Bobcat 863 Turbo High Flow 514440001 + Factory Service & Work Shop Manual

6900942 (2-06) Printed in U.S.A. © Bobcat Company 2006 Service Manual S/N 514440001 & Above S/N 514540001 & Above S/N 514640001 & Above EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

MAINTENANCE SAFETY Never service the Bobcat Skid- Steer Loader without instructions. Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced. Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed. Stop, cool and clean engine of flammable materials before checking fluids. Never service or adjust loader with the engine running unless instructed to do so in the manual. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes. Never fill fuel tank with engine running, while smoking or when near open flame. Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device. Replace it if damaged. Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust. Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding. Keep rear door closed except for service. Close and latch door before operating the loader. Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged. Never modify equipment or add attachments not approved by Bobcat Company. Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries. Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention. Use the correct procedure to lift or lower operator cab. Cleaning and maintenance are required daily. MSW08-0805 WRONG B-6589 B-10731a CORRECT B-15590 CORRECT B-15591 CORRECT B-15599 WRONG WRONG B-15593 WRONG B-15592 B-15600 WRONG WRONG B-15601 WARNING Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. W-2003-0903 Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer. Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

863 Bobcat Loader Service Manual ALPHABETICAL INDEX ADVANCED CONTROL SYSTEM (ACS) ADVANCED HAND CONTROL ................. 60-01 ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND/FOOT CONTROL... 60-01 ADVANCED CONTROL SYSTEM (AHC) ............... 60-01 ADVANCED CONTROL SYSTEM (AHC) (W/PUSH BUTTON FLOAT) ..................... 60-01 AIR CLEANER ........................................................ 70-01 AIR CLEANER SERVICE ....................................... 10-01 AIR CONDITIONG SERVICE ................................. 80-01 AIR CONDITIONING SYSTEM FLOW ................... 80-01 ALTERNATOR (55 AMP) ........................................ 60-01 ALTERNATOR (90 AMP) ........................................ 60-01 BASIC TROUBLESHOOTING ................................ 80-01 BATTERY ............................................................... 60-01 BICS™ SYSTEM .................................................... 60-01 BOBCAT CONTROLLER ....................................... 60-01 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) ............................ 60-01 BOB-TACH ................................................... 10-01, 50-01 BRAKE .................................................................... 40-01 BRAKE (TWO-SPEED) ........................................... 40-01 BUCKET POSITITON VALVE 20-01 CHAINCASE ........................................................... 40-01 CHARGE PRESSURE ........................................... 30-01 COOLING FAN ...................................................... 70-01 COMPONENTS ..................................................... 80-01 COMPRESSOR ..................................................... 80-01 CONDENSER ......................................................... 80-01 CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) ADVANCED HAND CONTROL ................. 20-01 CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) .................................................................. 20-01 CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/PUSH BUTTON FLOAT) ..................... 20-01 CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL... 20-01 CONTROL PANEL .................................................. 50-01 CONTROL PEDALS ............................................... 50-01 CONTROL PEDALS (ACS) .................................... 50-01 CONVERSIONS ............................................... SPEC-01 CYLINDER (LIFT) ................................................... 20-01 CYLINDER (POWER BOB-TACH).......................... 20-01 CYLINDER (TILT) ................................................... 20-01 DELUXE INSTRUMENTATION SERVICE CODES 60-01 DRIVE BELT ........................................................... 30-01 DRIVE COMPONENTS .......................................... 40-01 ELECTRICAL/HYD. CONTROLS REFERENCE .... 60-01 ELECTRICAL SYSTEM INFORMATION ................ 60-01 ENGINE & ENGINE MOUNTS ............................... 70-01 ENGINE COMPONENTS AND TESTS .................. 70-01 ENGINE COOLING SYSTEM ................................. 10-01 ENGINE LUBRICATION SYSTEM ......................... 10-01 ENGINE SPECIFACATIONS ............................. SPEC-01 ENGINE SPEED CONTROL ................................... 70-01 EVAPORATOR ........................................................ 80-01 EVAPORATOR/HEATER UNIT................................ 80-01 EXPANSION VALVE ................................................ 80-01 FAN GEARBOX ....................................................... 10-01 FINAL DRIVE TRANSMISSION (CHAINCASE)......10-01 FLYWHEEL AND HOUSING .................................. 70-01 FRONT AUXILIARY HYD. COUPLER BLOCK ....... 20-01 FUEL SYSTEM........................................................ 10-01 FUEL TANK ............................................................. 50-01 GENERAL AIR CONDITIONING SERVICE GUIDELINES ........................................................ 80-01 HEATER COIL ......................................................... 80-01 HEATER/AC FAN ...................................................80-01 HEATER VALVE ...................................................... 80-01 HYDRAULIC CONNECTION SPECS ............... SPEC-01 HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS) .......... 20-01 HYDRAULIC CONTROL VALVE (FOOT CONTROL) ............................................... 20-01 HYDRAULIC FLUID RESERVOIR ..........................20-01 HYDRAULIC/HYDROSTATIC FILTER .................... 20-01 HYDRAULIC FLUID SPECIFICATIONS ............ SPEC-01 HYDRAULIC/HYDROSTATIC SYSTEM .............. 10-01 HYDRAULIC PUMP ................................................ 20-01 HYDRAULIC SYSTEM INFORMATION .................. 20-01 HYDROSTATIC MOTOR ......................................... 30-01 HYDROSTATIC MOTOR (TWO-SPEED) ................ 30-01 HYDROSTATIC PUMP ............................................ 30-01 HYDROSTATIC SYSTEM INFORMATION.............. 30-01 INSTRUMENT PANEL ............................................ 60-01 LIFT ARMS .............................................................. 50-01 LIFT ARM BY-PASS VALVE .................................... 20-01 LIFT ARM SUPPORT DEVICE................................ 10-01 LIFTING AND BLOCKING THE LOADER............... 10-01 LIGHTS.................................................................... 60-01 LOADER SPECIFICATIONS ............................. SPEC-01 LOADER TORQUE............................................ SPEC-01 LUBRICATING THE LOADER ................................. 10-01 MAIN RELIEF VALVE (FOOT CONTROL) .............. 20-01 MUFFLER................................................................ 70-01

863 Bobcat Loader Service Manual ALPHABETICAL INDEX (CONT’D) OIL COOLER ........................................................... 30-01 OPERATOR CAB..........................................10-01, 50-01 OPERATOR SEAT ................................................... 50-01 OPERATOR SEAT (SUSPENSION) ........................ 50-01 POWER BOB-TACH (OPTION) ....................10-01, 50-01 POWER BOB-TACH BLOCK................................... 20-01 PRESSURE RELIEF VALVE ................................... 80-01 PRESSURE SWITCH .............................................. 80-01 RADIATOR............................................................... 70-01 REAR AUXILIARY DIVERTER VALVE .................... 20-01 REAR DOOR ..........................................................50-01 REAR GRILL ..........................................................50-01 RECEIVER/DRIER..................................................80-01 RECOMMENDED SERVICE TOOLS ...................... 80-01 RECONDITIONING THE ENGINE .......................... 70-01 REMOTE START ..................................................... 10-01 RPM SENSOR.........................................................70-01 SAFETY ................................................................... 80-01 SEAT BAR ............................................................... 50-01 SEAT BAR SENSOR ............................................... 60-01 SELECT VALVE....................................................... 20-01 SERVICE SCHEDULE.............................................10-01 STARTER ................................................................ 60-01 SYSTEM CHARGING AND RECLAMATION .......... 80-01 SYSTEM TROOUBLESHOOTING CHART ............. 80-01 TEMPERATURE/PRESSURE.................................80-01 THERMOSTAT ........................................................ 80-01 TIRE MAINTENANCE..............................................10-01 TORQUE SPECIFICATIONS FOR BOLTS........ SPEC-01 TOWING THE LOADER .......................................... 10-01 TRACTION LOCK.................................................... 60-01 TRANSPORTING THE LOADER ............................ 10-01 TROUBLESHOOTING............................................. 70-01

863 Bobcat Loader I Service Manual CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . XI SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01 MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 80-01 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 SAFETY AND MAINTENANCE HYDRAULIC SYSTEM HYDROSTATIC SYSTEM s A ENGINE SERVICE HVAC DRIVE SYSTEM MAIN FRAME ELECTRICAL ANALYSIS SYSTEM & SPECIFICATIONS

863 Bobcat Loader II Service Manual FOREWORD This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, Starting procedure, daily checks, etc. A general inspection of the following items must be made after the loader has had service or repair: 1. Check that the ROPS/FOPS (Including side screens) is in good condition and is not modified. 9. The parking brake must function correctly. 2. Check that ROPS mounting hardware is tightened and is Bobcat approved. 10. Enclosure door latches must open and close freely. 3. The seat belt must be correctly installed, functional and in good condition. 11. Bob-Tach wedges and linkages must function correctly and be in good condition. 4. The seat bar must be correctly adjusted, clean and lubricated. 12. Safety treads must be in good condition. 5. Check lift arm support device, replace if damaged. 13. Check for correct function of indicator lamps (Optional on some models). 6. Machine signs must be legible and in the correct location. 14. Check hydraulic fluid level, engine oil level and fuel supply. 7. Steering levers and foot pedals must return to neutral. 15. Inspect for fuel, oil or hydraulic fluid leaks. 8. Check for correct function of the work lights 16. Lubricate the loader.

863 Bobcat Loader III Service Manual 17. Check the condition of the battery and cables. 22. Operate the loader and check all functions. 18. Inspect the air cleaner for damage or leaks. Check the condition of the element. 23. Check for any field modification not completed. 19. Check the electrical charging system. 24. Check for correct function of the Bobcat Interlock Control System (BICS) before the machine is returned to the customer. 20. Check tires for wear and pressure. 25. Recommend to the owner that all necessary corrections be made before the machine is returned to service. 21. Inspect for loose or broken parts or connections. CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

863 Bobcat Loader IV Service Manual

Bobcat 863 Turbo High Flow 514440001 + Factory Service & Work Shop Manual

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