DOWNLOAD PDF Bobcat 863 High Flow Operation & Maintenance Manual SN 514427600 thru 514439999

Operation & Maintenance Manual HIGH FLOW

S/N 514427600 thru 514439999 S/N 514525300 thru 514539999 S/N 514625300 thru 514639999

EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM) 6900790 (7–99) Revised (9–00)

Printed in U.S.A.

© Bobcat Company 2000

OPERATOR SAFETY WARNINGS CORRECT Operator must have instructions before running the machine.

Untrained operators can cause injury or death.

W–2001–1285 Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

CORRECT

CORRECT

B–10731

Never use the loader without instructions. See machine signs (decals), Operation & Maintenance Manual and Handbook.

WRONG

B–7403

B–6582

B–13418

Always use the seat bar and fasten seat belt snugly.

Always keep feet on the foot pedals or footrests when operating loader.

Never use loader without operator cab with ROPS and FOPS approval. Fasten your seat belt.

Never use loader as man lift or elevating device for personnel.

WRONG

WRONG

WRONG

B–6578

B–6585

B–6595

Keep bystanders away from work area.

Always carry bucket or attachments as low as possible.

Do not travel or turn with lift arms up.

Load, unload and turn on flat level ground.

WRONG

WRONG

WRONG

B–6587

B–6594

B–6591

Never exceed rated operating capacity.

Never leave loader with engine running or with lift arms up.

To park, engage parking brake and put attachment flat on the ground.

Do not use loader in atmosphere with explosive dust or gas or where exhaust can contact flammable material.

Never carry riders.

Never modify equipment.

Use only attachments approved

by Bobcat Company for this model loader.

SAFETY EQUIPMENT The Bobcat loader must be equipped with safety items necessary for each job. Ask your dealer for information on the safe use of attachments and accessories.

1. SEAT BELT: Check belt fasteners and check for damaged webbing or buckle.

2. SEAT BAR: When up, it must lock the loader controls.

3. OPERATOR CAB (ROPS and FOPS): It must be on the loader with all fasteners tight.

4. HANDBOOK: Must be in the cab.

5. SAFETY SIGNS (DECALS): Replace if damaged.

6. SAFETY TREADS: Replace if damaged.

7. GRAB HANDLES: Replace if damaged.

8. LIFT ARM SUPPORT DEVICE: Replace if damaged.

9. PARKING BRAKE 10. BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM) OSW03–0600

CONTENTS

863,863HOperation&MaintenanceManual#6900373–ContentsSection

FOREWORD

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 SYSTEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 MACHINE SIGN TRANSLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

SAFETY

OPERATING INSTRUCTIONS

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.

PREVENTIVE MAINTENANCE

REFERENCE INFORMATION Write the correct information for YOUR Bobcat loader in the spaces below.

Always use these numbers when referring to your Bobcat loader.

SYSTEM ANALYSIS

Loader Serial Number . . . . . . . .

Engine Serial Number . . . . . . . .

MACHINE SIGN TRANSLATIONS

NOTES: SPECIFICATIONS

YOUR LOADER DEALER: ADDRESS: PHONE: Bobcat Company P.O. Box 128 Gwinner, ND 58040–0128 Bobcat Company Europe J. Huysmanslaan 59 B–1651 LOT BELGIUM

i

863, 863H Bobcat Loader Operation & Maintenance Manual

Bobcat Company is ISO 9001 certified ISO 9001 is a set of international standards that control the processes and procedures which we use to design, develop, manufacture, distribute, and service Bobcat products.

British Standards Institute (BSI) is the Certified Registrar Bobcat Company chose to assess the Company’s compliance with the ISO 9001 set of standards. The BSI registration certifies that the two Bobcat Company manufacturing plants and the Bobcat Company corporate offices (Gwinner, Bismarck & West Fargo) in North Dakota are in compliance with ISO 9001. Only certified assessors, like BSI, can grant registrations. Since registration requires this third–party auditing, it is irrefutable evidence of conformance. Continued certification is subject to periodic audits.

ISO 9001 means that as a company we say what we do and do what we say. In other words, we have established procedures and policies, and we provide evidence that the procedures and policies are followed.

What does ISO 9001 mean to Bobcat Customers? It means that Bobcat Company produces your Bobcat loader, excavator, and attachments with strict attention to details, using the latest technology and proven techniques.

REGULAR MAINTENANCE ITEMS 6665603

ENGINE OIL FILTER (6 Pack)

6667352

FUEL FILTER

6666375

AIR CLEANER, OUTER

6666376

AIR CLEANER, INNER

6661248

HYDROSTATIC FILTER

6665427

BATTERY

6724094

PROPYLENE GLYCOL ANTI–FREEZE, Premixed – [–34°F (–37°C)]

6724354

PROPYLENE GLYCOL ANTI–FREEZE, Concentrate

6563328

BLACK GOLD Hydraulic/Hydrostatic Fluid – 5 Gallons

6657299

MOTOR OIL 15W40 CE/SG – 1 Quart

6657301

MOTOR OIL 10W30 CE/SG – 1 Quart

6657303

MOTOR OIL 30 CE/SG – 1 Quart

ii

863, 863H Bobcat Loader Operation & Maintenance Manual

FOREWORD FOREWORD This Operation & Maintenance Manual was written to give the owner/operator instructions on the safe operation and maintenance of the Bobcat loader. READ AND UNDERSTAND THIS OPERATION & MAINTENANCE MANUAL BEFORE OPERATING YOUR LOADER. If you have any questions, see your Bobcat loader dealer.

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi OPTIONS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

iii

863, 863H Bobcat Loader Operation & Maintenance Manual

iv

863, 863H Bobcat Loader Operation & Maintenance Manual

SERIAL NUMBER LOCATIONS 1.2.

1.

Always use the serial number of the loader when requesting service information or when ordering parts.

Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation.

A

LOADER SERIAL NUMBER The loader serial number plate is located on the outside of the loader frame [A].

Explanation of loader Serial Number: XXXX

P–10817

XXXXX

B

Module 2. – Production Sequence (Series) Module 1. – Model/Engine Combination 1. The four digit Model/Engine Combination Module number identifies the model number and engine combination.

2. The five digit Production Sequence Number identifies the order which the loader is produced.

P–04602

ENGINE SERIAL NUMBER The engine serial number is located on the valve cover at the right side of the engine [B].

DELIVERY REPORT The Delivery Report must be filled out by the dealer and signed by the owner or operator when the Bobcat loader is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely [C].

C

v

863, 863H Bobcat Loader Operation & Maintenance Manual

BOBCAT LOADER IDENTIFICATION ◊ FRONT LIGHTS

OPERATOR SEAT

GRAB HANDLES STEERING LEVER SEAT BELT ◊ REAR AUXILIARY QUICK COUPLERS TILT CYLINDER

BUCKET

◊ FRONT AUXILIARY QUICK COUPLERS SAFETY TREAD BUCKET STEPS

◊ REAR WINDOW

OPERATOR CAB (ROPS & FOPS) SEAT BAR LIFT ARM

REAR GRILL

LIFT ARM SUPPORT DEVICE LIFT CYLINDER ◊ REAR LIGHT ◊ TAIL LIGHT

REAR DOOR * TIRES

B–15017 B–15016

◊ OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment) * TIRES – Flotation tires (optional) are shown. The Bobcat loader is factory equipped with standard tires.

BUCKET – Several different buckets and other attachments are available for the Bobcat loader.

ROPS, FOPS – Roll Over Protective Structure, Falling Object Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level l. Level ll is available. The Bobcat loader is base–equipped with a standard operator cab as shown. Extra insulated cab is available as an option (Reduced noise level). vi

863, 863H Bobcat Loader Operation & Maintenance Manual

OPTIONS AND ACCESSORIES Bobcat loader Model 863 is equipped with the following Standard items: Bob–Tach Spark Arrestor Exhaust System (Turbo Charger) Lift Arm Support Device Operator Cab (with ROPS & FOPS Approval) Bobcat Interlock Control System (BICS™) Seat Belt Seat Bar Parking Brake Gauges/Warning Lights Glow Plug Preheat system Tires, 12–16.5, 10PR Bobcat Heavy Duty Adjustable Cushion Seat Below is a list of some equipment available as a Factory Installed Option or as a Field Installed Accessory from your Bobcat Loader dealer. See your Bobcat dealer for other available accessories and attachments.

Tires 31 x 15.5–15, 8PR Ultra Grip Tread . . . . .

8.25 x 15 Air Boss Segmented Tires . . . .

12 x 16.5 Air Boss Segmented Tires . . . .

8.00–16, Solid Tires . . . . . . . . . . . . . . . . . .

10 x 33, Bobcat Solid Tires . . . . . . . . . . . .

12–16.5, 10 PR Bobcat Heavy Duty . . . . .

Instrumentation Bobcat Operation Sensing System (BOSS®) . . . . . . . . . . . . . . . . . .

Keyless Start System . . . . . . . . . . . . . . . . .

Opt. & FA FA FA Opt. & FA FA Std. & FA

Hydraulics

Operator Cab Sound Cab (Reduces Noise at Operator’s Ear) . . . . . . . . . . . . . . . . . . . .

Deluxe Cab . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Lights (Front & Rear) . . . . . . . .

Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Back–up Alarm . . . . . . . . . . . . . . . . . . . . . . .

Top Window . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Window . . . . . . . . . . . . . . . . . . . . . . . .

Cab Enclosure and Heater . . . . . . . . . . . . .

Vinyl Cab Enclosure . . . . . . . . . . . . . . . . . .

Cover Kit (Pedals Area) . . . . . . . . . . . . . . .

Cover Kit (Hydraulic Reservoir Area) . . . .

Fire Extinguisher . . . . . . . . . . . . . . . . . . . . .

Flasher Lights . . . . . . . . . . . . . . . . . . . . . . . .

Strobe or Rotating Beacon Light . . . . . . . .

3’’ Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . .

Special Applications Kit* . . . . . . . . . . . . . . .

Suspension Seat . . . . . . . . . . . . . . . . . . . . .

Rear Window Wiper . . . . . . . . . . . . . . . . . .

Large Operator Seat Bar Kit . . . . . . . . . . .

Advanced Hand Controls . . . . . . . . . . . . . .

Opt. FA

Front Auxiliary Hydraulics . . . . . . . . . . . . .

Rear Auxiliary Hydraulics . . . . . . . . . . . . . .

Hydraulic Bucket Positioning (Includes On/Off Selection) . . . . . . . . . .

Hi Flow Hydraulics . . . . . . . . . . . . . . . . . . . .

Servo Steering Pump . . . . . . . . . . . . . . . . .

Opt. Opt. & FA Opt. & FA FA Opt. & FA FA FA Opt. & FA FA FA FA FA FA FA FA FA Opt. & FA FA FA Opt.

Opt. & FA Opt. & FA Opt. & FA Opt. Opt.

Other Catalytic Exhaust Purifier . . . . . . . . . . . . . .

Engine Heater (Oil Pan) . . . . . . . . . . . . . . .

Single Point Lift or Four Point Lift . . . . . . .

Locking Fuel Cap . . . . . . . . . . . . . . . . . . . . .

Radiator Screen Kit . . . . . . . . . . . . . . . . . . .

Tailgate Lock . . . . . . . . . . . . . . . . . . . . . . . .

Tool Box . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counterweight Kit . . . . . . . . . . . . . . . . . . . .

Opt. & FA Opt. & FA FA FA FA FA FA Opt. & FA

Opt. = Factory Installed Option FA = Field Accessory N/A = Not Available * Includes 1/2 inch Lexan Front Door; 1/4 inch Lexan Top & Rear Windows

Specifications subject to change without notice

vii

863, 863H Bobcat Loader Operation & Maintenance Manual

viii

863, 863H Bobcat Loader Operation & Maintenance Manual

SAFETY SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi, xii FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii MACHINE SIGNS (DECALS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv, xv

ix

SAFETY

863, 863H Bobcat Loader Operation & Maintenance Manual

x

863, 863H Bobcat Loader Operation & Maintenance Manual

SAFETY INSTRUCTIONS FOR BOBCAT SKID–STEER LOADERS AND ATTACHMENTS SAFETY IS THE OPERATOR’S RESPONSIBILITY All Bobcat loaders and attachments are designed to give maximum safety, but no machine design can prevent operator error or carelessness.

The Bobcat skid–steer loader is highly maneuverable and compact. It is rugged and useful under a wide variety of conditions.

This presents an operator with hazards associated with off highway, rough terrain applications, common with Bobcat loader usage.

The Bobcat loader has an internal combustion engine with resultant heat and exhaust. All exhaust gases can kill or cause illness so use the loader with adequate ventilation. The loader has a spark arrestor exhaust system or muffler which is required for operation in certain areas.

The dealer explains the capabilities and restrictions of the Bobcat loader and attachments for each application. The dealer demonstrates the safe operation according to Bobcat instructional materials, which are also available to operators. The dealer can also identify unsafe modifications or use of unapproved attachments. The attachments and buckets are designed for a Rated Operating Capacity (some have restricted lift heights) and secure fastening to the Bobcat loader. The user must check with the dealer, or Bobcat literature, to determine safe loads of materials of specified densities for the loader–attachment combination.

The following publications and training materials provide information on the safe use and maintenance of the Bobcat loader and attachments:

• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the Bobcat loader and attachment is in safe operating condition.

• The Operation & Maintenance Manual delivered with the Bobcat loader or attachment gives operating information as well

as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided inside the cab of the loader. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.

• Machine signs (decals) instruct on the safe operation and care of your Bobcat loader or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.

• An Operator’s Handbook is fastened to the operator cab of the loader. 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 Safety Manual delivered with the Bobcat loader gives general safety information.

• Operator Training Courses are available from your local Bobcat dealer. They provide information for safe and efficient operation of the Bobcat loader and some attachments. The courses are available in English and Spanish versions.

• Service Safety Training Courses are available from your Bobcat dealer. They provide information for safe and correct service procedures.

• See the ADDITIONAL PUBLICATIONS Page in this manual or your Bobcat dealer for Service and Parts Manuals, printed materials, videos, or training courses available. Also check the Bobcat web site www.bobcat.com

The dealer and owner/operator review the recommended uses of the product when delivered. If the owner/operator will be using the machine for a different application(s) he must ask the dealer for recommendations on the new use.

Call Before You Dig 1–888–258–0808 When you call, you will be directed to a location in your state/ city for information about buried lines (telephone, cable TV, water, sewer, gas, etc.)

SI01–0400

xi

863, 863H Bobcat Loader Operation & Maintenance Manual

BEFORE OPERATING THE BOBCAT LOADER Safety Alert Symbol This symbol with a warning statement means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

Operator must have instructions before running the machine. Untrained operators can cause injury or death.

W–2001–1285

The Bobcat loader and attachment must be in good operating condition before use.

Check all of the items on the Bobcat Service Schedule Decal under the 8–10 hour column or as shown in this Manual.

SAFE OPERATION NEEDS A QUALIFIED OPERATOR *

This notice identifies procedures which must be followed to avoid damage to the machine.

A QUALIFIED OPERATOR MUST DO THE FOLLOWING: • UNDERSTAND THE WRITTEN INSTRUCTIONS, RULES AND REGULATIONS

I–2019–0284

• The written instructions from Bobcat Company

include the Delivery Report, Operation & Maintenance Manual, Operator’s Handbook, Safety Manual and machine signs (decals).

• Check the rules and regulations at your location. The

rules may include an employer’s work safety requirements. Regulations may apply to local driving requirements or use of a Slow Moving Vehicle (SMV) emblem. Regulations may identify a hazard such as a utility line.

Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.

W–2044–1285

• HAVE TRAINING WITH ACTUAL OPERATION • Operator training must consist of a demonstration and verbal instruction. This training is given by your Bobcat dealer before the product is delivered.

• The new operator must start in an area without bystanders and use all the controls until he can operate the machine and attachment safely under all conditions of the work area. Always fasten seat belt before operating.

• Operator Training Courses are available from your Bobcat dealer in English and Spanish. They provide information for safe and efficient equipment operation. Safety videos are also available.

• Service Safety Training Courses are available from your Bobcat dealer. They provide information for safe and correct service procedures.

• KNOW THE WORK CONDITIONS • Know the weight of the materials being handled. Avoid exceeding the Rated Operating Capacity of the machine. Material which is very dense will be heavier than the same volume of less dense material. Reduce the size of load if handling dense material.

• The operator must know any prohibited uses or work areas, for example, he needs to know about excessive slopes.

• Know the location of any underground lines. Call local utilities or the TOLL FREE phone number found in the SAFETY INSTRUCTIONS Section of this manual.

• Wear tight fitting clothing. Always wear safety glasses when doing maintenance or service. Safety glasses, hearing protection or special applications kit are required for some work. See your dealer about Bobcat Safety equipment.

* For an operator be qualified, he must not use drugs or alcoholic drinks which impair his alertness or coordination while working. An operator who is taking prescription drugs must get medical advice to determine if he can safely operate a machine.

SI02–0400

xii

863, 863H Bobcat Loader Operation & Maintenance Manual

FIRE PREVENTION The machines and some attachments have components that are at high temperatures under normal operating conditions.

The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.

Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it can cause a fire hazard. Clean often to avoid this accumulation. Flammable debris in the engine compartment is a potential fire hazard.

The spark arrestor exhaust system (if equipped) is designed to control the emission of hot particles from the engine and exhaust system, but the muffler and the exhaust gases are still hot.

• Do not use the machine where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases.

• The operator cab, engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazards and overheating.

• Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any damaged part.

• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.

• Do not use ether or starting fluids on any engine which has glow plugs. These starting aids can cause explosion and injure you or bystanders.

• Always clean the machine, disconnect the battery, and disconnect the wiring from the electronic controllers before welding.

Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the machine when welding. Have good ventilation when grinding or welding painted parts. Wear dust mask when grinding painted parts. Toxic dust or gas can be produced.

• Stop the engine and let it cool before adding fuel. No smoking!

• Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump starting.

• Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler (if equipped).

• Know where fire extinguishers and first aid kits are located and how to use them. Fire extinguishers are available from your Bobcat dealer.

SI03–0400

xiii

863, 863H Bobcat Loader Operation & Maintenance Manual

MACHINE SIGNS (DECALS) Follow the instructions on all the machine signs (decals) that are on the loader. Replace any damaged machine signs (decals) and be sure they are in the correct locations. Machine signs (decals) are available from your Bobcat dealer.

6715944

6703723 (Foot Pedal) 6715940 (Hand Control) 6703724 (Hand Control) 6727452 (Later Models w/Float button) OPERATION INSTRUCTIONS FOR

6705720

LOADERS WITH ADVANCED HAND CONTROLS (AHC)

OPERATION INSTRUCTIONS

TO OPERATE LOADER: 1. Fasten seat belt and lower seat bar.

2. Put hand controls in neutral.

3. Start engine.

4. Activate green “PRESS TO OPERATE” button on left instrument panel.

• Both green lights on left hand control must be on.

• If hydraulic functions do not operate, stop engine.

Check that both hand controls are in the neutral position. Re–start engine.

NOTE: Activate “PRESS TO OPERATE” button again if seat bar is raised and lowered or key is turned off.

TO OPERATE LOADER: 1. Fasten seat belt and lower seat bar.

2. Start engine.

3. Activate green “PRESS TO OPERATE” button on left instrument panel.

NOTE: Activate “PRESS TO OPERATE” button again if seat bar is raised and lowered or key is turned off.

6708021 (Foot Control) 6708158 (Hand Control)

See Operation & Maintenance Manual and Handbook for more instructions.

See Operation & Maintenance Manual and Handbook for more instructions.

6713715

6717639 (Advanced Hand Control Only)

6717640

6703726 (Hand Control) 6577754 (3)

6710449 6703725 (Hand Control) 6557565

6711840

6579510 (Foot Control)

6561383

6717343 (2) Under Cab

6702302

6702301

6710358

6579528 *

* Decal located behind lift arm crossmember.

B–15016

xiv

863, 863H Bobcat Loader Operation & Maintenance Manual

MACHINE SIGNS (DECALS) (Cont’d)

863/873

THIS MODEL LOADER IS FACTORY EQUIPPED WITH A U.S.D.A. FORESTRY SERVICEAPPROVEDSPARKARRESTOREXHAUSTSYSTEM. THE TURBOCHARGER MUST OPERATE TO KEEP THE SPARK ARRESTOR EXHAUSTSYSTEM IN WORKING CONDITION. IF THIS MACHINE IS OPERATED ON FLAMMABLE FOREST, BRUSH OR GRASS COVERED LAND, IT MUST BE EQUIPPED WITH A SPARK ARRESTOR ATTACHED TO THE EXHAUST SYSTEM AND MAINTAINEDIN WORKING ORDER. FAILURE TO DO DO WILL BE IN VIOLATION OF CALIFORNIA STATELAW,SECTION4442.PRC

6565990

6578368

REFER TO LOCAL LAWS AND REGULATIONS FOR SPARK ARRESTOR REQUIREMENTS. SEETHE OPERATION ANDMAINTENANCEMANUALFORMOREINSTRUCTIONS.

SW97 6708937

6708937

25

6707867

AUX/EHC

6706558

6715991

6709030

6718398

* Located inside the engine compartment.

xv

B–15017

863, 863H Bobcat Loader Operation & Maintenance Manual

xvi

863, 863H Bobcat Loader Operation & Maintenance Manual

OPERATING INSTRUCTIONS ATTACHMENTS AND BUCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Installing The Bucket Or Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Removing The Bucket Or Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . . 6 Auxiliary Hydraulic System (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Traction Lock Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 BOSS® OPTION PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

OPERATING INSTRUCTIONS

ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 GETTING READY FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Advanced Hand Controls (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Attachment Functions Control (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . 18 Auxiliary Hydraulics (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Auxiliary Hydraulics Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Continuous Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Disengage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Momentary Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Bucket Position Valve Operation (If Equipped) . . . . . . . . . . . . . . . . . . . 13, 14 Foot Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Lift Arm Float Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Lift Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Tilt Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Hand Controls (Mechanical and Advanced Hand Controls) . . . . . . . . . . . . 14 Lift Arm Float Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Lift Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Tilt Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Front Auxiliary Hydraulics Continuous Operation . . . . . . . . . . . . . . . . . . . . . 16 Front Auxiliary Hydraulics Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 High–Flow Hydraulics Operation (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . 17 Rear Auxiliary Hydraulics Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Relieving Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Secondary Front Auxiliary Hydraulics (If Equipped) . . . . . . . . . . . . . . . . . . . 17 Quick Couplers (Flush Face) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 With BOSS® (Front Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 With BOSS® (Side Console) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Without BOSS® (Front Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Without BOSS® (Side Console) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Continued On Next Page 1

863, 863H Bobcat Loader Operation & Maintenance Manual

OPERATING INSTRUCTIONS (Cont’d) LIFTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Four Point Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Single Point Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 OPERATING PROCEDURE (FOOT PEDALS) . . . . . . . . . . . . . . . . . . . . . . . . 29 Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Emptying The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Digging Into The Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Filling The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Leveling The Ground (Using Lift Arms In Float Position) . . . . . . . . . . . . . . . 30 OPERATING PROCEDURE (HAND CONTROLS) . . . . . . . . . . . . . . . . . . . . . 32 Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Emptying The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Digging Into The Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Filling The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Leveling The Ground (Using Lift Arms In Float Position) . . . . . . . . . . . . . . . 33 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 PARKING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31, 34 SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS) . . . . 12 SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS) . . 11 SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS) . . . . . . . . . . . . . . . . . . . 10 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Normal Starting (With BOSS®) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Normal Starting (Without BOSS®) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Cold Temperature Starting (With BOSS®) . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Cold Temperature Starting (Without BOSS®) . . . . . . . . . . . . . . . . . . . . . . . . 22 Warming The Hydraulic/Hydrostatic System . . . . . . . . . . . . . . . . . . . . 22 & 24 STEERING LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Forward, Reverse, Normal Turn, Fast Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 STOPPING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9, 35 STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 & 24 TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 TRACTION LOCK CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2

863, 863H Bobcat Loader Operation & Maintenance Manual

INSTRUMENT PANEL

A

Without BOSS® (Front Panel) [A] 3.a 1. TRACTION LOCK OVERRIDE BUTTON – (Functions Only When The Seat Bar Raised) Allows you to use the steering levers to move the loader when using the backhoe attachment or for loader service. (See Page 7.)

2. PRESS TO OPERATE BUTTON (Functions Only When The Seat Bar Is Down) – Activates BICS™ System when the Seat Bar is down and operator is seated in the operating position.

3. KEY SWITCH – For starting and stopping the engine.

4. TRANSMISSION WARNING LIGHT – Low transmission charge pressure, hydraulic filter needs replacement or high fluid temperature. Stop the engine if the light comes ON. 5. ENGINE WARNING LIGHT – Low engine oil pressure or high coolant temperature. Stop the engine if the light comes ON. 6. LIGHT SWITCH (Opt./FA) – Controls the available work and travel lights.

7. HIGH–FLOW SWITCH (Opt.) – Controls the ON/OFF function of the high–flow auxiliary hydraulics. (Only on High–Flow loaders.)

8. BUCKET LEVEL SWITCH (Opt./FA) – Controls the ON/OFF function of the available Bucket Position Valve, 9. PREHEAT BUTTON – For preheating the engine (glow plugs) before starting the engine.

10. HOURMETER – Records the total operating hours of the loader.

11. FUEL GAUGE – Shows the amount of fuel in the fuel tank.

12. VOLTMETER – Shows the condition of the battery and the rate of charge.

13. ENGINE TEMPERATURE GAUGE – Shows the engine coolant temperature.

14. AUXILIARY HYDRAULIC SWITCH (Opt./FA) – For engaging the available Auxiliary Hydraulics (front and rear).

Without BOSS

12

9

6 7

10

5

8

11 4 13

3 2

1

14

N–16959

B

P–10466

Side Console 1

2

3 P–10742

Without BOSS (Side Console•) [B] 1. REAR WIPER/WASHER (FA) – Controls operation of the available rear window wiper and washer.

2. HAZARD SWITCH / HAZARD INDICATORS (Opt./FA) – Controls the available hazard lights.

(Hazard Lights is a separate available accessory.)

Both panel indicators blink for hazard condition when the hazard switch is ON. A red light indicates fuse out for taillights, headlights, worklights, etc.

3. BEACON OR STROBE SWITCH (Opt./FA) – Controls the available flashing beacon or strobe light.

• Available only with Deluxe Cab or with Cab Enclosure

Kit. Opt. – Factory Installed Option FA – Field Installed Accessory – See your Bobcat loader dealer about available Field Accessories.

3

863, 863H Bobcat Loader Operation & Maintenance Manual

INSTRUMENT PANEL

A

With BOSS® (Front Panel) [A] 2.a 1. TRACTION LOCK OVERRIDE BUTTON – (Functions Only When The Seat Bar Is Raised) Allows you to use the steering levers to move the loader when using the backhoe attachment or for loader service. (See Page 7.)

2. PRESS TO OPERATE BUTTON (Functions Only When The Seat Bar Is Down) – Activates BICS™ System when the Seat Bar is down and operator is seated in the operating position.

3. KEY SWITCH – For starting and stopping the engine.

4. BOSS DIAGNOSTIC PORT – Connector for diagnostic tool to make service checks of the system operation unit and other components.

5. LIGHT SWITCH (Opt./FA) – Controls the available work and travel lights.

6. HIGH–FLOW SWITCH (Opt.) – Controls the ON/OFF function of the high–flow auxiliary hydraulics. (Only on High–Flow loaders.)

7. BUCKET LEVEL SWITCH (Opt./FA) – Controls the ON/OFF function of the available bucket Position Valve.

8. BOSS DISPLAY PANEL – Display panel for BOSS system and functions (See Page 5.)

9. AUXILIARY HYDRAULIC SWITCH (Opt./FA) – For engaging the available Auxiliary Hydraulics (front and rear).

With BOSS

5 6 7 4 8

3 1

9

2 N–16962

B

P–10489

Side Console 1

2

3 P–10742

With BOSS (Side Console•) [B] 1. REAR WIPER/WASHER (FA) – Controls operation of the available rear window wiper and washer.

3. HAZARD SWITCH / HAZARD INDICATORS (Opt./FA) – Controls the available hazard lights.

(Hazard Lights is a separate available accessory.)

Both panel indicators blink for hazard condition when the hazard switch is ON. A red light indicates fuse out for taillights, headlights, worklights, etc.

4. BEACON OR STROBE SWITCH (Opt./FA) – Controls the available flashing beacon or strobe light.

• Available only with Deluxe Cab or with Cab Enclosure

Kit. Opt. – Factory Installed Option FA – Field Installed Accessory – See your Bobcat loader dealer about available Field Accessories.

4

863, 863H Bobcat Loader Operation & Maintenance Manual

BOSS® OPTION PANEL 3.4.

The following items are located on the BOSS Option Display Panel [A] & [(Item 8) [A] Page 4]: 10.a 1. FUEL LEVEL – Shows the amount of fuel in the tank. Flashing pump symbol indicates low fuel level.

H2O symbol is non–functional. (See WARNING SYMBOL)

A

1

2. BATTERY VOLTAGE – Shows the condition of the battery and charge rate. It will also indicate a WARNING for high or low voltage (See WARNING SYMBOL).

3. ENGINE OIL PRESSURE – Shows engine oil pressure. Flashing symbol indicates low oil pressure (See WARNING and SHUTDOWN SYMBOL).

4. ENGINE COOLANT TEMPERATURE/LEVEL – Shows engine coolant temperature (See WARNING and SHUTDOWN SYMBOL).

5. SHUTDOWN SYMBOL – This symbol is associated with any SHUTDOWN condition. When this symbol comes ON the SHUTDOWN will occur in 30 seconds. During SHUTDOWN the buzzer will sound continuously and the symbol will flash until the key switch is turned OFF.

5

NOTE: The engine can be restarted for 30–second periods to move the loader after a SHUTDOWN condition.

6. WARNING SYMBOL – The symbol will be ON when any WARNING or SHUTDOWN is activated.

The warning symbol is also used to indicate a WARNING if there is no related symbol on the display. During a WARNING, the buzzer will beep three times and the symbol will be ON continuously.

7. HOURMETER – Records the total operating hours of the loader. The five character code will display the operating hours to the nearest tenth. When WARNING or SHUTDOWN occurs, an alpha–numeric code will be displayed in the hourmeter area to inform the operator of the problem (See SYSTEM ANALYSIS, Page 75).

During a WARNING or SHUTDOWN the hourmeter symbol is not visible.

8. CHARGE PRESSURE AND FILTER CONDITION – Flashing symbol indicates low fluid charge pressure (See SHUTDOWN SYMBOL). If arrows are ON with gear/drop, it is fluid charge pressure.

This symbol will also indicate a clogged hydraulic fluid filter.

9. AIR FILTER CONDITION – This symbol will indicate a clogged air filter element.

10. GLOW PLUG (Diesel) – The symbol will flash when the glow plugs are energized. The hourmeter will also contain characters GLOXX where XX indicates the remaining time the glow plugs will be ON. Time remaining will count down in 5 second increments.

11. ENGINE SPEED – This symbol will indicate an engine overspeed (See WARNING and SHUTDOWN SYMBOL).

BRAKE INDICATOR LIGHT 12. PARKING (Non–Functional) .

13. HYDRAULIC FLUID TEMPERATURE – This symbol will indicate a high fluid temperature. (See WARNING or SHUTDOWN SYMBOL above).

2

4

3

7

6

8

9

12

13

10

11

MC–02320

5

863, 863H Bobcat Loader Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

A

The Bobcat Interlock Control System (BICS™) requires the operator to be seated in the operating position with the Seat Bar fully lowered and the green PRESS TO OPERATE Button [B] activated before the lift, tilt and traction functions can be operated. The Seat Belt must be fastened anytime you operate the loader.

1 2 3 4

NOTE: Press the green PRESS TO OPERATE Button [B] again if Seat Bar is raised and lowered or key is turned off.

5

N–17979

B

AVOID INJURY OR DEATH The Bobcat 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–2151–0394

The lift, tilt and traction drive functions are interlocked with the Seat Bar.

PRESS TO OPERATE

1

The BICS Controller is located inside the cab; behind and to the right of the operator’s seat [A].

There are five green lights on the BICS Controller and all must be ON to operate the loader.

N–16884

The light functions are as follows [A]: 1. SYSTEM ACTIVATED – ON when the green PRESS TO OPERATE Button is activated.

2. SEAT BAR – ON when the seat bar is in down position.

3. VALVE – ON when lift and tilt hydraulic functions can be used.

4. TRACTION – ON when loader can be moved forward or backward.

5. POWER – ON when the Controller is operating correctly.

NOTE: If any of the lights are off or blinking, see SERVICE CODES Page 77, BICS Troubleshooting Chart, Page 79, or see BICS Inspection and Maintenance Instructions Page 48.

6

863, 863H Bobcat Loader Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) (Cont’d) 5.6.

A

Lift Arm By–Pass Control The lift arm by–pass control knob (Item 1) [A] is used to lower the lift arms if the lift arms can not be lowered during normal operation.

With the operator in the seat, seat belt fastened and the seat bar fully lowered, turn the lift arm by–pass control knob (Item 1) [A] clockwise 1/4 turn. Then, pull up and hold the lift arm by–pass control until the lift arms slowly lower.

1

Traction Lock Override 6.

(Functions Only When The Seat Bar Is Raised) There is a Traction Lock Override button (Item 1) [B] on the left hand instrument panel which will allow you to use the steering levers to move the loader forward & backward when using the backhoe attachment or for loader service.

P–09707

B

• Press the button once to unlock traction drive (green traction light on BICS Controller will be ON).

• Press the button a second time to lock the traction drive (green traction light on BICS Controller will be OFF).

PRESS TO OPERATE

1

NOTE: The Traction Lock Override button will unlock the traction drive when the operator is NOT in the seat and the seat bar is raised.

N–16884

The Traction Lock Override button will function if brake pedal is in the engaged or disengaged position.

C

Without BOSS

With BOSS

Auxiliary Hydraulic System (If Equipped) When the operator is seated and raises the seat bar, the Auxiliary Hydraulic System will deactivate. Press the Auxiliary Hydraulics Switch (Item 1) [C] to reselect operating mode. (See Auxiliary Hydraulics Page 48.)

1

1

TRACTION LOCK CONTROL SYSTEM The Traction Lock Control System will lock the traction drive system when the engine stops.

P–10466

P–10489

NOTE: When the Traction Lock Override button is activated, the Traction Lock Control System will NOT engage the Traction Lock if the engine stops.

The Traction Lock Control System is incorporated into the BICS system. See BICS Inspection & Maintenance Page 48.

NOTE: The traction light on the BICS controller will remain OFF until the engine is started and if the parking brake is disengaged.

7

863, 863H Bobcat Loader Operation & Maintenance Manual

ENGINE SPEED CONTROL

A

The speed control lever (Item 1) [A] is at the right side of the operator’s seat. Engine speed is controlled by moving the lever forward to increase the engine RPM and backward to decrease the engine RPM.

1

P–02145

B

PARKING BRAKE Engage the parking brake by pushing down on the top of the pedal [B]. The traction drive system will be locked.

(See Traction Lock Override, Page 7.)

MC–01914

P–03990

To release the parking brake, push down on the bottom of the pedal [C].

C

NOTE: If the loader will not move when operator is in the operating position with brake pedal released or when Traction Lock Override button is pushed, move the steering levers either forward or backward a small amount to unlock the traction drive.

MC–01914

P–03989

8

863, 863H Bobcat Loader Operation & Maintenance Manual

STEERING LEVERS

A 1

AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls or footrests.

W–2261–0397 P–05086

The steering levers (Item 1) [A] are on the right and left side in front of the seat (foot pedal loader shown).

B

Move levers smoothly. Avoid sudden starting and stopping.

FORWARD

REVERSE

The steering levers control forward and reverse travel and turning of the loader [B].

Forward Travel – Push both levers forward.

Reverse Travel – Pull both levers backward.

Normal Turning – Move one lever farther forward than the other.

Fast Turning – Push one lever forward and pull the other lever backward.

For slow travel speed, push the steering levers forward only a small amount.

LEFT TURN

RIGHT TURN

LEFT FAST TURN

RIGHT FAST TURN

To increase travel speed, push both levers farther forward.

For maximum pushing force, push the levers forward only a small amount with the engine at full RPM. STOPPING THE BOBCAT LOADER When the steering levers are moved to the neutral position the hydrostatic transmission will act as a service brake to stop the loader.

PI–01849

9

863, 863H Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)

A

The seat bar restraint system has a pivoting, spring assist seat bar (Item 1) [A] with arm rests and has spring loaded interlocks for the lift and tilt control pedals.

1

The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat.

The interlocks require the operator to lower the seat bar in order to operate the foot pedal controls.

When the seat bar is up, the lift and tilt control pedals are locked when returned to the NEUTRAL POSITION.

P–07638

AVOID INJURY OR DEATH

B

When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

SEAT BAR DOWN 2

Seat Bar

W–2046–0595

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move pedals until both lock.

1 Interlock

Pedal Linkage

W–2045–1086

3

The seat bar system must lock the lift and tilt control pedals in neutral when the seat bar is up. Service the system if pedals do not lock correctly.

Interlock Shield

W–2105–1285 MC–01668

The spring loaded interlocks (Item 1) [B] control the locking and unlocking functions of the Foot Pedal controls.

C

SEAT BAR RAISED Seat Bar

The interlocks (Item 1) [B] require the operator to lower the seat bar (Item 2) [B] which allows the operator to move the foot pedals to control the lift and tilt functions.

When the seat bar is lowered, it pushes the interlock (Item 1) [B] down on both sides, releasing the pedal linkages (Item 3) [B] from the interlocks.

Interlock

The pedals will pivot in both directions when the interlock is down.

When the seat bar is raised, spring forces raise the interlocks [C].

Interlock Shield

The foot pedals will not pivot when the interlock is up.

See Page 45 for SEAT BAR RESTRAINT SYSTEM Inspection & Maintenance.

MC–01668

10

863, 863H Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS)

A

The seat bar restraint system has a pivoting seat bar (Item 1) [A] with arm rests and has spring loaded interlocks for the lift and tilt control functions.

1

The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat.

The interlocks require the operator to lower the seat bar in order to operate the hand controls.

When the seat bar is up, the lift and tilt control functions are locked when returned to the NEUTRAL POSITION.

P–03563

SEAT BAR DOWN

B

AVOID INJURY OR DEATH

2

When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the foot rests.

Seat Bar

W–2179–0694

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move hand controls until both lock.

The seat bar system must lock the lift and tilt control in neutral when the seat bar is up.

Service the system if hand controls do not lock correctly.

1 Hand Control Linkage

3

Interlock Interlock Shield

W–2153–0594 MC–01950

SEAT BAR RAISED

C

The spring loaded interlocks (Item 1) [B] control the locking and unlocking functions of the hand controls.

Seat Bar

The interlocks (Item 1) [B] require the operator to lower the seat bar (Item 2) [B] which allows the operator to move the hand controls to control the lift and tilt functions.

When the seat bar is lowered, it pushes the interlock (Item 1) [B] down on both sides, releasing the hand control linkages (Item 3) [B] from the interlocks.

The hand controls will pivot in both directions when the interlock is down.

Interlock Shield

When the seat bar is raised, spring forces raise the interlocks [C].

Interlock

The hand controls will not function when the interlock is up.

See Page 46 for SEAT BAR RESTRAINT SYSTEM Inspection & Maintenance.

MC–01950

11

863, 863H Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)

A

The seat bar restraint system has a pivoting seat bar (Item 1) [A] with arm rests.

The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat.

1

When the seat bar is down, and the green PRESS TO OPERATE Button is activated, the lift, tilt, and traction drive functions can be operated.

When the seat bar is up, the lift, tilt, and traction drive functions are deactivated.

P–03563

AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the foot rests.

W–2179–0694

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar.

• Move the hand controls to the NEUTRAL POSITION to make sure that both lift and tilt functions are deactivated.

The seat bar system must deactivate the lift and tilt control functions when the seat bar is up.

Service the system if hand controls do not deactivate.

W–2302–0698

See Page 47 for SEAT BAR RESTRAINT SYSTEM Inspection & Maintenance.

12

863, 863H Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS

A

Foot Pedals

3

2 P–05085

1 Keep both feet on pedals while operating machine. Failure to do so can cause serious injury.

W–2002–1285 Put your feet on the pedals and KEEP THEM THERE any time you operate the loader.

Two foot pedals (Item 1) [A] control the hydraulic cylinders for the lift and tilt functions.

Lift Arm Operation

B–07440

The left pedal controls the lift arms. Push on the bottom (heel) (Item 2) [A] of the pedal to raise the lift arms.

Push on the top (toe) (Item 3) [A] of the pedal to lower the lift arms.

4

Lift Arm Float Position Push the top (toe) (Item 3) [A] of the pedal all the way forward until it locks into the float position.

1

5 P–05085

Use the float position of the lift arms to level loose material while driving backward.

Push the bottom (heel) of the lift pedal to unlock from the float position.

Tilt Operation The right pedal controls the action of the bucket. Push the top (toe) (Item 4) [A] of the pedal to tilt the bucket forward.

Push the bottom of the pedal (heel) (Item 5) [A] to tilt the bucket backward.

Bucket Position Valve Operation (If Equipped)

B–07441

The function of the bucket position valve is to keep the bucket in the same approximate position it is placed in, prior to the upward lift cycle.

Bucket positioning functions automatically during the upward lift cycle only.

The bucket positioning function (if equipped) can be turned OFF with the bucket level switch. (See Pages 3 & 4.)

13

863, 863H Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS (Cont’d) Hand Controls (Mechanical and Advanced Hand Controls)

A 1 5

2

Keep both feet on footrests while operating machine. Failure to do so can cause serious injury.

B–15781

W–2152–0594

2

Put your feet on the footrests and KEEP THEM THERE for comfort and safety any time you operate the loader.

1

Two hand levers [A] control the hydraulic cylinders for the lift and tilt functions.

Lift Arm Operation The left hand lever controls the lift arms. Move the left hand lever away (Item 1) [A] from the operator to raise the lift arms.

B–07440

Move the left hand lever toward (Item 2) [A] the operator to lower the lift arms.

Lift Arm Float Position Move the left hand lever all the way toward the operator (Item 2) [A] until it locks into the float position.

3

Later AHC Models With Float Button – Press anbd hold the Float Button (Item 5) [A] before moving the lever.

– Press again to disengage.

4 B–15781

Use the float position of the lift arms to level loose material while driving backward.

Move the left hand lever upward to unlock from the float position.

3

Tilt Operation The right hand lever controls the action of the bucket.

Move the right hand lever away (Item 3) [A] from the operator to tilt the bucket forward.

4

Move the right hand lever toward (Item 4) [A] the operator to tilt the bucket backward.

B–07441

Bucket Position Valve Operation (If Equipped) The function of the bucket positioning valve is to keep the bucket in the same approximate position it is placed in before beginning the upward lift cycle.

B

Bucket positioning functions automatically during the upward lift cycle only.

The bucket positioning function (if equipped) can be turned OFF with the bucket level switch. (See Page 3 and 4).

1

Advanced Hand Controls (AHC) (If Equipped) AHC operation is the same as mechanical hand controls above.

Two lights (Item 1) [B] on the left handle are always ON when the AHC is functioning correctly. If lights are blinking or do not come ON, see Advanced Hand Controls Troubleshooting Chart Page 79.

Left Steering Lever 14

P–13255

863, 863H Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS (Cont’d)

A

Auxiliary Hydraulics (If Equipped)

AVOID BURNS Hydraulic fluid, tubes, fittings and quick couplers can get hot when running machine and attachments. Be careful when connecting and disconnecting quick couplers.

W–2220–0396

P–07968

NOTE: The loader has auxiliary proportional control for front auxiliary hydraulics only.

Proportional control allows for slow–to–fast movement of auxiliary functions. EXAMPLE: If you move the auxiliary switch half way, the auxiliary function will move at approximately one–half speed.

B

Locked

1

2

Quick Couplers To Connect: Remove any dirt or debris from the surface of both the male and female couplers, and from the outside diameter of the male coupler. Visually check the couplers for corroding, cracking, damage, or excessive wear. If any of these conditions exist, the coupler(s) must be replaced [A].

3

Install the male half coupler into the female coupler.

Full connection is made when the ball release sleeve slides forward on the female coupler and the sleeve is rotated so that the locking pins (Item 1) [B] and the groove (Item 2) [B] do NOT align (Locked Position).

This will prevent accidental disconnection.

P–10566

C

REAR AUXILIARY QUICK COUPLERS

NOTE: If the locking pins and grooves (Item 3) [C] are aligned, accidental disconnection is possible.

To Disconnect: Rotate the ball release sleeve so that the grooves are aligned with the pins (Item 3) [B] in the female coupler.

Hold the male coupler. Retract the sleeve on the female coupler until the couplers disconnect.

NOTE: Caps and plugs are not used with flush face couplers.

P–03052

Relieving Hydraulic Pressure 7.

With the engine running, turn the key switch quickly to the left (counterclockwise) past the OFF position. Hold key for at least five seconds after the engine comes to a complete stop. This relieves pressure that can be trapped in the auxiliary circuit which would make it difficult to engage quick couplers from an attachment.

15

863, 863H Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS (Cont’d)

A

Auxiliary Hydraulics (Cont’d) 8.

Auxiliary Hydraulics Switch • Momentary Operation Press the Auxiliary Hydraulics Switch (Item 1) [A] once.

With BOSS

Without BOSS

The light (Item 2) [A] will be ON.

1

1

• Continuous Operation Press the Auxiliary Hydraulics Switch (Item 1) [A] a second time.

Both lights (Items 2 & 3) [A] will be ON.

2

2

3

3 P–10466

• Disengage Press the Auxiliary Hydraulics Switch (Item 1) [A] a third time.

B

Both lights (Items 2 & 3) [A] will be OFF. NOTE: When the operator is seated and raises the seat bar, the Auxiliary Hydraulic System (Front and Rear) will deactivate. Press the Auxiliary Hydraulics Switch (Item 1) [A] to reselect operating mode.

P–10489

TWO–SWITCH HANDLES

3

1 2

FRONT Auxiliary Hydraulics Operation (RIGHT Steering Lever) • Set the Auxiliary Hydraulics Switch for Momentary Operation (See above).

Left Steering Lever

Right Steering Lever

P–02154

• Push the switch (Item 1) [B] or [C] to the right or left to change the fluid flow direction to the front quick couplers. (EXAMPLE: Open and close grapple teeth.)

C

FRONT Auxiliary Hydraulics Continuous Operation (RIGHT Steering Lever)

3

P–02152

DELUXE HANDLES

1

• Set the Auxiliary Hydraulics Switch for Continuous Operation (See above).

• Push the front switch (Item 2) [B] or [C] to give the front quick couplers a constant flow of fluid (EXAMPLE: Operate a backhoe.)

• To release from continuous operation, press the front switch (Item 2) [B] or [C] a second time.

2 Left Steering Lever

NOTE: The secondary front auxiliary hydraulics and the rear auxiliary hydraulics operate from the same auxiliary section of the control valve.

To operate only one of these auxiliary functions, disconnect the other.

Right Steering Lever

P–13255

D

REAR Auxiliary Hydraulics Operation (LEFT Steering Lever)

P–13254

REAR AUXILIARY QUICK COUPLERS

• Set the Auxiliary Hydraulics Switch for Momentary or Continuous Operation (See above).

• Push the switch (Item 3) [B] or [C] to the right or left to change the fluid flow direction to the rear quick couplers [D]. (EXAMPLE: Raise and lower rear stabilizers.) This switch also controls the secondary front auxiliary. (Rear Auxiliary Hydraulics required) NOTE: See System Analysis Page 75 troubleshooting malfunctions with Auxiliary Hydraulics Operation.

for the P–00386

16

863, 863H Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS (Cont’d.)

A

Auxiliary Hydraulics (Cont’d.)

HI FLOW

High–Flow Hydraulics Operation (If Equipped)

SECONDARY COUPLERS 1

The High–Flow function provides additional flow to the system to operate an attachment which requires more hydraulic flow (EXAMPLE: Planer).

Continuous Operation For continuous flow (through female coupler only).

(See Page 16.)

Momentary Operation For momentary operation. (See Page 16.)

3

2 N–00334

N–00333

• Be sure Hi–Flow switch is OFF • Connect the attachment to the large quick couplers (Item 1) [A].

B

Without BOSS

With BOSS

• Some attachments may have a case drain which needs to be the connected to the small quick coupler (Item 2) [A].

• When all hydraulic connections have been made, turn the Hi–Flow switch ON (Item 1) [B] (amber light is ON).

1 1

Secondary Front Auxiliary Hydraulics (If Equipped) The secondary front auxiliary quick couplers are a part of the Hi–Flow Hydraulics (factory option) [A]. (Also available as a Field Installed Accessory.) These are used when there is a need for additional auxiliary hydraulics (EXAMPLE: Planer side shift).

N–16959

C

• Connect the attachment to the secondary auxiliary hydraulics (Item 3) [A].

1

N–16962

DELUXE HANDLES

• Set the Auxiliary Hydraulic Switch for Momentary or Continuous Operation. (See Page 16.)

• Push switch (Item 1) [C] to the right or left to change fluid flow direction. (EXAMPLE: Side shift on the Planer.)

NOTE: The secondary front auxiliary hydraulics and the rear auxiliary hydraulics operate from the same auxiliary section of the control valve.

To operate only one of these auxiliary functions, disconnect the other.

Left Steering Lever P–13255

Right Steering Lever P–13254

If the high–flow switch is in the ON position, High–Flow Hydraulics will flow through the front auxiliary quick couplers. Damage to unapproved attachments can result. Leave the switch OFF for backhoe operation.

I–2063–0295

17

863, 863H Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS (Cont’d.)

A

Attachment Functions Control (If Equipped) (Attachment Control Kit Required) (Item 1) [A]

1

This kit, when installed, allows the use of other switches on the right and left control handles (Deluxe Handles) for functions such as water spray, left/right turn signals (Europe only), raise/lower the left/right ends of the moldboard on a Grader, etc.

The following are examples only, consult Attachment Operation & Maintenance Manual.

Switch (Item 1) [B] . . . Left/Right Turn Signals Switch (Item 2) [B] . . . Left Moldboard Up/Down Switch (Item 3) [B] . . . Right Moldboard Up/Down Switch (Item 4) [B] . . . Water Spray

N–00334

B

DAILY INSPECTION

1

DELUXE HANDLES 2

4

3

Maintenance work must be done at regular intervals.

Failure to do so will result in excessive wear and early failures. The Service Schedule [C] is a guide for correct maintenance of the Bobcat loader. It is located inside the rear door of the loader and also in the MACHINE SIGN TRANSLATION Section Page 81.

Daily Inspection and Maintenance: • Engine Oil Level • Hydraulic/Hydrostatic Fluid Level • Engine Air Filter, Air System for Damage or Leaks • Engine Coolant Level, System for Damage or Leaks • Operator Cab, Seat Belt, Seat Bar, Pedal Interlocks, & Hand Control Interlocks Mounting Hardware • Grease Pivot Pins (Lift Arms, Bob–Tach, Cylinders, Bob–Tach Wedges • Tires for Wear or Damage and Correct Air Pressure • Fuel Filter, Remove Trapped Water • Loose or Broken Parts • Safety Treads and Safety Signs (Decals) • Bobcat Interlock Control System (BICS™) • Lift Arm Support Device

Left Steering Lever P–13255

Right Steering Lever P–13254

C

NOTE: Fluids such as engine oil, hydraulic fluid, coolant, etc. must be disposed of in an environmentally safe manner.

Some regulations require that certain spills and leaks on the ground must be cleaned in a specific manner. See local, state and federal regulations for correct disposal.

6718398

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

W–2072–0496

18

863, 863H Bobcat Loader Operation & Maintenance Manual

GETTING READY FOR OPERATION

A

Read and understand the Operation & Maintenance Manual and the Operator’s Handbook (Item 1) [A] before operating the loader.

1

The Operation & Maintenance Manual and other manuals can be kept in a box (Item 2) [A] provided at the right hand side of the operator seat.

2

P–10159

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. Failure to follow instructions can cause injury or death.

B

W–2003–1298

Operator must have instructions before running the machine. Untrained operators can cause injury or death.

W–2001–0596

Use the bucket or attachment steps, grab handles and safety treads (on top of the loader lift arms and frame) to get on and off the loader [B].

Safety treads are installed on the Bobcat loader to provide a slip resistant surface for getting on and off the loader.

Keep safety treads clean and replace when damaged.

Replacement treads are available from your Bobcat loader dealer.

P–10827

19

863, 863H Bobcat Loader Operation & Maintenance Manual

GETTING READY FOR OPERATION (Cont’d.)

A

Pull the seat lever (Item 1) [A] and adjust the seat position for comfortable operation of the loader controls.

Fasten the seat belt snugly and adjust it so that the buckle is centered between your hips [B].

1

AVOID INJURY OR DEATH

P–10163

When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls or footrests.

B

W–2261–0397

Lower the seat bar [B].

Be sure the parking brake is engaged.

All controls must be in the neutral position before you start the engine.

After you start the engine, press the green PRESS TO OPERATE Button on the left instrument panel to operate lift, tilt and traction functions.

P–07639

C Foot Pedals: Keep your hands on the steering levers and feet on the foot pedals while seated in the loader [C] Keep your hands on the steering levers and feet on the foot pedals or foot rests while seated in the loader [C].

STARTING THE ENGINE P–07638

D

WRONG

WRONG

B–03724

B–06578

When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside.

Exhaust fumes contain odorless, invisible gases which can kill without warning [D].

W–2050–1285

AVOID INJURY OR DEATH • Engines can have hot parts and hot exhaust gas. Keep flammable material away.

• Do not use machines in atmosphere containing explosive gas [D].

W–2051–1086

20

863, 863H Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

Normal Starting (Without BOSS®) 9.

Adjust the seat position for comfortable operation of the foot pedals or hand controls and steering levers.

Fasten the seat belt snugly and adjust it so the buckle is centered between your hips.

Lower the seat bar [A].

Put the foot pedals or hand controls and steering levers in NEUTRAL POSITION (center) (Item 1) [B].

Set the engine speed control to the 1/2 SPEED position (Item 2) [B].

P–07639

Turn the key switch to the ON POSITION. The engine and transmission warning lights will be ON when the key switch is on and the engine is stopped (Item 3) [B].

B

Turn the key switch to START POSITION (Item 4) [B] and release it when the engine starts. (See Cold Temperature Starting if the engine does not start.)

NEUTRAL POSITION

1

Advanced Hand Controls Only: Make sure both hand controls are in neutral before starting the engine.

Do not move the Advanced Hand Control levers from the neutral position when turning the key ON.

1/2 SPEED

If either hand control is moved:

2

a. – The neutral position for the hydraulic valve spool and hand control may not be correctly calibrated. This can result in movement of the lift or tilt hydraulic cylinders when the hand control lever is returned to the neutral position after start– up.

ON POSITION

3

OR

START POSITION

b. – The hydraulics will not operate (corresponding diagnostic lights on the left handle will blink).

4

If either condition occurs, turn the key OFF. Put the controls in neutral position and re–start the engine.

RUN POSITION

5

PI–02188 MC–02033

Do not engage the starter for longer than 15 seconds at a time. Longer use can damage the starter by overheating. Cool the starter for one minute between uses.

I–2034–0284 When you release the key, it will return to the RUN POSITION (Item 5) [B].

STOP THE ENGINE IF THE WARNING LIGHTS DO NOT GO OFF.

21

863, 863H Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

Cold Temperature Starting (Without BOSS®) See Normal Starting Page 21. Turn the key switch to the RUN position.

Push the preheat switch (Item 1) [A] on the left side of the Instrument Panel.

1

P–16964

The decal [B] on the left side of the operator cab shows the correct amount of time to hold the preheat switch.

B

Follow the steps under Normal Starting and repeat the Preheat procedure until the engine starts.

Continue to hold the preheat switch after the engine starts to preheat the combustion air [B]: If the temperature is below 32°F. (0°C.), perform the following to make starting the engine easier:

• Replace the engine oil with the correct type and viscosity for the anticipated starting temperature.

(See Engine Lubrication System Page 59.)

• Make sure the battery is fully charged.

6708942

• Install an engine heater, available from your Bobcat

C

loader dealer.

Warming The Hydraulic/Hydrostatic System Let the engine run for a minimum of 5 minutes to warm the engine and hydrostatic transmission fluid before operating the loader. If the warning light comes ON when operating loader (cold), more warm up time is needed.

STOPPING THE ENGINE Pull the engine speed control fully backward to decrease the engine speed. Turn the key switch to the OFF position [B].

P–07639

STARTING THE ENGINE (Cont’d) Normal Starting (With BOSS®) Adjust the seat position for comfortable operation of the foot pedals or hand controls and steering levers.

Fasten the seat belt snugly and adjust it so the buckle is centered between your hips.

Lower the seat bar [C].

22

863, 863H Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

Put the foot pedals or hand controls and steering levers in NEUTRAL POSITION (center) (Item 1) [A].

NEUTRAL POSITION

Be sure the parking brake is engaged.

Set the engine speed control to 1/2 SPEED position (Item 2) [A].

1 1/2 SPEED

Turn the key switch to the ON POSITION, one beep will sound and the display symbols will be ON (Item 1) [B].

2

Turn the key switch to START. (See Cold Temperature Starting.) Release the key when the engine starts.

PI–02188

B

Advanced Hand Controls Only: Make sure both hand controls are in neutral before starting the engine.

Do not move the Advanced Hand Control levers from the neutral position when turning the key ON. If either hand control is moved: a. – The neutral position for the hydraulic valve spool and hand control may not be correctly calibrated. This can result in movement of the lift or tilt hydraulic cylinders when the hand control lever is returned to the neutral position after start– up.

OR b. – The hydraulics will not operate (corresponding diagnostic lights on the left handle will blink).

If either condition occurs, turn the key OFF. Put the controls in neutral position and re–start the engine.

1

Do not engage the starter for longer than 15 seconds at a time. Longer use can damage the starter by overheating. Cool the starter for one minute between uses.

MC–02320

I–2034–0284

When the key switch is turned ON, watch the alpha numeric display for SERVICE CODES. These codes are from the previous work shift when a WARNING may have occurred. (See SYSTEM ANALYSIS Section, Page 75.)

The codes may be viewed again by turning the key switch OFF and then ON again without starting the engine.

After the engine has been started, the BOSS Controller will clear all codes from memory. The codes will not appear again unless the problem reoccurs. The alphanumeric display will again show the operating hours.

23

863, 863H Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

Cold Temperature Starting (With BOSS®)

Do not use ether with glow plug (preheat) systems. Explosion can result which can cause injury or death.

W–2071–1285 See Normal Starting. Turn the Key Switch to the ON position. The glow plug symbol will be ON (Item 1) [A].

NOTE: If the display is showing SERVICE CODES, the timing of the glow plug activation may not be visible on the display. However, the glow plugs will be energized.

Characters on the display will be GLOXX where XX will indicate the remaining time the glow plugs will be energized (Item 1) [A].

Turn the key switch to the START position, release when the engine starts. If the engine does not start, turn key to OFF position [B] and ON again to start the glow plug cycle again. When the engine is running, slowly move the engine speed control forward to increase engine RPM.

1

If the starting temperature is below 32°F. (0°C.), perform the following to make starting easier: • Replace the engine oil with the correct type and viscosity for the anticipated starting temperature. (See Engine Lubrication System Page 59) • Make sure the battery is fully charged.

• Install an engine heater, available from your Bobcat loader dealer.

MC–02042

B

OFF POSITION

Warming The Hydraulic/Hydrostatic System Let the engine run for a minimum of 5 minutes to warm the engine and hydrostatic transmission fluid before operating the loader. If the warning light comes ON when operating loader (cold), more warm up time is needed.

PRESS TO OPERATE

STOPPING THE ENGINE N–16961

Pull the engine speed control fully backward to decrease the engine speed. Turn the key switch to the OFF position [B].

When the temperature is below –20°F. (–30°C.), hydrostatic oil must be warmed before starting. The hydrostatic system will not get enough oil at low temperatures and will be damaged. Park the machine in an area where the temperature will be above 0°F. (–18°C.) if possible.

I–2007–1285

24

863, 863H Bobcat Loader Operation & Maintenance Manual

ATTACHMENTS AND BUCKETS

A

NOTE: Warranty is void if non–approved attachments are used on the Bobcat loader.

Never use attachments or buckets which are not approved by Bobcat Company. Buckets and attachments for safe loads of specified densities are approved for each model.

Unapproved attachments can cause injury or death.

W–2052–1285

B–06587

The dealer can identify, for each model loader, the attachments and buckets approved by Bobcat Company.

The buckets and attachments are approved for rated operating capacity and for secure fastening to the Bob–Tach.

The rated operating capacity for this loader is shown on a label in the operator cab. (See SPECIFICATIONS Section Page 91.)

AVOID INJURY OR DEATH Do not exceed rated operating capacity.

Excessive load can cause tipping or loss of control.

The rated operating capacity is determined by using a standard dirt bucket, and material of normal density, such as dirt or dry gravel. If longer buckets are used, the load center moves forward and reduces the rated operating capacity. If very dense material is loaded, the volume must be reduced.

W–2053–0887

B

Exceeding the rated operating capacity [A] can cause the following problems:

WEIGHT OF LOADS LBS. (KG)

1470 (665)

• Tires will wear faster.

• There will be a loss of stability.

• The life of the Bobcat loader will be reduced.

Use the correct size bucket for the type and density of material being handled. For safe handling of materials and avoiding machine damage, the attachment (or bucket) should handle a full load without going over the rated operating capacity for the loader. Partial loads make steering more difficult.

1290 (585)

(Without counterweights)

• Steering the loader may be difficult.

15.75 (400)

Maximum load to be carried when using a pallet fork are shown in figure [B]. See your Bobcat loader dealer for more information about loader counterweights, pallet forks and other available attachments.

24.00 (610)

CENTER OF LOAD LOCATION Inches (mm) 6712931 6712932

25

863, 863H Bobcat Loader Operation & Maintenance Manual

ATTACHMENTS AND BUCKETS (Cont’d)

A

Installing The Bucket Or Attachment

1

The loader is equipped with the Bob–Tach system. The Bob–Tach is used for fast changing of buckets and attachments. See the Attachment Operation & Maintenance Manual to install other attachments.

Pull the Bob–Tach levers all the way up (Item 1) [A].

Enter the loader.

Fasten the seat belt, lower the seat bar, start the engine and press the green PRESS TO OPERATE Button.

N–17054

Release the parking brake.

Lower the lift arms and tilt the Bob–Tach forward.

B

Drive the loader forward until the top edge of the Bob–Tach is completely under the top flange of the bucket [A] (or other attachments).

Be sure the Bob–Tach levers do not hit the bucket.

Tilt the Bob–Tach backward until the cutting edge of the bucket (or other attachment) is slightly off the ground [B].

Stop the engine and exit the loader.

N–17055

C

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar.

• (Foot Pedal Controls) Move pedals until both lock.

• (Mechanical Hand Controls) Move the hand controls until both lock.

The seat bar system must lock the lift and tilt controls in neutral when the seat bar is up.

Service the system if hand controls do not lock correctly.

1

N–17059 N–17058

• (Advanced Hand Controls) Move the hand

controls to the NEUTRAL POSITION to make sure that both lift and tilt functions are deactivated.

The seat bar system must deactivate the lift and tilt control functions when the seat bar is up. Service the system if hand controls do not deactivate.

W–2323–0698

Push down on the Bob–Tach levers until they are fully engaged in the locked position [C].

Bob–Tach levers have spring tension. Hold lever tightly and release slowly. Failure to obey warning can cause injury.

The levers will contact the frame as shown (Item 1) [C] when locked.

W–2054–1285

If the levers do not engage in the locked position, see your Bobcat loader dealer for maintenance.

26

863, 863H Bobcat Loader Operation & Maintenance Manual

ATTACHMENTS AND BUCKETS (Cont’d)

A

The wedges (Item 1) [A] must extend through the holes (Item 1) [B] in the mounting frame of the bucket (or attachment), securely fastening the bucket to the Bob–Tach. The wedge is shown extending through the hole in the bucket [A].

1

N–17053

B Bob–Tach wedges must extend through the holes in attachment. Levers must be fully down and locked. Failure to secure wedges can allow attachment to come off and cause injury or death.

W–2102–0588

1 N–17056

Removing The Bucket Or Attachment

C

Put the attachment flat on the ground and lower or close the hydraulic equipment. If the attachment is hydraulically controlled (ie: combination bucket, backhoe, etc.), stop the engine and relieve hydraulic pressure in the auxiliary circuit. (See Relieving Hydraulic Pressure, Page 15).

Raise the seat bar, unfasten the seat belt, set the parking brake and exit the loader.

Pull the Bob–Tach levers [C] all the way up.

Disconnect the hydraulic hoses, if necessary.

Enter the loader.

N–17057

Fasten the seat belt, lower the seat bar, start the engine and press the green PRESS TO OPERATE Button.

D

Release the parking brake.

Lower the lift arms and tilt the Bob–Tach forward.

Move the loader backward, away from the bucket or attachment [D].

N–17054

27

863, 863H Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURE

A

When operating on a public road or highway, always follow local regulations. For example: Slow Moving Vehicle Sign or direction signals may be required.

WITH BUCKET FULL

Always warm the engine and hydrostatic system before operating the loader.

Going Up Slope

Machines warmed up with moderate engine speed and light load have longer life.

I–2015–0284

B

B–12878

WITH BUCKET FULL

Operate the loader with the engine at full speed for maximum horsepower. Move the steering levers only a small amount to operate the loader slowly.

New operators must operate the loader in an open area without bystanders. Operate the controls until the loader can be handled at an efficient and safe rate for all conditions of the work area.

With a full bucket, go up or down the slope with the heavy end toward the top of the slope [A] & [B].

Going Down Slope With empty bucket, go down or up the slope with the heavy end toward the top of the slope [C] & [D].

C

• Keep the lift arms as low as possible.

• Do not travel or turn with the lift arms up.

• Turn on level ground.

• Go up and down slopes, not across them.

• Keep the heavy end of the machine uphill.

• Do not overload the machine.

WITH BUCKET EMPTY

Going Down Slope

Failure to obey warnings can cause the machine to tip or roll over and cause injury or death.

D

B–15230

B–12873

WITH BUCKET EMPTY

W–2018–1187

Raise the bucket only high enough to avoid obstructions on rough ground.

Going Up Slope

28

B–13297

863, 863H Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURE (FOOT PEDALS)

A

Filling The Bucket Push down on the top of the lift pedal until the lift arms are all the way down.

B–12830

Push the top of the tilt pedal to put the cutting edge of the bucket on the ground [A].

B–12872

B

Drive slowly forward into the material. Push the bottom of the tilt pedal to raise the front of the bucket [B].

B–12830

Load, unload and turn on flat level ground. Do not exceed rated operating capacity shown on sign (decal) in cab. Failure to obey warnings can cause the machine to tip or roll over and cause injury or death.

W–2056–1187

Drive backward away from the material.

Emptying The Bucket

B–12871

Push down on the bottom of the lift pedal to raise the lift arms [C]. Push the top of the tilt pedal while raising the lift arms to level the bucket or attachment and help prevent material from falling off the back of the bucket or attachment.

C

Drive forward slowly until the bucket is over the top of the truck box or bin. Push the top of the tilt pedal until the bucket is empty [C]. If all the material is near the side of the truck or bin, push it to the other side with the bucket.

B–12830

Never dump over an obstruction, such as a post, that can enter the operator cab. The machine could tip forward and cause injury or death.

W–2057–0694 B–12869

29

863, 863H Bobcat Loader Operation & Maintenance Manual

OPERATING (Cont’d)

PROCEDURES

(FOOT

PEDALS)

A

Digging Into The Ground Put the lift arms all the way down. Push the top of the tilt pedal until the cutting edge of the bucket is on the ground.

Drive forward slowly and continue to tilt the bucket down until it enters the ground [A].

B–12830

Push the bottom of the tilt pedal a small amount to increase traction and keep an even digging depth.

Continue to drive forward until the bucket is full. When the ground is hard, raise and lower the cutting edge of the bucket with the tilt pedal while driving forward slowly.

B–12874

B

Push the bottom of the tilt pedal to tilt the bucket backward as far as it will go when the bucket is full [B].

B–12830

B–12876

Leveling The Ground (Using Lift Arms In Float Position)

C

Push the top (toe) of the lift pedal all the way forward until the pedal is in the locked position to put the lift arms in a float position [C].Push the tilt pedal to change the position of the cutting edge on the bucket. With the bucket tilted farther forward, there is more force on the cutting edge and more loose material can be moved.

B–12830

Never drive forward when the hydraulic control for lift arms is in float position.

I–2005–1285

Drive backward to level loose material. Push the bottom of the lift pedal to unlock from the float position.

B–12875

30

863, 863H Bobcat Loader Operation & Maintenance Manual

OPERATING (Cont’d)

PROCEDURES

(FOOT

PEDALS)

A

Backfilling Lower the lift arms and put the cutting edge of the bucket on the ground. Drive forward to the edge of the hole to push the material into the hole [A].

B–12830

Tilt the bucket forward as soon as it is past the edge of the hole [A].

If necessary, raise the lift arms to empty the bucket.

PARKING THE BOBCAT LOADER Stop the Bobcat loader on level ground.

Lower the lift arms fully and put the attachment flat on the ground.

B–12877

Pull the engine speed control lever all the way backward.

Turn the key switch to the OFF POSITION.

AVOID INJURY OR DEATH Before you leave the operator’s seat:

• Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move pedals until both lock.

W–2045–1086

Engage the parking brake.

Lift the seat bar and make sure the foot pedals are in the locked position.

Unbuckle the seat belt. Remove the key from the switch to prevent operation of the loader by unauthorized personnel.

31

863, 863H Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURE (HAND CONTROLS)

A

Filling The Bucket Move the left hand lever toward the operator until the lift arms are all the way down. Move the right hand away from the operator to put the cutting edge of the bucket on the ground [A].

B–15781

B–12872

Drive slowly forward into the material. Move the right hand lever toward the operator to raise the front of the bucket [B].

B

Load, unload and turn on flat level ground. Do not exceed rated operating capacity shown on sign (decal) in cab. Failure to obey warnings can cause the machine to tip or roll over and cause injury or death.

B–15781

W–2056–1187

Drive backward away from the material.

Emptying The Bucket B–12871

Move the left hand lever away from the operator to raise the lift arms [C]. Move the right hand lever away from the operator to level the bucket or attachment and help prevent material from falling off the back of the bucket or attachment.

C

Drive forward slowly until the bucket is over the top of the truck box or bin. Move the right hand lever away from the operator until the bucket is empty [C]. If all the material is near the side of the truck or bin, push it to the other side with the bucket.

B–15781

Never dump over an obstruction, such as a post, that can enter the operator cab. The machine could tip forward and cause injury or death.

W–2057–0694 B–12869

32

863, 863H Bobcat Loader Operation & Maintenance Manual

OPERATING (Cont’d)

PROCEDURE

(HAND

CONTROLS)

A

Digging Into The Ground Put the lift arms all the way down. Move the right hand lever away from the operator until the cutting edge of the bucket is on the ground. Drive forward slowly and continue to tilt the bucket down until it enters the ground [A].

B–15781

Move the right hand lever toward the operator a small amount to increase traction and keep an even digging depth. Continue to drive forward until the bucket is full.

When the ground is hard, raise and lower the cutting edge of the bucket with the hand lever while driving forward slowly.

B–12874

B

Move the right hand lever toward the operator to tilt the bucket backwards as far as it will go when the bucket is full [B].

B–15781

Leveling The Ground (Using Lift Arms In Float Position) Move the left hand lever all the way down and in until the hand lever is in the locked position to put the lift arms in a float position [C].

B–12876

Later AHC Models With Float Button – Press anbd hold the Float Button (Item 1) [C] before moving the lever.

– Press again to disengage.

C

Move the right hand lever to change the position of the cutting edge on the bucket. With the bucket tilted farther forward, there is more force on the cutting edge and more loose material can be moved.

1

B–15781

Never drive forward when the hydraulic control for lift arms is in float position.

I–2005–1285

Drive backward to level loose material. Move the left hand lever upward to unlock from the float position.

B–12875

33

863, 863H Bobcat Loader Operation & Maintenance Manual

OPERATING (Cont’d)

PROCEDURE

(HAND

CONTROLS)

A

Backfilling Lower the lift arms and put the cutting edge of the bucket on the ground. Drive forward to the edge of the hole to push the material into the hole [A].

Tilt the bucket forward as soon as it is past the edge of the hole [A]. If necessary, raise the lift arms to empty the bucket.

B–15781

PARKING THE BOBCAT LOADER Stop the Bobcat loader on level ground.

Lower the lift arms fully and put the attachment flat on the ground.

Pull the engine speed control all the way backward. Turn the key switch to the OFF POSITION.

B–12877

AVOID INJURY OR DEATH When operating the machine:

• Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the foot rests.

W–2179–0694

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar.

• (Mechanical Hand Controls) Move the hand controls until both lock.

The seat bar system must lock the lift and tilt controls in neutral when the seat bar is up.

Service the system if hand controls do not lock correctly.

• (Advanced Hand Controls) Move the hand

controls to the NEUTRAL POSITION to make sure that both lift and tilt functions are deactivated.

The seat bar system must deactivate the lift and tilt control functions when the seat bar is up. Service the system if hand controls do not deactivate.

W–2302–0698

Engage the parking brake.

Lift the seat bar. Make sure the hand controls are in the locked position (mechanical only).

Unbuckle the seat belt. Remove the key from the switch to prevent operation of the loader by unauthorized personnel.

34

863, 863H Bobcat Loader Operation & Maintenance Manual

TRANSPORTING THE BOBCAT LOADER

A

Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury.

W–2058–0494

Support P–10458

A loader with an empty bucket or no attachment must be loaded backward onto the transport vehicle [A].

B

The rear of the trailer must be blocked or supported when loading or unloading the loader to prevent the front end of the trailer from raising up. Some ramps provide support [A].

Be sure the transport and towing vehicles are of adequate size and capacity (See SPECIFICATIONS Page 91, for weight of loader.)

P–10462

P–10464

Use the following procedure to fasten the Bobcat loader to the transport vehicle to prevent the loader from moving during sudden stops or when going up or down slopes [B].

Lower the bucket or attachment to the floor. Stop the engine. Engage the parking brake. Install chains at the front and rear loader tie down positions Inset [B]. Fasten each end of the chain to the transport vehicle.

TOWING THE LOADER To prevent damage to the loaders hydrostatic system, the loader must be towed only a short distance at slow speed.

(Example: Moving the loader onto a transport vehicle).

The towing chain (or cable) must be rated at 1 & 1/2 times the weight of the loader. (See SPECIFICATIONS Page 91.)

• Turn the key switch to ON and press the Traction Lock Override button. This will not work unless the engine is running because of the RPM sesnor.

• Tow the Bobcat at 2 MPH (3,2 km/hr) or less for not more than 25 feet (7,6 meters).

6707867

If the electrical system is not functioning, contact your Bobcat loader dealer. (Part of the brake system must be disassembled to move the loader.)

P–10460

STOPPING THE BOBCAT LOADER When the steering levers are moved to the neutral position, the hydrostatic transmission will act as a service brake to stop the loader.

35

863, 863H Bobcat Loader Operation & Maintenance Manual

LIFTING THE LOADER

A

863/863H BICSOperation&MaintenanceManual(S/N514427600&Above)#6900790–OperatingInstructionsSection

Four Point Lift

AVOID INJURY OR DEATH • Before lifting, check fasteners on four point lift.

• Never allow riders in the cab or bystanders within 15 feet (5 meters) while lifting the machine.

MC–02365

W–2160–0694

B

The loader can be lifted with the four point lift which is available as a kit from your Bobcat loader dealer.

Attach cables or chains to lift eyes as shown [A].

Single Point Lift

MC–02366

AVOID INJURY OR DEATH • Before lifting, check fasteners on single point lift and operator cab.

• Assemble front cab fasteners as shown in manual.

• Never allow riders in the cab or bystanders within 15 feet (5 meters) while lifting the machine.

W–2007–0694

The loader can also be lifted with the single point lift which is available as a kit from your Bobcat loader dealer.

Install the kit and lift as shown [B].

The single point lift, supplied by Melroe Company is designed to lift and support the Bobcat loader without affecting roll over and falling object protection features of the operator cab.

36

863, 863H Bobcat Loader Operation & Maintenance Manual

PREVENTIVE MAINTENANCE AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . 48 Additional Inspection For Loaders With Advanced Hand Controls . . . . . . . 48 Inspecting Deactivation Of The Auxiliary Hydraulic System . . . . . . . . . . . . 48 Inspecting The Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Inspecting The BICS™ Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Inspecting The Seat Bar Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Inspecting The Traction Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

PREVENTIVE MAINTENANCE

DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Adjusting The Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Replacing The Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Removing And Installing The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Servicing The Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Replacing The Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 FAN GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Checking And Maintaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . . . . . . . . . . 69 Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Removing Oil From The Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Hydraulic Reservoir Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Replacing The Hydraulic/Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Replacing The Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Disengaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Engaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Continued On Next Page 37

863, 863H Bobcat Loader Operation & Maintenance Manual

PREVENTIVE MAINTENANCE (Cont’d) LUBRICATION OF THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . 73 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Latch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS) . . . . 47 Inspecting The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Maintaining The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS) . . . . . . . . . . . . . . . . . . . 45 Inspecting The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Maintaining The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS) . . 46 Inspecting The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Maintaining The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 TRACTION LOCK CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Inspecting The Traction Lock Control System . . . . . . . . . . . . . . . . . . . . . . . . 49 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

38

863, 863H Bobcat Loader Operation & Maintenance Manual

MAINTENANCE SAFETY 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.

W–2003–0199

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

CORRECT

CORRECT

CORRECT

B–10731

B–12365

B–7469

Never service the Bobcat® Skid Steer Loader without instructions.

Use the correct procedure to lift or lower operator cab.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B–11799

B–15231

B–15280

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.

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 if damaged.

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.

WRONG

WRONG

WRONG

B–6590

B–6580

B–6589

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.

Keep body, jewelry and clothing away from moving parts, electrical contacts, 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.

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.

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.

39

MSW01–0600

863, 863H Bobcat Loader Operation & Maintenance Manual

40

863, 863H Bobcat Loader Operation & Maintenance Manual

SERVICE SCHEDULE 7.8.

Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The schedule is a guide for correct maintenance of the Bobcat loader. service 10.

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. Failure to follow instructions can cause injury or death.

W–2003–1298

ITEM Engine Oil Engine Air Filter and Air System Engine Cooling System Lift Arms, Cyl., Bob–Tach Pivot Pins and Wedges Tires Seat Belt, Seat Bar & Pedal Interlocks or Hand Control Interlocks Bobcat Interlock Control System (BICSTM) Safety Signs and Safety Treads Operator Cab Fuel Filter Hyd. Fluid, Hoses and Tubelines Final Drive Trans.(Chaincase) Battery Foot Pedals or Hand Controls and Steering Wheel Nuts Parking Brake Alternator Belt Engine/Hydro. Drive Belt Fuel Filter Steering Shaft Hydraulic Reservoir Breather Cap Hyd./Hydro. Filter Engine Oil and Filter Final Drive Trans.

Hydraulic Reservoir Hydraulic Motors Bobcat Interlock Control System (BICSTM) Fan Drive Gearbox Engine Valves Engine Timing Belt

* ∞ ◊

SERVICE REQUIRED

8–10

50

◊

250 500 1000 3000

Check the oil level and add oil as needed.

Check condition indicator or display panel. Service only when required. Check for leaks and damaged components.

Clean debris from oil cooler radiator & grill. Check coolant level cold, add premixed coolant as needed.

Lubricate with multi–purpose lithium based grease (12 places).

Check for damaged tires and correct air pressure.

Check the condition of seat belt. Check the seat bar and foot pedal interlocks or hand control interlocks for correct operation.

Clean dirt and debris from moving parts.

Check BICS™ functions.

Check for damaged signs (decals) and safety treads. Replace any signs or safety treads that are damaged or worn.

Check the fastening bolts, washers and nuts. Check the condition of cab.

Remove trapped water.

Check fluid level & add as needed. Check for damage & leaks.

Repair or replace as needed.

Check oil level.

Check cables, connections and electrolyte level. Add distilled water as needed.

Check for correct operation. Repair or adjust as needed.

Check for loose wheel nuts and tighten to 105–115 ft.–lbs.

(142–156 Nm) torque.

Check operation of the brake.

Check tension and adjust as needed. * Check for wear or damage. Check idler arm stop.

Replace filter element.

Grease three fittings.

Replace the reservoir breather cap.

Replace the filter element.

Replace oil and filter. Use CD or better grade oil and Bobcat filter.

Replace the oil in the chaincase.

Clean or replace the fluid.

Clean or replace the case drain filters.

Check lift arm by–pass control.

Check gear lube level.

∞ Adjust the engine valves. ◊ Replace the timing belt and belt tensioner assy.

Check wheel nut torque every 8 hours for the first 24 hours.

Also replace hydraulic/hydrostatic filter element when the transmission warning light comes ON. Or every 12 months.

Inspect the new belt after first 50 hours.

First oil and filter change must occur at 50 hours, 500 hours thereafter.

After the first 500 hours on new engine, adjust engine valves; 1000 hours thereafter. (See Service Manual for procedure.)

Or every 5 years.

863, 863H Bobcat Loader 41 Operation & Maintenance Manual

OPERATOR CAB 9.10.

A

The Bobcat loader has an operator cab (ROPS and FOPS) as standard equipment to protect the operator from rollover and falling objects. Check with your dealer if the operator cab has been damaged.

P–10887

ROPS/FOPS – Roll Over Protective Structure per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level l. Level ll is available.

P–10888

B

Level l – Protection from falling bricks, small concrete blocks and hand tools encountered in operations such as highway maintenance, landscaping, and other construction site services.

Level ll – Protection from falling trees, rocks; for machines involved in site clearing, overhead demolition or forestry.

P–03470

Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Bobcat Company.

Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death.

C

W–2069–1285

Raising The Operator Cab 11.

Always stop the engine before raising or lowering the cab.

Stop the loader on a level surface. Lower the lift arms.

Stop the engine. If the lift arms must be up while raising the operator cab, install the lift arm support device. (See LIFT ARM SUPPORT DEVICE Page 51.)

Install jackstands under the rear of the loader frame (Inset) [C].

P–10449

P–10826

Loosen the nut (both sides) at the front corner of the operator cab [A].

Remove the nut and plate (both sides) [A].

Mechanical Hand controls Only: Disconnect the control linkage joint from the bottom hole (work position) and move to the TOP hole on the control handle (both sides) [B].Both control handles must be in the vertical position so there will be no cab interference with the steering levers when the operator cab is raised or lowered.

Before the cab or the lift arms are raised for service, jackstands must be put under the rear corners of the frame. Failure to use jackstands can allow the machine to tip backward causing injury or death.

Advanced Hand Controls Only: Hold the steering levers forward so that the cab does not hit the levers when raising the cab.

W–2014–0895

Lift on the grab handle and bottom of the operator cab slowly until the cab latching mechanism engages and the cab is all the way up [C].

42

863, 863H Bobcat Loader Operation & Maintenance Manual

OPERATOR CAB (Cont’d)

A

Lowering the Operator Cab Always stop the engine before raising or lowering the cab.

NOTE: Make sure the seat bar is fully raised or lowered when lowering the cab. Always use the grab handles to lower the cab.

Advanced Hand Controls Only: Hold the steering levers forward so that the cab does not hit the levers when lowering the cab.

Pull down on the bottom of the operator cab until it stops at the latching mechanism.

P–10825

Release the latching mechanism and pull the cab all the way down [A].

B Install the plate and nut (both sides) [B].

Tighten the nuts to 40–50 ft.–lbs. (54–68 Nm) torque.

Use care when raising or lowering the operator cab to prevent damaging the shaft of the lift lock by–pass valve.

I–2070–0495

P–10888

P–10887

C

Mechanical Hand Controls Only Move the control linkage from the top hole to the BOTTOM hole (work position) on the control handle (both sides) [C].

P–03561

43

863, 863H Bobcat Loader Operation & Maintenance Manual

OPERATOR CAB (Cont’d)

A

Emergency Exit The front opening on the operator cab and rear window provide exits.

Rear Window: (If Equipped) Pull on the tag on the top of the rear window to remove the rubber cord [A].

P–10168

Push the rear window out of the rear of the operator cab.

B

Exit through the rear of the operator cab [B].

Front Door: (If Equipped)

P–10810

NOTE: When an Operator Cab Enclosure Kit is installed, the window of the front door can be used as an emergency exit. [C]

C

Pull the plastic loop at the top of the window in the front door to remove the rubber cord [C].

P–09216

D

Push the window out with your foot [D].

Exit through the front door.

P–09217

44

863, 863H Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS) 13.

The seat bar restraint system has a pivoting, spring assist seat bar with arm rests and has spring loaded interlocks for the lift and tilt control functions.

A Clean (Both Sides)

The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat.

The interlocks require the operator to lower the seat bar in order to operate the hand controls.

When the seat bar is up, the lift and tilt control functions are locked when returned to the NEUTRAL POSITION.

P–10361

AVOID INJURY OR DEATH The Seat Bar System must lock the lift and tilt foot pedals or hand controls in neutral when the Seat Bar is up. Service the system if controls do not lock correctly.

AVOID INJURY OR DEATH

W–2263–0597

Never operate loader without interlock shield 6705474 on both interlocks. Shields prevent foot from unlocking interlocks when leaving loader seat.

W–2158–0594

Inspecting The Seat Bar Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Start the engine. Press the green PRESS TO OPERATE Button.

Operate each foot pedal to check both the lift and tilt functions. Raise the lift arms until the bucket is about 2 feet (600 mm) off the ground.

B

Raise the seat bar. Try to move each foot pedal. Pedals must be firmly locked in neutral position. There must be no motion of the lift arms or tilt (bucket) when the pedals are pushed.

Pull the seat bar down, press the green PRESS TO OPERATE Button, lower the lift arms. Operate the lift pedals. While the lift arms are going up, raise the seat bar and the lift arms must stop.

Lower the seat bar, press the green PRESS TO OPERATE Button, lower the lift arms and put the bucket flat on the ground. Stop the engine. Raise the seat bar and operate the foot pedals to be sure that the pedals are firmly locked in the neutral position. Unbuckle the seat belt.

Interlock Interlock Shield Shield Clean (Both Sides)

Maintaining The Seat Bar 12.

See the SERVICE SCHEDULE Page 41 and on the loader for correct service interval.

Clean any debris or dirt from the moving parts [A] & [B].

Inspect the linkage bolts and nuts for tightness. The correct torque is 25–28 ft.–lbs. (34–38 Nm).

If the seat bar system does not function correctly, check for free movement of each linkage part. Check for excessive wear. Adjust pedal control linkage. Replace parts that are worn or damaged. Use only genuine Bobcat replacement parts.

P–10821

45

863, 863H Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS) 14.

The seat bar restraint system has a pivoting, spring assist seat bar with arm rests and has spring loaded interlocks for the lift and tilt control functions.

A Clean (Both Sides)

The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat.

The interlocks require the operator to lower the seat bar in order to operate the hand controls.

When the seat bar is up, the lift and tilt control functions are locked when returned to the NEUTRAL POSITION. P–10361

AVOID INJURY OR DEATH The Seat Bar System must lock the lift and tilt foot pedals or hand controls in neutral when the Seat Bar is up. Service the system if controls do not lock correctly.

AVOID INJURY OR DEATH Never operate loader without interlock shield 6705474 on both interlocks. Shields prevent foot from unlocking interlocks when leaving loader seat.

W–2158–0594

W–2263–0597

Inspecting The Seat Bar Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Start the engine. Operate each hand control to check both the lift and tilt functions. Raise the lift arms until the bucket is about 2 feet (600 mm) off the ground.

B

Raise the seat bar. Try to move each hand control. The controls must be firmly locked in NEUTRAL POSITION. There must be no motion of the lift arms or tilt (bucket) when the controls are moved.

Interlock Interlock Shield Shield

Pull the seat bar down, lower the lift arms. Operate the lift control. While the lift arms are going up, raise the seat bar and the lift arms must stop.

Clean (Both Sides)

Lower the seat bar, lower the lift arms and put the bucket flat on the ground. Stop the engine. Raise the seat bar and operate the hand controls to be sure that the controls are firmly locked in the NEUTRAL POSITION. Unbuckle the seat belt.

Maintaining The Seat Bar See the SERVICE SCHEDULE Page 41 for correct service interval.

Clean any debris or dirt from the moving parts [A] & [B].

Inspect the linkage bolts and nuts for tightness. The correct torque is 25–28 ft.–lbs. (34–38 Nm).

If the seat bar system does not function correctly, check for free movement of each linkage part. Check for excessive wear. Adjust hand control linkage. Replace parts that are worn or damaged. Use only genuine Bobcat replacement parts.

P–09671

46

863, 863H Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS) 15.

The seat bar restraint system has a pivoting seat bar (Item 1) [A] with arm rests.

A

The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat.

1

When the seat bar is down and the green PRESS TO OPERATE Button is activated, the lift, tilt, and traction drive functions can be operated.

When the seat bar is up, the lift, tilt, and traction drive functions are deactivated.

P–03563

Inspecting The Seat Bar

B

Sit in the operator’s seat. Turn the key ON, lower the seat bar and press the green PRESS TO OPERATE Button.

Both lights on the left handle should be ON.

Clean (Both Sides)

Move each hand control back and forth. You should hear the zip,zip sound of the lift and tilt actuators moving the control valve spools (under the seat).

Raise the seat bar fully. Both lights on the left handle should be OFF. Move each hand control back and forth. There must be no zip–zip sound of the lift or tilt actuators. If either actuator makes a sound while the seat bar is raised, contact your dealer for service.

P–10361

Maintaining The Seat Bar See the SERVICE SCHEDULE Page 41 for correct service interval.

Clean any debris or dirt from the moving parts [B].

If the seat bar system does not function correctly replace parts that are worn or damaged. Use only genuine Bobcat replacement parts.

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar.

• (Advanced Hand Controls) Move the hand controls to the NEUTRAL POSITION to make sure that both lift and tilt functions are deactivated.

The seat bar system must deactivate the lift and tilt control functions when the seat bar is up. Service the system if hand controls do not deactivate.

W–2321–0698

47

863, 863H Bobcat Loader Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 16.a 11.12.

Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 1. Sit in the operator’s seat. Turn key ON, lower the seat bar and disengage the parking brake. Press the green PRESS TO OPERATE Button. Four (4) BICS controller lights should be ON (Items 1, 2, 3, & 5) [A].

2. Engage the parking brake and raise the seat bar fully. System Activated (Item 1) [A], seat bar light (Item 2) [A], valve light (Item 3) [A] and traction light (Item 4) [A] should be OFF.

A

1 2 3 4 5

NOTE: If lights on BICS Controller are blinking, see BICS Troubleshooting Chart, Page 79.)

3. 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. Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 18.a 4. Sit in the operator’s seat. Lower the Seat Bar. Press the green PRESS TO OPERATE Button. Press the auxiliary hydraulics switch. The auxiliary switch light will 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. Press the green PRESS TO OPERATE button. Engage the parking brake. Fasten the seat belt.

N–17979

AVOID INJURY OR DEATH The Bobcat 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–2151–0394

6. Start the engine and operate at low idle. While raising the lift arms, raise the seat bar fully. The lift arms should stop. Repeat using the tilt function.

Inspecting The Traction Lock (Engine RUNNING) 17.7. 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.

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 feet (2 m) off the ground. Stop the engine. Turn the Lift Arm By–Pass Control Knob clockwise 1/4 turn. 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. Sit in the operator’s seat and fasten the Seat Belt.

Lower the Seat Bar, start the engine and press the green PRESS TO OPERATE Button.

11. Raise the lift arms about 6 feet (2 meters) off the ground.

12. Turn the key OFF and wait for the engine to come to a complete stop.

13. Turn the key ON. Press the green PRESS TO OPERATE Button, move the left hand control toward the operator. The lift arms should not lower.

14. Move the right hand control away from the operator.

The bucket (or attachment) should not tilt forward.

48

863, 863H Bobcat Loader Operation & Maintenance Manual

TRACTION LOCK CONTROL SYSTEM

A

Inspecting The Traction Lock Control System

1 2

1. Sit in the operator’s seat. Turn the key ON, lower the seat bar. Press the green PRESS TO OPERATE Button, and disengage the parking brake. Four (4) of the BICS Controller lights should be ON (Items 1,2,3, and 5) [A]. The Traction light (Item 4) [A] should be OFF.

3 4 5

2. Fasten the Seat Belt, engage the parking brake, start the engine and press the PRESS TO OPERATE Button. Disengage the parking brake and operate at low idle. The Traction light (Item 4) [A] should be ON.

P–10157

Maintenance

B

Check the wire connections at the engine speed sensor (Item 1) [B].

NOTE: When the Traction Lock Override Button is activated, the Traction Lock Override Control System will NOT engage the Traction Lock if the engine stops.

1

P–09440

49

863, 863H Bobcat Loader Operation & Maintenance Manual

PIVOT PINS

A

All lift arm and cylinder pivots have a large pin held in position with a retainer bolt and lock nut (Item 1) [A].

Check that the lock nuts are tightened to 18–20 ft.–lbs.

(24–27 Nm) torque.

1 TIRE MAINTENANCE Wheel Nuts See the SERVICE SCHEDULE Page 41 for the service interval to check the wheel nuts. The correct torque is 105–115 ft.–lbs. (142–156 Nm) torque [B].

P–01529

Tire Rotation Check the tires regularly for wear, damage and pressure.

(See SPECIFICATIONS Page 91 for the correct tire pressure.)

Rear tires usually wear faster than front tires. To keep tire wear even, move the front tires to the rear and rear tires to the front [C].

It is important to keep the same size tires on each side of the loader. If different sizes are used, each tire will be turning at a different rate and cause excessive wear. The tread bars of all the tires must face the same direction.

Inflate tires to the MAXIMUM pressure shown on the sidewall of the tire. DO NOT mix brands of tires used on the same loader.

I–2057–0794

Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling capability. Check for the correct pressure before operating the loader.

B

Tire Mounting Tires are to be repaired only by an authorized person using the proper procedures and safety equipment. Tires and rims must always be checked for correct size before mounting. Check rim and tire bead for damage.

The rim flange must be cleaned and free of rust. The tire bead and rim flange must be lubricated with a rubber lubricant before mounting the tire, avoid excessive pressure which can rupture the tire and cause serious injury or death. During inflation of the tire, check the tire pressure frequently to avoid over inflation.

P–01535

C Do not inflate tires above specified pressure.

Failure to use correct tire mounting procedure can cause an explosion which can result in injury or death.

W–2078–1285

B–09976

50

863, 863H Bobcat Loader Operation & Maintenance Manual

LIFT ARM SUPPORT DEVICE 3.

Maintenance and service work can be done with the lift arms lowered. If the lift arms are raised, use the following procedures to engage and disengage an approved lift arm support device:

A

2

Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.

W–2059–0598

1 P–10829

B

1

Service lift arm support device if damaged or if parts are missing. Using a damaged lift arm support or with missing parts can cause lift arms to drop causing injury or death.

W–2271–1197 P–10830

Engaging The Lift Arm Support Device

C

Install jackstands under the rear of the loader frame.

4.

Disconnect the spring from the lift arm support device retaining pin (Item 1) [A]. Support the lift arm support device (Item 2) [A] with your hand and remove the retaining pin.

Lower the lift arm support device on top of the lift cylinder.

Hook the free end of the spring (Item 1) [B] to the lift arm support device so there will be no interference with the support device engagement.

P–10707

1

With the operator in the seat, seat belt fastened and seat bar lowered, start the engine.

P–10833

Raise the lift arms, until the lift arm support device drops onto the lift cylinder rod (Inset) [C].

Lower the lift arms slowly until the support device is held between the lift arm and the lift cylinder. Stop the engine.

Raise the seat bar and move pedals until both pedals lock.

Install pin (Item 1) [C] into the rear of the lift arm support device below the cylinder rod.

51

863, 863H Bobcat Loader Operation & Maintenance Manual

LIFT ARM SUPPORT DEVICE (Cont’d)

A

Disengaging The Lift Arm Support Device Remove the pin from the lift arm support device.

Connect the spring (Item 1) [A] from the lift arm support device to the bracket below the lift arms.

1

With the operator in the seat, seat belt fastened and seat bar lowered, start the engine.

P–10834

B

Raise the lift arms a small amount and the spring will lift the support device off the lift cylinder rod [B]. Lower the lift arms. Stop the engine.

Raise the seat bar and move pedals until both pedals lock.

Disconnect the spring from the bracket.

Raise the support device into storage position and insert pin through lift arm support device and bracket. [See Page 51, (Item 1) [A].]

Connect spring to pin. (See Page 51, [A].)

P–10831

52

863, 863H Bobcat Loader Operation & Maintenance Manual

BOB–TACH

A

Inspection And Maintenance Move the Bob–Tach levers to engage the wedges [A].

The levers and wedges must move freely.

1

The wedges must extend through the holes in the attachment mounting frame (Item 1) [A].

N–17027

Bob–Tach wedges must extend through the holes in attachment. Levers must be fully down and locked. Failure to secure wedges can allow attachment to come off and cause injury or death.

B

W–2102–0588

The spring loaded wedge (Item 1) [A] must contact the lower edge of the hole in the attachment (Item 1) [B] and [C].

If the wedge does not contact the lower edge of the hole [B] and [C], the attachment will be loose and can come off the Bob–Tach.

1

N–17023

C

Bob–Tach Wedge

Wedge Must Contact Lower Edge Of Hole In The Attachment B–15177

Inspect the mounting frame on the attachment and the Bob–Tach, linkages and wedges for excessive wear or damage [D]. Replace any parts that are damaged, bent, or missing. Keep all fasteners tight.

D

Look for cracked welds. Contact your Bobcat dealer for repair or replacement parts.

Lubricate the wedges (See SERVICE SCHEDULE, Page 41 and LUBRICATION OF THE BOBCAT LOADER, Page 73).

TS–01062

53

863, 863H Bobcat Loader Operation & Maintenance Manual

REAR DOOR

A

AVOID INJURY

1

Never service or adjust the machine when the engine is running unless instructed to do so in the manual.

P–10350

W–2012–0290

Put your fingers into the slot in the rear door and pull on the latch handle [A].

Pull the rear door open.

Push the door stop (Item 1) [A] up into the hinge before closing the rear door.

Keep the rear door closed when operating the machine. Failure to do so could seriously injure a bystander.

W–2020–1285

P–10350

P–10812

Adjusting the Rear Door

B

The door latch catch (Item 1) [B] can be adjusted side to side for alignment with the door latch mechanism.

2

The door latch mechanism (Item 2) [B] can be adjusted backward or forward for alignment with the door catch.

1

P–10333

REAR GRILL

P–10339

C

Open the rear door.

Raise the rear grill [C].

1

The rear grill is held open by the cylinder (Item 1) [C] on the right side of the rear grill.

P–10816

P–10824

54

863, 863H Bobcat Loader Operation & Maintenance Manual

AIR CLEANER SERVICE

A

Without BOSS®: Replace the outer filter element only when the red ring shows in the window of the condition indicator (Item 1) [A].

2 1

NOTE: Before replacing the filter element, push the button on the condition indicator (Item 2) [A].

Start the engine, then stop the engine. If the red ring does not show, do not replace the filter element.

P–10799

Replace the inner filter every third time the outer filter is replaced or when the red ring still shows in the indicator window after the outer filter has been replaced.

B

With BOSS®: It is important to change the air filter element only when the service codes (on the BOSS® option instrument panel) shows the symbols AF.2 [B].

MC–02322

C

Release the three dust cover fasteners (Item 1) [C].

1

Remove the dust cover.

P–10800

55

863, 863H Bobcat Loader Operation & Maintenance Manual

AIR CLEANER SERVICE (Cont’d)

A

Remove the outer filter element [A].

NOTE: Make sure all sealing surfaces are free of dirt and debris.

Install the new outer filter element.

P–10798

B

Only replace the inner filter element under the following conditions [B]: Replace the inner filter every third time the outer filter is replaced or when the red ring still shows in the indicator window after the outer filter has been replaced.

When the service codes on the instrument panel shows symbol AF.2 during full engine speed, replace the inner filter element only after the outer filter element has been changed. (See Page 77.)

P–10802

Align the tab on the cover with one of the slots on air cleaner housing.

C

The evacuator (Item 1) [C] must be at the bottom.

Push dust cover into place and secure with wire fasteners.

Check the air intake hose for damage. Check the air cleaner housing for damage. Check to make sure all connections are tight.

1 P–10353

56

863, 863H Bobcat Loader Operation & Maintenance Manual

FUEL SYSTEM

A

Fuel Specifications Use only clean, high quality diesel fuel, Grade No. 2 or Grade No. 1.

1

The following is one suggested blending guideline which should prevent fuel gelling problems during cold temperatures: Temp. F° (C°) No. 2 No.1 +15° (9°) Down to –20° (–29°) Below –20° (–29°)

100% 50% 0%

0% 50% 100% P–07644

We recommended an operator contact their fuel supplier for local recommendations.

B

Filling The Fuel Tank

WRONG

Stop and cool the engine before adding fuel.

NO SMOKING! Failure to obey warnings can cause an explosion or fire.

W–2063–0887

Remove the fuel fill cap (Item 1) [A].

B–13456

Use a clean, approved safety container to add fuel of the correct specifications. Add fuel only in an area that has free movement of air and no open flames or sparks. NO SMOKING! [B].

Install and tighten the fuel fill cap [A].

57

863, 863H Bobcat Loader Operation & Maintenance Manual

FUEL SYSTEM (Cont’d)

A

Fuel Filter See the SERVICE SCHEDULE Page 41 for the recommended service interval when to remove the water from the fuel filter.

2

Loosen the drain (Item 1) [A] at the bottom of the filter element to drain water from the filter.

See the SERVICE SCHEDULE Page 41 for the recommended service interval when to replace the fuel filter.

Remove the filter element [A].

1

Clean the area around the filter housing. Put oil on the seal of the new filter element. Install the fuel filter, and hand tighten. Remove the air from the fuel system.

Removing Air From The Fuel System After replacing the fuel filter element or when the fuel tank has run out of fuel, the air must be removed from the fuel system prior to starting the engine.

Loosen the air vent plug (Item 2) [A] at the top of the fuel filter.

3

Squeeze the priming bulb (Item 3) [A] until fuel with no air bubbles flows from the vent Tighten the air vent plug.

P–10803

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

W–2103–1285

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece or cardboard or wood to find leaks. Do not use your bare hand.

Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

W–2072–0496

58

863, 863H Bobcat Loader Operation & Maintenance Manual

ENGINE LUBRICATION 5.

Checking

A

Check the engine oil level every day before starting the engine for the work shift. Open the rear door and remove the dipstick (Item 1) [A].

Keep the oil level between the marks on the dipstick.

Engine oil is also used to provide engine cooling. Check oil level every day for correct engine lubrication and also engine cooling.

2

1

Use a good quality motor oil that meets API Service Classification of CD or better (See Oil Chart below).

P–10801

Oil Chart RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)

C° –40

–34

–29

–23

–18

–13

–7

–1

+4

+10

+15

+21

+27

+32

+38

+43 +49

SAE 40W or 20W–50 SAE 10W–30 SAE 15W–40

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

SAE 30W

* SAE 5W–30 SAE 20W–20

W–2103–1285

SAE 10W SYNTHETIC OIL Use recommendation from Synthetic Oil Mfgr.

–40 –30

F°

–20

–10

0

+10

+20

+30

+40

+50

+60

+70

+80

+90

+100 +110 +120

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API CLASSIFICATION CD, CF4, CG4 )

* Can be used ONLY when available with appropriate diesel rating.

Replacing The Oil And Filter See the SERVICE SCHEDULE Page 41 for the service interval for replacing the engine oil and filter.

Run the engine until it is at operating temperature. Stop the engine.

Open the rear door. Remove the drain plug (Item 2) [A].

Drain the oil into container and dispose of used oil in an environmentally safe manner. Reinstall the drain plug.

59

863, 863H Bobcat Loader Operation & Maintenance Manual

ENGINE LUBRICATION (Cont’d)

A

Replacing Oil And Filter (Cont’d)

2

Remove the oil filter (Item 1) [A].

1

Clean the filter housing surface. Put clean oil on the new oil filter gasket. Install the filter and hand tighten only.

3

Use only genuine Bobcat filter.

Remove the fill cap (Item 2) [A].

Put 10 qts. (9,5 L) of oil in the engine. Start the engine and let it run for several minutes. Stop the engine. Check for leaks and check the oil level.

P–10801

Remove the dipstick (Item 3) [A]. Check the oil level.

Add oil as needed if it is not at the top mark on the dipstick (Item 1) [B].

B 1

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

W–2103–1285

P–01575

60

863, 863H Bobcat Loader Operation & Maintenance Manual

ENGINE COOLING SYSTEM Check the cooling system every day to prevent over–heating, loss of performance or engine damage.

Engine oil is used to provide both engine lubrication and cooling. No anti–freeze/water mixture is used for engine cooling.

Wear safety glasses to prevent eye injury when any of the following conditions exist:

• When fluids are under pressure.

• Flying debris or loose material is present.

• Engine is running.

• Tools are being used.

It is important to check the engine oil level every day to maintain adequate engine lubrication and also engine cooling.

When engine oil is changed, only the oil in the engine oil pan and filter is replaced. Approximately 7 quarts (6.6 liters) of oil remains in the cooling system (hoses and radiator).

W–2019–1285

When changing engine oil, follow the procedures carefully for correct quantity.

A

Cleaning The Cooling System Raise the rear grill [A].

1

Use air pressure or water pressure to clean the top of the hydraulic/hydrostatic oil cooler (Item 1) [A].

P–10822

B

Remove the hair pin (Item 1) [B] (both sides) so the oil cooler can be raised.

1

P–10816

Raise the oil cooler. Use air pressure or water pressure to clean the top of the engine oil cooler (Item 1) [C].

C

1

P–10823

61

863, 863H Bobcat Loader Operation & Maintenance Manual

ALTERNATOR BELT

A

Adjusting The Alternator Belt Stop the engine.

Loosen the alternator mounting and adjustment bolts (Item 1) [A].

1

P–10797

B

Move the alternator until the belt has 5/16 inch (8,0 mm) movement at the middle of the belt span with 15 lbs. (66 N) of force (Item 1) [B].

Tighten the adjustment and mounting bolts.

1

P–10807

62

863, 863H Bobcat Loader Operation & Maintenance Manual

TIMING BELT

A

The timing belt (Item 1) [A] MUST be replaced every 3,000 hours or every 5 years.

1

P–05298

DRIVE BELT

B

Adjusting The Drive Belt 6.

The drive belt idler arm stop is located on the left side of the engine below the air cleaner [B].

Loosen the two bolts (Item 1) [B] and slide the stop against the idler arm. Tighten the bolts.

2

1

There is no adjustment for the spring, just make sure the spring bolt (Item 2) [B] is tight.

P–05554

P–10805

63

863, 863H Bobcat Loader Operation & Maintenance Manual

DRIVE BELT (Cont’d)

A

Replacing The Drive Belt Stop the engine.

Open the rear door.

2

Remove the three belt shield fasteners (Item 1) [A]. The fasteners can be more easily removed if you remove the end of the fastener from the cast housing first then remove from the cover.

1

Remove the belt shield (Item 2) [A] from the drive belt housing.

P–10814

B

Loosen the two stop mounting bolts (Item 1) [B].

1

Loosen the spring tension bolt (Item 2) [B].

Remove the fan drive belt from the tensioner pulley.

2

P–10805

C

Remove the drive belt (Item 1) [C].

Install new drive belt and adjust the drive belt idler arm stop (See Adjusting The Drive Belt Page 63.)

1 P–10804

64

863, 863H Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM

A

Description The loader has a 12 volt, negative ground alternator charging system. The electrical system is protected by fuses located in the engine compartment. The fuses will protect the electrical system when there is an electrical overload. The reason for the overload must be found before starting the engine again.

Servicing The Electrical System The battery cables must be clean and tight. Check the water level in the battery. Remove any acid or corrosion from the battery and cables with a sodium bicarbonate and water solution [A].

P–00742

Cover the battery terminals and cable ends with grease.

B 2 1

Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes.

N–17636

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

C

W–2065–1296

Fuse Location The electrical system for this model loader is protected by fuses (Item 1) [B] located at the right side of the engine.

Remove the covers from the fuse holders (Item 1) [C] to access the fuses.

The fuse capacity and circuits are shown on the decal (Item 2) [B] and below.

P–13771

Fuse Capacity

Circuit

10 AMP. 15 AMP. 10 AMP. 15 AMP. or (25 AMP.) 25 AMP. 25 AMP. 25 AMP. 25 AMP.

BICS™ Engine BOSS® (if equipped) P.W.M. (or AHC) Lights Brake Accessory Accessory

65

863, 863H Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

A

Using A Booster Battery (Jump Starting) If it is necessary to use a booster battery to start the engine, BE CAREFUL! There must be one person in the operator’s seat and one person to connect and disconnect the battery cables.

2 4

The key switch must be in the OFF position. The booster battery must be 12 volt.

P–10813

Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

1 3

In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes.

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

W–2065–1296

P–10808

Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at engine frame.

Damage to the alternator can occur if:

Do not jump start or charge a frozen or damaged battery. Warm battery to 60°F. (16°C.) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery.

Never lean over battery while boosting, testing or charging.

• Engine is operated with battery cables disconnected.

• Battery cables are connected when using a

fast charger or when welding on the loader (Remove both cables from the battery).

• Extra battery cables (booster cables) are connected wrong.

Battery gas can explode and cause serious injury.

I–2023–1285

W–2066–1296

Connect the end of the first cable (Item 1) [A] to the positive (+) terminal of the booster battery. Connect the other end of the same cable (Item 2) [A] to the positive terminal on the starter.

Connect the end of the second cable (Item 3) [A] to the negative (–) terminal of the booster battery. Connect the other end of the same cable (Item 4) [A] to the ground cable connection on the engine mounting bracket.

Keep cables away from moving parts. Start the engine After the engine has started, remove the ground (–) cable (Item 4) [A] first. Remove the cable from the positive terminal on the starter.

66

863, 863H Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

A

Removing And Installing The Battery

1

2 Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes.

P–10809

B

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

1

W–2065–1296

Open the rear door.

Disconnect the negative (–) cable (Item 1) [A] from the battery.

Disconnect the main frame ground bolt and cable clamp (Item 2) [A] Remove the battery hold down clamp (Item 1) [B].

P–10809

Disconnect the positive (+) cable (Item 1) [C] from the battery.

C

1

Remove the battery from the loader.

P–10806

67

863, 863H Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

A

Removing And Installing The Battery (Cont’d) Always clean the terminals and cable ends when installing a new battery [A].

When installing the battery in the loader, do not touch any metal parts with the battery terminals.

Connect and tighten the battery cables.

Install cable clamp and ground bolt (Item 1) [B] as shown for correct ground and cable routing.

Connect the negative (–) cable last to prevent sparks.

P–09589

P–09590

B Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at engine frame.

1

Do not jump start or charge a frozen or damaged battery. Warm battery to 60°F. (16°C.) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery.

Never lean over battery while boosting, testing or charging.

P–10814

Battery gas can explode and cause serious injury.

W–2066–1296

C

FAN GEARBOX

1

Checking And Maintaining See the SERVICE SCHEDULE Page 41 for the correct service interval.

Gear Lube Level

Raise the operator cab. (See Raising the Operator Cab Page 42.)

Remove the plug (Item 1) [C] to check the lubricant level.

When maintaining the gearbox lube level, make sure the level does not go above the center line of the shaft in the gearbox [C]. Use SAE 90W gear lube if the level is low.

P–07616

68

863, 863H Bobcat Loader Operation & Maintenance Manual

FINAL DRIVE TRANSMISSION (CHAINCASE)

A

Checking And Adding Oil The chaincase contains the final drive sprockets and chains and uses the same type of oil as the hydraulic/hydrostatic system. (See SPECIFICATIONS Section Page 91.)

1

To check the chaincase oil level, use the following procedure: Park the loader on a level surface. Stop the engine.

Remove the plug (Item 1) [A] from the front of the chaincase housing.

P–07610

If oil can be reached with the tip of the your finger through the hole, the oil level is correct.

B

If the level is low, add oil through the check plug hole until the oil flows from the hole. Install and tighten the plug.

Removing Oil From The Chaincase To drain the oil from the chaincase, remove the cover (Item 1) [B] which is installed over the drain plug at the bottom rear of the chaincase.

1

P–01616

C

Remove the drain plug (Item 1) [C] and drain the oil into a container.

Check the condition of the drain plug and replace as necessary.

1

P–01619

69

863, 863H Bobcat Loader Operation & Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM

A

Checking And Adding Fluid Use only recommended fluid in the hydraulic system.

(See SPECIFICATIONS Section Page 91.)

To check the reservoir fluid level, use the following procedure:

2

Stop the loader on a level surface. Lower the lift arms and tilt the Bob–Tach fully back.

1

Stop the engine.

Remove the dipstick (Item 1) [A].

P–07671

B

The fluid level must be between the marks on the dipstick [B].

If fluid is needed, remove the fill cap (Item 2) [A].

Add the fluid as needed to bring the level to the top mark on the dipstick [B].

P–07673

C

Replacing the Hydraulic/Hydrostatic Filter 7.

See the SERVICE SCHEDULE Page 41 for the correct service interval.

Raise the operator cab. (See Raising the Operator Cab Page 42.)

Remove the filter element (Items 1) [C].

Clean the surface of the filter housing where the element seal contacts the housing. Put clean oil on the rubber seal of the filter element.

1

Install and hand tighten the filter element.

N–17395

70

863, 863H Bobcat Loader Operation & Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

A

Replacing The Hydraulic Fluid See the SERVICE SCHEDULE Page 41 for the correct service interval.

Replace the fluid if it becomes contaminated or after major repair.

Remove the fill cap. Remove the screen from the reservoir [A]. Wash the screen in clean solvent and air dry.

NOTE: Be sure the rubber gasket is installed on the fill cap.

P–07672

Also replace the two hydrostatic motor case drain filters thoroughly after a major repair.

B

Raise the operator cab. (See Raising the Operator Cab Page 42.)

Disconnect the hose (Item 1) [B] from the hydraulic fluid reservoir and drain the fluid into a container.

1

Replace both hydrostatic motor case drain filters (Item 1) [C] & [D].

Install the case drain filters and tighten all the hoses.

Replace the two hydraulic/hydrostatic filter elements.

(See Page 70.)

Add the correct fluid to the reservoir until the fluid level is between the marks on the dipstick. (See Page 70.) DO NOT fill above the top mark on the dipstick.

P–07690

C

Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin and cause serious injury and possibly death if proper medical treatment by a physician familiar with this injury is not received immediately.

RIGHT CASE DRAIN FILTER

1

W–2145–0290

P–07608

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

D

LEFT CASE DRAIN FILTER

W–2103–1285

Lower the operator cab.

Start the engine and operate the loader hydraulic controls.

1

Stop the engine and check for leaks.

Check the fluid level in the reservoir and add as needed.

P–07611

71

863, 863H Bobcat Loader Operation & Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

A

Hydraulic Reservoir Breather Cap

1

See SERVICE SCHEDULE Page 41 for the correct service interval.

Remove the breather cap (Item 1) [A].

P–05080

NOTE: Check to make sure the rubber gasket (Item 1) [B] is installed on the fill cap.

B

Clean the filter (Item 2) [B] from the breather cap.

1

Make sure the baffle washer (Item 3) [B] is installed in the hydraulic reservoir.

3

Replace the breather cap if it is worn or damaged, or beyond the 500 hour service life.

2 P–01502

72

P–01497

863, 863H Bobcat Loader Operation & Maintenance Manual

LUBRICATION OF THE BOBCAT LOADER 8.

Lubricate the loader as specified in the SERVICE SCHEDULE Page 41 for the best performance of the loader.

A

Record the operating hours each time you lubricate the Bobcat loader.

1

Always use a good quality lithium based multi–purpose grease when you lubricate the loader. Apply the lubricant until extra grease shows.

Lubricate the following locations on the loader: 1. Rod End Lift Cylinder (Both Sides) [A].

P–07655

2. Base End Lift Cylinder (Both Sides) [B].

B

2

P–10815

3. Lift Arm Pivot Pin (Both Sides) [C].

C

3

P–10817

4. Base End Tilt Cylinder [D].

D

4

P–07641

73

863, 863H Bobcat Loader Operation & Maintenance Manual

LUBRICATION OF THE BOBCAT LOADER (Cont’d)

A

863/863H BICSOperation&MaintenanceManual(S/N514427600&Above)#6900790–PreventiveMaintenanceSection

5. Rod End Tilt Cylinder [A].

6. Bob–Tach Pivot Pin (Both Sides) [A].

5 7. Bob–Tach Wedge (Both Sides) [A].

7

6

P–07653

B

8. 250 Hours: Steering Lever Shaft (2) [B].

8

9. 250 Hours: Centering bracket pivot pin [B].

9

P–07609

10. 250 Hours: Steering Linkage Pivot (2) [C] (If Equipped).

C 10

N–17398

74

863, 863H Bobcat Loader Operation & Maintenance Manual

SYSTEMS ANALYSIS 11.

13.14.

ADVANCED HAND CONTROLS Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 AUXILIARY HYDRAULICS OPERATION Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

SYSTEMS ANALYSIS

75

863, 863H Bobcat Loader Operation & Maintenance Manual

76

863, 863H Bobcat Loader Operation & Maintenance Manual

SERVICE CODES 12.

15.16.

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 BOBCAT SERVICE PERSONNEL.

SUBJECT Engine Temperature

Engine Oil Pressure

Engine Speed

Air Filter Battery Fuel Level

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. Failure to follow instructions can cause injury or death.

W–2003–1298

DISPLAY READS

CONDITION

EC–1.1 EC–2.1 EC 3 EC 4

SHUTDOWN, Engine Temperature WARNING, Engine Temperature Wiring Not Connected Wiring Shorted

EC 5 EC 7 EP 1 EP 2

High Sensor Voltage Sensor Out Of Range SHUTDOWN, Pressure WARNING, Pressure

EP 3 EP 4 EP 5

Wiring Not Connected Wiring Shorted High Sensor Voltage

EP 7 ES 1 ES–2.1 ES–6

Sensor Out Of Range SHUTDOWN, Engine Speed Too High WARNING, Engine Speed Slightly High Sensor No Signal

ES–7 AF 2 AF 6 b–2.1

Sensor Out Of Range WARNING, Restriction Too High Sensor No Signal WARNING, Bad Battery

b–2.2 FUEL2 FUEL3 FUEL4

WARNING, Battery Voltage WARNING, Low Level Wiring Not Connected Wiring Shorted

FUEL5 FUEL7

High Sensor Voltage Sensor Out Of Range

77

863, 863H Bobcat Loader Operation & Maintenance Manual

SUBJECT

DISPLAY READS

Hydrostatic Charge Filter Conditions

Return Filter Condition (853, 863, 873 Only) Hydrostatic Fluid

Hydrostatic Fluid Temperature

CONDITION

HF1–2 HF1–6 HF2–2 HF2–6 HF2–2 HF2–6

WARNING, High Restriction (1st Filter) Sensor No Signal WARNING, High Restriction (2nd Filter) Sensor No Signal WARNING, High Restriction Sensor No Signal

HP 1 HP 2 HP 3 HP 4 HP 5 HP 7 HC 1 HC 2 HC 3 HC 4 HC 5 HC 7

SHUTDOWN, Pressure WARNING, Pressure Wiring Not Connected Wiring Shorted High Sensor Voltage Sensor Out Of Range SHUTDOWN, Temperature WARNING, Temperature Wiring Not Connected Wiring Shorted High Sensor Voltage Sensor Out Of Range

AUXILIARY HYDRAULICS OPERATION Troubleshooting Chart The Auxiliary Hydraulics Control has a built–in diagnostics function.

The two lights will blink in a specific pattern to indicate a problem (See Below).

1 2 P–3272

INDICATIONS Blinking Momentary Light (Item 1) Detent Light (Item 2) Problem

Causes

Check

Off

Blinking

X

Off X

X Base Solenoid

X Rod Solenoid

Blinking

Off

Blinking

X

X

At same time

Alternating

X

X

Diverter Solenoid

Wires Disconnected Wires Shorted Wires Cut Solenoid Failed

Off

Right Handle

Spring in the thumb switch is broken

Check for voltage (1–10 volts) at the solenoid connector.

Check for the thumb switch in centered position. Check for voltage to Dk. Blue & Dk. Blue/White wires.

NOTE: Check all of the above first. Any of the above can also indicate a problem with the Auxiliary Control Module. See your Bobcat dealer for module replacement.

78

863, 863H Bobcat Loader Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 13.

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.

Indicator Light System Activated

Light ON

PRESS TO OPERATE PRESS TO OPERATE Lift, tilt and traction button is activated button not activated functions will not operate.

Seat Bar Seat Bar Down.

Valve

Traction

Light OFF

Flashing Indicator Means System Problem (See Your Bobcat Dealer for Service) Effect on Operation of Loader When Light Is Number of OFF Flashes Cause

Control Valve Can Be Used.

Loader can be moved forward & backward.

Seat Bar Up.

Control Valve Cannot Be Used.

Lift, tilt and traction functions will not operate.

Lift and tilt functions will not operate.

Loader cannot be Loader cannot be moved forward and moved forward and backward. backward.

2 3 2 3 2 3 3 1 2 3 4 5 6

Power

BICS Controller is operating correctly.

BICS Controller is not operating correctly.

Lift, tilt and traction functions will not operate.

N/A

System Activated circuit shorted to battery.

System Activated circuit shorted to ground.

Seat bar sensor circuit shorted to battery voltage*.

Seat bar sensor circuit shorted to ground.

Valve output circuit shorted to battery voltage*.

Valve output circuit shorted to ground.

Valve output circuit is not grounded.

Traction lock hold coil circuit is open.

Traction lock hold coil circuit shorted to battery voltage*.

Traction lock hold coil circuit shorted to ground.

Traction lock pull coil circuit is open.

Traction lock pull coil circuit is shorted to battery voltage*.

Traction lock pull coil circuit is shorted to ground.

N/A

* 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. If one of the lights stay OFF, check the circuit for continuity. See Inspection & Maintenance Instructions in Preventive Maintenance section.

(2) If all 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.

ADVANCED HAND CONTROLS (AHC) Troubleshooting Chart The AHC has a built–in diagnostic function which uses the two lights on the left handle.

Both lights will be ON when the AHC is functioning correctly. The lights will flash in a specific pattern to indicate a problem (See Below). (See your Bobcat dealer for service information.)

Number of Flashes Left Hand Light (Lift Circuit) Right Hand Light (Tilt Circuit)

1 Handle Not Calibrated

FLASHING LIGHT MEANS SYSTEM PROBLEM (See Your Bobcat Dealer for Service) 2 3 4 Actuator Not Calibrated

Wiring Fault (Handle)

Wiring Fault (Actuator)

5 Actuator Fault

NOTE: Flashing patterns will repeat every six seconds. One blink will occur if Right or Left Hand Control is not in neutral position before key is turned ON or engine is started and green PRESS TO OPERATE button is activated.

79

863, 863H Bobcat Loader Operation & Maintenance Manual

80

863, 863H Bobcat Loader Operation & Maintenance Manual

MACHINE SIGN TRANSLATIONS 14.

17.18.

IMPORTANT (6710456) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 SERVICE SCHEDULE (6715563) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 WARNING (6579510 – Foot Pedal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 WARNING (6703725 – Hand Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 WARNING/DANGER (6579528, 6577754, 6702301, 6702302) . . . . . . . . . . 88 WARNING (6715944) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 DANGER (6717343) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

MACHINE SIGN TRANSLATIONS

MACHINE SIGNS (DECALS) Machine signs (decals) are an esential part of the loader. (See Page xiv & xv.) This section provides French and Spanish translations of the machine signs that are in English.

81

863, 863H Bobcat Loader Operation & Maintenance Manual

82

863, 863H Bobcat Loader Operation & Maintenance Manual

IMPORTANTE (SPANISH) 863 ESTE MODELO DE CARGADOR VIENNE EQUIPADO DE FÁBRICA CON UN SISTEMA DE ESCAPE CON DISPOSITIVO PARACHISPAS APROBADO POR EL SERVICIO FORESTAL DEL MINISTERIO DE AGRICULTURA DE LOS ESTADOS UNIDOS. EL TURBOALIMENTADOR DEBE ESTAR FUNCIONANDO PARA MANTENER OPERANDO EL SISTEMA DE ESCAPE CON DISPOSITIVO PARACHISPAS. SI SE OPERA ESTA MÁQUINA EN BOSQUES INFLAMABLES, MATORRALES O TERRENOS CUBIERTOS DE PASTOS, ÉSTA DEBE ESTAR EQUIPADA CON UN DISPOSITIVO PARACHISPAS CONECTADO AL SISTEMA DE ESCAPE Y DEBE MANTENERSE EN BUENAS CONDICIONES DE FUNCIONAMIENTO. EL NO HAVERLO CONSTITUYE UNA VIOLACIÓN A LA LEY DEL ESTADO DE CALIFORNIA, SECCIÓN 4442. PRC. CONSULTE LAS LEYES Y REGULACIONES LOCALES SOBRE REQUISITOS RELACIONADOS CON LOS DISPOSITIVOS PARACHISPAS. PARA MAS INSTRUCCIONES, CONSULTE EL MANUAL DE OPERACIÓN Y MANTENIMIENTO.

IMPORTANT (FRENCH) 863 LE SYSTÈME D’ÉCHAPPEMENT DE CETTE CHARGEUSE EST ÉQUIPÉ D’UN PARA–ÉTINCELLES INSTALLÉ EN USINE ET APPROUVÉ PAR LE SERVICE DES FORÊTS DU DÉPARTMENT DE L’AGRICULTURE DES ÉTATS–UNIS (U.S.D.A. FORESTRY SERVICE).

LE TURBOCOMPRESSEUR DOIT ÊTRE EN BON ÉTAT DE MARCHE POUR QUE LE SYSTÈME D’ÉCHAPPEMENT À PARE–ÉTINCELLE FONCTIONNE. SI CETTE MACHINE EST UTILISÉE SUR UN TERRAIN COUVERT D’ARBRES, DE BROUSSAILLES, OU D’HERBAGES INFLAMMABLES, SON SYSTÈME D’ÉCHAPPEMENT DOIT ÊTRE ÉQUIPÉD D’UN PARE–ÉTINCELLE ET MAINTENU EN BON ÉTAT DE FONCTIONNEMENT. CETTE EXIGENCE EST IMPOSÉE PAR LA LOI DE L’ÉTAT DE LA CALIFORNIE, SECTION 4442. PRC. CONSULTER LA RÉGLEMENTATION LOCALE RELATIVE AUX PARE–ÉTINCELLES. CONSULTER LE MANUEL DE L’OPÉRATEUR ET D’ENTRETIEN POUR DE PLUS AMPLES RENSEIGNEMENTS.

83

863, 863H Bobcat Loader Operation & Maintenance Manual

ADVERTENCIA (SPANISH) EVITE LESIONES O LA MUERTE

• Mantenga la puerta cerrada excepto durante tareas de mantenimiento

•

contactos eléctricos, partes móviles, partes calientes y escapes.

•

• Mantenga el motor libre de material inflamable • Mantenga el cuerpo, objetos sueltos y la vestimenta alejados de • No utilice la cargadora en un espacio con polvos o gases explosivos o con material inflamable cerca de un escape.

• Todos los gases de escape puede provocar la muerte. Siempre • • • • •

ventile.

Jamás utilice éter o fluidos de arranque en un motor diesel con bujías incandescentes. Utilice sólo dispositivos de arranque aprobados por el fabricante del motor.

Los fluidos que gotean bajo presión pueden penetrar en la piel y provocar lesiones graves. En ese caso, obtenga asistencia médica inmediata. Utilice anteojos de seguridad. Utilice un trozo de cartón al verificar la existencia de fugas.

Los ácidos de la batería ocasionan quemaduras graves, utilice anteojos de seguridad. Si el ácido entra en contacto con los ojos, la piel o la vestimenta, enjuague bien con agua. En caso de contacto con los ojos, enjuague y obtenga asistencia médica.

Las baterías producen gases explosivos e inflamables. Aleje arcos, chispas, llamas y tabaco encendido.

Para arranque en puente, conecte el cable negativo al motor de la cargadora en último lugar (jamás en la batería). Luego del arranque en puente, quite la conexión negativa del motor primero.

PROGRAMA DE MANTENIMIENTO (SPANISH) CADA 10 HORAS (ANTES DE ARRANCAR LA CARGADORA)

• ACEITE DEL MOTOR – revise el nivel y agregue según sea • • •

• FILTRO DEL COMBUSTIBLE – quite el agua atrapada.

• BRAZO DE ELEVACIÓN DE LA CARGADORA, UNIONES DE

necesario. No lo llene en exceso.

FILTRO DE AIRE DEL MOTOR – revise el indicador y/o el visor.

Repare sólo en caso de ser necesario.

SISTEMA DE AIRE DEL MOTOR – verifique que no existan fugas o componentes dañados.

SISTEMA DE REFRIGERACIÓN DEL MOTOR – limpie el refrigerador de aceite y las parrillas.

MODELOS 500 Y 700 – revise el nivel del fluido refrigerante frío, agregue 53% de propilenglicol premezclado con 47% de agua según sea necesario.

• •

ELEVACIÓN, CILINDROS, PIVOTES Y CUÑAS DEL ENGANCHE RÁPIDO – lubrique con grasa multiuso a base de litio.

CINTURÓN DE SEGURIDAD, BARRA DE SEGURIDAD Y ENGANCHES DE CONTROL– revise las funciones. Repare o cambie según sea necesario. Limpie las partes móviles.

BICSMR – revise la función. Elimine desperdicios, suciedad u objetos debajo y/o detrás del asiento del operador según sea necesario.

NEUMÁTICOS – verifique la presión de aire. Infle los neumáticos con la presión MÁXIMA que se indica en la pared lateral del neumático.

GENERAL – verifique que no existan partes sueltas o rotas, que la cabina del operador no presente daños, revise la operación de los instrumentos, la existencia de tuercas sueltas, fugas de aceite, rótulos de seguridad dañados o faltantes. Repare o cambie según sea necesario.

CADA 50 HORAS

• FLUIDO HIDRÁULICO, MANGUERAS Y TUBERÍA – revise el • • •

nivel del fluido. Verifique que no existan daños o fugas. Repare o cambie según sea necesario.

TRANSMISIÓN DE DIRECCIÓN FINAL (caja de cadenas) – revise el nivel del fluido.

CONTROLES HIDRÁULICOS (PEDALES O CONTROLES MANUALES) Y PALANCAS DE DIRECCIÓN – revise la operación. Ajuste según sea necesario.

TUERCAS DE LAS RUEDAS – revise que no existan tuercas sueltas y ajuste según lo indicado en el manual de operación y mantenimiento.

CADA 100 HORAS

• SILENCIADOR DEL SISTEMA PARACHISPAS – en los modelos 500 y 700 solamente. Vacíe la cámara de chispas.

• BATERÍA – verifique que la batería no presente daños, revise las abrazaderas, las conexiones de los cables y el nivel de electrolito. Agregue agua destilada según sea necesario.

CADA 250 HORAS (O CADA 12 MESES)

• PIVOTES DE LA PALANCA DE DIRECCIÓN – lubrique con grasa multiuso a base de litio (3 lugares).

• CORREA DE DESPLAZAMIENTO DE TRANSMISIÓN –

modelos 700. Verifique que no se encuentre gastada o dañada.

Ajuste o cambie según sea necesario. *Revise las correas de desplazamiento cambiadas después de 50 horas de operación y ajústelas según sea necesario.

84

863, 863H Bobcat Loader Operation & Maintenance Manual

• LÍNEA DE DESPLAZAMIENTO – modelos 500 solamente. • FILTRE À CARBURANT – Éliminez l’eau retenue.

Lubrique la junta U. • BRAS DE LEVAGE, AXES DE LEVAGE, VÉRINS, PIVOTS • ENGRANAJE DEL VENTILADOR – revise el nivel del fluido.

BOBTACH ET CLAVETTES – Lubrifiez avec une graisse à base de lithium de type universel.

• Revise todas las correas de desplazamiento. Revise el estado y la tensión de la bomba hidrostática y de agua, el alternador y • CEINTURE DE SÉCURITÉ, ARCEAU DE SÉCURITÉ ET •

el desplazamiento del ventilador. Ajuste o cambie según sea necesario.

BICSMR – revise el control de desvío de los brazos de elevación.

CADA 500 HORAS (O CADA 12 MESES)

• SISTEMA HIDRÁULICO/HIDROSTÁTICO – cambie la tapa del respiradero del depósito.

CADA 1000 HORAS (O CADA 12 MESES)

• DEPÓSITO HIDRÁULICO – cambie el fluido.

• TRANSMISIÓN DE DIRECCIÓN FINAL (CAJA DE CADENAS)

• • •

– cambie el fluido.

AVERTISSEMENT (FRENCH) ÉVITEZ DES BLESSURES OU LA MORT

TOUTES LES 50 HEURES

• FLUIDE

• Gardez la portière fermée, sauf en cas d’intervention de service.

• Gardez la région du moteur exempte de matières inflammables.

• Gardez toute partie du corps, tout objet lâche et toute pièce de

•

•

•

• • • •

• •

vêtement à l’écart des points de contact électrique, des pièces en mouvement, des parties chaudes et de l’échappement.

N’utilisez pas la chargeuse dans des espaces contenant des poussières explosives, des gaz explosifs ou des matières inflammables pouvant se trouver à proximité de l’échappement.

Tous les gaz d’échappement peuvent être mortels. Prévoyez toujours une ventilation.

N’utilisez jamais d’éther ni de fluide de démarrage avec un moteur diesel comportant des bougies de préchauffage.

N’utilisez que des auxiliaires de démarrage approuvés par le fabricant du moteur.

Des fluides qui fuient sous pression peuvent pénétrer la peau et provoquer de graves lésions. Consultez un médecin immédiatement. Portez des lunettes de protection. Utilisez des morceaux de carton pour vérifier toute fuite.

L’acide que contiennent les batteries provoque de graves brûlures; portez des lunettes de protection. En cas de contact avec les yeux, la peau ou les vêtements, rincez à grande eau.

S’il y a eu contact avec les yeux, rincez à fond et consultez un médecin.

Les batteries produisent des gaz inflammables et explosifs.

Tenez à distance toute source d’arcs électriques, d’étincelles et de flammes, ainsi que tout produit de tabac allumé.

Pour effectuer des démarrages avec câbles d’appoint, reliez en dernier le câble négatif au moteur de la chargeuse (jamais à la batterie). Après le démarrage, enlevez d’abord la connexion négative au moteur.

CALENDRIER D’ENTRETIEN (FRENCH) TOUTES LES 10 HEURES (AVANT DE DÉMARRER LA CHARGEUSE)

ENCLENCHEMENTS SOLIDAIRES – Vérifiez leur bon fonctionnement. Réparez ou remplacez au besoin. Débarrassez les pièces mobiles de toute saleté et de tous débris.

BICSt – Vérifiez le bon fonctionnement. Débarrassez le dessous /ou l’arrière du siège de l’opérateur de tous débris, saletés et objets divers, le cas échéant.

PNEUS – Vérifiez la pression d’air. Gonflez à la valeur de pression MAXIMALE qui est indiquée sur le flanc du pneu.

GÉNÉRAL – Vérifiez si des pièces sont desserrées ou brisées, si la cabine de l’opérateur est en bon état, si les instruments fonctionnent correctement, si les écrous de roue sont bien serrés, s’il y a fuites d’huile, si des enseignes de sécurité sont endommagées ou ont été arrachées. Réparez ou remplacez au besoin.

•

HYDRAULIQUE, TUYAUX SOUPLES ET TUBULURES – Vérifiez le niveau du fluide. Vérifiez s’il y a dommages et fuites. Réparez ou remplacez au besoin.

TRANSMISSION FINALE (CARTER GARDE–CHAÎNE) – Vérifiez le niveau de liquide à transmission.

COMMANDES HYDRAULIQUES (À PÉDALE OU MANUELLES) ET DIRECTION – Vérifiez le bon fonctionnement. Réglez au besoin. ÉCROUS DE ROUE – Vérifiez si des écrous de roue sont desserrés et, le cas échéant, resserrez suivant les indications du Manuel de l’opérateur et d’entretien.

TOUTES LES 100 HEURES

• SILENCIEUX PARE–ÉTINCELLES – Modèles 500 et 700 seulement – Videz la chambre d’étincelles.

• BATTERIE – Vérifiez si la batterie est endommagée; vérifiez les

dispositifs de retenue, les câbles, les connexions ainsi que le niveau d’électrolyte. Ajoutez de l’eau distillée au besoin.

TOUTES LES 250 HEURES (OU TOUS LES 12 MOIS)

• AXES DE LEVIER DE DIRECTION – Lubrifiez (trois points de

graissage) avec une graisse à base de lithium de type universel.

• COURROIE DE TRANSMISSION – Modèles 700 – Vérifiez l’état • • • •

d’usure et d’endommagement. Réglez ou remplacez au besoin. *Vérifiez toute nouvelle courroie de transmission au bout de 50 heures de service, et réglez–la au besoin.

ARBRE DE TRANSMISSION – Modèles 500 seulement – Lubrifiez le joint universel.

CARTER D’ENGRENAGES D’ENTRAÎNEMENT DU VENTILATEUR – Vérifiez le niveau d’huile.

Vérifiez tous les entraînements par courroie. Vérifiez l’état et la tension des entraînements de pompe hydrostatique, de pompe à eau, d’alternateur et de ventilateur. Réglez ou remplacez au besoin.

BICSt – Vérifiez la commande de dérivation du bras de levage.

TOUTES LES 500 HEURES (OU TOUS LES 12 MOIS)

• HUILE MOTEUR – Vérifiez le niveau, et faites l’appoint au • SYSTÈME HYDRAULIQUE/HYDROSTATIQUE – Remplacez besoin. Évitez de remplir à l’excès. le chapeau de reniflard du réservoir.

• FILTRE À AIR DU MOTEUR – Vérifiez la jauge /ou l’affichage.

N’effectuez d’entretien que si nécessaire.

TOUTES LES 1000 HEURES (OU TOUS LES 12

• CIRCUIT D’AIR DU MOTEUR – Vérifiez s’il y a des fuites et si MOIS) des composants sont endommagés.

• RÉSERVOIR HYDRAULIQUE – Remplacez le fluide • CIRCUIT DE REFROIDISSEMENT DU MOTEUR – hydraulique.

Débarrassez le refroidisseur d’huile et les grillages de tous • TRANSMISSION FINALE (CARTER GARDE-CHAÎNE) – débris.

Modèles 500 et 700 – Vérifiez le niveau de liquide de refroidissement, à froid; ajoutez au besoin un mélange préparé constitué de 53 p. 100 de propylène glycol et de 47 p. 100 d’eau.

Remplacez le liquide à transmission.

85

863, 863H Bobcat Loader Operation & Maintenance Manual

Solamente con control de piso

Commande au pied seulement

ADVERTENCIA (SPANISH)

ATTENTION (FRENCH)

EVITE HERIDAS O LA MUERTE

EVITER LES BLESSURES OU LA MORT

NO USE NUNCA EL CARGADOR SIN LEER LAS INSTRUCCIONES. LEA EL MANUAL DEL OPERATIO, EL MANUAL DE SERVICIO Y LA GIA DEL OPERARIO.

NE JAMAIS SE SERVIR DE LA CHARGEUSE SANS INSTRUCTIONS. LIRE LE MANUEL DE L’OPERATEUR EL D’ENTRETIEN AINSI QUE LE GUIDE D’UTILISATION.

NO VIAJE O DE LA VUELTA CON LOS BRAZOS DE ELEVACION ARRIBA. CARGUE, DESCARGUE Y DE LA VUELTA ESTANDO EN UN SITIO PLANO Y NIVELADO. NO EXCEDA LA CAPACIDAD NOMINAL DE FUNCIONAMIENTO (VEA EL AVISO EN EL CARGADOR).

NE PAS SE DEPLACER NI VIRER AVEC LE BRAS RELEVES. CHARGER, DECHARGER ET VIRER SUR UN SOL PLAT ET HORIZONTAL. NE PAS DEPASSER LE CAPACITE NOMINALE (CONSULTER L’AUTOCOLLANT APPOSE SUR LA CARGEUSE).

USE LA BARRA DEL ASIENTO. ASEGURESE BIEN EL CINTURON DE SEGURIDAD.

UTILISER L’ARCEAU DE SECURITE. ATTACHER SOIGNEUSEMENT LA CEINTURE DE SECURITE.

NUNCA MODIFIQUE EL EQUIPO NI USE ADITAMENTOS QUE NO ESTEN APROBADOS POR LA COMPAÑIA BOBCAT.

NE JAMAIS MODIFIER L’EQUIPEMENT NI SE SERVIR D’ACCESSOIRES QUE NE SONT PAS APPROUVES PAR BOBCAT COMPANY.

MANTENGA LOS PIES EN LOS PEDALES. MAINTENIR LES PIEDS SUR LES PEDALES. EN LA PENDIENTES, MANTENGA EL EXTREMO PESADO DE CARGADOR EN POSICION ASCENDENTE.

DANS LES PENTES, TOUJOURS MAINTENIR LA PARTIE LA PLUS LOURDE DE LA CHARGEUSE VERS LE HAUT.

ANTES DE BAJARSE DEL CARGADOR POUR QUITTER LA CHARGEUSE: 1. BAJE LOS BRAZOS DE ELEVACION. COLOQUE EL ADITAMENTO BEIN EN EL SUELO. 2. PARE EL MOTOR

1. ABAISSER LES BRAS DE LEVAGE. POSER L’EQUIPEMENT A PLATE SUR LE SOL. 2. ARRETER LE MOTEUR.

3. PONGA EL FRENO.

3. ENCLENCHER LE FREIN DE STATIONNEMENT.

4. LEVANTE LA BARRA DEL ASIENTO. MUEVA LOS PEDALES HASTA QUE AMBOS SE TRABEN.

4. RELEVER L’ARCEAU DE SECURITE. DEPLACER LES PEDALES JUSQU’A CE QU’ELLES SOIENTE TOUTES DEUX VERROILLEES. 86

863, 863H Bobcat Loader Operation & Maintenance Manual

Solamente con control de mano

Commande à la main seulement

ADVERTENCIA (SPANISH)

ATTENTION (FRENCH)

EVITE HERIDAS O LA MUERTE

EVITER LES BLESSURES OU LA MORT

NO USE NUNCA EL CARGADOR SIN LEER LAS INSTRUCCIONES. LEA EL MANUAL DEL OPERATIO, EL MANUAL DE SERVICIO Y LA GIA DEL OPERARIO.

NE JAMAIS SE SERVIR DE LA CHARGEUSE SANS INSTRUCTIONS. LIRE LE MANUEL DE L’OPERATEUR EL D’ENTRETIEN AINSI QUE LE GUIDE D’UTILISATION.

NO VIAJE O DE LA VUELTA CON LOS BRAZOS DE ELEVACION ARRIBA. CARGUE, DESCARGUE Y DE LA VUELTA ESTANDO EN UN SITIO PLANO Y NIVELADO. NO EXCEDA LA CAPACIDAD NOMINAL DE FUNCIONAMIENTO (VEA EL AVISO EN EL CARGADOR).

NE PAS SE DEPLACER NI VIRER AVEC LE BRAS RELEVES. CHARGER, DECHARGER ET VIRER SUR UN SOL PLAT ET HORIZONTAL. NE PAS DEPASSER LE CAPACITE NOMINALE (CONSULTER L’AUTOCOLLANT APPOSE SUR LA CARGEUSE).

USE LA BARRA DEL ASIENTO. ASEGURESE BIEN EL CINTURON DE SEGURIDAD.

UTILISER L’ARCEAU DE SECURITE. ATTACHER SOIGNEUSEMENT LA CEINTURE DE SECURITE.

NUNCA MODIFIQUE EL EQUIPO NI USE ADITAMENTOS QUE NO ESTEN APROBADOS POR LA COMPAÑIA BOBCAT.

NE JAMAIS MODIFIER L’EQUIPEMENT NI SE SERVIR D’ACCESSOIRES QUE NE SONT PAS APPROUVES PAR BOBCAT COMPANY.

MANTENGA LOS PIES EN LOS PEDALES. MAINTENIR LES PIEDS SUR LES PEDALES. EN LA PENDIENTES, MANTENGA EL EXTREMO PESADO DE CARGADOR EN POSICION ASCENDENTE.

DANS LES PENTES, TOUJOURS MAINTENIR LA PARTIE LA PLUS LOURDE DE LA CHARGEUSE VERS LE HAUT.

ANTES DE BAJARSE DEL CARGADOR POUR QUITTER LA CHARGEUSE: 1. BAJE LOS BRAZOS DE ELEVACION. COLOQUE EL ADITAMENTO BEIN EN EL SUELO. 2. PARE EL MOTOR

1. ABAISSER LES BRAS DE LEVAGE. POSER L’EQUIPEMENT A PLATE SUR LE SOL. 2. ARRETER LE MOTEUR.

3. PONGA EL FRENO.

3. ENCLENCHER LE FREIN DE STATIONNEMENT.

4. LEVANTE LA BARRA DEL ASIENTO. MUEVA LOS PEDALES HASTA QUE AMBOS SE TRABEN.

4. RELEVER L’ARCEAU DE SECURITE. DEPLACER LES PEDALES JUSQU’A CE QU’ELLES SOIENTE TOUTES DEUX VERROILLEES. 87

863, 863H Bobcat Loader Operation & Maintenance Manual

ADVERTENCIA (SPANISH) EVITE HERIDAS O LA MUERTE

PELIGRO (SPANISH)

LLEVE LA CARGA EN POSICION BAJA

EVITE LA MUERTE

EL NO OBEDECER ESTA ADVERTENCIA PUEDE CAUSAR LADEAMIENTO O VUELCOS O PERDIDAD DE LA CARGA Y DE LA VISIBILIDAD.

AVERTISSEMENT (FRENCH)

• MANTENGASE RETIRADO DE ESTA AREA CUANDO

LOS BRAZOS DE ELEVACION ESTAN ELEVADOS, A MENOS QUE ESTEN TRABADOS POW EL TOPE. • EL MOVER EL PIE DEL PEDAL O FALLA DE UNA PIEZA PUEDEN CAUSAR LA CAIDA DE LOS BRAZOS DE ELEVACION.

EVITER DES BLESSURES OU LA MORT

DANGER (FRENCH)

TENIR LA CHARGE VERS LE BAS. LE NON RESPECT PEUT ENTRAINER UN BASCULEMENT OU UN RENVERSEMENT DE LA MACHINE, UNE PERTE DE LA CHARGE OU DE VISIBILITE.

EVITER LA MORT

• EVITER CETTER ZONE LORSQUE LES BRAS DE LEVAGE RELEVÉS NE SONT PAS ASSURÉS PAR DES ARRETS DE BRAS DE LEVAGE. • UNE PEDALE ACTIONNÉE OU UNE PICE DEFECTUEUSE. PEUT PROVOQUER L’ABAISSEMENT DES BRAS DE LEVAGE.

ADVERTENCIA (SPANISH) EL CILINDRO CONTIENE GAS BAJO ALTA PRESION. EL ABNRIR EL CILINDRO PUEDE SOLTAR LA VARILLA Y CAUSAR HERIDAS O LA MUERTE.

AVERTISSEMENT (FRENCH) LES VERINS RENFERMENT UN GAZ SOUS PRESSION. NE JAMAIS OUVRIR UN VERIN CAR LA TIGE RISQUE DE S’ECHAPPER BRUTALEMENT ET DE CAUSER DES BLESSURES OU MEME LA MORT.

PELIGRO (SPANISH) EVITE LA MUERTE

• EL FORZAR EL IMPLEMENTO CONTRA EL SUELO

HACE QUE LA RUEDDAS DELANTERAS SE ELEVEN.

• NUNCA SE META DEBAJO NI ALCANCE NADA DEBA-

JO DE LOS BRAZOS DE ELEVACION O DEL CILINDRO DE ELEVACION SIN QUE ESTE INSLADO UN TOPE APROBADO EN LOS BRAZOS DE ELEVACION.

DANGER (FRENCH) EVITER LA MORT

• L’ACCESSOIRE PEUT ETRE APPUYE CONTRE LE SOL ET SOULEVER LES ROUES AVANT.

• NE JAMAIS ALLER SOUS NI METTRE LES MAINS

SOUS LES BRAS OU LE VERIN DE LEVAGE SANS QU’UN ARRET DE BRAS DE LEVAGE APPROUVE SOIT INSTALLE.

88

863, 863H Bobcat Loader Operation & Maintenance Manual

PELIGRO (SPANISH) EVITE LA MUERTE

• La desconexión o el aflojamiento de cualquier tubería, manguera, conector, componente hidráulico o la falla de una parte puede ocasionar la caída de los brazos de elevación.

• Manténgase alejado del área cuando los brazos de elevación se encuentren elevados, a menos que estén sostenidos por medio de un dispositivo de soporte para brazos de elevación aprobado. Cámbielo si está dañado.

ADVERTENCIA (SPANISH) El movimiento inesperado del cargador, brazo de levantamiento o implementos causado por el contacto de la cabina con las palancas de dirección puede causar lesiones graves o muerte.

DANGER (FRENCH) ÉVITEZ LA MORT!

ANTES DE LEVANTAR O BAJAR LA CABINA: • Apague el motor

• La déconnexion ou le desserrage de toute canalisation,

de tout tuyau, de tout raccord et de tout composant de circuit hydraulique, ainsi qu’une défaillance de pièce connexe peuvent provoquer la chute des bras de levage.

• Tenez-vous à l’écart de cette région lorsque les bras de levage sont en position levée, à moins qu’ils ne soient soutenus par un dispositif de support de bras de levage de type approuvé. Remplacez si endommagé.

AVERTISSEMENT (FRENCH) Tout déplacement intempestif de la chargeuse, du bras de levage ou de l’accessoire causé par le contact de la cabine avec les leviers de direction peut causer des blessures graves, voire mortelles.

AVANT DE SOULEVER OU D’ABAISSER LA CABINE : • Couper le moteur

89

863, 863H Bobcat Loader Operation & Maintenance Manual

90

863, 863H Bobcat Loader Operation & Maintenance Manual

SPECIFICATIONS 5.

19.

ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS . . . . . . . . . . . 97 CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 FLOOR PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 BOBCAT CO. APPROVED ATTACHMENTS & ACCESSORIES . . . . . . . . . 95 PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

SPECIFICATIONS

91

863, 863H Bobcat Loader Operation & Maintenance Manual

92

863, 863H Bobcat Loader Operation & Maintenance Manual

SKID STEER LOADER SPECIFICATIONS 83.7 (2166)

•

Dimensions are given for loader equipped with standard tires and dirt bucket and may vary with other bucket types. All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.

‘‘C” 93°

156.2 (3968)

45° 21.3 (540)

121.0 (3073)

81.2 (2063)

91.5 (2324)

25°

29° 43.7 (1110) 106.9 (2716) 135.4 (3439)

8.5 (216)

‘‘B” ‘‘A” ‘‘A”

‘‘B “

12–16.5 TIRES – 67.2 inch (1707) 12–16.5 TIRES – 72.0 inch (1829) 31–15.5 x 15 TIRES – 73.0 inch (1853) 12–16.5 TIRES – 54.4 inch (1382) 12–16.5 TIRES –59.2 inch (1503) 31–15.5 x 15 TIRES – 57.5 inch (1459)

“C”

MC–1113

72 inch C/I BUCKET – 74.0 (1879) 72 inch L/P BUCKET – 74.0 (1879) 66 inch C/I BUCKET – 68.1 (1731)

Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the loader parts.

SPECIFICATIONS PERFORMANCE Rated Operating Capacity (SAE) . . . . . . . . . . . . . . . . .

Tipping Load (SAE Rating) . . . . . . . . . . . . . . . . . . . . . .

Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAE Breakout Force –Lift . . . . . . . . . . . . . . . . . . . . . . .

–Tilt . . . . . . . . . . . . . . . . . . . . . . .

Axle Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROLS Vehicle Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader Hydraulics Lift and Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Auxiliary (Option) . . . . . . . . . . . . . . . . . . . . . . . .

9.5 (240)

863

863H 1900 lbs. (861 kg) 3800 lbs. (1723 kg)

7135 lbs. (3236 kg)

7180 lbs. (3257 kg) 3700 lbf. (16400 N) 3800 lbf. (16900 N) 6100 ft.–lbf. (8400 Nm) 0–7.2 MPH (11,6 km/hr.)

Direction and Speed controlled by two hand levers.

Rear Auxiliary (Option) . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Secondary Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controlled by separate foot pedals or optional hand controls.

Proportional Controls Controlled by electrical switch on RH steering lever.

Controlled by electrical switch on LH steering lever.

Hand lever throttle: Key–type starter switch and shutdown.

Glow plug– Rocker Switch operated OR BOSS activated glow plug (If so equipped).

Two independent hydrostatic systems controlled by two hand operated steering levers.

One of the hydrostatic transmissions Mechanical Disc, foot operated pedal.

ENGINE Make/Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel/Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horsepower (SAE Net) . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Governed RPM . . . . . . . . . . . . . . . . . . . . . . .

Torque @ 1800 RPM (SAE Net) . . . . . . . . . . . . . . . . . . . . . .

Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Deutz/BF4M1011F Turbo–Charged Diesel/Oil 73.0 HP (54 kW) 2350 RPM 176 ft.–lbs. (238 Nm) Four 177.7 cu. in. (2912 cu.cm.)

3.58/4.41 (91/112) Pressure System W/Filter Closed Dry replaceable cartridge w/safety element Diesel–Compression

93

863, 863H Bobcat Loader Operation & Maintenance Manual

SPECIFICATIONS (Cont’d) HYDRAULIC SYSTEM Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– Secondary (863H Option) . . . . . . . . . . . . . . . . . . .

System Relief at Quick Couplers . . . . . . . . . . . . . . . . .

Filters (charge & implement) . . . . . . . . . . . . . . . . . . . . .

Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bore Diameter: Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rod Diameter: Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stroke: Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

863

Engine Driven, Gear Type 18.0 GPM (68,0 L/min.) @ 2750 RPM 10.0 GPM (37.9 L/min.) @ 2750 RPM 3000 PSI (20600 kPa) Full flow replaceable, 3 micron synthetic media element Doubleacting; Tilt cylinder has custioning feature on dump & rollback 2.50 (63,5) 3.50 (88,9) 1.75 (44,5) 1.625 (41,3) 32.50 (825,0) 18.17 (461,5) 3–spool, open center type w/float detent on lift and electrically controlled auxiliary spool.

SAE standard tubes, hoses & fittings Bobcat Fluid (P/N 6563328) if fluid is not available, use 10W–30/10W–40 Class SE motor oil for temp. above 0°F (–18°C) 5W–30 Motor Oil for temperatures below 0°F (–18° C).

Hydraulic Function Time Raise Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lower Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket Dump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket Rollback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE SYSTEM Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

863H

5.1 Seconds 3.3 Seconds 2.8 Seconds 2.4 Seconds

Belt driven, 50 amp, open 12 volt, 1000 cold cranking amps. @ 0°F. (–18°C); 180 minute reserve capacity 12 volt, Direct Drive; 4.0 HP (3.0 kW) Gauges:Hourmeter, Fuel, Voltmeter, Engine Temperature.

Warning Lights: Engine Temperature, Engine Oil Pressure, Hydraulic Oil Temperature & Pressure, Hydraulic Filter.

Optional BOSS System Monitors; Engine Oil Temperature, Engine Oil Pressure, Hydraulic System Temperature & Pressure, Hydraulic & Air Filters, RPM, Battery Condition, Fuel Level & Machine Hours.

Displays visual warnings & sounds audible alarm. Also controls automatic shutdown function and has diagnostic capability.

Hydrostatic 4 wheel drive Infinitely variable tandem hydrostatic piston pumps, driving 2 fully reversing hydrostatic motors #100 HS endless roller chain & sprockets in sealed chaincase with oil lubrication

Total Engine to Wheel Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39:1 2.76 (70,0) (8) 9/16 inch

CAPACITIES Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Lubrication and Cooling System . . . . . . . . . . . .

Engine Oil Change W/Filter . . . . . . . . . . . . . . . . . . . . . .

Hydraulic/Hydro. Reservoir . . . . . . . . . . . . . . . . . . . . . .

Hydraulic/Hydro. System . . . . . . . . . . . . . . . . . . . . . . . .

Chaincase Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 gals. (94 L) 16 qts. (9,5 L) 10.0 qts. (15,1 L) 4 gals. (15,2 L) 10 gals. (38 L) 11 gals. (41,6 L)

TIRES Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Pressure . . . . . . . . . . . . . . . . . . . . . . .

12–16.5, 10 ply rating 31–15.5 x 15,8 Ply Rating Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT mix brands of tires used on the same loader.

94

863, 863H Bobcat Loader Operation & Maintenance Manual

BOBCAT COMPANY APPROVED ATTACHMENTS & ACCESSORIES These and other attachments are approved for use on this model Bobcat loader. Do not use unapproved attachments.

Attachments not manufactured by Bobcat Company may not be approved.

The versatile Bobcat loader quickly turns into a multi–job machine with a tight–fit attachment hook–up . . . from bucket to grapple to pallet fork to backhoe and a variety or other attachments.

See your Bobcat dealer for more details on the these and other attachments and field accessories.

Increase the versatility of your Bobcat Loader with a variety of bucket styles and sizes.

BUCKETS AVAILABLE Many bucket styles, widths and different capacities are available for a variety of different applications. They include Construction & Industrial, Utility, Fertilizer and Snow, to name a few. See your Bobcat dealer for the correct bucket for your Bobcat loader and application.

ATTACHMENTS Vibratory Roller

Sweeper

Angle Broom

Planer

Pack and level ground.

Surface preparation for Use it to sweep driveways, Sweeps and collects debris concrete, asphalt or other. sidewalks, parking lots, etc. with one attachment.

Scarifier

Stump Grinder

Prepares hard packed ground for digging or landscaping.

Remove stumps and roots.

Ideal for landscapers.

For handling baled palleted material.

Longwood Grapple

Industrial Bucket Grapple

Industrial Fork Grapple

For handling logs.

SPECIAL APPLICATIONS KIT WHICH INCLUDES A 1/2 INCH LEXAN FRONT DOOR WITH 1/4 INCH TOP AND REAR WINDOWS MUST BE USED WHEN OPERATING THE LONGWOOD GRAPPLE.

Tiller

Pallet Fork

Chipper

or

Grind branches & tree limbs; reduce volume 10 to 1.

Utility Fork (Grapple Available)

For brush clearing, handling Ideal for handling bundled Ideal for handling scrap, irregular shaped metal and material, loose straw, and other scrap. manure. waste, or pipe.

Bale Handler

Water Kit

Dozer

Great for breaking up clumps, mixing compost, Used with attachments to Move bales from ground to tilling. control dust. trailer or bale feeder.

3–Point Hitch

Removes asphalt surfaces for repair, replacement or utility work.

Snow Blade

Level II FOPS Top Kit

Turn your loader into a mini–crawler with 6–way blade.

Brushcat Rotary Cutter

Use for 3–point mounted Clean sidewalks, driveways, Additional protection from attachments. parking lots. falling trees, rocks.

Tilt Tatch Power Rake Landplane

Great for clearing brush, saplings and grass.

Grader

Make buckets and pallet forks more versitile with side tilt action.

Turn your Bobcat loader into a high performance grading machine.

Separate rocks & debris, grade, level, prepare for landscaping.

Remove large clumps and rocks as you level and grade.

95

863, 863H Bobcat Loader Operation & Maintenance Manual

BOBCAT COMPANY APPROVED ATTACHMENTS & ACCESSORIES (Cont’d) These and other attachments are approved for use on this model Bobcat loader. Do not use unapproved attachments.

Attachments not manufactured by Bobcat Company may not be approved.

See your Bobcat dealer for more details on the these and other attachments and field accessories.

ATTACHMENTS (Cont’d) Auger

Rear Stabilizer

Snow Blower

Sod Layer

Clear snow from driveways, sidewalks, etc.

Carry and lay a roll of sod.

Cut to length from the operator’s seat.

(Use with backhoe)

Dig 6”–36” holes with ease Increase your backhoe and accuracy. performance and versatility.

Concrete Mixer

Tracks

Mix, transport and dump concrete right where you need it.

Better performance in sand, snow and mud.

Hydraulic Breaker

Break up concrete quickly and easily.

SPECIAL APPLICATIONS KIT WHICH INCLUDES A 1/2 INCH LEXAN FRONT DOOR WITH 1/4 INCH TOP AND REAR WINDOWS MUST BE USED WHEN OPERATING THE BOB–TACH MOUNTED HYDRAULIC BREAKER.

Tree Transplanter

Dig and load trees for transplanting.

Wheel Saw

Backhoe

Trencher

Designed for high production digging.

Landscape Rake

Versatile trenching ability for utility lines, etc.

Combination Bucket

Break up lumpy soil, pick up rocks.

Get precise cuts through concrete, Ground preparation,, for seeding, Heavy duty bucket for dozing, sodding, leveling. asphalt, rebar or frozen ground. grappling, digging, leveling & loading.

Laser

Use with grader attachment to increase preparation accuracy.

96

863, 863H Bobcat Loader Operation & Maintenance Manual

ADDITIONAL PUBLICATIONS and TRAINING MATERIALS The following publications and training materials are also available for your Bobcat Loader. You can order them from your Bobcat dealer.

For the latest information on Bobcat products and the Bobcat Company, visit our website at www.bobcat.com

OPERATOR’S HANDBOOK 6708021–Foot Pedals 6708158–Hand Controls –gives basic operation instruction and safety warnings.

PARTS MICROFICHE

OPERATION & MAINTENANCE SERVICE MANUAL MANUAL 6724799 6900790 –complete instruction on the correct operation and the routine maintenance of the BOBCAT loader.

–Up–to–date PARTS information is also available. See your BOBCAT dealer.

–complete maintenance overhaul instructions for BOBCAT loader.

and your

SKID STEER LOADER SERVICE SAFETY TRAINING COURSE 6900641 SKID STEER LOADER OPERATOR TRAINING COURSE 6722720 –Introduces operator to step–by–step basics of Skid–Steer loader operation.

Also available in Spanish P/N 6724036.

–Introduces Service Technicians to step–by–step basics of proper and safe skid–steer loader maintenance and servicing procedures.

SAFETY MANUAL 6556500

OPERATION SAFETY VIDEO 6724793

Skid–Steer Loader

EQUIPMENTMANUFACTURERS INSTITUTE 10S.RIVERSIDEPLAZACHICAGO,ILLINOIS60606–37100

–provides basic safety instructions.

–provides basic safety procedures and warnings for your BOBCAT loader. Also available in Spanish P/N 6724451.

97

863, 863H Bobcat Loader Operation & Maintenance Manual

98

863, 863H Bobcat Loader Operation & Maintenance Manual

WARRANTY Bobcat Loaders Bobcat Company warrants to its authorized dealers and authorized dealers of Bobcat Equipment Ltd., who in turn warrant to the original buyer (owner), that each new Bobcat loader will be free from proven defects in material and workmanship for twelve months after delivery to the original buyer (owner).

During the warranty period, the authorized Bobcat dealer shall repair or replace, at its option, without charge for parts and labor, any part of the Bobcat product which fails because of defects in material or workmanship. The owner shall provide the authorized Bobcat dealer with prompt written notice of the defect and allow reasonable time for replacement or repair. Bobcat Company may, at its option, request failed parts to be returned to the factory. Travel time of mechanics and transportation of the Bobcat product to the authorized Bobcat dealer for warranty work are the responsibility of the owner.

The warranty does not apply to tires or other trade accessories not manufactured

by Bobcat Company. The owner shall rely solely on the warranty, if any, of the respective manufacturers thereof. The warranty does not cover replacement of scheduled service items such as oil, filters, tune–up parts, and other high–wear items. The warranty does not cover damages resulting from abuse, accidents, alterations, use of the Bobcat product with any bucket or attachment not approved

by Bobcat Company, air flow obstructions, or failure to maintain or use the Bobcat product according to the instructions applicable to it.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES (EXCEPT THOSE OF TITLE), EXPRESSED OR IMPLIED, AND THERE ARE NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL BOBCAT COMPANY OR THE AUTHORIZED BOBCAT DEALER BE LIABLE FOR DOWNTIME EXPENSES, LOSS OF MACHINE USE OR OTHER INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES.

6570162 (5–00)

Printed in U.S.A.