Bobcat Turbo 863 & Turbo 863 High Flow Loader Service Manual 6900942 – PDF DOWNLOAD

Description

Bobcat Turbo 863 & Turbo 863 High Flow Loader Service Manual 6900942 – PDF DOWNLOAD

FILE DETAILS:

Bobcat Turbo 863 & Turbo 863 High Flow Loader Service Manual 6900942 – PDF DOWNLOAD

Language : English
Pages : 970
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat Turbo 863 & Turbo 863 High Flow Loader Service Manual 6900942 – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 8
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrestor Exhaust System 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Loader Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
BOBCAT LOADER IDENTIFICATION 17
SAFETY AND MAINTENANCE 19
LIFTING AND BLOCKING THE LOADER 21
Procedure 21
LIFT ARM SUPPORT DEVICE 23
Engaging The Lift Arm Support Device 23
Disengaging The Lift Arm Support Device 24
OPERATOR CAB 25
Raising The Operator Cab 25
Lowering The Operator Cab 26
Emergency Exit 27
TRANSPORTING THE LOADER 29
Procedure 29
Adjusting The Bumper 29
TOWING THE LOADER 31
Procedure For Non-Two-Speeds 31
Procedure For Two-Speeds (S/N 51464170, 514540172, 514449389 And Below) 32
Procedure (S/N 51451171, 514540173, 514449390 and Above) 33
REMOTE START 35
Procedure For Loader Without, Attachments Control Harness 35
Procedure For Loader With, Attachments Control Harness 36
Procedure 38
SERVICE SCHEDULE 39
Chart 39
AIR CLEANER SERVICE 41
Replacing Filter Element 41
ENGINE COOLING SYSTEM 43
Cleaning The Cooling System 43
FUEL SYSTEM 45
Fuel Specifications 45
Filling The Fuel Tank 45
Fuel Filter 46
Fuel Lift Pump Strainer 47
Removing Air From The Fuel System 47
ENGINE LUBRICATION SYSTEM 49
Checking Engine Oil 49
Replacing Oil And Filter 49
HYDRAULIC / HYDROSTATIC SYSTEM 51
Checking And Adding Fluid 51
Replacing The Hydraulic / Hydrostatic Fluid 52
Replacing Hydraulic Fluid And Case Drain Filters 52
Breather Cap 54
FINAL DRIVE TRANSMISSION (CHAINCASE) 55
Checking And Adding Oil 55
Replacing The Oil 55
FAN GEAR BOX 57
Checking And Adding Oil 57
BOB-TACH 59
Inspection And Maintenance 59
POWER BOB-TACH (OPTION) 61
Inspection And Maintenance 61
LUBRICATING THE LOADER 63
Procedure 63
TIRE MAINTENANCE 65
Wheel Nuts 65
Tire Rotation 65
Tire Mounting 65
HYDRAULIC SYSTEM 67
HYDRAULIC / HYDROSTATIC SCHEMATICS 73
HYDRAULIC SYSTEM INFORMATION 113
Tighten Procedures 117
Troubleshooting Chart 117
CYLINDER (LIFT) 119
Checking 119
Removal And Installation 120
Parts Identification 122
Disassembly 123
Assembly 125
CYLINDER (TILT) 129
Checking 129
Removal And Installation 129
Rod End Seal 131
Parts Identification 132
Disassembly 133
Assembly 135
CYLINDER (POWER BOB-TACH) 139
Checking 139
Removal And Installation 140
Parts Identification 141
Disassembly 142
Assembly 143
MAIN RELIEF VALVE (FOOT CONTROL) 147
Checking The Main Relief Valve At Front Auxiliary Hydraulics 147
Checking The Main Relief Valve Without Front Auxiliaries 148
Removal And Installation 150
Adjustment 151
HYDRAULIC CONTROL VALVE (FOOT CONTROL) 153
Removal And Installation (S/N 514447863 & Below) 153
Removal And Installation (S/N 514447864 & Above) 156
BICS™ Valve, Removal And Installation 162
BICS™ Valve, Lift arm Bypass Orifice Disassembly And Assembly 163
BICS™ Valve, Check Valve Disassembly And Assembly (S/N 514450007 & Below) 164
BICS™ Valve, Check Valve Disassembly And Assembly (514450007 & Above) 165
BICS™ Valve, Lock Valve Disassembly And Assembly 166
BICS™ Valve, Solenoid Disassembly And Assembly 167
BICS™ Valve, Solenoid Testing 168
Identification Chart 168
Load Check Valve 169
Main Relief Valve 170
Port Relief Valve, Tilt Spool 171
Port Relief Valve, Lift Spool 171
Anti-Cavitation Valve / Port Relief Valve, Tilt Spool 172
Anti-Cavitation Valve, Lift Spool 172
Rubber Boot 173
Lift And Tilt Block 173
Lift Spool And Detent 174
Tilt Spool Removal And Installation 183
Auxiliary Spool Removal And Installation 185
Auxiliary Plug Removal And Installation 187
Auxiliary Electric Solenoid Disassembly 188
Port Relief-Auxiliary Section Disassembly 189
Cleaning And Inspection 190
HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS) 191
Description 191
Actuator Removal And Installation (In Loader) 191
Removal & Installation (S/N 514447863 & Below) 193
Removal And Installation (S/N 514447864 & Above) 197
Actuator Removal And Installation (Out Of Loader) 202
BICS™ Valve Removal And Installation 203
BICS™ Valve Lift Arm Bypass Orifice Removal And Installation 205
BICS™ Valve Check Valve Removal And Installation 206
BICS™ Valve Lock Valve Removal And Installation 207
BICS™ Valve Removal Solenoid And Installation 208
BICS™ Valve Solenoid Testing 209
Identification Chart 209
Lift Base End Restrictor 210
Load Check Valve 210
Main Relief Valve 212
Port Relief Valve(s) 213
Anti-Cavitation Valve / Port Relief Valve 214
Anti-Cavitation Valve 215
Lift Spool Removal And Installation 216
Tilt Spool Removal And Installation 217
Lift And Tilt Spool Disassembly And Assembly 218
Auxiliary Spool Removal And Installation 219
Auxiliary Electric Solenoid Disassembly And Assembly 220
Port-Auxiliary Section Disassembly 221
Cleaning And Inspection 222
LIFT ARM BYPASS CONTROL VALVE 223
Inspecting 223
Additional Inspection For Loaders With ACS 223
Removal And Installation 223
Disassembly And Assembly 224
HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 & BELOW) 225
Checking The Output Of The Pump 225
Removal And Installation 226
Parts Identification 227
Disassembly 228
Inspection 230
Assembly 231
HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N 514449483 & Below) 233
Checking The Output Of The High Flow Pump 233
Removal And Installation 234
Parts Identification 236
Disassembly 237
Inspection 241
Assembly 242
HYDRAULIC PUMP (CAST IRON) (S/N 514449260 & ABOVE) 247
Check The Output Of The Hydraulic Pump Without Power Bob-Tach 247
Check The Output Of The Hydraulic Pump With Power Bob-Tach 249
Removal And Installation 250
Identification 252
Disassembly And Assembly 253
HYDRAULIC PUMP (CAST IRON HIGH FLOW) (S/N 514449484-514450945) 259
Check The Output Of The Hydraulic Pump Without Power Bob-Tach 259
Check The Output Of The Hydraulic Pump With Power Bob-Tach 260
Removal And Installation 262
Identification 264
Disassembly And Assembly 265
HYDRAULIC PUMP (CAST IRON HI FLOW) (514450846 & aBOVE) 275
Hydraulic Pump Test 275
Inline Hydraulic Pump Test (Standard) 276
Inline Hydraulic Pump Test (High Flow) 278
High Flow Relief Adjustment Procedure 280
High Flow Relief Valve Removal and Installation 282
Removal And Installation 284
Identification 286
Disassembly And Assembly 287
HYDRAULIC / HYDROSTATIC FILTER 297
Housing Removal And Installation 297
HYDRAULIC FLUID RESERVOIR 299
Draining The Fluid Reservoir 299
Removal And Installation 299
Hydraulic Fluid Screen 301
BUCKET POSITION VALVE 303
Solenoid Removal And Installation 303
Solenoid Testing 304
Removal And Installation 304
Disassembly And Assembly 306
SELECT VALVE 309
Checking The High Flow Pump Relief Valve (S/N 514450945 & Below) 309
Removal And Installation 310
Disassembly And Assembly 312
REAR AUXILIARY DIVERTER VALVE 315
Disassembly 315
Inspection 316
Solenoid Testing 316
Assembly 316
POWER BOB-TACH BLOCK (6676547-ALUMINUM) 317
Removal And Installation 317
Disassembly And Assembly 319
POWER BOB-TACH BLOCK (6678554-CAST IRON) 327
Removal And Installation 327
Disassembly And Assembly 328
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 337
Removal And Installation (514449564 & Above) 337
Disassembly And Assembly (518916011 & Above) 337
HYDROSTATIC SYSTEM 339
HYDROSTATIC SYSTEM INFORMATION 341
Troubleshooting Chart 341
Replentishing The Valve Function 342
HYDROSTATIC MOTOR 343
Removal And Installation 343
Parts Identification 345
Disassembly 346
Inspection 349
Assembly 350
Carrier Removal And Installation 353
Carrier Parts Identification 354
Carrier Disassembly 355
Carrier Assembly 356
HYDROSTATIC MOTOR (TWO-SPEED) 359
Removal And Installation 359
Parts Identification 362
Disassembly 363
Inspection 370
Assembly 371
CHARGE PRESSURE 379
Hydrostatic Charge Pressure Sender Removal And Installation 379
HYDROSTATIC PUMP 381
Replenishing / High Pressure Relief Valve 381
Charge Pressure Relief Valve 382
Removal And Installation 383
Parts Identification (Right Half) 385
Parts Identification (Left Half) 386
Hydraulic Pump Removal & Installation 387
Disassembly 388
Assembly 396
DRIVE BELT 405
Shield Removal And Installation 405
Adjustment 405
Replacement 406
Tensioner Pulley Removal And Installation 406
Tensioner Pulley Tension Spring 408
OIL COOLER 409
Removal And Installation With STC (Seal Tight Connector) 409
DRIVE SYSTEM 411
BRAKE 413
Pedal Removal And Installation 413
Pedal Disassembly And Assembly 414
Disc Removal And Installation 415
BRAKE (TWO-SPEED) (S/N 514449389 & Below) 419
Block Removal And Installation 419
Block Disassembly And Assembly 420
BRAKE (TWO-SPEED) (S/N 514449390 & Above) 425
Block Removal And Installation 425
Block Disassembly And Assembly 427
DRIVE COMPONENTS 431
Axle Seal Removal And Installation 431
Axle, Sprocket And Bearings Removal And Installation 433
Drive Chain Removal And Installation 438
CHAINCASE 439
Front Chaincase Cover Removal And Installation 439
Rear Chaincase Cover Removal And Installation 439
MAINFRAME 443
SEAT BAR 447
Removal And Installation 447
Assembling Components 448
Compression Spring Assembly And Assembly 450
OPERATOR CAB 451
Gas Cylinder Removal And Installation 451
Gas Cylinder Bracket Disassembly And Assembly 452
Removal And Installation 453
OPERATOR SEAT 455
Removal And Installation 455
Seat Belt Removal And Installation 455
OPERATOR SEAT (SUSPENSION) 457
Removal And Installation 457
Slide Rail Removal And Installation 458
Cushion Removal And Installation 459
Back Removal And Installation 460
Shock Removal And Installation 460
BOB-TACH 463
Removal And Installation 463
Bob-Tach Lever And Wedge 465
Bob-Tach Stops 466
Pivot Pin Bushing And Seal Replacement 467
POWER BOB-TACH 469
Removal And Installation 469
Power Bob-Tach Lever And Wedge 470
Pivot Pin Bushing And Seal Replacement 472
LIFT ARMS 473
Removal And Installation 473
REAR GRILL 477
Removal And Installation 477
REAR DOOR 479
Removal And Installation (S/N 514449208 & Below) 479
Adjusting The Rear Door Latch (S/N 514449208 & Below) 480
Striker Removal And Installation (S/N 514449209 & Above) 481
Adjusting The Striker (S/N 514449209 & Above) 481
Latch Removal And Installation (S/N 514449209 & Above) 482
FUEL TANK 483
Removal And Installation 483
Fuel Level Sender 484
CONTROL PEDALS 485
Removal And Installation 485
Pedal Adjustment 485
Crossbar Linkage Removal And Installation 486
Lift Foot Pedal Linkage Removal And Installation 487
Tilt Foot Pedal Linkage Removal And Installation 488
CONTROL PEDALS (ACS) 489
Foot Sensor Removal And Installation 489
Foot Pedal Removal And Installation 490
Foot Pedal Linkage Disassembly And Assembly 490
CONTROL PANEL 491
Removal And Installation 491
CONTROL HANDLE 495
Lever Removal And Installation 495
Lever Disassembly And Assembly 495
Linkage Removal And Installation 496
Linkage Neutral Adjustment 499
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) 505
Components Identification 505
Trouble shooting Guide 506
Parts Identification 507
AHC Controller Removal And Installation 508
Handle Control Unit Connector 509
Control Handle Removal And Installation 510
Actuators Disassembly And Assembly 513
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/ PUSH BUTTON FLOAT) 515
Components Identification 515
Trouble shooting Guide 516
Controller Connector and Wire Identification 517
AHC Controller Removal And Installation 518
Handle Sensor Removal And Installation 519
Handle Sensor Connector 521
Control Handle Removal And Installation 522
Actuators Disassembly And Assembly 525
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) ADVANCED HAND CONTROL 527
Components Identification 527
Handle Sensor Removal And Installation 527
Control Handle Removal And Installation 531
Control Handle Disassembly and Assembly 532
Control Lever Removal And Installation 533
Control Lever Boot 534
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL 535
Components Identification 535
Handle Sensor Removal And Installation 535
Control Handle Removal And Installation 539
Control Handle Disassembly and Assembly 540
Control Lever Removal And Installation 540
Control Lever Boot 542
ELECTRICAL SYSTEM & ANALYSIS 543
ELECTRICAL SCHEMATICS 547
ELECTRICAL SYSTEM INFORMATION 555
Troubleshooting Chart 557
Description 559
Fuse Location 561
Relay Switches Location 561
Solenoid Test 562
BATTERY 565
Removal And Installation 565
Servicing The Electrical System 567
Using A Booster Battery (Jump Starting) 568
ALTERNATOR (55 AMP) 569
Alternator Output Test 569
Rectifier (Diode) Test 569
Alternator Regulator Test 570
Removal And Installation 571
Disassembly 572
Stator Continuity Test 572
Stator Ground Test 572
Rotor Continuity Test 573
Rotor Ground Test 573
Rectifier Continuity (Diode) Test 573
Assembly 574
ALTERNATOR (90 AMP) 575
Adjusting The Alternator Belt 575
Alternator Identification 575
Charging System Check 576
Alternator Voltage Test 577
Low Voltage Test 578
High Voltage Test 578
Removal And Installation 579
Rectifier Continuity (Diode) Test 580
Alternator Regulator Test 581
Disassembly 581
Stator Continuity Test 582
Stator Ground Test 582
Rotor Continuity Test 582
Rotor Ground Test 582
Assembly 583
STARTER (NIPPONDENSO) 585
Removal And Installation 585
Parts Identification 586
Disassembly And Assembly 587
External Pinion 590
Inspection And Repair 591
No Load Test 595
STARTER (VALEO) 597
Checking 597
Removal And Installation 598
Parts Identification 599
Disassembly and Assembly 600
Inspection And Repair 603
No Load Test 605
INSTRUMENT PANEL 607
Left Panel 607
Right Panel – Standard Instrument Panel (With Key Switch) 608
Right Panel – (Deluxe) (With Keyless Start) 609
Right Panel Setup Display Options (Deluxe) 610
Deluxe Panel Setup 611
Passwords 611
Changing The Password 611
Option And Field Accessory Panels 613
Standard Panel Removal And Installation (Right Side) 614
Deluxe Panel Removal And Installation (Right Side) 615
Standard & Deluxe Panel Removal And Installation (Left Side) 616
LIGHTS 619
Front Removal And Installation 619
Rear Removal And Installation 620
BOBCAT CONTROLLER 621
Identification Chart (S/N 514450763 & Below) 621
Identification Chart (S/N 514450764 & Above) 622
Removal And Installation 624
DELUXE INSTRUMENTATION SERVICE CODES 627
BICS™ SYSTEM 629
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 629
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 629
Inspecting The Seat Bar Sensor (Engine RUNNING) 629
Inspecting The Traction Lock (Engine RUNNING) 629
Inspecting The Lift Arm Bypass Control 629
Additional Inspection For Loaders With Advanced Hand Controls 630
Troubleshooting Chart 631
Troubleshooting Guide 632
SEAT BAR SENSOR 633
Troubleshooting Chart 633
Test 634
Removal And Installation 635
BICS™ Circuit Test 636
TRACTION LOCK 637
Troubleshooting Chart 637
Removal And Installation (Single Speed) 638
Description Of The Control System (Two-Speed) 639
Inspecting The Control System (Two-Speed) 639
ADVANCED HAND CONTROL SYSTEM (AHC) 641
Components Identification 641
Trouble shooting Guide 642
Parts Identification 643
AHC Controller Removal And Installation 644
Handle Control Unit Connector 645
Switch Handle Removal And Installation 646
Actuators Disassembly And Assembly 649
ADVANCED HAND CONTROL SYSTEM (AHC) (W/ PUSH BUTTON FLOAT) 651
Components Identification 651
Trouble shooting Guide 652
Controller Connector and Wire Identification 653
AHC Controller Removal And Installation 654
Handle Control Unit Removal And Installation 655
Handle Control Unit Connector 657
Switch Handle Removal And Installation 658
Actuators Disassembly And Assembly 661
ADVANCED CONTROL SYSTEM (ACS) ADVANCED HAND CONTROL 663
Components Identification 663
Troubleshooting Guide 664
Controller, Connector And Wire Identification 665
ACS Controller Removal And Installation 666
Handle Sensor Connector 667
Switch Handle Removal 668
Switch Handle Installation 670
Actuators Disassembly and Assembly 673
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND / FOOT CONTROL 675
Components Identification 675
Troubleshooting Guide 677
Controller, Connector And Wire Identification 678
ACS Controller Removal And Installation 679
Handle Sensor Connector 680
Switch Handle Removal 681
Switch Handle Installation 683
Actuators Disassembly and Assembly 686
Handle Lock Solenoid Removal And Installation 687
Handle Lock Solenoid Disassembly And Assembly 688
Handle Lock Solenoid Connector 688
Calibration Of The ACS System 689
Switchable Hand / Foot Controls Calibration Procedure 689
Hand Controls Only Calibration Procedure 691
Foot Sensor Disassembly And Assembly 692
Foot Sensor Connector 693
Foot Lock Solenoid Removal And Installation 694
Foot Lock Solenoid Connector 694
ELECTRICAL / HYDRAULIC CONTROLS REFERENCE 697
Controls Identification Chart 697
ENGINE SERVICE 699
TROUBLESHOOTING 701
Chart 701
ENGINE SPEED CONTROL 703
Removal And Installation 703
Speed Control Cable 704
Speed Control Linkage 705
MUFFLER 707
Removal And Installation 707
AIR CLEANER 709
Housing Removal And Installation 709
RADIATOR 711
Oil Cooler Removal And Installation 711
COOLING FAN 713
Drive Tension Pulley Removal And Installation 713
Gearbox / Blower Housing Removal And Installation 714
Blower Removal And Installation 717
Gearbox Parts Identification 718
Gearbox Disassembly 719
Gearbox Assembly 724
Gearbox, Checking Backlash 729
ENGINE COMPONENTS AND TESTS 733
Engine Compression, Checking 733
Glow Plug, Checking 734
Fuel Shut-Off Solenoid, Checking 735
Fuel Shut-Off Solenoid Removal and Installation 736
Fuel Injection Pump Removal 736
Fuel Injection Pump Timing 738
Fuel Injection Pump Installation 739
Fuel Injector Removal and Installation 741
Fuel Injector, Checking 742
Fuel Injector Disassembly 743
Fuel Injector Assembly 744
Timing Belt Inspection 746
Timing Belt Removal 746
Timing Belt Installation 747
Timing Belt, Replacement In the Loader 751
Valve Clearance Adjustment 756
Valve Timing, Checking 757
Thermostat, Oil Pressure Control Valves And Heater Connections 759
ENGINE AND ENGINE MOUNTS 763
Removal And Installation 763
Engine Mount Replacement 769
FLYWHEEL AND HOUSING 771
Flywheel Removal And Installation 771
Ring Gear Removal And Installation 771
Flywheel Housing Removal And Installation 771
RPM SENSOR 773
Adjustment 773
RECONDITIONING THE ENGINE 775
Deutz Engine Tools Identification Chart 775
Disassembly 776
Assembly 780
Cylinder, Checking 796
Camshaft Bearing, Checking 797
Camshaft Bearing, Removal And Installation 797
Control Rod Guide Bushing Removal 798
Control Rod Guide Bushing Installation 800
Rear Cover Seal Removal And Installation 804
Crankshaft, Checking 805
Connecting Rod, Checking 807
Piston, Checking 809
Piston Pin, Checking 810
Piston Rings Installation 810
Piston Installation On the Connecting Rod 811
Cylinder Head Disassembly 813
Valves, Checking 813
Valve Seats, Checking 814
Valve Spring, Checking 815
Cylinder Head Assembly 815
Rocker Arm and Bracket, Checking 816
Front Cover Disassembly 817
Front Cover Assembly 822
Turbo Charger Removal and Installation 831
Crankshaft Gear Mounting Bolt Torque Procedure 832
HEATING, VENTILATION, AIR CONDITIONING 835
AIR CONDITIONING SYSTEM FLOW 838
Principals 838
Chart 839
COMPONENTS 841
Identification 841
SAFETY 845
Safety Equipment 845
REGULAR MAINTENANCE 847
Cleaning The Condenser 847
Compressor Drive Belt Inspection 848
Filter Elements Removal And Installation 848
BASIC TROUBLESHOOTING 851
Cleaning The A/C Evaporator Coil & Heater Coil 851
Checking The Electrical System 853
Compressor Drive Belt Inspection: 861
Engine Coolant Bypassing The Heater Valve 861
Heater Valve Not Opening Or Closing 862
Poor A/C Performance 863
GENERAL AIR CONDITIONING SERVICE GUIDELINES 865
Compressor Oil 865
Compressor Oil Check 865
Component Replacement And Refrigeration Leaks 867
SYSTEM TROUBLESHOOTING CHART 869
Gauge Pressure Related Troubleshooting 870
Troubleshooting Tree 872
TEMPERATURE / PRESSURE 877
Chart 877
AIR CONDITIONING SERVICE 879
Chart 879
SYSTEM CHARGING AND RECLAMATION 881
Reclamation Procedure 881
Charging Procedure With A Manifold Gauge Set 883
Charging Procedure 884
COMPRESSOR 887
Removal And Installation 887
Compressor Clutch Disassembly 888
CONDENSER 893
Removal And Installation 893
RECEIVER / DRIER 895
Removal And Installation 895
PRESSURE RELIEF VALVE 897
Removal And Installation 897
PRESSURE SWITCH 899
Removal And Installation 899
EVAPORATOR / HEATER UNIT 901
Removal And Installation 901
Disassembly And Assembly 902
THERMOSTAT 903
Removal And Installation 903
EXPANSION VALVE 905
Removal And Installation 905
EVAPORATOR 907
Removal And Installation 907
HEATER COIL 909
Removal And Installation With A/C 909
Removal And Installation Without A/C 910
HEATER / AC FAN 913
Removal And Installation 913
Disassembly And Assembly 914
Wire Connector Removal And Installation 916
HEATER VALVE 919
Removal and Installation 919
Disassembly And Assembly 920
SPECIFICATIONS 923
LOADER SPECIFICATIONS 925
Loader Dimensions 925
Performance 926
Controls 926
Engine 926
Hydraulic System 927
Electrical 927
Drive System 928
Capacities 928
Tires 928
ENGINE SPECIFICATIONS 929
General 929
Fuel System 929
Valve and Valve Guide and Seat Insert 930
Piston and Rings 931
Connecting Rod 931
Cylinder Head and Block 932
Crankshaft and Main Bearings 932
Camshaft and Bearings 932
Oil Pump 932
LOADER TORQUE 933
Specifications 933
TORQUE SPECIFICATIONS FOR BOLTS 937
Torque For General SAE Bolts 937
Torque For General Metric Bolts 938
HYDRAULIC CONNECTION SPECIFICATIONS 939
O-ring Face Seal Connection 939
Straight Thread O-ring Fitting 939
Tubelines And Hoses 939
Flare Fitting 940
O-ring Flare Fitting 941
Port Seal Fitting 943
HYDRAULIC FLUID SPECIFICATIONS 945
Specifications 945
CONVERSIONS 947
Decimal And Millimeter Equivalents 947
U S To Metric Conversion 948
SERVICE MANUAL REVISION 949
863/863H-1 949
863/863H-2 951
863/863H-3 953
863/863H-4 955
863/863H-5 957
863/863H-6 959
863/863H-7 961
863/863H-8 963
863/863H-9 965
863/863H-10 967
863/863H-11 969

DESCRIPTION:

Bobcat Turbo 863 & Turbo 863 High Flow Loader Service Manual 6900942 – PDF DOWNLOAD

S/N 514440001 & Above
S/N 514540001 & Above
S/N 514640001 & 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 Bobcat machine 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.

Contact us: [email protected]

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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• Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted

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