= c SYSTEMS ANALYSIS BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) (S/N 509648900 & Above) (S/N 509617300 & Avove) \dditional Inspection For Loaders With Advanced Hand Controls .... 8-3 We pacing Daactation Of The Auxiliary ee System ngine STOPPED — Key Ns 4 sees gece The Bics™ S) yon ‘ontroller™ (Engine STOPPED ~ Key ON) 2... Inspecting The Seat Bar & eners (Engin e Running) : Inspecting The Traction Lock (Engine Running) Inspecting The Lift Am By-Pass Control Additional inspection For Loaders Troubleshooting Chart .......... BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) (SIN 509648899 & Below) (S/N 509617299 & Below) ing ecting The Deactivation Of The Auxiliary Hydraulics System ngine STOPPED — Key ON) ... é 85 Genes The Bics™ S) stem ontroiler (Engine STOPPED ~ Key ON) : Inspecting The Seat And Seat Bar Sensors (Engine Running) Ll 85 Inspecting The Traction Lock srt Running) : Inspecting The Lift Arm By-Pass Control. Maintenance .. i Troubleshooting Chart’ BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) ‘Troubleshooting Guide BICS Controller . Seat Bar Sensor Seat Sensor Traction Lock BICS™ SYSTEM CONTROLLER Removal And Installation 8-15 ELECTRICAUVHYDRAULIC CONTROLS REFERENCE Controls Identification Chart ......... ie cess 8-28 SEAT BAR SENSOR BICS™ Controller Seat Sensor Circuit Test Removal And Installation 8-18 817 Seat Bar Sensor Test . 8-16 SEAT SENSOR BICS™ Controller Seat Sensor Circuit Test ............00eee0eeee) B14 Removal And Installation 8-13 Seat Sensor Test .. . 1 812 TRACTION LOCK Fldtnoval'And-Inetallation. 20 icv cee seca esececeveus coseeat deere BS: Continued On Next Page Revised Jan. 99 peas Nea) NNR) 773 BICS Loader Service ManualSYSTEMS ANALYSIS. Page Number BOBCAT OPERATION SENSING SYSTEM (BOSS®) BOSSE DIAGNOSTIC TOOL Procedure ..... 7 eee ee BOSS® INSTRUMENT PANEL Removal And Installation MONITOR SERVICE CODES ‘Alphabetic Codes: Numeric Codes Service Codes = OPERATION SENSING SYSTEM UNIT Removal And Installation weeteetegeccessuweceeteess BOB RPM SENSOR Adjustment ............0.ee0008 SENDER AND SENSOR ‘Service Checks . 8-28 Component .. 2 8-28 8-25 773 BICS Loader Service ManualBOBCAT INTERLOCK CONTROL SYSTEM (BICS™) (S/N 509648900 & Above) (S/N 509617300 & Above) Inspecting The BICS™ Controller (Engine STOPPED ~ Key ON) 1. Sitin the operator's seat, Turn key ON, lower the geal bar aa disengage the parking brake pedal Press the greon PRESS TO OPERATE Button. Al five BICS controler lights Should be ON (Items 1, 2,8,4 8 5)1Al 2. Engage the parking brake pedal and aise tho seat Barfly. System Activated tem 1), Seat Bar (ern 2), Valve (Hem 3) and Traction lights (Item 4) [A] should be OFF. NOTE: Record what lights are blinking (if any) and number of blinks. Refer to Page 8-4. 3. Exit the loader and press Traction Lock Override: button. Traction light (Wtem 4) [A] should be ON. Press override button again arid Traction light (item 4) [A] should be OFF, Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED — Key ON) 4. Sit in the operator's seat. Lower the Seat Bar Bross the green PRESS TO OPERATE Button. Press the auxiliary hydraulics switch, The auxliary ‘switch light wil come ON. Raise the Seat Bar. The light should be OFF. Inspecting The Seat Bar Sensor (Engine RUNNING) 5. Sit in the operator's seat. Lower the seat bar. Engage the parking brake pedal. Fasten the seat 6. Start the engine and operate at low idle. Press the green PRESS TO. OPERATE Button. While Faising the lift arms, raise the Seat Bar fully. The lift arms Should stop. Repeat using the fil function Inspecting The Traction Lock (Engine RUNNING) 7. Fasten the seat belt, disengage the parking brake Pedal, press the geen Pass 70 OPERATE utton ‘and raise ‘he Seat Bar fuly, Move the steering levers sow forward and backwara, The Traction lock should be engaged: Lower he Seat Bar, Press the. green ‘PRESS 70" OPERATE ution. 8. Engage the parking brake pedal and move the steering levers slowly forward and backward. The ‘Traction lock should be engaged. Inspecting The Lift Arm By-Pass Control 9. Raise the lift arms 6 feot (2 meters) off the ground. Stop the engine, ‘Tum the lift arm by-pass control knob clockwise 4/4 tum. Then pull up and hold the lift arm by-pass control knob until the lift arms slowly lower. Additional Inspection For Loaders With Advanced Hand Controls’ 10. Sin the operator's seat and faston the Seat Bel Lower the Seat Bar, star the engine and press the Green PRESS TO OPERATE Button, 11. Raise the it arms about 6 fest (2 meters) off the grounc 12. Tum the key OFF and wait for the engine to come to a complete stop, 13, Tum the key ON. Press the green PRESS TO OPERATE Button, move the left hand control towardthe operator. The lit arms should noflower. 14, Move, the. right hand control away from the ‘operator. The bucket (or attachment) should not tit forward: Revised Jan, 99 33. A WARNING AVOID INJURY OR DEATH ‘The Bobeat Interlock Control System (BICS) must deactivate the lift, tilt and traction drive functions. If it does not, contact your dealer for service. DO NOT modify the system. w-2151-0904 773 BICS Loader Service ManualBOBCAT INTERLOCK CONTROL SYSTEM (BICS™) (S/N 509648900 & Above) (S/N 509617300 & Above) (Cont'd) Troubleshooting Chart ‘The following list shows the effects which can happen to the loader, and the probable causes when the BICS Controller lights are off or flashing, Have the service procedure performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. g Flashing Indicator Means System Problem Effect on Operation| (See Your Bobcat Dealer for Service) of Loader Indicator when ight te [Number of ght "| tight On Light OFF ore Fishes Cause Syston | PRESS TOORERITE | PRESSTOOPEFATE [Rana wacion | 2 — [Sym Acad ceil shored to Ata | bution s actvated| bution not activate] functione wll not ater vtage. operate. 3 [System Activated Groat arora ound Seat Bar] Seat Bar Down, | Seat Bar Up. | Ut tand'wasion | 2 ]Seat bar sensor cheat shoted To functions wil not barter vokage™ ut operate 3 [Beat bar sensor Great owed To aqound Vaive | Conver Valve | Conol vave | Titand ut functions | 2 Valve ouput veut ehoriod to batory Gan 8e Used. [Cannot Be Used. | wil not operate. vokage" 3 3 [vate ouput crated io gound 3 [Waive ouput crete not grounded “Taciion | Coadercan be —| Loader cannat be] Leader cannot be [1 [Taco lock hoi cl seus open mmoved forward | moved forward and moved forward and [——2—TTracton tok hold col erat shorted EB) | Sbaceward. | backwares backward. to battery voltage’ 3 [Traction ook hold cat eV sored to ground Traction lock pull col arour is open: Traction lock pull col cuit is shorted to battery voltage” © | Traction lock pull collircuitis shorted to ground, Power | BIGS Controller | BICS Controller s_| Lift, tit and traction is operating not operating functions will not NA {NWA correctly. correctly operate. * Normal BICS operating voltage is less than the electrical system voltage. If voltage is more, the circuit is shorted to system voltage. NOTES: (1) If the System Activated and/or seat bar sensor circuits are open, the corresponding lights will be OFF. It ‘one of the lights stay OFF, check the circuit for continuity. 2} Wall five lights flash repeatedly, the voltage supply is greater than 16 volts or less than 9 volts 3} Flashing patterns will repeat every 3.25 seconds. 773 BICS Loader Revised June 01 4 Service ManualC BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) (SIN 509648899 & Below) (S/N 509617299 & Below) Inspecting The BICS™ Controller (Engine STOPPED — Key ON) 1, Sitin the operator's seat. Tum key ON, lower the Seat bar and disengage the parking brake. All five BICS Controller lights should be ON (Items 1, 2, 3, 485) (Al 2. Engage the parking brake, raise the seat bar fully. Seat bar fight (ern 2) (A, valve fight (item 3) [A] {and traction light (Item 4) [A] should be OFF 3. Raise up slightly off the seat. Seat light (Item 1) [A] should be OFF. NOTE: Record what lights are blinking (it any) and number of blinks. Refer_ to BICS ‘Troubleshooting Chart, Page 8-7. 4. Exit the loader and press traction lock override ‘button. Traction light (Item 4) [A] should be ON. Press override button again and traction light (item 4) [A] should be OFF. (Later Model Loaders Only) inspecting Deactivation OF The Auxiliary Hydraulics System (Engine STOPPED ~ Key ON) 5. Sit in the operator's seat. Lower the seat bar, Press the auxiliary hydraulics auxiliary switch. The auxiliary switch light will come ON. Raise the seat bar. The light should be OFF. Inspecting The Seat And Seat Bar Sensors (Engine Running) 6. Sit in the operator’s seat, lower the seat bar and engage the parking brake. Fasten the seat belt. 7. Start the engine and operate at low idle, While raising the lft arms, raise the seat bar fully. The lift ‘arms should stop. Repeat using the tit function. Inspecting The Traction Lock (Engine Running) 8. Fasten the seat belt, disengage the parking brake, and raise the seat bar fully. Move the steering levers slowly forward and backward. The traction, lock should be engaged. Lower the seat bar. '9. Engage the parking brake pedal and move the steering levers siowly forward and backward. The traction lock should be engaged. Inspecting The Lift Arm By-Pass Control Early Models with or without mechanical Hand Controls Raise the lift arms six feet (2 m) off the ground. Stop the engine, pull and hold the by-pass control knob. Push the {08 of the left foot pedal or move the left hand control in, toward the operator (hand controls) and the lift arms should lower slowly. Later Models with or without machanical Hand Controls Raise the litt arms six feet (2 m) off the ground. Stop the ‘engine. Turn the lift Arm By-Pass Control Knob clockwise 1/4 tum. Then pull up and hold the Lift Arm By-Pass Control Knob until the lift arms slowly lower. Revised June 01 ‘773 BICS Loader Service ManualBOBCAT INTERLOCK CONTROL SYSTEM (BICS™) (SIN 509648899 & Below) (S/N 509617299 & Below)Cont’d) Maintenance ‘Clean any debris, dit or objects from under or behind the ‘operator seat [A] & [B]. The rear of the seat must move up and down. Inspect both Seat Rail Covers [B] for wear or damage. Replace if necessary. Clearance is necessary under the seat spring (Item 1) [B] ‘and the seat, to allow the seat to move up and down freely. With adequate clearance, the seat sensor will be allowed = my to function propery. > E 09763 Inspect seat bar pivot area for tightness of linkage bolts. Replace parts that are damaged. Use only genuine Meiroe replacement part, A WARNING AVOID INJURY OR DEATH ‘The Bobcat Interlock Control System (BICS) must deactivate the lift, tit and traction drive functions. If itdoes not, contact your dealer for service. DO NOT modify the system. w-2151-0296 773 BICS Loader Revised June 01 86 Service Manualc BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) (S/N 509648899 & Below) (S/N 509617299 & Below)(Cont'd) ‘Troubleshooting Chart ‘The following list shows the effects which can happen to the loader, and the probable causes when the BICS Controller lights are off or flashing. Have the service procedure performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Flashing Indicator Means System Problem Effect on Operation (See Your Bobeat Dealer for Service) ci toaaer Indigsto| : wen ight umber Tight | Light on Light OFF 2 inches cause eat | Operatorin Seat | No Operator in Seat] Lit and th fancione| 2 | Seat eoneorcreut choriod to batay val ot operate, vottage” 5 Seat tenor ea anata ean Seat Bar| Seat Bar Down | Soar Bar Up Tat Wand wacior| 2 [Seat bar sensor ciel shorted to function will not batery voltage be repairs or agjustments can eause injury oF Seath. W-2008-1265 BICS CONTROLLER PROBLEM SOLUTION # Power indicator light does not come ON 1,2,3,6 Al indicator lights flashing. 4 One of the indicator lights flashing. 5 Intermittent indicator lights. 6,7,8,9 SOLUTION SUGGESTIONS 1. Check that ignition switch ON. 2. Check BICS 10 amp. fuse. 3. Check wiring and connections. Make sure the connector is securely connected to the controller. Remove controller and pull on connector to check. 4. Look at indicator light windows, if they are milky white in appearance it is most likely caused by moisture in the controller. Allow to dry or replace the controller. Refer to BICS troubleshooting chart for your loader. (See Page 84 & 8-7.) Check wire connections to make sure connectors are locked into place. Check pins in connectors for pins pushed back or bent. en og Move the system wiring back & forth to try to find area that may be causing the intermittent connection. 9. _ Use sensor tester MEL 1428 to isolate problem between sensor and controller and wiring. — 773 BICS Loader Revised June 01 88 Service ManualBOBCAT INTERLOCK CONTROL SYSTEM (BICS™) (Cont'd) Troubleshooting Guide (Cont'd) A WARNING ‘The following troubleshooting guide is provided for assisiance in locating and correcting BICS. system Probloms, It's recommended that these procedures be Check for correct function after adjustments, Sone by authorized Bobcat Service Personnel ony. repairs or service. to make correct Fepairs or adjustments can cause injury of death. w-2008-1205 TRACTION LOCK PROBLEM SOLUTION # Traction lock stays engaged. 1,2,3,4,5,6,7,8 Intermittent activation of traction lock. 9,10, 14 SOLUTION SUGGESTIONS 1 Check that controller power indicator light is ON. 2. Make sure brake pedal is not engaged. 3. Maneuver loader to allow brake discs to move and remove pressure on the brake wedge so it can retract. 4. _ Ifall lights indicate the brake should be released, but it doesn’t, check the brake 25 amp. fuse. 5. When checking fuse, also check other fuses. Check the fuse block for correct orientation and location of fuses. (See Electrical System, Page 6-1.) 6. To test the solenoid, the pull coil should be 0.4 to 0.5 ohms and the hold coil 10.5 to 11.0 ohms. 7. Check brake solenoid and cover mounting hardware for the correct torque, 8. Remove brake cover and check wedges for binding in the wedge guides. 9. Check wire connections for loose connector body. 10. Check for loose or bent pins in connectors 11. Check for loose spade connectors in fuse holder. 773 BICS Loader Revised Jan. 99 8 ‘Service ManualBOBCAT INTERLOCK CONTROL SYSTEM (BICS™) (Cont'd) Troubleshooting Guide (Conta) A WARNING The following troubleshooting guide is provided for assistance in locating and correcting BICS system problems It is recommended that these procedures be Gone by authorized Bobcat Service Personnel only. ‘Check for correct function after adjustments, repairs or service. Failure to make correct repairs or adjustments can cause injury or death, w-2008-1265 SEAT SENSOR PROBLEM SOLUTION # tr = Seat indicator light does not come ON with operator in seat. 1,2,3,4,5,6,7,8,9, 10, 11 Seat indicator light stays ON when operator out of seat. 2, 3, 6, 10, 11, 12, 13, 14 Intermittent indicator light during operation. te eee SOLUTION SUGGESTIONS 1. Check to make sure power indicator light is ON 2. Check for debris under and around seat. 3. Look for any obstruction around seat, 4. Check to make sure seat rail lowers when weight is in seat. 5. Raise cab and check for magnet collar movement when weight is added to seat. (Magnet collar should extend approximately 3/8” beyond the sensor assembly with weight in the seat). 6. Use sensor tester to check operation of sensor and controller. Follow instructions ‘on tester. 7. Check to make sure the magnet guide pin is in place. 8. Check for contamination on magnets such as metal particles or for shipping plate ‘over magnets. 9. Check to make sure both magnets are in collar. 10. Check for binding of magnet collar or bushing with hex head on other side for bindin 41. Check for correct mounting. One spring for standard seat. Two springs for suspension seats. Thick washers should be under front seat mounting rails on both sides. 12, Check for loose hardware mounting magnet collar. Check to make sure the magnet collar bushing is threaded on all the way so it is contacting seat rail 13. Check to make sure Seat rail raises when weight is removed from the seat 14. Raise cab and check for magnet collar movement when weight is removed from seat. (Magnet collar should extend approximately 1/8 inch beyond the sensor assembly without weight in seat.) 15. With smaller operators that operate with the seat forward some mounting alterations may be required. (See solution suggestions 16, 17 and 18.) 16. Adjust suspension seat to lightest weight settin: 18, Chickiomake sure the seat rails move up and down freely when weight is added 18. Add washer between the bushing the magnet collar assembly slides on and the seat fail. This will reduce the amount of seat travel required to activate the system Must check, with seat moved all the way back, that indicator light does not stay on with operator out of seat. Iflight does not go out with operator out of the seat, the washer must be removed. 773 BICS Loader Revised Jan. 99 -8-10- Service ManualBOBCAT INTERLOCK CONTROL SYSTEM (BICS™) (Cont'd) Troubleshooting Guide (Cont'd) A WARNING The following troubleshooting guide is provided tor assistance in locating and correcting BICS system Problems, Itis recommended that these procedures be done by authorized Bobcat Service Personnel only. repairs or service. Failure to mal repairs or adjustments can cause injury or death. W-2004-1205 SEAT BAR SENSOR PROBLEM SOLUTION # Indicator light does not come ON when seat bar is lowered. 1,2,3,4,5,6 SOLUTION SUGGESTIONS ‘Check controller power indicator light . It must be ON. Check sensor wire connection. Use the BICS sensor tester (MEL1428) to check sensor and controller. Check for loose hardware. Check keyed bushing to make sure magnet collar rotates with seat bar. 727 Rens Check magnet collar magnets for contamination such as metal particles. 773 BICS Loader Revised Jan. 99 -en- Service ManualSEAT SENSOR Seat Sensor Test Use Sensor Tester procedure: (MeEL1428) for the following Disconnect the short adatper test leads if connected. NOTE: Clean any debris, dirt or objects from under or behind the operator seat before starting the test, The rear of the seat must move up and down. Raise the operator cab. (See Page 1-1.) Disconnect the seat sensor connector (Item 1 — Inset) (Al Connect Sensor Tester (Item 2) [A] inline as shown to the seat sensor. Lower the operator cab. (See Page 1-1.) Move the toggle switch (Item 1) [B] on the sensor tester to the Absent position. ‘Turn the key to the ON position. DO NOT START THE. ENGINE, ‘The power light (item 2) [B] williluminate, i the lightis not con, check the tester or wiring hamess. Sit on the operator seat. The Sensor Test light (item 1) [C] should iiuminate. Get off the operator seat. The Sensor Test light (Item 1) Te] should go oft. HH the above tests fail, there Is a problem with the seat sensor. Disconnect the Sensor Tester. Replace the Seat Sensor. (See Page 8-13.) Ifthe above tests pass, run BICS™ controller seat sensor circuit test. (See Page 8-14.) 08609 773 BICS Loader et Service ManualSEAT SENSOR (Cont'd) Removal And Installation Raise the loader operator cab. (See Page 1-1.) Locate the seat sensor (Item 1) [A] beneath the operator cab. Remove the sensor connector (Item 1) [B] from the holder and disconnect from the hamess. Remove the magnet collar mounting bolt (item 2) [B] and washer (item 1) [C] Installation: Tighten the bolt to 180-200 in.~Ibs. (21-23 Nm) torque. IMPORTANT DO NOT overtighten the magnet mounting bolt to prevent damage to the magnet. 12089-1095 Remove the magnet (tem 2) [C] trom the sensor (Item 3) I Installation: Ifthe magnet collar (item 2) [C]is tapered, install the tapered end to the seat. If the magnet collar (item 2) {¢} Is not tapered, install as shown [C} Remove the sensor mounting bolt (Item 4) [B] and nut Installation: Tighten the nut and bolt (Item 4) {B] untit light pressure is applied to the sensor (Item 3) [B], IMPORTANT mounting bolt and nut to prevent breakage of the sensor. 1-2086-1095 Remove the sensor (Item 3) [C] NOTE: Be sure not to lose the magnet collar alignment pin (Item 4) {C] which is located in the sensor (Item 3) [C] when removing the Remove the threaded bushing (Item 5) [C] from the seat, track mounting bolt (Item 1) [D], Inspect all parts for damage and wear and replace if necessary. Reverse the removal procedure to install the seat sensor. Revised Jan. 99 -13- p-o40si 773 BICS Loader Service ManualSEAT SENSOR (Cont'd) BICS™ Controller Seat Sensor Circuit Test Use Sensor Tester (MEL1428) for the following procedure: Disconnect the short adatper test leads i connected NOTE: Clean any debris, dirt or objects from under or behind the operator seat before starting the test. The rear of the seat must move up and down. Raise the operator cab. (See Page 1-1.) Disconnect the seat sensor connector (Item 1 ~ Inset) fA). Connect MEL1428 Sensor Tester (Item 2) [A] inline as shown to the seat sensor. Lower the operator cab, (See Page 1-1.) ‘Tum the key to the ON position. DO NOT START THE ENGINE. ‘The power light (iter 1) [B] willilluminate, ifthe lightis not ‘on, check the tester or wiring harenss. Move the toggle switch (Item 2) [B] on the sensor tester to the Present position. NOTE: The sensor test light (Item 3) [B] is activated bby the seat sensor switch. ‘The Seat light (tem 1) [C] on the controller wil iltuminate. Move the toggle switch to Absent position, the seat light, (on the controller will go off. If the tests above fail, there is a problem with the BICS system controller or the wiring hamess. Revised Jan. 99 SENSOR TEST o CORTROLLER Te 4 773 BICS Loader Service Manual© c BICS™ SYSTEM CONTROLLER Removal And Installation NOTE: Photo's may be different but the procedure is the same for all models. Raise the operator cab. (See Page 1-1.) ‘The controller mounting bolts are located on the back of the operator cab [A] Remove the top mounting bolt (Item 1) (A] from the controller, Loosen the two lower mounting bolts (Item 2) [A]. Lower the operator cab, NOTE: The operator seat is removed in photo [B] for clarity purpose only. The seat does not need to be removed to remove the controll Slide the controller (Item 1) [B] up and remove itfrom the back of the operator cab. Disconnect the electrical hamess from the controller and remove the controlier from the loader. NOTE: Install the harness connector (Item 1)[C] into the controller (Item 2) [C] before installing the controller. IMPORTANT Be sure the connector to the BICS system controller are correctly engaged in the controller when installing the controller. An audible snap can be heard when the connector is correctly installed. Try to pull the Connector out of the controller, if it cannot be removed it has been correctly installed [C]. {-2087-1095 Installation: Tighten the controller mounting bolts to ‘80-90 in.—ibs. (9-10 Nm) torque. Reverse the removal procedure to install the controller. Revised Jan. 99 -2415- 773 BICS Loader Service ManualSEAT BAR SENSOR ‘Seat Bar Sensor Test Use Sensor Tester (MEL1428) for the following procedure: Disconnect the short adatper test leads if connected. Disconnect the seat bar sensor connector (Item 1) [A]. Connect Sensor Tester (Item 1) [BJ inline as shown to the seat bar sensor connectors. See inset [B]. ‘Tum the key to the ON position. DO NOT START THE ENGINE. ‘The toggle switch (Item 2) [C]can be in either the Absent or Present position. ‘The power light (item 1) [C} williluminate, ifthe lightis not con, check the tester or wing hamess. Lower the seat bar. The Sensor Test light (Item 1) [D] should illuminate. Raise the seat bar. The Sensor Test light (Item 1) [D] should go off. the above tests fail, there is a problem with the seat bar sensor. Disconnect the Sensor Tester. Replace the Seat Bar Sensor. (See Page 8-17.) If the above tests pass, run BICS controller seat bar circuit test. (See Page 8-18.) Revised Jan. 99 nro es —& cf SENSOR TESTER: 773 BICS Loader ‘Service Manual‘SEAT BAR SENSOR (Cont'd) Removal And Installation Disconnect the seat bar sensor connector (Item 1) [AJ poasr02 Remove the mounting bolt (Item 1) [B] from the pivot bushing, Installation: Tighten the mounting bolt to 25-28 ft Ibs. (34-38 Nm) torque. Remove the sensor mounting bolt (Item 2) [B] and nut IMPORTANT Be careful to not overtighten the sensor ‘mounting bolt and nut to prevent breakage of the sensor. 2085-1095 Installation: Be sure the tabs on the pivot bushing are positioned in the slotted hole (Item 1) [C] of the operator cab as shown, Pull the seat bar back and remove the assembly as follows: NOTE: The sensor assembly [D] is shown removed from the operator cab for clarity purpose only. The sensor assembly can be removed without removing the seat bar from the operator cab. Remove the pivot bushing mounting bolt (Item 1) [D] and ‘washer (Item 2) [D] from the pivot bushing (Item 3) [D}, Installation: Tighten the pivot bushing mounting bolt to 180-200 in.-Ibs. (21-23 Nm) torque. Remove the pivot bushing (Item 3) [D}, sensor (ltem 4) [D], magnet (item 5) [D] and plastic bushing (Item 6) [D} from the seat bar. Inspect all parts for damage and wear and replace if necessary. Reverse the removal procedure to install the seat bar sensor. Left Side of Seat Bar poea 773 BICS Loader Revised Jan. 99 -e47— Service ManualSEAT BAR SENSOR (Cont'd) BICS™ Controller Seat Bar Sensor Circuit Test Use Sensor Tester (MEL1428) for the following procedure: Disconnect the short adatper test leads if connected. Disconnect the seat bar sensor connector (Item 1) [A]. Connect Sensor Tester (Item 1) [B] inline as shown to the seat bar sensor connectors, See inset [A]. ‘Tum the key to the ON position. DO NOT START THE ENGINE. No power light on the sensor tester check the tester or wiring hamess. Power light iltuminated, move the toggle switch (Item 2) [B] on the sensor tester (Item 1) [B] to the Present position, NOTE: The sensor tost light (tem. 3) [8] is only activated by the seat bar. It will be off with the ‘seat bar up or on with the seat bar down. ‘The seat bar light (Item 1) [C] on the BICS controller should illuminate. Moye the toggle switch (Item 1) [D] on the sensor tester to the Absent position. ‘The Seat Bar light (Item 1) [C] should go off, Ifthe tests above fall, there is a problem with the BICS™ system controller or the wiring hamess, Revised Jan. 99, CoNTRORLER Test ee e418. 773 BICS Loader Service Manualj TRACTION LOCK Removal And Installation A WARNING AVOID INJURY OR DEATH Do not modify the electrical wiring connected to the traction lock solenoid or any part of the traction lock system. The traction lock provides the locking function of the parking brake. Service work on the traction lock system should only be performed by a qualified technician. Use only genuine Bobcat parts if repair is necessary. w-2165-0100 Raise the loader operator cab. (See Page 1-1.) NOTE: The loader control panel is removed for clarity purpose only. The traction lock can be removed without removing the control panel. Remove the Do Not Modify sta~strap (P/N 6665527) from the electric solenoid connector (Item 1) [A] Installation: Install a new Do Not Modify sta-strap (PIN (6685527) on the electric solenoid connector. Remove the two mounting bolts (Item 2) [A] from the ‘electric solenoid mounting bracket. Installation: Tighten the mounting bolts to 25-28 ft-Ibs. (34-38 Nm) torque. Be sure the solenoid mounting bracket Is installed in the same position. The solenoid ‘mounting surface has a slight angle which tips the top of, the solenoid toward the rear of the loader when installed correctly. See inset photo [A]. Remove the electric solenoid and bracket assembly from the chaincase cover [B]. Remove and inspect the compression spring Item 1) [6] for wear oF damage, Replace necessary, The spring may also stay with the shaft when the electric solenoid land bracket are removed from the chaincase. Installation: Install the compression spring (Item 1) [B] ‘on the collar located on the electric solenoid, Revised June 01 -8-19- 773 BICS Loader ‘Service ManualTRACTION LOCK (Cont'd) Removal And Installation (Cont'd) remove the traction lock assembly (Item 1) [A] from the chaincase. Remove the shatt mounting bolt (Item 1) [B], washer and spring from the assembly shaft (Item 2) {B]. Remove the wedge (Item 3) [B] and inspect all parts for damage or wear. Replace if necessary. Installation: Thoroughly clean. and dry. the, shat ‘mounting bolt (Item 1) [B], the shaft (Item 2) [B} and wedge (item 3) [B]. Use LOCTITE #242 when assembling these parts to the traction lock assembly. IMPORTANT Failure to use LOCTITE may allow the traction. lock assembly to loosen up which can cause damage to the traction lock system. 1-2090-1095 Refer to Page 88 for the traction lock inspection procedure. Revised Jan. 99 -8-20- 773 BICS Loader ‘Service Manual —BOSS® DIAGNOSTIC TOOL Procedure _= The too! listed will be needed to do the following procedure: ~~ MEL 1400 — Diagnostic Too! Stop the engine. Liff and block the loader. (See Page 1-1.) Flemove the dust cap from the diagnostic connector plug, Connect the diagnostic too! plug {hem 1) TA] inte tye loader connector Use the instructions from the BOSS® Operation & Maintenance Manual to make service checks of BOSS® system operating unit and other components [A] ‘SENDER AND SENSOR Service Checks Use the following information when checking the senders and sensor with a volvohmmeter. Component Value TEMPERATURE SENDER 79 gogroes F 21 degrees ©.) 970 ohms 80 degrees F. (27 degrees C. 4013 ohms ENGINE OIL PRESSURE SENDER OPS! ji sesses Sohms Max, SPSL (a) kPa 7 ohms Min. 59 Bil (ads kal 49 ohms, 70 PSI (483 kPa) 59 ohms TRANSMISSION CHARGE PRESSURE SENDER OPS ‘0-5 ohms. 400 PS! (680 KPa) ; 58 ohms 430 PSI (896 kPa} 5 75 ohms, 150 PSI (1034 kPa} 87 ohms FUEL SENDER Full : 30 ohms Empty 2200000. SII 270 ohms RPM SENSOR Adjustment Continuity Resistance of 3000-3500 ohms. Disconnect the connector (Item 1) [B] from the engine hamess. Loosen the jam nut (ltem 2) [B] on the RPM sensor. Tur the RPM sensor Item 1) [C] in until it makes contact with the engine flywheel Turn the jam nut untilitcontacts the flywheel housing. The jam nut should not be tightened, It needs to turn with the PM_sengor when the sensor is tured back out for adjustment, Jum the RPM sensor and the jam nut out from the flywheel. Seta clearance of 0.050 Inch (1.27 mm) between the jam nu and the housing wih aeeler gauge Retighten the jam nut, NOTE: The pla used as a gauge to set anew RPM SENSOR, the plastic tip Is designed to ‘come off after the engine is started. 773 BICS Loader Revised Jan, 99 -8-21- Service ManualMONITOR SERVICE CODES One of the following Alphabetic Codes may appear on your monitor. J 3 Battery CS Engine on Pr Engine Speea 2S Air Finer a CS Hydrostatic Fluid Temperature 15) Hydrautc | Hyarautc Fiuid Pressure One of the following Numeric Codes will appear following one of the above Shut Down Warning 5| Wiring Not Connected Wiring Shorted High Sensor Voltage Sensor No Signal Sensor Out of Range scor-o1" — 773 BICS Loader Revised Jan. 99, -8-22- Service ManualMONITOR SERVICE CODES ‘The following list references the defect codes that are transmitted to the instrument panel display which can ‘occur. Some service procedures for correcting the problems can be found in this manual and other procedures must be performed ONLY BY QUALIFIED SOBCAT SERVICE PERSONNEL, A WARNING Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death See service Codes Benes SUBJECT _| DISPLAY READS CONDITION Engine Goolant Level_| ECL SHUTDOWN, No Coolant Saree ly Engine Coolant Temp. | EC-11 SHUTDOWN, Engine Temperature g8eeehilecs WARNING, Engine Temperature C3 Wiring Not Connected C4 Wiring Shorted ECS High Sensor Votage E07 Sensor Out Of Range Engine OW Pressure | EP 1 SHUTDOWN, Pressure seegsOiere WARNING, Pressure Epa Wiring Not Connected Epa Wiring Shorted EPS High Sensor Voltage EP7 Sensor Out OF Range Engine Speed Est SHUTDOWN, Engine Speed Too High pgeeshless: WARNING, Engine Speed Sightly High 5-6 ‘Sensor No Signal ES-7 Sensor Out OF Range Air Fier “AF WARNING, Restriction Too High BSSRSL are Sensor No Signal Battery [beet WARNING, Bad Battery B88 R v22 WARNING, Battery Vollage Fuel Level ~ [FUEL WARNING, Low Level 88808 |_ruas Wiring Not Connected FUELS Wiring Shorted FUELS Tigh Sensor Voltage FUEL ‘Sensor Out Of Range 773 BICS Loader Revised June 01 -8-2- Service ManualMONITOR SERVICE CODES (Cont'd) Service Codes (Cont'd) i SUBJECT DISPLAY READS CONDITION Hydrostatic Charge HFI-2 WARNING, High Restriction (1st Filter) Filter Conditions HFI-6 ‘Sensor No Signal BESET wre WARNING, High Restriction (2nd Filter) HF2-6 ‘Sensor No Signal HP 4 SHUTDOWN, Pressure HP 2 WARNING, Pressure HPS. Wiring Not Connected HP 4 Wiring Shorted HPS High Sensor Voltage: HP 7, ‘Sensor Out Of Range Hydrostatic Fluid HOT SHUTDOWN, Temperature Temperature | HO2 WARNING, Temperature HESS8Q) nes Wiring Not Connected Hos Wiring Shorted HOS: High Sensor Voltage HOT, ‘Sensor Out Of Range 773 BICS Loader Revised Jan. 99 8-24 Service Manuatc c ‘TROUBLESHOOTING THE BOSS® & LCD DISPLAY Bad ees beeen acu cuaie Chart es Temperature related| 12 volt supply and 1 Check stored defects with the BOSS tool the BOSS. ‘shutdown ‘codes | BOSS failure. "2. If defect list has EC1, HC1, EC2.1, HC2. EP3, when no heating EP7, HP7,_ 82.2, low fuel, Fuel 7 and last occurs. ccuirence hr. readings are within a. hundredth, the BOSS js defective and must be replaced “NOTE: You may have some or all of the| 3. Using a voltmeter, check the alfernator output codes listed. You will have high temps, high press, low voltage and low fuel. TCD Display J iniermitient code of] Sensor No Signal or] 1. E56 wil occur ifthe loaders slaled or shuldown ES6 "while engine | No RPM's. during run cycle. The code ie generated due tothe running. lack ‘of APM and. the exietence of residual pressure in the system, Display is dead —No| Lack of 5.0 volts] 1. Check pin A for 5.0 volts. If 5.0 volts is present Icons, Bar Graphs, | regulated power. replace the display. Hourmeter 2. If ho power exists at pin A, install BOSS backup to\confirm the BOSS system. LCD DISPLAY 3. Ifthe problem stil exists, check the hamess for CONNECTOR bales ABCDE . | 12VoNt-Back Light § (Ground __ Negative Com, 51018 Volts | Positive Com. 3.5104 Volts 1.0 Volts Regulated Power Power Display Operation During an active |Low voltage (6.0)| 1. Tum the ignition switch OFF. Re-starting will WARNING” display, | triggered reset retum hourmeter reading. reset occurs and the 2, [re-starting will not return hourmeter reading, hhourmeter’ becomes check pins 8 & C as slated in Step 5 below. all zeros, Garbled message, | The displayisnotiault| 1. Tum the ignition switch OFF and re-start. Al missing segments, | tolerant. Also can be | | faultis an invalid message that the display ties etc an indication of poor| 10 display. Generally” a fault occurs internal connections. communieaitons of two messages are combined on the display. After glow sequence 1, Tum the key OFF and re-start. or after. a WARNING ‘9088 away, the Icon remains ON. No Bar Graphs, no| Bad display or BOSS] 7. Plugin the BOSS tool and star the engine. Hours. isnotcommunicaing, | 2: It data is being received by the BOSS too, the BOSS unit is nat the cause ofthe problem. 3. It-no data’ is received at the’ BOSS. tool disconnect the LED display. +4, Ih moscagas are now focbived al the tool, the . display is the problem. It problem stil exists goto “NOTE: The display has caused the ‘Step 5. problem” by” locking. the| 5. Chick pins 6 & C for signa Communication tines” _and| 6. If there'is no signal, instal BOSS backup unit, Stopping communications from| 7. If the problem sil exists, check the harness for continuity Revised Jan. 99 825 773 BICS Loader Service ManualOPERATION SENSING SYSTEM UNIT Removal And Installation Raise the loader operator cab. (See Page 1-1.) Loosen the three nuts (Item 1) [A] from the sensing system unit (Item 2) [A] Slide the unit forward in the mounting slots and remove it from the operator cab, Use a screw driver and remove the two connectors (Item 1) [B] from the sensing system unit (Item 2) [8]. Installation: Put the heads of the mounting botts into the slots of the operator cab and slide the unit backinto place. Tighten the three mounting nuts to 80-90 in.-1bs. (0-10 Nm) torque. 773 BICS Loader Revised Jan. 99 -8-26- Service ManualBOSS® INSTRUMENT PANEL Removal And Installation Pry the rubber light mount free from the operator cab, a (Oa Sides) ta, 09995 Lower the light from the operator cab to locate the three instrument panel mounting bolts (Item 1) [B] (both sides) Remove the three mounting bolts and pull the left pane! {item 1) [C] down from the operator cab. Installation: Be caretul to not overighten the panel mounting bots to prevent stripping the threaded holes of the panels, Disconnect the wire hamess connectors from the panel, and remove the panel, Remove the three mounting bolts and pull the right panel (item 1) [D] down from the operator cab, Installation: Be careful to not overtighten the panel ‘mounting bolts to prevent stripping the threaded hoies of the panels, Disconnect the wire hamess connectors from the panel and remove the panel. c TTB BICS Loader Revised Jan. 99 -8-27- Service ManualELECTRICAL/HYDRAULIC CONTROLS REFERENCE Controls Identification Chart ‘Attachment Solenoid | "Harness Attachment switch | Number | Terminal Hamess ee Number | Activated | Activated Connector int dele Control Handle RH Control Handle ‘Switches ‘Switches 1 feat kK 2 2 [2 K +3 1 [4 K a 2 [23 | KAD 5 a [ae | Kac 6 1 [48 KE 7 1 [13 KF s 1s KG _| | Viewad from tron pin side of connector) s 1 1.48 nn of loader. Ho, +1,42,[ - | — K 43, 14 RH ~ Loaders with Rear Hydraulics Option. HFH - Loaders with High Flow Hydraulics Option. * if hamess terminals K & L are jumped together, switches 4 thru 9 provide flow on demand to female coupler. (DETENT is not needed.) * Terminal K is activated with Key switch ON. Solenoid | Hydraulic Wiring co Number oupler Color 1 Front Dk. Green! Female Red 2 Front Dk. Green! Male Lt. Green 3 Diverter Yellow (Rear Couplers) 4 Bleed—Rear | Dk. Green/ Male & Female Yellow NOTE: To relieve the hydraulic pressure trapped in the front auxiliary circuit, with the engine running, turn the key switch quickly to the left (counterclockwise) past the OFF position. Hold key until the engine comes to a complete stop. 773 BICS Loader 8-28 ‘Service Manual