Bobcat 863 & 863 High Flow Loader Service Manual 6900648 (10-12) – PDF DOWNLOAD

Description

Bobcat 863 & 863 High Flow Loader Service Manual 6900648 (10-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 863 & 863 High Flow Loader Service Manual 6900648 (10-12) – PDF DOWNLOAD

Language : English
Pages : 572
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 863 & 863 High Flow Loader Service Manual 6900648 (10-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 8
SAFETY INSTRUCTIONS 11
SERIAL NUMBER LOCATIONS 13
LOADER SERIAL NUMBER 13
ENGINE SERIAL NUMBER 13
DELIVERY REPORT 13
BOBCAT LOADER IDENTIFICATION 14
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
Raising The Operator Cab 22
Lowering The Operator Cab 23
Emergency Exit 24
SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS) 25
Description 25
Seat Bar Inspection 25
Seat Bar Maintenance 25
SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS) 26
Description 26
Seat Bar Inspection 26
Seat Bar Maintenance 26
SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS) 27
Description 27
Seat Bar Maintenance 27
Seat Bar Inspection 27
AIR CLEANER SERVICE 28
Replacing Filter Element 28
FUEL SYSTEM 30
Fuel Specifications 30
Filling The Fuel Tank 30
Fuel Filter 30
Removing Air From The Fuel System 30
ENGINE LUBRICATION SYSTEM 31
Checking Engine Oil 31
Replacement Of Oil And Filter 31
COOLING SYSTEM 32
Cleaning The Cooling System 32
ALTERNATOR BELT 33
Adjusting The Alternator Belt 33
HYDRAULIC/HYDROSTATIC SYSTEM 34
Replacing The Hydraulic/Hydrostatic Filter 34
Checking And Adding Fluid 34
Replacing The Hydraulic Fluid 35
TIRE MAINTENANCE 36
Wheel Nuts 36
Tire Rotation 36
Tire Mounting 36
FINAL DRIVE TRANSMISSION (CHAINCASE) 37
Checking And Adding Oil 37
Removing Oil From The Chaincase 37
LUBRICATION OF THE BOBCAT LOADER 38
Procedure 38
FAN GEARBOX 40
Checking And Maintaining 40
BOB–TACH 41
Inspection And Maintenance 41
REMOTE START SWITCH 42
Procedure 42
HYDRAULIC SYSTEM 45
HYDRAULIC/HYDROSTATIC SCHEMATICS 48
TROUBLESHOOTING 63
HYDRAULIC SYSTEM INFORMATION 64
Tighten Procedures 64
LIFT CYLINDER(S) 65
Checking The Lift Cylinder(s) 65
Removal And Installation 65
TILT CYLINDER 67
Checking The Tilt Cylinder 67
Removal And Installation 67
Rod End Seal 68
HYDRAULIC CYLINDER 69
Lift Cylinder Identification 69
Tilt Cylinder Identification 70
Disassembly 71
Assembly 73
MAIN RELIEF VALVE 76
Checking The Main Relief Valve 76
Checking The Main Relief Valve Without Auxiliaries 77
Removal And Installation 78
Adjustment 78
MAIN RELIEF VALVE (Advanced Hand Control) 79
Adjustment 79
SELECT VALVE 863H 80
Checking The High Flow Pump Relief Valve 80
Removal And Installation 81
Disassembly And Assembly 82
Solenoid Testing 83
LIFT ARM BY–PASS CONTROL VALVE 84
Removal And Installation 84
Disassembly And Assembly 85
BICS™ CONTROL VALVE 86
Removal And Installation 86
BICS™ VALVE ASSEMBLY 89
Lift Arm By–Pass Orifice 89
Check Valve 90
Lock Valve 91
BICS™ Valve Solenoid 92
HYDRAULIC CONTROL VALVE 93
Removal And Installation 93
Identification Chart 96
Disassembly And Assembly 97
Load Check Valve 97
Lift Base End Restrictor 97
Main Relief Valve 98
Port Relief Valve 99
Anti–Cavitation/Port Relief Valve 99
Rubber Boot 101
Lift Spool And Detent 102
Tilt Spool And Centering Spring 106
Auxiliary Spool 107
Auxiliary Electric Solenoid 108
H Port – Auxiliary Section 109
Inspection 109
Spool Seal Installation 110
HYDRAULIC PUMP 111
Checking The Output Of The Pump 111
Removal And Installation 112
Parts Identification 113
Disassembly 114
Inspection 116
Assembly 117
HYDRAULIC PUMP (Double Gear) 863H 119
Checking The Output Of The High Flow Pump 119
Removal And Installation 120
Parts Identification 122
Disassembly 123
Inspection 127
Assembly 128
HYDRAULIC FLUID RESERVOIR 131
Removal And Installation 131
HYDROSTATIC FILTER HOUSING 132
Removal And Installation 132
Hydrostatic Charge Pressure Sender 132
CONTROL PEDALS 133
Removal And Installation 133
Pedal Adjustment 133
PEDAL INTERLOCK LINKAGE 134
Removal And Installation 134
Pedal Interlock Linkage Adjustment 135
REAR AUXILIARY DIVERTER 136
Disassembly 136
Inspection 136
Solenoid Testing 136
Assembly 136
HYDROSTATIC SYSTEM 137
TROUBLESHOOTING 139
HYDROSTATIC SYSTEM INFORMATION 140
Replenishing Valve Function 140
FRONT PANEL (M46 Pump & AHC) 141
Removal And Installation 141
FRONT PANEL (M44 Hydraulic Pump) 143
Removal And Installation 143
STEERING LEVERS (M46 Pumps & AHC) 145
Disassembly And Assembly 145
STEERING LEVERS (M44 Pumps) 147
Removal And Installation 147
Disassembly And Assembly 147
CONTROL TOWER (M46 Pump & AHC) 149
Removal And Installation 149
Disassembly And Assembly 150
SOLID STEERING LINKAGE NEUTRAL ADJUSTMENT (M46 Pump) 152
Procedure 152
STEERING LINKAGE (M44 Pump) 155
Removal And Installation 155
Steering Linkage Adjustment 158
HYDROSTATIC MOTOR (S/N 514427762 & Above; 514525304 & Above; 514625302 & Above) 163
Removal And Installation 163
Parts Identification 164
Disassembly 165
Inspection 167
Assembly 168
HYDROSTATIC MOTOR (S/N 514427761 & Below; 514525303 & Below; 514625301 & Below) 172
Removal And Installation 172
Parts Identification 174
Disassembly 175
Inspection 176
Assembly 177
MOTOR CARRIER 179
Removal And Installation 179
Parts Identification 180
Disassembly 181
Assembly 183
HYDROSTATIC PUMP (M46) 185
Removal And Installation 185
Replenishing/High Pressure Relief Valve 187
Charge Pressure Relief Valve 187
Parts Identification (Right Half) 188
Parts Identification (Left Half) 190
Hydraulic Pump Removal 192
Hydrostatic Pump Separation 192
Charge Pump Disassembly 193
Disassembly 194
Inspection 203
Assembly 206
Charge Pump Assembly 215
Hydrostatic Pump Connection 216
Hydraulic Pump Installation 216
Swashplate Neutral Adjustment 217
Displacement Control Servo (Solid Linkage) 218
HYDROSTATIC PUMP (M44) 220
Parts Identification (Right Half) 220
Parts Identification (Left Half) 222
Replenishing/High Pressure Relief Valve 224
Charge Pressure Relief Valve 225
Hydraulic Pump Removal 226
Hydraulic Pump Separation 227
Charge Pump Disassembly 227
Disassembly 229
Assembly 235
CHARGE PUMP (M44) 240
Assembly 240
DRIVE BELT SHIELD 243
Removal And Installation 243
DRIVE BELT 244
Adjusting The Drive Belt 244
Replacing The Drive Belt 244
DRIVE BELT TENSIONER PULLEY 245
Removal And Installation 245
Tension Spring 247
HYDRAULIC/HYDROSTATIC OIL COOLER 248
Removal And Installation 248
DRIVE SYSTEM 249
PARKING BRAKE PEDAL 251
Removal And Installation 251
Disassembly And Assembly 252
PARKING BRAKE DISC 253
Removal And Installation 253
FRONT CHAINCASE COVER 256
Removal And Installation 256
REAR CHAINCASE COVER 256
Removal And Installation 256
AXLE SEAL 257
Removal And Installation 257
AXLE, SPROCKET AND BEARINGS 259
Removal And Installation 259
DRIVE CHAIN 264
Removal And Installation 264
CHAINCASE FLUID 265
Removing The Fluid From The Chaincase 265
MAIN FRAME 267
SEAT BAR 269
Removal And Installation 269
Assembling Components 272
Compression Spring Disassembly And Assembly 272
OPERATOR CAB GAS CYLINDER 273
Removal And Installation 273
Disassembly And Assembly 274
OPERATOR CAB 275
Removal And Installation 275
OPERATOR SEAT 277
Removal And Installation 277
BOB–TACH 278
Bob–Tach Lever And Wedge 278
Bob–Tach Stops 279
Removal And Installation 280
Pivot Pin Bushing And Seal Replacement 282
LIFT ARMS 283
Removal And Installation 283
REAR GRILL 286
Removal And Installation 286
REAR DOOR 287
Removal And Installation 287
Door Latch And Catch Adjustment 288
FUEL TANK 289
Removal And Installation 289
Fuel Level Sender 290
Fuel Pick–Up Screen/Check Valve 290
Inlet Screen 291
ELECTRICAL SYSTEM 293
ELECTRICAL SCHEMATICS 295
TROUBLESHOOTING 309
ELECTRICAL SYSTEM INFORMATION 310
Description 310
Fuse Location 310
BATTERY 311
Removal And Installation 311
Servicing The Battery 312
Using A Booster Battery 313
ALTERNATOR 314
Alternator Output Test 314
Rectifier (Diode) Test 314
Alternator Regulator Test 315
Removal And Installation 316
Disassembly 317
Stator Continuity Test 317
Stator Ground Test 317
Rotor Continuity Test 318
Rotor Ground Test 318
Rectifier Continuity (Diode) Test 318
Assembly 319
STARTER 319
Removal And Installation 319
Parts Identification 320
Disassembly And Assembly 321
External Pinion 325
Inspection And Repair 326
Magnetic Switch Test 329
No Load Test 329
STANDARD INSTRUMENT PANEL 330
Removal And Installation 330
FRONT LIGHTS 331
Removal And Installation 331
RELAY SWITCHES 332
Location 332
ENGINE SERVICE 333
TROUBLESHOOTING 335
ENGINE SPEED CONTROL 336
Removal And Installation 336
Speed Control Cable 337
Speed Control Linkage 337
ENGINE MUFFLER 338
Removal And Installation 338
AIR CLEANER HOUSING 339
Removal And Installation 339
BLOWER HOUSING/FAN GEARBOX 340
Removal And Installation 340
FAN DRIVE TENSION PULLEY 342
Removal And Installation 342
BLOWER FAN 343
Removal And Installation 343
FAN GEARBOX 344
Parts Identification 344
Disassembly 345
Assembly 350
Checking Backlash 355
ENGINE 358
Removal And Installation 358
Replacement 364
FLYWHEEL 365
Removal And Installation 365
Flywheel Ring Gear 365
FLYWHEEL HOUSING 365
Removal And Installation 365
GLOW PLUG 366
Checking The Glow Plug 366
VALVE CLEARANCE 367
Adjustment 367
FUEL INJECTION PUMP 368
Description 368
Removal 368
Injection Pump Timing 369
Installation 370
FUEL INJECTOR 372
Removal and Installation 372
Checking 373
Disassembly 374
Assembly 375
TIMING BELT 377
Inspection 377
Removal 377
Installation 378
Belt Replacement In Loader 381
VALVE TIMING 386
Checking 386
DEUTZ ENGINE TOOLS 387
Identification Chart 387
RECONDITIONING THE ENGINE 388
Disassembly 388
Assembly 392
CYLINDER LINERS 407
Checking The Cylinder Liners 407
CAMSHAFT BEARINGS 408
Checking 408
Removal And Installation 408
CONTROL ROD GUIDE BUSHING 410
Removal 410
Installation 412
REAR COVER SEAL 416
Removal And Installation 416
CRANKSHAFT 417
Checking The Crankshaft 417
CONNECTING ROD 418
Checking The Connecting Rod 418
PISTON AND PISTON PIN 421
Checking the Piston 421
Installing Piston Rings 422
CYLINDER HEAD 423
Disassembly 423
Checking The Valves 423
Checking Valve Seats 424
Valve Spring 424
Assembly 424
ROCKER ARM AND BRACKET 426
Checking 426
FRONT COVER 427
Disassembly 427
Assembly 432
TURBOCHARGER 442
Removal and Installation 442
Disassembly 443
Inspection 447
Assembly 448
ENGINE OIL COOLER 453
Removal And Installation 453
CRANKSHAFT GEAR MOUNTING BOLT 454
Torque Procedure 454
SYSTEMS ANALYSIS 455
BICS™ (With Press To Operate Button) 457
Inspecting The BICS™ Controller (Engine STOPPED– Key ON) 457
Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 457
Inspecting The Seat Bar Sensor (Engine RUNNING) 457
Inspecting The Traction Lock (Engine RUNNING) 457
Inspecting The Lift Arm By–Pass Control 457
Additional Inspection For Loaders With Advanced Hand Controls 457
Troubleshooting Chart 458
BICS™ (Without Press To Operate Button) 459
Inspecting The BICS™ Controller (Engine STOPPED– Key ON) 459
Inspecting Deactivation of the Auxiliary HydraulicsSystem (Engine STOPPED – Key ON) 459
Inspecting The Seat And Seat Bar Sensors (Engine RUNNING) 459
Inspecting The Traction Lock (Engine RUNNING) 459
Inspecting The Lift Arm By–Pass Control 459
Maintenance 459
Troubleshooting Chart 460
SEAT SENSOR OVERRIDE ONLY (If Equipped) 460
BICS SYSTEM CONTROLLER 461
Removal And Installation 462
SEAT BAR SENSOR 463
Troubleshooting Guide 463
Seat Bar Sensor Test 464
Removal And Installation 465
BICS™ Controller Seat Bar Sensor Circuit Test 466
SEAT SENSOR 467
Troubleshooting Guide 467
Seat Sensor Test 468
Removal And Installation 469
BICS™ Controller Seat Sensor Circuit Test 470
TRACTION LOCK 471
Troubleshooting Guide 471
Removal And Installation 472
TRACTION LOCK CONTROL SYSTEM (S/N 514427600 & Above; 514525300 & Above; 514625300 & Above) 473
Inspecting The Traction Lock Control System 473
Maintenance 473
TRACTION LOCK CONTROL SYSTEM (S/N 514123809 & Below; 514222299 & Below) 473
Description 473
Inspection 473
Maintenance 473
BOSS® DIAGNOSTIC TOOL 474
Procedure 474
SENDER AND SENSOR 474
Service Checks 474
RPM SENSOR 474
Adjustment 474
MONITOR SERVICE CODES 475
TROUBLESHOOTING THE BOSS® & LCD DISPLAY 477
BOSS® UNIT 478
Removal And Installation 478
BOSS® INSTRUMENT PANEL 479
Removal And Installation 479
PWM MODULE 480
Description 480
PWM TROUBLESHOOTING 481
Chart 482
PWM CONTROL HANDLE 483
Handle Testing 483
PWM ELECTRIC SOLENOID 483
Solenoid Coil Testing 483
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE 484
SPECIFICATIONS 485
LOADER SPECIFICATIONS 487
LOADER DIMENSIONS 487
PERFORMANCE 487
CONTROLS 487
ENGINE 487
HYDRAULIC SYSTEM 488
ELECTRICAL 488
DRIVE SYSTEM 488
CAPACITIES 489
TIRES 489
ENGINE SPECIFICATIONS (BF4M1011) 490
General 490
Fuel System 490
Valve And Valve Guide And Seat Insert 490
Piston And Rings 491
Connecting Rod 491
Cylinder Head And Block 491
Crankshaft And Main Bearings 492
Camshaft And Bearings 492
Oil Pump 492
ENGINE SPECIFICATIONS (BF4M1011F) 493
General 493
Fuel System 493
Valve And Valve Guide And Seat Insert 493
Piston And Rings 494
Connecting Rod 494
Cylinder Head And Block 494
Crankshaft And Main Bearings 495
Camshaft And Bearings 495
Oil Pump 495
ENGINE TORQUE 496
Specifications 496
Torque For General Metric Bolts 497
TORQUE SPECIFICATIONS FOR LOADER 498
HYDRAULIC CONNECTION SPECIFICATIONS 499
O–ring Face Seal Connection 499
Straight Thread O–ring Fitting 499
Tubelines And Hoses 499
Flare Fitting 499
O–ring Flare Fitting 500
Port Seal Fitting 502
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 503
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 504
DECIMAL AND MILLIMETER EQUIVALENTS 505
U S TO METRIC CONVERSION 505
ADVANCE HAND CONTROL SYSTEM (A H C) 507
ADVANCE HAND CONTROL ELECTRICAL SCHEMATICS 509
A H C COMPONENTS 519
Identification 519
TROUBLESHOOTING (A H C ) 520
ACTUATOR VOLTAGE TEST 522
Procedure 522
HANDLE CONTROL UNIT TEST 525
Procedure 525
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 528
Troubleshooting Chart 528
A H C /PWM CONTROLLER 529
Removal and Installation 529
Test 529
Description 530
Conditions 531
Troubleshooting Chart 531
Handle Testing 532
Solenoid Coil Testing 532
HANDLE CONTROL UNIT 533
Removal And Installation 533
Control Unit Connector 536
SWITCH HANDLE 537
Removal And Installation 537
A H C HANDLE 540
Removal And Installation 540
Disassembly And Assembly 541
A H C STEERING LEVER 542
Removal And Installation 542
Steering Lever Boot 542
ACTUATORS 543
Removal And Installation 543
Disassembly And Assembly 544
Mounting Plate 545
BICS™ VALVE 546
Lift Arm By–Pass Orifice 546
Check Valve 547
Lock Valve 547
BICS™ Valve Solenoid 548
Removal And Installation 549
HYDRAULIC CONTROL VALVE 550
Removal And Installation 550
Identification Chart 553
Disassembly And Assembly 554
Load Check Valve 554
Lift Base End Restrictor 554
Main Relief Valve 555
Port Relief Valve (Lift) 556
Anti–Cavitation/Port Relief Valve 556
Port Relief Valve (Tilt) 557
Anti–Cavitation Valve 557
Rubber Boot 558
Lift And Tilt Spool 559
Inspection 561
Auxiliary Spool 562
Auxiliary Electrical Solenoid 563
Spool Seal Installation 564
H–Port Auxiliary Section 565
SERVICE MANUAL REVISIONS 567
863/863H–1 567
863/863H-2 569
863/863H-3 571

DESCRIPTION:

Bobcat 863 & 863 High Flow Loader Service Manual 6900648 (10-12) – PDF DOWNLOAD

S/N 514425001 & Above
S/N 514525001 & Above
S/N 514625001 & Above

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.

SAFETY INSTRUCTIONS:

The following publications provide information on the safe use and maintenance of the loader and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine
is in safe operating condition.
• The Operation & Maintenance Manual delivered with the loader gives operating information as well as routine
maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement
Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.
• The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are
shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.
• The loader has a plastic Operator’s Handbook fastened to the operator cab. Its brief instructions are convenient to the
operator. The Handbook is available from your dealer in an English edition or one of many other languages. See your
Bobcat dealer for more information on translated versions.
• The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and
repair work.
• The Skid–Steer Loader Operator Training Course is available through your local dealer. This course is intended to provide
rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish version.
• The Service Safety Training Course is available from your Bobcat dealer. This course provides information for safe and
correct service procedures for Bobcat Skid–Steer loaders.
• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.

Questions? Email us: [email protected]

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.V