Front Auxiliary Hydraulics...8308
      Checking The Main Relief Valve Without Front Auxiliaries...8309
      Removal And Installation...8310
      Adjustment...8311
    MAIN RELIEF VALVE (AHC)...8312
      Checking The Main Relief Valve At Front Auxiliary Hydraulics...8312
      Checking The Main Relief Valve Without Front Auxiliaries...8313
      Removal and Installation...8314
      Adjustment...8315
    HYDRAULIC CONTROL VALVE (FOOT CONTROL)...8316
      Removal And Installation...8316
      BICS™ Valve, Removal And Installation...8322
      BICS™ Valve, Lift Arm Bypass Orifice Disassembly And Assembly...8323
      BICS™ Valve, Check Valve Disassembly And Assembly...8324
      BICS™ Valve, Lock Valve Disassembly And Assembly...8325
      BICS™ Valve, Solenoid Disassembly And Assembly...8326
      BICS™ Valve, Solenoid Testing...8327
      Identification Chart...8328
      Load Check Valve...8329
      Main Relief Valve...8330
      Port Relief Valve, Tilt Spool (Linkage End)...8330
      Port Relief Valve, Lift Spool (Bonnet End)...8331
      Anti-Cavitation Valve/Port Relief Valve, Tilt Spool (Bonnet End)...8331
      Anti-Cavitation Valve, Lift Spool (Linkage End)...8332
      Rubber Boot...8332
      Lift And Tilt Lock Block...8333
      Lift Spool and Detent...8334
      Tilt Spool Removal And Installation...8342
      Auxiliary Spool Removal And Installation (Bonnet End)...8344
      Auxiliary Spool Removal And Installation (Linkage End)...8345
      Auxiliary Plug Removal And Installation...8346
      Auxiliary Electric Solenoid Disassembly...8347
      Port Relief-Auxiliary Section Disassembly...8348
      Cleaning And Inspection...8348
    HYDRAULIC CONTROL VALVE (ADVANCE HAND...8350
    CONTROL) (AHC), ADVANCE CONTROL SYSTEM (ACS)...8350
      Actuator Removal And Installation (In Loader)...8350
      Removal And Installation...8352
      Actuator Removal And Installation (Out Of Loader)...8358
      BICS™ Valve, Removal And Installation...8359
      BICS™ Valve, Lift Arm Bypass Orifice Disassembly And Assembly...8360
      BICS™ Valve, Check Valve Disassembly And Assembly...8361
      BICS™ Valve, Lock Valve Disassembly And Assembly...8362
      BICS™ Valve, Solenoid Disassembly And Assembly...8363
      BICS™ Valve, Solenoid Testing...8364
      Identification Chart...8365
      Identification Chart...8366
      Lift Base End Restrictor...8367
      Load Check Valve...8367
      Main Relief Valve...8368
      Port Relief Valve...8369
      Anti-Cavitation Valve/Port Relief Valve...8370
      Anti-Cavitation Valve...8371
      Lift Spool Removal...8372
      Lift Spool Removal And Installation...8373
      Lift and Tilt Spool Disassembly And Assembly...8374
      Auxiliary Spool Removal And Installation...8375
      Auxiliary Electric Solenoid Disassembly...8376
      Port-Auxiliary Section Disassembly...8377
      Cleaning And Inspection...8377
    LIFT ARM BYPASS CONTROL VALVE...8378
      Inspecting...8378
      Additional Inspection For Loaders With Advanced Hand Controls...8378
      Removal And Installation...8378
      Disassembly And Assembly...8380
    HYDRAULIC PUMP (SINGLE GEAR)...8382
      Checking The Output Of The Pump...8382
      Removal And Installation...8383
      Parts Identification...8385
      Disassembly...8386
      Inspection...8388
      Assembly...8389
    HYDRAULIC PUMP (HI-FLOW)...8392
      Checking The Output Of The High Flow Pump...8392
      Removal And Installation...8393
      Parts Identification...8395
      Disassembly...8396
      Inspection...8399
      Assembly...8400
    HYDRAULIC/HYDROSTATIC FILTER...8404
      Housing Removal And Installation...8404
      Mount Removal And Installation...8405
    HYDRAULIC FLUID RESERVOIR...8406
      Draining The Hydraulic Fluid Reservoir...8406
      Removal And Installation...8406
      Hydraulic Fluid Screen...8408
    CONTROLS...8410
      Control Pedal Removal And Installation...8410
      Control Pedal Adjustment...8410
      Crossbar Linkage Removal And Installation...8410
      Crossbar Linkage Inspection...8411
      Control Foot Sensor (ACS) Removal And Installation...8411
      Control Pedal (ACS) Removal And Installation...8413
      Control Pedal Linkage (ACS) Disassembly And Assembly...8413
    BUCKET POSITION VALVE...8414
      Solenoid Removal And Installation...8414
      Solenoid Testing...8414
      Removal And Installation...8415
      Disassembly And Assembly...8415
    REAR AUXILIARY DIVERTER...8418
      Disassembly...8418
      Inspection...8418
      Solenoid Testing...8419
      Assembly...8419
    SELECT VALVE...8420
      Checking The High Flow Pump Relief Valve...8420
      Removal And Installation...8421
      Disassembly And Assembly...8422
      Solenoid Testing...8427
    REAR AUXILIARY DIVERTER VALVE (SINGLE SHUTTLE)...8428
      Removal And Installation...8428
      Disassembly...8430
      Inspection...8430
      Solenoid Testing...8431
      Assembly...8431
    POWER BOB-TACH BLOCK...8432
      Removal And Installation...8432
      Disassembly And Assembly...8434
    AUXILIARY PRESSURE RELEASE (ACCUMULATOR)...8440
      Removal and Installation...8440
      Disassembly And Assembly...8441
  HYDROSTATIC SYSTEM...8442
    HYDROSTATIC SYSTEM INFORMATION...8444
      Troubleshooting Chart...8444
      Replenishing Valve Function...8445
    CONTROL PANEL...8446
      Removal and Installation...8446
    STEERING...8448
      Lever Removal And Installation...8448
      Lever Disassembly And Assembly...8448
      Linkage Removal And Installation...8449
      Linkage Neutral Adjustment...8453
    STEERING (ADVANCED HAND CONTROL) (AHC)...8458
      Components Identification...8458
      Handle Control Unit Removal And Installation...8459
      Switch Handle Removal And Installation...8462
      Handle Removal And Installation...8463
      Handle Disassembly And Assembly...8464
      Steering Lever Removal And Installation...8464
      Steering Lever Boot...8465
    STEERING (ADVANCED HAND CONTROL) (AHC) W/ PUSH BUTTON FLOAT...8466
      Components Identification...8466
      Handle Sensor Removal And Installation...8466
      Control Handle Removal and Installation...8468
      Control Handle Disassembly and Assembly...8469
      Control Lever Removal and Installation...8470
      Control Lever Boot...8471
    STEERING (ADVANCED CONTROL SYSTEM) (ACS)...8472
      Components Identification...8472
      Handle Sensor Removal And Installation...8472
      Control Handle Removal and Installation...8476
      Control Handle Disassembly and Assembly...8477
      Control Lever Removal and Installation...8477
      Control Lever Boot...8478
    HYDROSTATIC MOTOR...8480
      Removal And Installation...8480
      Parts Identification...8483
      Disassembly...8485
      Inspection...8493
      Assembly...8494
      Filling...8502
    CHARGE PRESSURE SENDER...8504
      Removal and Installation...8504
    HYDROSTATIC PUMP...8506
      Removal And Installation...8506
      Replenishing/High Pressure Relief Valve(s)...8508
      Charge Pressure Relief Valve...8508
      Parts Identification (Right Half)...8511
      Parts Identification (Left Half)...8513
      Hydraulic Pump Removal And Installation...8515
      Disassembly...8516
      Assembly...8524
    DRIVE BELT...8532
      Shield Removal And Installation...8532
      Adjustment...8533
      Replacement...8533
      Tensioner Pulley Removal And Installation...8534
      Tensioner Pulley Disassembly And Assembly...8535
      Tensioner Pulley Tension Spring...8536
    OIL COOLER...8538
      Removal and Installation...8538
      Removal And Installation With STC (Seal Tight Connector)...8539
  DRIVE SYSTEM...8540
    BRAKE...8542
      Pedal Removal And Installation...8542
      Pedal Disassembly And Assembly...8543
      Switch Operated Parking Brake...8544
      Block Removal And Installation...8544
      Block Disassembly And Assembly...8546
      Traction Lock Bypass Knob...8547
    DRIVE COMPONENTS...8548
      Track Checking...8548
      Track Adjustment...8549
      Track Removal And Installation...8550
      Track Idler (Front) Removal And Installation...8553
      Track Idler (Front) Parts Identification...8555
      Track Idler (Front) Disassembly...8556
      Track Idler (Front) Assembly...8557
      Track Idler (Rear) Removal And Installation...8560
      Track Idler (Rear) Parts Identification...8560
      Track Idler (Rear) Disassembly...8561
      Track Idler (Rear) Assembly...8562
      Track Roller Removal And Installation...8564
      Track Roller Parts Identification...8564
      Track Roller Disassembly...8565
      Track Roller Assembly...8566
      Track Housing Removal And Installation...8568
      Track Damage Identification...8569
  MAINFRAME...8580
    SEAT BAR...8582
      Removal And Installation...8582
      Assembling Components...8583
      Compression Spring Disassembly And Assembly...8585
    OPERATOR CAB...8586
      Gas Cylinder Removal And Installation...8586
      Gas Cylinder Disassembly And Assembly...8587
      Removal And Installation...8588
    OPERATOR SEAT...8590
      Removal And Installation...8590
      Seat Belt Removal And Installation...8590
    OPERATOR SEAT (SUSPENSION)...8592
      Removal And Installation...8592
      Slide Rail Removal And Installation...8593
      Cushion Removal And Installation...8593
      Back Removal And Installation...8594
      Shock Removal And Installation...8595
    BOB-TACH...8596
      Inspection And Maintenance...8596
      Bob-Tach Lever And Wedge...8597
      Removal And Installation...8599
      Pivot Pin Bushing And Seal Replacement...8601
    POWER BOB-TACH...8602
      Inspection And Maintenance...8602
      Power Bob-Tach Lever And Wedge...8603
      Removal And Installation...8605
      Pivot Pin Bushing And Seal Replacement...8607
    LIFT ARMS...8608
      Removal And Installation...8608
    REAR GRILL...8612
      Removal And Installation...8612
    REAR DOOR...8614
      Removal And Installation...8614
      Adjusting The Rear Door Latch...8615
    FUEL TANK...8616
      Removal And Installation...8616
      Fuel Level Sender...8619
      Fuel Pick-up Screen/Check Valve...8619
  ELECTRICAL SYSTEM & ANALYSIS...8620
    ELECTRICAL SCHEMATICS...8624
    ELECTRICAL SYSTEM INFORMATION...8636
      Troubleshooting Chart...8636
      Description...8637
      Fuse Location...8639
      Relay Switch Location...8639
      Solenoid Test...8640
    BATTERY...8642
      Removal And Installation...8642
      Servicing The Battery...8643
      Using A Booster Battery...8644
    ALTERNATOR (55 AMP)...8646
      Adjusting The Alternator Belt...8646
      Alternator Output Test...8647
      Rectifier (Diode) Test...8647
      Alternator Regulator Test...8648
      Removal And Installation...8649
      Disassembly...8650
      Stator Continuity Test...8650
      Stator Ground Test...8650
      Rotor Continuity Test...8651
      Rotor Ground Test...8651
      Rectifier Continuity (Diode) Test...8651
      Assembly...8652
    ALTERNATOR (90 AMP)...8654
      Adjusting The Alternator Belt...8654
      Alternator Identification...8654
      Charging System Check...8655
      Alternator Voltage Test...8656
      Low Voltage Test...8656
      High Voltage Test...8657
      Removal And Installation...8658
      Rectifier Continuity (Diode) Test...8659
      Alternator Regulator Test...8660
      Disassembly...8660
      Stator Continuity Test...8661
      Stator Ground Test...8661
      Rotor Continuity Test...8661
      Rotor Ground Test...8661
      Assembly...8662
    STARTER...8664
      Removal And Installation...8664
      Parts Identification...8665
      Disassembly And Assembly...8666
      External Pinion...8669
      Inspection And Repair...8670
      No Load Test...8674
    INSTRUMENT PANEL...8676
      Left Panel (Standard)...8676
      Right Panel-Standard Instrument Panel (With Key Switch) [Figure 60-50-2]...8677
      Right Panel (Deluxe) (With Keyless Start) [Figure 60- 50-3]...8678
      Right Panel Setup Display Options (Deluxe)...8680
      Passwords...8681
      Option And Field Accessory Panels...8683
      Standard Panel Removal And Installation (Right Side)...8684
      Deluxe Panel Removal And Installation (Right Side)...8685
      Standard And Deluxe Panel Removal And Installation (Left Side)...8686
      Front Accessory Panel Removal And Installation...8687
    LIGHTS...8690
      Front Removal And Installation...8690
      Rear Removal And Installation...8691
    BOBCAT CONTROLLER...8692
      Identification Chart...8692
      Removal And Installation...8693
    DIAGNOSTICS SERVICE CODES...8694
      Display...8694
    BICS™ SYSTEM...8696
      Inspecting The BICS™ Controller (Engine STOPPED - Key ON)...8696
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...8696
      Inspecting The Seat Bar Sensor (Engine RUNNING)...8696
      Inspecting The Traction Lock (Engine RUNNING)...8696
      Inspecting The Lift Arm Bypass Control...8696
      Additional Inspection For Loaders With Advanced Hand Controls (AHC)...8697
      Troubleshooting Chart...8698
      Troubleshooting Guide...8699
    SEAT BAR SENSOR...8702
      Troubleshooting Chart...8702
      Test...8703
      Removal And Installation...8704
      BICS™ Circuit Test...8705
    TRACTION LOCK...8706
      Description Of The Control System...8706
      Inspecting The Control System...8706
      Parking Brake Solenoid Removal And Installation...8707
      Traction Lock Bypass Knob...8708
    ADVANCE HAND CONTROL (AHC) SYSTEM...8710
      Components Identification...8710
      Troubleshooting Guide...8711
      Parts Identification...8712
      AHC Controller Removal And Installation...8713
      Handle Control Unit Connector...8713
      Switch Handle Removal and Installation...8714
      Actuators Disassembly and Assembly...8717
    ADVANCED HAND CONTROL (AHC) SYSTEM (W/ PUSH BUTTON FLOAT) (CONT’D)...8720
      Components Identification...8720
      Troubleshooting Guide...8721
      Controller Connector And Wire Identification...8722
      AHC Controller Removal And Installation...8723
      Handle Sensor Removal And Installation...8723
      Handle Sensor Connector...8725
      Switch Handle Removal and Installation...8726
      Actuators Disassembly and Assembly...8729
    ADVANCED CONTROL SYSTEM (ACS)...8732
      Components Identification...8732
      Troubleshooting Guide...8734
      Controller, Connector And Wire Identification...8735
      ACS Controller Removal And Installation...8736
      Handle Sensor Connector...8736
      Switch Handle Removal...8737
      Switch Handle Installation...8740
      Actuators Disassembly and Assembly...8743
      Handle Lock Solenoid Removal And Installation...8744
      Handle Lock Solenoid Disassembly And Assembly...8745
      Handle Lock Solenoid Connector...8745
      Calibration Of The ACS System...8746
      Switchable Hand/Foot Controls Calibration Procedure...8746
      Hand Controls Only Calibration Procedure...8748
      Foot Sensor Disassembly And Assembly...8749
      Foot Sensor Connector...8749
      Foot Lock Solenoid Removal And Installation...8750
      Foot Lock Solenoid Connector...8750
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE...8752
      Controls Identification Chart...8752
  ENGINE SERVICE...8754
    TROUBLESHOOTING...8756
      Chart...8756
    ENGINE SPEED CONTROL...8758
      Removal And Installation...8758
      Speed Control Cable...8759
      Speed Control Linkage...8759
    MUFFLER...8760
      Removal And Installation...8760
    AIR CLEANER...8762
      Housing Removal And Installation...8762
    RADIATOR...8764
      Oil Cooler Removal And Installation...8764
    COOLING FAN...8766
      Drive Tension Pulley Removal And Installation...8766
      Gearbox/Blower Housing Removal And Installation...8767
      Blower Removal And Installation...8770
      Gearbox Parts Identification...8771
      Gearbox Disassembly...8772
      Gearbox Assembly...8777
      Gearbox, Checking Backlash...8782
    ENGINE COMPONENTS AND TESTS...8786
      Engine Compression, Checking...8786
      Glow Plug, Checking...8787
      Fuel Shut-Off Solenoid, Checking...8788
      Fuel Shut-Off Solenoid Removal and Installation...8789
      Fuel Injection Pump Removal...8789
      Fuel Injection Pump Timing...8791
      Fuel Injection Pump Installation...8792
      Fuel Injector Removal and Installation...8794
      Fuel Injector, Checking...8795
      Fuel Injector Disassembly...8796
      Fuel Injector Assembly...8797
      Timing Belt Inspection...8799
      Timing Belt Removal...8799
      Timing Belt Installation...8800
      Timing Belt, Replacement In the Loader...8804
      Valve Clearance Adjustment...8809
      Valve Timing, Checking...8810
      Thermostat, Oil Pressure Control Valves And Heater Connections...8812
    ENGINE AND ENGINE MOUNTS...8816
      Removal And Installation...8816
      Engine Mount Replacement...8822
    FLYWHEEL AND HOUSING...8824
      Flywheel Removal And Installation...8824
      Ring Gear Removal And Installation...8824
      Flywheel Housing Removal And Installation...8824
    RECONDITIONING THE ENGINE...8826
      Deutz Engine Tools Identification Chart...8826
      Disassembly...8827
      Assembly...8831
      Cylinder, Checking...8847
      Camshaft Bearing, Checking...8848
      Camshaft Bearing, Removal And Installation...8848
      Control Rod Guide Bushing Removal...8849
      Control Rod Guide Bushing Installation...8851
      Rear Cover Seal Removal And Installation...8855
      Crankshaft, Checking...8856
      Connecting Rod, Checking...8858
      Piston, Checking...8860
      Piston Pin, Checking...8861
      Piston Rings Installation...8861
      Piston Installation On The Connecting Rod...8862
      Cylinder Head Disassembly...8864
      Valves, Checking...8864
      Valve Seats, Checking...8865
      Valve Spring, Checking...8866
      Cylinder Head Assembly...8866
      Rocker Arm and Bracket, Checking...8867
      Front Cover Disassembly...8868
      Front Cover Assembly...8873
      Turbo Charger Removal and Installation...8882
      Crankshaft Gear Mounting Bolt Torque Procedure...8883
  HEATING, VENTILATION, AIR CONDITIONING...8886
    AIR CONDITIONING SYSTEM FLOW...8889
      Principals...8889
      Chart...8890
    COMPONENTS...8892
      Identification...8892
    SAFETY...8896
      Safety Equipment...8896
    REGULAR MAINTENANCE...8898
      Filter Elements Removal And Installation...8898
      Compressor Drive Belt Inspection...8899
      Cleaning The Condenser...8900
    BASIC TROUBLESHOOTING...8902
      Poor A/C Performance...8902
      Cleaning The A/C Evaporator Coil & Heater Coil...8902
      Receiver/Drier Sight Glass Inspection...8905
      Compressor Drive Belt Inspection:...8906
      Checking The Electrical System...8906
      Engine Coolant Bypassing The Heater Valve...8914
      Heater Valve Not Opening Or Closing...8914
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...8916
      Compressor Oil...8916
      Compressor Oil Check...8916
      Component Replacement And Refrigeration Leaks...8918
    SYSTEM TROUBLESHOOTING CHART...8920
      Gauge Pressure Related Troubleshooting...8921
    TEMPERATURE/PRESSURE...8924
      Chart...8924
    ELECTRICAL...8926
      Chart...8926
    AIR CONDITIONING SERVICE...8928
      Chart...8928
    RECOMMENDED SERVICE TOOLS...8930
      Full Service A/C Tools...8930
      Basic Field Diagnostic Tools...8931
    SYSTEM CHARGING AND RECLAMATION...8934
      Reclamation Procedure...8934
      Charging Procedure With A Manifold Gauge Set...8936
      Charging Procedure...8937
    COMPRESSOR...8940
      Removal And Installation...8940
      Compressor Clutch Disassembly...8941
    CONDENSER...8946
      Removal And Installation...8946
    RECEIVER/DRIER...8948
      Removal And Installation...8948
    PRESSURE RELIEF VALVE...8950
      Removal And Installation...8950
    PRESSURE SWITCH...8952
      Removal And Installation...8952
    THE EVAPORATOR/HEATER UNIT...8954
      Removal And Installation...8954
      Disassembly And Assembly...8955
    THERMOSTAT...8956
      Removal And Installation...8956
    THE EXPANSION VALVE...8958
      Removal And Installation...8958
    THE EVAPORATOR...8960
      Removal And Installation...8960
    HEATER COIL...8962
      Removal And Installation With A/C...8962
      Removal And Installation Without A/C...8963
    HEATER/AC FAN...8966
      Removal And Installation...8966
      Disassembly And Assembly...8967
      Wire Connector Removal and Installation...8969
    HEATER VALVE...8972
      Removal and Installation...8972
      Disassembly And Assembly...8973
  SPECIFICATIONS...8976
    LOADER SPECIFICATIONS...8978
      Loader Dimensions...8978
      Performance...8979
      Controls...8979
      Engine...8979
      Hydraulic System...8980
      Electrical...8980
      Drive System...8981
      Capacities...8981
      Tracks...8981
      Ground Pressure...8981
    ENGINE SPECIFICATIONS...8982
      General...8982
      Fuel System...8982
      Valve and Valve Guide and Seat Insert...8983
      Piston and Rings...8984
      Connecting Rod...8984
      Cylinder Head and Block...8985
      Crankshaft and Main Bearings...8985
      Camshaft and Bearings...8985
      Oil Pump...8986
    LOADER TORQUE...8988
      Specifications...8988
    TORQUE SPECIFICATIONS FOR BOLTS...8992
      Torque For General SAE Bolts...8992
      Torque For General Metric Bolts...8993
    HYDRAULIC CONNECTION SPECIFICATIONS...8994
      O-ring Face Seal Connection...8994
      Straight Thread O-ring Fitting...8994
      Tubelines And Hoses...8994
      Flare Fitting...8995
      O-ring Flare Fitting...8996
      Port Seal Fitting...8998
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...9000
      Specifications...9000
    CONVERSIONS...9002
      Decimal And Millimeter Equivalents...9002
      U.S. To Metric Conversion...9002
  SERVICE MANUAL REVISION...9004
    864/864H-1...9004
    864/864H-2...9006
    864/864H-3...9010
    864/864H-4...9012
    864/864H-5...9014
    864/864H-6...9016
6900945 (3-06) - 864, 864 High Flow Service Manual...9018
  MAINTENANCE SAFETY...9020
  ALPHABETICAL INDEX...9022
  CONTENTS...9024
    FOREWORD...9025
    SAFETY INSTRUCTIONS...9028
      Fire Prevention...9030
    SERIAL NUMBER LOCATIONS...9032
      Loader Serial Number...9032
      Engine Serial Number...9032
    DELIVERY REPORT...9032
    BOBCAT LOADER IDENTIFICATION...9033
  SAFETY AND MAINTENANCE...9034
    LIFTING AND BLOCKING THE LOADER...9036
      Procedure...9036
    LIFT ARM SUPPORT DEVICE...9038
      Engaging The Lift Arm Support Device...9038
      Disengaging The Lift Arm Support Device...9040
    OPERATOR CAB...9042
      Raising The Operator Cab...9042
      Lowering The Operator Cab...9043
      Emergency Exit...9044
    TRANSPORTING THE BOBCAT LOADER...9046
      Procedure...9046
    TOWING THE LOADER...9048
      Procedure...9048
    REMOTE START...9050
      Procedure For Loader Without Attachments Control Harness...9050
      Procedure For Loader With Attachments Control Harness...9051
    SERVICE SCHEDULE...9054
      Chart...9054
    AIR CLEANER SERVICE...9056
      Replacing Filter Element...9056
    ENGINE COOLING SYSTEM...9058
      Cleaning The Cooling System...9058
    FUEL SYSTEM...9060
      Fuel Specifications...9060
      Filling The Fuel Tank...9060
      Fuel Filter...9061
      Removing Air From The Fuel System...9061
    ENGINE LUBRICATION SYSTEM...9062
      Checking Engine Oil...9062
      Replacing Oil And Filter...9062
    HYDRAULIC/HYDROSTATIC SYSTEM...9064
      Checking And Adding Fluid...9064
      Hydraulic/Hydrostatic Filter Replacement...9064
      Replacing Hydraulic Fluid...9065
    FAN GEARBOX...9068
      Checking And Adding Oil...9068
    BOB-TACH...9070
      Inspection And Maintenance...9070
    POWER BOB-TACH (OPTION)...9072
      Inspection And Maintenance...9072
    LUBRICATING THE LOADER...9074
      Procedure...9074
  HYDRAULIC SYSTEM...9076
    HYDRAULCI/HYDROSTATIC SCHEMATICS...9080
    HYDRAULIC SYSTEM INFORMATION...9088
      Glossary Of Hydraulic/Hydrostatic Symbols For Loaders...9088
      Troubleshooting...9092
      Tighten Procedures...9093
    CYLINDER (LIFT)...9094
      Checking...9094
      Removal And Installation...9094
      Parts Identification...9096
      Disassembly...9097
      Assembly...9098
    CYLINDER (TILT)...9102
      Checking...9102
      Removal And Installation...9102
      Rod End Seal...9103
      Parts Identification...9105
      Disassembly...9106
      Assembly...9108
    CYLINDER (POWER BOB-TACH)...9112
      Checking...9112
      Removal And Installation...9113
      Parts Identification...9114
      Disassembly...9115
      Assembly...9116
    MAIN RELIEF VALVE (FOOT CONTROL)...9120
      Checking The Main Relief Valve At Front Auxiliary Hydraulics...9120
      Checking The Main Relief Valve Without Front Auxiliaries...9121
      Removal And Installation...9122
      Adjustment...9123
    MAIN RELIEF VALVE (AHC)...9124
      Checking The Main Relief Valve At Front Auxiliary Hydraulics...9124
      Checking The Main Relief Valve Without Front Auxiliaries...9125
      Removal and Installation...9126
      Adjustment...9127
    HYDRAULIC CONTROL VALVE (FOOT CONTROL)...9128
      Removal And Installation...9128
      BICS™ Valve, Removal And Installation...9134
      BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly...9135
      BICS™ Valve, Check Valve Disassembly And Assembly...9136
      BICS™ Valve, Lock Valve Disassembly And Assembly...9137
      BICS™ Valve, Solenoid Disassembly And Assembly...9138
      BICS™ Valve, Solenoid Testing...9139
      Identification Chart...9140
      Load Check Valve...9141
      Main Relief Valve...9142
      Port Relief Valve, Tilt Spool (Linkage End)...9142
      Port Relief Valve, Lift Spool (Bonnet End)...9143
      Anti-Cavitation Valve/Port Relief Valve, Tilt Spool (Bonnet End)...9143
      Anti-Cavitation Valve, Lift Spool (Linkage End)...9144
      Rubber Boot...9144
      Lift And Tilt Lock Block...9145
      Lift Spool and Detent...9146
      Tilt Spool Removal And Installation...9154
      Auxiliary Spool Removal And Installation (Bonnet End)...9156
      Auxiliary Spool Removal And Installation (Linkage End)...9157
      Auxiliary Plug Removal And Installation...9158
      Auxiliary Electric Solenoid Disassembly...9159
      Port Relief-Auxiliary Section Disassembly...9160
      Cleaning And Inspection...9160
    HYDRAULIC CONTROL VALVE (ADVANCE HAND...9162
    CONTROL) (AHC), ADVANCE CONTROL SYSTEM (ACS)...9162
      Actuator Removal And Installation (In Loader)...9162
      Removal And Installation...9164
      Actuator Removal And Installation (Out Of Loader)...9170
      BICS™ Valve, Removal And Installation...9171
      BICS™ Valve, Lift Arm By-Pass Orifice Dissembly And Assembly...9172
      BICS™ Valve, Check Valve Dissembly And Assembly...9173
      BICS™ Valve, Lock Valve Dissembly And Assembly...9174
      BICS™ Valve, Solenoid Dissembly And Assembly...9175
      BICS™ Valve, Solenoid Testing...9176
      Identification Chart...9177
      Identification Chart...9178
      Lift Base End Restrictor...9179
      Load Check Valve...9179
      Main Relief Valve...9180
      Port Relief Valve...9181
      Anti-Cavitation Valve/Port Relief Valve...9182
      Anti-Cavitation Valve...9183
      Lift Spool Removal...9184
      Lift Spool Removal And Installation...9185
      Lift and Tilt Spool Disassembly And Assembly...9186
      Auxiliary Spool Removal And Installation...9187
      Auxiliary Electric Solenoid Disassembly...9188
      Port-Auxiliary Section Disassembly...9189
      Cleaning And Inspection...9189
    LIFT ARM BY-PASS CONTROL VALVE...9190
      Inspecting...9190
      Additional Inspection For Loaders With Advanced Hand Controls...9190
      Removal And Installation...9190
      Disassembly And Assembly...9192
    HYDRAULIC PUMP (SINGLE GEAR)...9194
      Checking The Output Of The Pump...9194
      Removal And Installation...9195
      Parts Identification...9197
      Disassembly...9198
      Inspection...9200
      Assembly...9201
    HYDRAULIC PUMP (HI-FLOW)...9204
      Checking The Output Of The High Flow Pump...9204
      Removal And Installation...9205
      Parts Identification...9207
      Disassembly...9208
      Inspection...9211
      Assembly...9212
    HYDRAULIC/HYDROSTATIC FILTER...9216
      Housing Removal And Installation...9216
      Mount Removal And Installation...9217
    HYDRAULIC FLUID RESERVOIR...9218
      Draining The Hydraulic Fluid Reservoir...9218
      Removal And Installation...9218
      Hydraulic Fluid Screen...9220
    CONTROLS...9222
      Control Pedal Removal And Installation...9222
      Control Pedal Adjustment...9222
      Crossbar Linkage Removal And Installation...9222
      Crossbar Linkage Inspection...9223
      Control Foot Sensor (ACS) Removal And Installation...9223
      Control Pedal (ACS) Removal And Installation...9225
      Control Pedal Linkage (ACS) Disassembly And Assembly...9225
    BUCKET POSITION VALVE...9226
      Solenoid Removal And Installation...9226
      Solenoid Testing...9226
      Removal And Installation...9227
      Disassembly And Assembly...9227
    REAR AUXILIARY DIVERTER...9230
      Disassembly...9230
      Inspection...9230
      Solenoid Testing...9231
      Assembly...9231
    SELECT VALVE...9232
      Checking The High Flow Pump Relief Valve...9232
      Removal And Installation...9233
      Disassembly And Assembly...9234
      Solenoid Testing...9239
    REAR AUXILIARY DIVERTER VALVE (SINGLE SHUTTLE)...9240
      Removal And Installation...9240
      Disassembly...9242
      Inspection...9242
      Solenoid Testing...9243
      Assembly...9243
    POWER BOB-TACH BLOCK...9244
      Removal And Installation...9244
      Disassembly And Assembly...9246
    AUXILIARY PRESSURE RELEASE (ACCUMULATOR)...9252
      Removal and Installation...9252
      Disassembly And Assembly...9253
  HYDROSTATIC SYSTEM...9254
    HYDROSTATIC SYSTEM INFORMATION...9256
      Troubleshooting Chart...9256
      Replenishing Valve Function...9257
    CONTROL PANEL...9258
      Removal and Installation...9258
    STEERING...9260
      Lever Removal And Installation...9260
      Lever Disassembly And Assembly...9260
      Linkage Removal And Installation...9261
      Linkage Neutral Adjustment...9265
    STEERING (ADVANCED HAND CONTROL) (AHC)...9270
      Components Identification...9270
      Handle Control Unit Removal And Installation...9271
      Switch Handle Removal And Installation...9274
      Handle Removal And Installation...9275
      Handle Disassembly And Assembly...9276
      Steering Lever Removal And Installation...9276
      Steering Lever Boot...9277
    STEERING (ADVANCED HAND CONTROL) (AHC) W/PUSH BUTTON FLOAT...9278
      Components Identification...9278
      Handle Sensor Removal And Installation...9278
      Control Handle Removal and Installation...9280
      Control Handle Disassembly and Assembly...9281
      Control Lever Removal and Installation...9282
      Control Lever Boot...9283
    STEERING (ADVANCED CONTROL SYSTEM) (ACS)...9284
      Components Identification...9284
      Handle Sensor Removal And Installation...9284
      Control Handle Removal and Installation...9288
      Control Handle Disassembly and Assembly...9289
      Control Lever Removal and Installation...9289
      Control Lever Boot...9290
    HYDROSTATIC MOTOR...9292
      Removal And Installation...9292
      Parts Identification...9295
      Disassembly...9297
      Inspection...9305
      Assembly...9306
      Filling...9314
    CHARGE PRESSURE SENDER...9316
      Removal and Installation...9316
    HYDROSTATIC PUMP...9318
      Removal And Installation...9318
      Replenishing/High Pressure Relief Valve(s)...9320
      Charge Pressure Relief Valve...9320
      Parts Identification (Right Half)...9323
      Parts Identification (Left Half)...9325
      Hydraulic Pump Removal And Installation...9327
      Disassembly...9328
      Assembly...9336
    DRIVE BELT...9344
      Shield Removal And Installation...9344
      Adjustment...9345
      Replacement...9345
      Tensioner Pulley Removal And Installation...9346
      Tensioner Pulley Disassembly And Assembly...9347
      Tensioner Pulley Tension Spring...9348
    OIL COOLER...9350
      Removal and Installation...9350
      Removal And Installation With STC (Seal Tight Connector)...9351
  DRIVE SYSTEM...9352
    BRAKE...9354
      Pedal Removal And Installation...9354
      Pedal Disassembly And Assembly...9355
      Switch Operated Parking Brake...9356
      Block Removal And Installation...9356
      Block Disassembly And Assembly...9358
      Traction Lock By-Pass Knob...9359
    DRIVE COMPONENTS...9360
      Track Checking...9360
      Track Adjustment...9361
      Track Removal And Installation...9362
      Track Idler (Front) Removal And Installation...9365
      Track Idler (Front) Parts Identification...9367
      Track Idler (Front) Disassembly...9368
      Track Idler (Front) Assembly...9369
      Track Idler (Rear) Removal And Installation...9372
      Track Idler (Rear) Parts Identification...9372
      Track Idler (Rear) Disassembly...9373
      Track Idler (Rear) Assembly...9374
      Track Roller Removal And Installation...9376
      Track Roller Parts Identification...9376
      Track Roller Disassembly...9377
      Track Roller Assembly...9378
      Track Housing Removal And Installation...9380
      Track Damage Identification...9381
  MAIN FRAME...9392
    SEAT BAR...9394
      Removal And Installation...9394
      Assembling Components...9395
      Compression Spring Disassembly And Assembly...9397
    OPERATOR CAB...9398
      Gas Cylinder Removal And Installation...9398
      Gas Cylinder Disassembly And Assembly...9399
      Removal And Installation...9400
    OPERATOR SEAT...9402
      Removal And Installation...9402
      Seat Belt Removal And Installation...9402
    OPERATOR SEAT (SUSPENSION)...9404
      Removal And Installation...9404
      Slide Rail Removal And Installation...9405
      Cushion Removal And Installation...9405
      Back Removal And Installation...9406
      Shock Removal And Installation...9407
    BOB-TACH...9408
      Inspection And Maintenance...9408
      Bob-Tach Lever And Wedge...9409
      Removal And Installation...9411
      Pivot Pin Bushing And Seal Replacement...9413
    POWER BOB-TACH...9414
      Inspection And Maintenance...9414
      Power Bob-Tach Lever And Wedge...9415
      Removal And Installation...9417
      Pivot Pin Bushing And Seal Replacement...9419
    LIFT ARMS...9420
      Removal And Installation...9420
    REAR GRILL...9424
      Removal And Installation...9424
    REAR DOOR...9426
      Removal And Installation...9426
      Adjusting The Rear Door Latch...9427
    FUEL TANK...9428
      Removal And Installation...9428
      Fuel Level Sender...9431
      Fuel Pick-up Screen/Check Valve...9431
  ELECTRICAL SYSTEM & ANALYSIS...9432
    ELECTRICAL SCHEMATICS...9438
    ELECTRICAL SYSTEM INFORMATION...9447
      Troubleshooting Chart...9447
      Description...9448
      Fuse Location...9450
      Relay Switch Location...9450
      Solenoid Test...9451
    BATTERY...9453
      Removal And Installation...9453
      Servicing The Battery...9454
      Using A Booster Battery...9455
    ALTERNATOR (55 AMP)...9457
      Adjusting The Alternator Belt...9457
      Alternator Output Test...9458
      Rectifier (Diode) Test...9458
      Alternator Regulator Test...9459
      Removal And Installation...9460
      Disassembly...9461
      Stator Continuity Test...9461
      Stator Ground Test...9461
      Rotor Continuity Test...9462
      Rotor Ground Test...9462
      Rectifier Continuity (Diode) Test...9462
      Assembly...9463
    ALTERNATOR (90 AMP)...9465
      Adjusting The Alternator Belt...9465
      Alternator Identification...9465
      Charging System Check...9466
      Alternator Voltage Test...9467
      Low Voltage Test...9467
      High Voltage Test...9468
      Removal And Installation...9469
      Rectifier Continuity (Diode) Test...9470
      Alternator Regulator Test...9471
      Disassembly...9471
      Stator Continuity Test...9472
      Stator Ground Test...9472
      Rotor Continuity Test...9472
      Rotor Ground Test...9472
      Assembly...9473
    STARTER...9475
      Removal And Installation...9475
      Parts Identification...9476
      Disassembly And Assembly...9477
      External Pinion...9480
      Inspection And Repair...9481
      No Load Test...9485
    INSTRUMENT PANEL...9487
      Left Panel (Standard)...9487
      Right Panel-Standard Instrument Panel (With Key Switch) [Figure 60-50-2]...9488
      Right Panel (Deluxe) (With Keyless Start) [Figure 60- 50-3]...9489
      Right Panel Setup Display Options (Deluxe)...9491
      Passwords...9492
      Option And Field Accessory Panels...9494
      Standard Panel Removal And Installation (Right Side)...9495
      Deluxe Panel Removal And Installation (Right Side)...9496
      Standard And Deluxe Panel Removal And Installation (Left Side)...9497
      Front Accessory Panel Removal And Installation...9498
    LIGHTS...9501
      Front Removal And Installation...9501
      Rear Removal And Installation...9502
    BOBCAT CONTROLLER...9503
      Identification Chart...9503
      Removal And Installation...9504
    DIAGNOSTICS SERVICE CODES...9505
      Display...9505
    BICS™ SYSTEM...9507
      Inspecting The BICS™ Controller (Engine STOPPED - Key ON)...9507
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...9507
      Inspecting The Seat Bar Sensor (Engine RUNNING)...9507
      Inspecting The Traction Lock (Engine RUNNING)...9507
      Inspecting The Lift Arm By-Pass Control...9507
      Additional Inspection For Loaders With Advanced Hand Controls (AHC)...9508
      Troubleshooting Chart...9509
      Troubleshooting Guide...9510
    SEAT BAR SENSOR...9513
      Troubleshooting Chart...9513
      Test...9514
      Removal And Installation...9515
      BICS™ Circuit Test...9516
    TRACTION LOCK...9517
      Description Of The Control System...9517
      Inspecting The Control System...9517
      Parking Brake Solenoid Removal And Installation...9518
      Traction Lock By-Pass Knob...9519
    ADVANCE HAND CONTROL (AHC) SYSTEM...9521
      Components Identification...9521
      Troubleshooting Guide...9522
      Parts Identification...9523
      AHC Controller Removal And Installation...9524
      Handle Control Unit Connector...9524
      Switch Handle Removal and Installation...9525
      Actuators Disassembly and Assembly...9528
    ADVANCED HAND CONTROL (AHC) SYSTEM (W/ PUSH BUTTON FLOAT) (CONT’D)...9531
      Components Identification...9531
      Troubleshooting Guide...9532
      Controller Connector And Wire Identification...9533
      AHC Controller Removal And Installation...9534
      Handle Sensor Removal And Installation...9534
      Handle Sensor Connector...9536
      Switch Handle Removal and Installation...9537
      Actuators Disassembly and Assembly...9540
    ADVANCED CONTROL SYSTEM (ACS)...9543
      Components Identification...9543
      Troubleshooting Guide...9545
      Controller, Connector And Wire Identification...9546
      ACS Controller Removal And Installation...9547
      Handle Sensor Connector...9547
      Switch Handle Removal...9548
      Switch Handle Installation...9551
      Actuators Disassembly and Assembly...9554
      Handle Lock Solenoid Removal And Installation...9555
      Handle Lock Solenoid Disassembly And Assembly...9556
      Handle Lock Solenoid Connector...9556
      Calibration Of The ACS System...9557
      Switchable Hand/Foot Controls Calibration Procedure...9557
      Hand Controls Only Calibration Procedure...9559
      Foot Sensor Disassembly And Assembly...9560
      Foot Sensor Connector...9560
      Foot Lock Solenoid Removal And Installation...9561
      Foot Lock Solenoid Connector...9561
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE...9563
      Controls Identification Chart...9563
  ENGINE SERVICE...9565
    TROUBLESHOOTING...9567
      Chart...9567
    ENGINE SPEED CONTROL...9569
      Removal And Installation...9569
      Speed Control Cable...9570
      Speed Control Linkage...9570
    MUFFLER...9571
      Removal And Installation...9571
    AIR CLEANER...9573
      Housing Removal And Installation...9573
    RADIATOR...9575
      Oil Cooler Removal And Installation...9575
    COOLING FAN...9577
      Drive Tension Pulley Removal And Installation...9577
      Gearbox/Blower Housing Removal And Installation...9578
      Blower Removal And Installation...9581
      Gearbox Parts Identification...9582
      Gearbox Disassembly...9583
      Gearbox Assembly...9588
      Gearbox, Checking Backlash...9593
    ENGINE COMPONENTS AND TESTS...9597
      Engine Compression, Checking...9597
      Glow Plug, Checking...9598
      Fuel Shut-Off Solenoid, Checking...9599
      Fuel Shut-Off Solenoid Removal and Installation...9600
      Fuel Injection Pump Removal...9600
      Fuel Injection Pump Timing...9602
      Fuel Injection Pump Installation...9603
      Fuel Injector Removal and Installation...9605
      Fuel Injector, Checking...9606
      Fuel Injector Disassembly...9607
      Fuel Injector Assembly...9608
      Timing Belt Inspection...9610
      Timing Belt Removal...9610
      Timing Belt Installation...9611
      Timing Belt, Replacement In the Loader...9615
      Valve Clearance Adjustment...9620
      Valve Timing, Checking...9621
      Thermostat, Oil Pressure Control Valves And Heater Connections...9623
    ENGINE AND ENGINE MOUNTS...9627
      Removal And Installation...9627
      Engine Mount Replacement...9633
    FLYWHEEL AND HOUSING...9635
      Flywheel Removal And Installation...9635
      Ring Gear Removal And Installation...9635
      Flywheel Housing Removal And Installation...9635
    RECONDITIONING THE ENGINE...9637
      Deutz Engine Tools Identification Chart...9637
      Disassembly...9638
      Assembly...9642
      Cylinder, Checking...9658
      Camshaft Bearing, Checking...9659
      Camshaft Bearing, Removal And Installation...9659
      Control Rod Guide Bushing Removal...9660
      Control Rod Guide Bushing Installation...9662
      Rear Cover Seal Removal And Installation...9666
      Crankshaft, Checking...9667
      Connecting Rod, Checking...9669
      Piston, Checking...9671
      Piston Pin, Checking...9672
      Piston Rings Installation...9672
      Piston Installation On The Connecting Rod...9673
      Cylinder Head Disassembly...9675
      Valves, Checking...9675
      Valve Seats, Checking...9676
      Valve Spring, Checking...9677
      Cylinder Head Assembly...9677
      Rocker Arm and Bracket, Checking...9678
      Front Cover Disassembly...9679
      Front Cover Assembly...9684
      Turbo Charger Removal and Installation...9693
      Crankshaft Gear Mounting Bolt Torque Procedure...9694
  HEATING, VENTILATION, AIR CONDITIONING...9697
    AIR CONDITIONING SYSTEM FLOW...9700
      Principals...9700
      Chart...9701
    COMPONENTS...9703
      Identification...9703
    SAFETY...9707
      Safety Equipment...9707
    REGULAR MAINTENANCE...9709
      Filter Elements Removal And Installation...9709
      Compressor Drive Belt Inspection...9710
      Cleaning The Condenser...9711
    BASIC TROUBLESHOOTING...9713
      Poor A/C Performance...9713
      Cleaning The A/C Evaporator Coil & Heater Coil...9713
      Receiver/Drier Sight Glass Inspection...9716
      Compressor Drive Belt Inspection:...9717
      Checking The Electrical System...9717
      Engine Coolant By-Passing The Heater Valve...9725
      Heater Valve Not Opening Or Closing...9725
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...9727
      Compressor Oil...9727
      Compressor Oil Check...9727
      Component Replacement And Refrigeration Leaks...9729
    SYSTEM TROUBLESHOOTING CHART...9731
      Gauge Pressure Related Troubleshooting...9732
    TEMPERATURE/PRESSURE...9735
      Chart...9735
    ELECTRICAL...9737
      Chart...9737
    AIR CONDITIONING SERVICE...9739
      Chart...9739
    RECOMMENDED SERVICE TOOLS...9741
      Full Service A/C Tools...9741
      Basic Field Diagnostic Tools...9742
    SYSTEM CHARGING AND RECLAMATION...9745
      Reclamation Procedure...9745
      Charging Procedure With A Manifold Gauge Set...9747
      Charging Procedure...9748
    COMPRESSOR...9751
      Removal And Installation...9751
      Compressor Clutch Disassembly...9752
    CONDENSER...9757
      Removal And Installation...9757
    RECEIVER/DRIER...9759
      Removal And Installation...9759
    PRESSURE RELIEF VALVE...9761
      Removal And Installation...9761
    PRESSURE SWITCH...9763
      Removal And Installation...9763
    THE EVAPORATOR/HEATER UNIT...9765
      Removal And Installation...9765
      Disassembly And Assembly...9766
    THERMOSTAT...9767
      Removal And Installation...9767
    THE EXPANSION VALVE...9769
      Removal And Installation...9769
    THE EVAPORATOR...9771
      Removal And Installation...9771
    HEATER COIL...9773
      Removal And Installation With A/C...9773
      Removal And Installation Without A/C...9774
    HEATER/AC FAN...9777
      Removal And Installation...9777
      Disassembly And Assembly...9778
      Wire Connector Removal and Installation...9780
    HEATER VALVE...9783
      Removal and Installation...9783
      Disassembly And Assembly...9784
  SPECIFICATIONS...9787
    LOADER SPECIFICATIONS...9789
      Loader Dimensions...9789
      Performance...9790
      Controls...9790
      Engine...9790
      Hydraulic System...9791
      Electrical...9791
      Drive System...9792
      Capacities...9792
      Tracks...9792
      Ground Pressure...9792
    ENGINE SPECIFICATIONS...9793
      General...9793
      Fuel System...9793
      Valve and Valve Guide and Seat Insert...9794
      Piston and Rings...9795
      Connecting Rod...9795
      Cylinder Head and Block...9796
      Crankshaft and Main Bearings...9796
      Camshaft and Bearings...9796
      Oil Pump...9797
    LOADER TORQUE...9799
      Specifications...9799
    TORQUE SPECIFICATIONS FOR BOLTS...9803
      Torque For General SAE Bolts...9803
      Torque For General Metric Bolts...9804
    HYDRAULIC CONNECTION SPECIFICATIONS...9805
      O-ring Face Seal Connection...9805
      Straight Thread O-ring Fitting...9805
      Tubelines And Hoses...9805
      Flare Fitting...9806
      O-ring Flare Fitting...9807
      Port Seal Fitting...9809
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...9811
      Specifications...9811
    CONVERSIONS...9813
      Decimal And Millimeter Equivalents...9813
      U.S. To Metric Conversion...9813
  SMR...9815
    Revision No: 864/864H-1...9815
    Revision No: 864/864H-2...9817
    Revision No: 864/864H-3...9821
    Revision No: 864/864H-4...9823
6900945 (7-10)  - 864, 864 High Flow Service Manual...9825
  MAINTENANCE SAFETY...9827
  ALPHABETICAL INDEX...9829
  CONTENTS...9831
    FOREWORD...9832
    SAFETY INSTRUCTIONS...9835
    FIRE PREVENTION...9837
      Maintenance...9837
      Operation...9837
      Electrical...9837
      Hydraulic System...9837
      Fueling...9837
      Starting...9837
      Spark Arrestor Exhaust System...9837
      Welding And Grinding...9838
      Fire Extinguishers...9838
    SERIAL NUMBER LOCATIONS...9839
      Loader Serial Number...9839
      Engine Serial Number...9839
    DELIVERY REPORT...9839
    BOBCAT LOADER IDENTIFICATION...9840
  SAFETY AND MAINTENANCE...9841
    LIFTING AND BLOCKING THE LOADER...9843
      Procedure...9843
    LIFT ARM SUPPORT DEVICE...9845
      Engaging The Lift Arm Support Device...9845
      Disengaging The Lift Arm Support Device...9847
    OPERATOR CAB...9849
      Raising The Operator Cab...9849
      Lowering The Operator Cab...9850
      Emergency Exit...9851
    TRANSPORTING THE BOBCAT LOADER...9853
      Procedure...9853
    TOWING THE LOADER...9855
      Procedure...9855
    REMOTE START...9857
      Procedure For Loader Without Attachments Control Harness...9857
      Procedure For Loader With Attachments Control Harness...9858
    SERVICE SCHEDULE...9861
      Chart...9861
    AIR CLEANER SERVICE...9863
      Replacing Filter Element...9863
    ENGINE COOLING SYSTEM...9865
      Cleaning The Cooling System...9865
    FUEL SYSTEM...9867
      Fuel Specifications...9867
      Filling The Fuel Tank...9867
      Fuel Filter...9868
      Removing Air From The Fuel System...9868
    ENGINE LUBRICATION SYSTEM...9869
      Checking Engine Oil...9869
      Replacing Oil And Filter...9869
    HYDRAULIC/HYDROSTATIC SYSTEM...9871
      Checking And Adding Fluid...9871
      Hydraulic/Hydrostatic Filter Replacement...9871
      Replacing Hydraulic Fluid...9872
    FAN GEARBOX...9875
      Checking And Adding Oil...9875
    BOB-TACH...9877
      Inspection And Maintenance...9877
    POWER BOB-TACH (OPTION)...9879
      Inspection And Maintenance...9879
    LUBRICATING THE LOADER...9881
      Procedure...9881
  HYDRAULIC SYSTEM...9883
    HYDRAULIC / HYDROSTATIC SCHEMATICS...9887
    HYDRAULIC SYSTEM INFORMATION...9895
      Glossary Of Hydraulic/Hydrostatic Symbols For Loaders...9895
      Troubleshooting...9899
      Tighten Procedures...9900
    CYLINDER (LIFT)...9901
      Checking...9901
      Removal And Installation...9901
      Parts Identification...9903
      Disassembly...9904
      Assembly...9905
    CYLINDER (TILT)...9909
      Checking...9909
      Removal And Installation...9909
      Rod End Seal...9910
      Parts Identification...9912
      Disassembly...9913
      Assembly...9915
    CYLINDER (POWER BOB-TACH)...9919
      Checking...9919
      Removal And Installation...9920
      Parts Identification...9921
      Disassembly...9922
      Assembly...9923
    MAIN RELIEF VALVE (FOOT CONTROL)...9927
      Checking The Main Relief Valve At Front Auxiliary Hydraulics...9927
      Checking The Main Relief Valve Without Front Auxiliaries...9928
      Removal And Installation...9929
      Adjustment...9930
    MAIN RELIEF VALVE (AHC)...9931
      Checking The Main Relief Valve At Front Auxiliary Hydraulics...9931
      Checking The Main Relief Valve Without Front Auxiliaries...9932
      Removal and Installation...9933
      Adjustment...9934
    HYDRAULIC CONTROL VALVE (FOOT CONTROL)...9935
      Removal And Installation...9935
      BICS™ Valve, Removal And Installation...9941
      BICS™ Valve, Lift Arm Bypass Orifice Disassembly And Assembly...9942
      BICS™ Valve, Check Valve Disassembly And Assembly...9943
      BICS™ Valve, Lock Valve Disassembly And Assembly...9944
      BICS™ Valve, Solenoid Disassembly And Assembly...9945
      BICS™ Valve, Solenoid Testing...9946
      Identification Chart...9947
      Load Check Valve...9948
      Main Relief Valve...9949
      Port Relief Valve, Tilt Spool (Linkage End)...9949
      Port Relief Valve, Lift Spool (Bonnet End)...9950
      Anti-Cavitation Valve/Port Relief Valve, Tilt Spool (Bonnet End)...9950
      Anti-Cavitation Valve, Lift Spool (Linkage End)...9951
      Rubber Boot...9951
      Lift And Tilt Lock Block...9952
      Lift Spool and Detent...9953
      Tilt Spool Removal And Installation...9961
      Auxiliary Spool Removal And Installation (Bonnet End)...9963
      Auxiliary Spool Removal And Installation (Linkage End)...9964
      Auxiliary Plug Removal And Installation...9965
      Auxiliary Electric Solenoid Disassembly...9966
      Port Relief-Auxiliary Section Disassembly...9967
      Cleaning And Inspection...9967
    HYDRAULIC CONTROL VALVE (ADVANCE HAND...9969
    CONTROL) (AHC), ADVANCE CONTROL SYSTEM (ACS)...9969
      Actuator Removal And Installation (In Loader)...9969
      Removal And Installation...9971
      Actuator Removal And Installation (Out Of Loader)...9977
      BICS™ Valve, Removal And Installation...9978
      BICS™ Valve, Lift Arm Bypass Orifice Disassembly And Assembly...9979
      BICS™ Valve, Check Valve Disassembly And Assembly...9980
      BICS™ Valve, Lock Valve Disassembly And Assembly...9981
      BICS™ Valve, Solenoid Disassembly And Assembly...9982
      BICS™ Valve, Solenoid Testing...9983
      Identification Chart...9984
      Identification Chart...9985
      Lift Base End Restrictor...9986
      Load Check Valve...9986
      Main Relief Valve...9987
      Port Relief Valve...9988
      Anti-Cavitation Valve/Port Relief Valve...9989
      Anti-Cavitation Valve...9990
      Lift Spool Removal...9991
      Lift Spool Removal And Installation...9992
      Lift and Tilt Spool Disassembly And Assembly...9993
      Auxiliary Spool Removal And Installation...9994
      Auxiliary Electric Solenoid Disassembly...9995
      Port-Auxiliary Section Disassembly...9996
      Cleaning And Inspection...9996
    LIFT ARM BYPASS CONTROL VALVE...9997
      Inspecting...9997
      Additional Inspection For Loaders With Advanced Hand Controls...9997
      Removal And Installation...9997
      Disassembly And Assembly...9999
    HYDRAULIC PUMP (SINGLE GEAR)...10001
      Checking The Output Of The Pump...10001
      Removal And Installation...10002
      Parts Identification...10004
      Disassembly...10005
      Inspection...10007
      Assembly...10008
    HYDRAULIC PUMP (HI-FLOW)...10011
      Checking The Output Of The High Flow Pump...10011
      Removal And Installation...10012
      Parts Identification...10014
      Disassembly...10015
      Inspection...10018
      Assembly...10019
    HYDRAULIC/HYDROSTATIC FILTER...10023
      Housing Removal And Installation...10023
      Mount Removal And Installation...10024
    HYDRAULIC FLUID RESERVOIR...10025
      Draining The Hydraulic Fluid Reservoir...10025
      Removal And Installation...10025
      Hydraulic Fluid Screen...10027
    CONTROLS...10029
      Control Pedal Removal And Installation...10029
      Control Pedal Adjustment...10029
      Crossbar Linkage Removal And Installation...10029
      Crossbar Linkage Inspection...10030
      Control Foot Sensor (ACS) Removal And Installation...10030
      Control Pedal (ACS) Removal And Installation...10032
      Control Pedal Linkage (ACS) Disassembly And Assembly...10032
    BUCKET POSITION VALVE...10033
      Solenoid Removal And Installation...10033
      Solenoid Testing...10033
      Removal And Installation...10034
      Disassembly And Assembly...10034
    REAR AUXILIARY DIVERTER...10037
      Disassembly...10037
      Inspection...10037
      Solenoid Testing...10038
      Assembly...10038
    SELECT VALVE...10039
      Checking The High Flow Pump Relief Valve...10039
      Removal And Installation...10040
      Disassembly And Assembly...10041
      Solenoid Testing...10046
    REAR AUXILIARY DIVERTER VALVE (SINGLE SHUTTLE)...10047
      Removal And Installation...10047
      Disassembly...10049
      Inspection...10049
      Solenoid Testing...10050
      Assembly...10050
    POWER BOB-TACH BLOCK...10051
      Removal And Installation...10051
      Disassembly And Assembly...10053
    AUXILIARY PRESSURE RELEASE (ACCUMULATOR)...10059
      Removal and Installation...10059
      Disassembly And Assembly...10060
  HYDROSTATIC SYSTEM...10061
    HYDROSTATIC SYSTEM INFORMATION...10063
      Troubleshooting Chart...10063
      Replenishing Valve Function...10064
    CONTROL PANEL...10065
      Removal and Installation...10065
    STEERING...10067
      Lever Removal And Installation...10067
      Lever Disassembly And Assembly...10067
      Linkage Removal And Installation...10068
      Linkage Neutral Adjustment...10072
    STEERING (ADVANCED HAND CONTROL) (AHC)...10077
      Components Identification...10077
      Handle Control Unit Removal And Installation...10078
      Switch Handle Removal And Installation...10081
      Handle Removal And Installation...10082
      Handle Disassembly And Assembly...10083
      Steering Lever Removal And Installation...10083
      Steering Lever Boot...10084
    STEERING (ADVANCED HAND CONTROL) (AHC) W/ PUSH BUTTON FLOAT...10085
      Components Identification...10085
      Handle Sensor Removal And Installation...10085
      Control Handle Removal and Installation...10087
      Control Handle Disassembly and Assembly...10088
      Control Lever Removal and Installation...10089
      Control Lever Boot...10090
    STEERING (ADVANCED CONTROL SYSTEM) (ACS)...10091
      Components Identification...10091
      Handle Sensor Removal And Installation...10091
      Control Handle Removal and Installation...10095
      Control Handle Disassembly and Assembly...10096
      Control Lever Removal and Installation...10096
      Control Lever Boot...10097
    HYDROSTATIC MOTOR...10099
      Removal And Installation...10099
      Parts Identification...10102
      Disassembly...10104
      Inspection...10112
      Assembly...10113
      Filling...10121
    CHARGE PRESSURE SENDER...10123
      Removal and Installation...10123
    HYDROSTATIC PUMP...10125
      Removal And Installation...10125
      Replenishing/High Pressure Relief Valve(s)...10127
      Charge Pressure Relief Valve...10127
      Parts Identification (Right Half)...10130
      Parts Identification (Left Half)...10132
      Hydraulic Pump Removal And Installation...10134
      Disassembly...10135
      Assembly...10143
    DRIVE BELT...10151
      Shield Removal And Installation...10151
      Adjustment...10152
      Replacement...10152
      Tensioner Pulley Removal And Installation...10153
      Tensioner Pulley Disassembly And Assembly...10154
      Tensioner Pulley Tension Spring...10155
    OIL COOLER...10157
      Removal and Installation...10157
      Removal And Installation With STC (Seal Tight Connector)...10158
  DRIVE SYSTEM...10159
    BRAKE...10161
      Pedal Removal And Installation...10161
      Pedal Disassembly And Assembly...10162
      Switch Operated Parking Brake...10163
      Block Removal And Installation...10163
      Block Disassembly And Assembly...10165
      Traction Lock Bypass Knob...10166
    DRIVE COMPONENTS...10167
      Track Checking...10167
      Track Adjustment...10168
      Track Removal And Installation...10169
      Track Idler (Front) Removal And Installation...10172
      Track Idler (Front) Parts Identification...10174
      Track Idler (Front) Disassembly...10175
      Track Idler (Front) Assembly...10176
      Track Idler (Rear) Removal And Installation...10179
      Track Idler (Rear) Parts Identification...10179
      Track Idler (Rear) Disassembly...10180
      Track Idler (Rear) Assembly...10181
      Track Roller Removal And Installation...10183
      Track Roller Parts Identification...10183
      Track Roller Disassembly...10184
      Track Roller Assembly...10185
      Track Housing Removal And Installation...10187
      Track Damage Identification...10188
  MAINFRAME...10199
    SEAT BAR...10201
      Removal And Installation...10201
      Assembling Components...10202
      Compression Spring Disassembly And Assembly...10204
    OPERATOR CAB...10205
      Gas Cylinder Removal And Installation...10205
      Gas Cylinder Disassembly And Assembly...10206
      Removal And Installation...10207
    OPERATOR SEAT...10209
      Removal And Installation...10209
      Seat Belt Removal And Installation...10209
    OPERATOR SEAT (SUSPENSION)...10211
      Removal And Installation...10211
      Slide Rail Removal And Installation...10212
      Cushion Removal And Installation...10212
      Back Removal And Installation...10213
      Shock Removal And Installation...10214
    BOB-TACH...10215
      Inspection And Maintenance...10215
      Bob-Tach Lever And Wedge...10216
      Removal And Installation...10218
      Pivot Pin Bushing And Seal Replacement...10220
    POWER BOB-TACH...10221
      Inspection And Maintenance...10221
      Power Bob-Tach Lever And Wedge...10222
      Removal And Installation...10224
      Pivot Pin Bushing And Seal Replacement...10226
    LIFT ARMS...10227
      Removal And Installation...10227
    REAR GRILL...10231
      Removal And Installation...10231
    REAR DOOR...10233
      Removal And Installation...10233
      Adjusting The Rear Door Latch...10234
    FUEL TANK...10235
      Removal And Installation...10235
      Fuel Level Sender...10238
      Fuel Pick-up Screen/Check Valve...10238
  ELECTRICAL SYSTEM & ANALYSIS...10239
    ELECTRICAL SCHEMATICS...10243
    ELECTRICAL SYSTEM INFORMATION...10254
      Troubleshooting Chart...10254
      Description...10255
      Fuse Location...10257
      Relay Switch Location...10257
      Solenoid Test...10258
    BATTERY...10260
      Removal And Installation...10260
      Servicing The Battery...10261
      Using A Booster Battery...10262
    ALTERNATOR (55 AMP)...10264
      Adjusting The Alternator Belt...10264
      Alternator Output Test...10265
      Rectifier (Diode) Test...10265
      Alternator Regulator Test...10266
      Removal And Installation...10267
      Disassembly...10268
      Stator Continuity Test...10268
      Stator Ground Test...10268
      Rotor Continuity Test...10269
      Rotor Ground Test...10269
      Rectifier Continuity (Diode) Test...10269
      Assembly...10270
    ALTERNATOR (90 AMP)...10272
      Adjusting The Alternator Belt...10272
      Alternator Identification...10272
      Charging System Check...10273
      Alternator Voltage Test...10274
      Low Voltage Test...10274
      High Voltage Test...10275
      Removal And Installation...10276
      Rectifier Continuity (Diode) Test...10277
      Alternator Regulator Test...10278
      Disassembly...10278
      Stator Continuity Test...10279
      Stator Ground Test...10279
      Rotor Continuity Test...10279
      Rotor Ground Test...10279
      Assembly...10280
    STARTER...10282
      Removal And Installation...10282
      Parts Identification...10283
      Disassembly And Assembly...10284
      External Pinion...10287
      Inspection And Repair...10288
      No Load Test...10292
    INSTRUMENT PANEL...10294
      Left Panel (Standard)...10294
      Right Panel-Standard Instrument Panel (With Key Switch) [Figure 60-50-2]...10295
      Right Panel (Deluxe) (With Keyless Start) [Figure 60- 50-3]...10296
      Right Panel Setup Display Options (Deluxe)...10298
      Passwords...10299
      Option And Field Accessory Panels...10301
      Standard Panel Removal And Installation (Right Side)...10302
      Deluxe Panel Removal And Installation (Right Side)...10303
      Standard And Deluxe Panel Removal And Installation (Left Side)...10304
      Front Accessory Panel Removal And Installation...10305
    LIGHTS...10308
      Front Removal And Installation...10308
      Rear Removal And Installation...10309
    BOBCAT CONTROLLER...10310
      Identification Chart...10310
      Removal And Installation...10311
    DIAGNOSTICS SERVICE CODES...10312
      Display...10312
    BICS™ SYSTEM...10314
      Inspecting The BICS™ Controller (Engine STOPPED - Key ON)...10314
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...10314
      Inspecting The Seat Bar Sensor (Engine RUNNING)...10314
      Inspecting The Traction Lock (Engine RUNNING)...10314
      Inspecting The Lift Arm Bypass Control...10314
      Additional Inspection For Loaders With Advanced Hand Controls (AHC)...10315
      Troubleshooting Chart...10316
      Troubleshooting Guide...10317
    SEAT BAR SENSOR...10320
      Troubleshooting Chart...10320
      Test...10321
      Removal And Installation...10322
      BICS™ Circuit Test...10323
    TRACTION LOCK...10324
      Description Of The Control System...10324
      Inspecting The Control System...10324
      Parking Brake Solenoid Removal And Installation...10325
      Traction Lock Bypass Knob...10326
    ADVANCE HAND CONTROL (AHC) SYSTEM...10328
      Components Identification...10328
      Troubleshooting Guide...10329
      Parts Identification...10330
      AHC Controller Removal And Installation...10331
      Handle Control Unit Connector...10331
      Switch Handle Removal and Installation...10332
      Actuators Disassembly and Assembly...10335
    ADVANCED HAND CONTROL (AHC) SYSTEM (W/ PUSH BUTTON FLOAT) (CONT’D)...10338
      Components Identification...10338
      Troubleshooting Guide...10339
      Controller Connector And Wire Identification...10340
      AHC Controller Removal And Installation...10341
      Handle Sensor Removal And Installation...10341
      Handle Sensor Connector...10343
      Switch Handle Removal and Installation...10344
      Actuators Disassembly and Assembly...10347
    ADVANCED CONTROL SYSTEM (ACS)...10350
      Components Identification...10350
      Troubleshooting Guide...10352
      Controller, Connector And Wire Identification...10353
      ACS Controller Removal And Installation...10354
      Handle Sensor Connector...10354
      Switch Handle Removal...10355
      Switch Handle Installation...10358
      Actuators Disassembly and Assembly...10361
      Handle Lock Solenoid Removal And Installation...10362
      Handle Lock Solenoid Disassembly And Assembly...10363
      Handle Lock Solenoid Connector...10363
      Calibration Of The ACS System...10364
      Switchable Hand/Foot Controls Calibration Procedure...10364
      Hand Controls Only Calibration Procedure...10366
      Foot Sensor Disassembly And Assembly...10367
      Foot Sensor Connector...10367
      Foot Lock Solenoid Removal And Installation...10368
      Foot Lock Solenoid Connector...10368
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE...10370
      Controls Identification Chart...10370
  ENGINE SERVICE...10372
    TROUBLESHOOTING...10374
      Chart...10374
    ENGINE SPEED CONTROL...10376
      Removal And Installation...10376
      Speed Control Cable...10377
      Speed Control Linkage...10377
    MUFFLER...10378
      Removal And Installation...10378
    AIR CLEANER...10380
      Housing Removal And Installation...10380
    RADIATOR...10382
      Oil Cooler Removal And Installation...10382
    COOLING FAN...10384
      Drive Tension Pulley Removal And Installation...10384
      Gearbox/Blower Housing Removal And Installation...10385
      Blower Removal And Installation...10388
      Gearbox Parts Identification...10389
      Gearbox Disassembly...10390
      Gearbox Assembly...10395
      Gearbox, Checking Backlash...10400
    ENGINE COMPONENTS AND TESTS...10404
      Engine Compression, Checking...10404
      Glow Plug, Checking...10405
      Fuel Shut-Off Solenoid, Checking...10406
      Fuel Shut-Off Solenoid Removal and Installation...10407
      Fuel Injection Pump Removal...10407
      Fuel Injection Pump Timing...10409
      Fuel Injection Pump Installation...10410
      Fuel Injector Removal and Installation...10412
      Fuel Injector, Checking...10413
      Fuel Injector Disassembly...10414
      Fuel Injector Assembly...10415
      Timing Belt Inspection...10417
      Timing Belt Removal...10417
      Timing Belt Installation...10418
      Timing Belt, Replacement In the Loader...10422
      Valve Clearance Adjustment...10427
      Valve Timing, Checking...10428
      Thermostat, Oil Pressure Control Valves And Heater Connections...10430
    ENGINE AND ENGINE MOUNTS...10434
      Removal And Installation...10434
      Engine Mount Replacement...10440
    FLYWHEEL AND HOUSING...10442
      Flywheel Removal And Installation...10442
      Ring Gear Removal And Installation...10442
      Flywheel Housing Removal And Installation...10442
    RECONDITIONING THE ENGINE...10444
      Deutz Engine Tools Identification Chart...10444
      Disassembly...10445
      Assembly...10449
      Cylinder, Checking...10465
      Camshaft Bearing, Checking...10466
      Camshaft Bearing, Removal And Installation...10466
      Control Rod Guide Bushing Removal...10467
      Control Rod Guide Bushing Installation...10469
      Rear Cover Seal Removal And Installation...10473
      Crankshaft, Checking...10474
      Connecting Rod, Checking...10476
      Piston, Checking...10478
      Piston Pin, Checking...10479
      Piston Rings Installation...10479
      Piston Installation On The Connecting Rod...10480
      Cylinder Head Disassembly...10482
      Valves, Checking...10482
      Valve Seats, Checking...10483
      Valve Spring, Checking...10484
      Cylinder Head Assembly...10484
      Rocker Arm and Bracket, Checking...10485
      Front Cover Disassembly...10486
      Front Cover Assembly...10491
      Turbo Charger Removal and Installation...10500
      Crankshaft Gear Mounting Bolt Torque Procedure...10501
  HEATING, VENTILATION, AIR CONDITIONING...10504
    AIR CONDITIONING SYSTEM FLOW...10507
      Principals...10507
      Chart...10508
    COMPONENTS...10510
      Identification...10510
    SAFETY...10514
      Safety Equipment...10514
    REGULAR MAINTENANCE...10516
      Filter Elements Removal And Installation...10516
      Compressor Drive Belt Inspection...10517
      Cleaning The Condenser...10518
    BASIC TROUBLESHOOTING...10520
      Poor A/C Performance...10520
      Cleaning The A/C Evaporator Coil & Heater Coil...10520
      Receiver/Drier Sight Glass Inspection...10523
      Compressor Drive Belt Inspection:...10524
      Checking The Electrical System...10524
      Engine Coolant Bypassing The Heater Valve...10532
      Heater Valve Not Opening Or Closing...10532
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...10534
      Compressor Oil...10534
      Compressor Oil Check...10534
      Component Replacement And Refrigeration Leaks...10536
    SYSTEM TROUBLESHOOTING CHART...10538
      Gauge Pressure Related Troubleshooting...10539
    TEMPERATURE/PRESSURE...10542
      Chart...10542
    ELECTRICAL...10544
      Chart...10544
    AIR CONDITIONING SERVICE...10546
      Chart...10546
    RECOMMENDED SERVICE TOOLS...10548
      Full Service A/C Tools...10548
      Basic Field Diagnostic Tools...10549
    SYSTEM CHARGING AND RECLAMATION...10552
      Reclamation Procedure...10552
      Charging Procedure With A Manifold Gauge Set...10554
      Charging Procedure...10555
    COMPRESSOR...10558
      Removal And Installation...10558
      Compressor Clutch Disassembly...10559
    CONDENSER...10564
      Removal And Installation...10564
    RECEIVER/DRIER...10566
      Removal And Installation...10566
    PRESSURE RELIEF VALVE...10568
      Removal And Installation...10568
    PRESSURE SWITCH...10570
      Removal And Installation...10570
    THE EVAPORATOR/HEATER UNIT...10572
      Removal And Installation...10572
      Disassembly And Assembly...10573
    THERMOSTAT...10574
      Removal And Installation...10574
    THE EXPANSION VALVE...10576
      Removal And Installation...10576
    THE EVAPORATOR...10578
      Removal And Installation...10578
    HEATER COIL...10580
      Removal And Installation With A/C...10580
      Removal And Installation Without A/C...10581
    HEATER/AC FAN...10584
      Removal And Installation...10584
      Disassembly And Assembly...10585
      Wire Connector Removal and Installation...10587
    HEATER VALVE...10590
      Removal and Installation...10590
      Disassembly And Assembly...10591
  SPECIFICATIONS...10594
    LOADER SPECIFICATIONS...10596
      Loader Dimensions...10596
      Performance...10597
      Controls...10597
      Engine...10597
      Hydraulic System...10598
      Electrical...10598
      Drive System...10599
      Capacities...10599
      Tracks...10599
      Ground Pressure...10599
    ENGINE SPECIFICATIONS...10600
      General...10600
      Fuel System...10600
      Valve and Valve Guide and Seat Insert...10601
      Piston and Rings...10602
      Connecting Rod...10602
      Cylinder Head and Block...10603
      Crankshaft and Main Bearings...10603
      Camshaft and Bearings...10603
      Oil Pump...10604
    LOADER TORQUE...10606
      Specifications...10606
    TORQUE SPECIFICATIONS FOR BOLTS...10610
      Torque For General SAE Bolts...10610
      Torque For General Metric Bolts...10611
    HYDRAULIC CONNECTION SPECIFICATIONS...10612
      O-ring Face Seal Connection...10612
      Straight Thread O-ring Fitting...10612
      Tubelines And Hoses...10612
      Flare Fitting...10613
      O-ring Flare Fitting...10614
      Port Seal Fitting...10616
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...10618
      Specifications...10618
    CONVERSIONS...10620
      Decimal And Millimeter Equivalents...10620
      U.S. To Metric Conversion...10620
  SERVICE MANUAL REVISION...10622
    864/864H-1...10622
    864/864H-2...10624
    864/864H-3...10628
    864/864H-4...10630
    864/864H-5...10632
6900953 (12-06) - 864, 864 High Flow Operation & Maintenance Manual...10634
  OPERATOR SAFETY WARNINGS...10636
  CONTENTS...10638
  FOREWORD...10640
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...10642
    REGULAR MAINTENANCE ITEMS...10642
    MOTOR OIL...10642
    SERIAL NUMBER LOCATIONS...10644
      Loader Serial Number...10644
      Engine Serial Number...10644
    DELIVERY REPORT...10644
    BOBCAT LOADER IDENTIFICATION...10645
    FEATURES AND ACCESSORIES...10646
  SAFETY...10648
    SAFETY INSTRUCTIONS...10650
      Before Operation...10650
      Safe Operation Is The Operator’s Responsibility...10651
      Safe Operation Needs A Qualified Operator...10651
      Fire Prevention...10652
    MACHINE SIGNS (DECALS)...10653
  OPERATING INSTRUCTIONS...10656
    INSTRUMENT PANEL IDENTIFICATION...10658
      Left Panel - Standard and Deluxe Instrument Panels...10658
      Right Panel - Standard Instrument Panel (With Key Switch)...10659
      Right Panel - Deluxe Instrument Panel (With Keyless Start)...10660
      Option and Field Accessory Panels (If Equipped)...10662
      Side Accessory Panel...10662
      Front Accessory Panel...10662
      Cab Light...10663
    LIFT ARM BY-PASS CONTROL...10663
    TRACTION LOCK OVERRIDE...10663
    ENGINE SPEED CONTROL...10664
    PARKING BRAKE (EARLY MODELS)...10664
    PARKING BRAKE (LATER MODELS)...10664
    STEERING LEVERS...10665
    STOPPING THE BOBCAT LOADER...10665
    SEAT BAR RESTRAINT SYSTEM...10666
    HYDRAULIC CONTROLS...10667
      Foot Pedals...10667
      Hand Controls (If Equipped)...10667
      Quick Couplers...10668
      Releasing Hydraulic Pressure (Loader and Attachment)...10669
      Attachment Auxiliary Hydraulics (If Equipped) Auxiliary Hydraulics Button...10669
      FRONT Auxiliary Hydraulics Operation...10670
      REAR Auxiliary Hydraulics Operation...10670
      High-Flow Hydraulics Operation (If Equipped)...10671
      Secondary Front Auxiliary Hydraulics (If Equipped)...10671
      Attachment Control Device (ACD) (If Equipped)...10672
      Bucket Position Valve Operation (If Equipped)...10673
    DAILY INSPECTION...10674
    PRE-STARTING PROCEDURE...10675
    STARTING THE ENGINE...10677
      Standard Instrument Panel (With Key Switch)...10677
      Deluxe Instrument Panel (With Keyless Start)...10678
      Cold Temperature Starting...10679
      Warming The Hydraulic/Hydrostatic System...10679
    STOPPING THE ENGINE...10680
    MONITORING THE DISPLAY PANEL...10681
    ATTACHMENTS AND BUCKETS...10682
      Hand Lever Bob-Tach...10683
      Power Bob-Tach...10685
    OPERATING PROCEDURES...10687
      Compact Track Loader Operating Tips...10688
      Filling the Bucket (Foot Pedals)...10689
      Filling the Bucket (Hand Controls)...10689
      Emptying the Bucket (Foot Pedals)...10690
      Emptying the Bucket (Hand Controls)...10690
      Leveling the Ground (Using Lift Arms in Float Position) (Foot Pedals)...10690
      Leveling the Ground (Using Lift Arms in Float Position) (Hand Controls)...10691
      Digging Into the Ground (Foot Pedals)...10691
      Digging Into the Ground (Hand Controls)...10692
      Backfilling (Foot Pedals)...10692
      Backfilling (Hand Controls)...10692
    TRANSPORTING THE BOBCAT LOADER...10693
    TOWING THE LOADER...10694
    LIFTING THE LOADER...10695
      Four Point Lift...10695
      Single Point Lift...10695
  PREVENTIVE MAINTENANCE...10696
    MAINTENANCE SAFETY...10700
    SERVICE SCHEDULE...10702
    LIFT ARM SUPPORT DEVICE...10703
      Engaging The Lift Arm Support Device...10703
      Disengaging The Lift Arm Support Device...10704
    OPERATOR CAB...10705
      Raising The Operator Cab...10705
      Lowering the Operator Cab...10706
      Emergency Exit...10706
    SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)...10708
      Inspecting The Seat Bar...10708
      Maintaining The Seat Bar...10708
    SEAT BAR RESTRAINT SYSTEM ADVANCED HAND CONTROLS (AHC) and ADVANCED CONTROL SYSTEM (ACS)...10709
      Inspecting The Seat Bar...10709
      Maintaining The Seat Bar...10709
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...10710
      Inspecting The BICS Controller (Engine STOPPED - Key ON)...10710
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...10710
      Inspecting The Seat Bar Sensor (Engine RUNNING)...10710
      Inspecting The Traction Lock (Engine RUNNING)...10710
      Inspecting The Lift Arm By-Pass Control...10710
      Additional Inspection For Loaders With Advanced Hand Controls (AHC) and Advanced Control System (ACS)...10711
    TRACK TENSION...10711
      Adjusting...10712
    REAR DOOR...10713
      Opening And Closing The Rear Door...10713
      Adjusting The Rear Door...10713
    REAR GRILL...10714
    PIVOT PINS...10714
    AIR CLEANER SERVICE...10715
      Replacing Filter Element...10715
    FUEL SYSTEM...10717
      Fuel Specifications...10717
      Filling The Fuel Tank...10717
      Fuel Filter...10717
      Fuel Lift Pump Strainer...10718
      Removing Air From The Fuel System...10718
      Removing Fuel From The Fuel Tank...10719
    ENGINE LUBRICATION SYSTEM...10720
      Checking Engine Oil...10720
      Replacing The Oil And Filter...10720
    ENGINE COOLING SYSTEM...10721
      Cleaning The Cooling System...10721
    ELECTRICAL SYSTEM...10722
      Description...10722
      Cleaning Battery And Terminals...10722
      Fuse Location...10722
      Using A Booster Battery (Jump Starting)...10723
      Removing And Installing The Battery...10724
    HYDRAULIC/HYDROSTATIC SYSTEM...10726
      Checking And Adding Fluid...10726
      Replacing Hydraulic/Hydrostatic Filter...10726
      Replacing The Hydraulic Fluid...10727
      Hydraulic Reservoir Breather Cap...10728
    HYDROSTATIC MOTOR CARRIER OIL...10729
      Removing And Replacing Oil...10729
    TRACK ROLLER AND IDLER LUBRICATION...10729
      Removing And Replacing Oil...10729
    FAN GEARBOX...10730
      Checking And Maintaining...10730
    DRIVE BELT...10731
      Adjusting The Drive Belt...10731
      Replacing The Drive Belt...10731
    Alternator Belt...10732
      Adjusting The Alternator Belt...10732
    TIMING BELT...10732
    LUBRICATION OF THE BOBCAT LOADER...10733
    HEATER AND AIR CONDITIONING...10735
      Cleaning and Maintenance...10735
    BOB-TACH...10736
      Inspection And Maintenance...10736
    POWER BOB-TACH (OPTION)...10737
      Inspection And Maintenance...10737
  SYSTEM SETUP & ANALYSIS...10738
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...10740
      Troubleshooting Chart...10740
    DELUXE INSTRUMENTATION SERVICE CODES...10741
    DELUXE INSTRUMENTATION PANEL SETUP...10743
      Deluxe Panel Upgrade...10743
      Icon Identification...10743
      Deluxe Panel Setup...10744
      Passwords...10744
      Changing the Password...10745
    SHUTDOWN FEATURE...10746
    SERVICE CLOCK RESET...10746
  MACHINE SIGN TRANSLATIONS...10748
    SERVICE SCHEDULE (6734534)...10750
    WARNING (6718390)...10751
    WARNING (6718400)...10752
    WARNING (6577754)...10753
    WARNING (6718391)...10753
    DANGER (6718392)...10754
    DANGER (6718393)...10754
    DANGER (6717343)...10754
    WARNING (6804114)...10754
    IMPORTANT (6560573)...10755
    WARNING (6718397)...10755
    LIFT ARM SUPPORT DEVICE (6706558)...10756
  SPECIFICATIONS...10758
    864/864H COMPACT TRACK LOADER SPECIFICATIONS...10760
      Performance Specifications...10760
      Engine...10760
      Loader Controls...10760
      Drive System...10761
      Hydraulic System...10761
      Electrical System...10761
      Standard System Instrumentation...10761
      Optional BOSS System Instrumentation...10761
      Capacities...10761
    BOBCAT APPROVED ATTACHMENTS & ACCESSORIES...10762
      Buckets Available...10762
      Attachments...10763
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS...10765
  WARRANTY...10766
 
Bobcat Loaders 863, 863 High Flow, 863 Turbo, 863 Turbo High Flow, 864, 864 High Flow Repair Service Manuals