PREVENTIVE MAINTENANCE oC AIR CLEANER SERVICE Replacing Filter Element ALTERNATOR BELT Adjusting the Alternator Belt ee COOLING SYSTEM Cleaning the Cooling System ENGINE LUBRICATION SYSTEM ‘Checking Engine Oil... Replacing of Oil and Filter FAN GEARBOX ‘Checking and Maintaining . FINAL DRIVE TRANSMISSION (CHAINCASE) — Checking and Adding Oi Removing Oil From the Chaincase FUEL SYSTEM Filling the Fuel Tank Fuel Filter Fuel Specifications. Removing Air From the Fuel System . HYDRAULIC/HYDROSTATIC SYSTEM | ©) Checking and Adding Fiuid OO Replacing Hydraulichtydrostatic Fitter | Replacing Hydraulic Fluid . LIFT ARM SUPPORT DEVICE Te install the Lift Arm Support Device To Remove the Lift Arm Support Device - LIFTING AND BLOCKING G THE LOADER Procedure LUBRICATING THE LOADER Procedure . OPERATOR CAB Description Lowering the Operator Cab - Raising the Operator Cab Emergency Exit REMOTE START SWITCH Procedure SEAT BAR RESTRAINT SYSTEM Description .......... , ‘Seat Bar Inspection - Seat Bar Maintenance... © SERVICE SCHEDULE Chart ...... Revised Dec. 96 atte Page Number aa IW oS 863, 863H Bobcat Loader ‘Service ManualPREVENTIVE MAINTENANCE (Cont'd) Page Number TIRE MAINTENANCE ) Tire Mounting . . 1-18 Tire Rotation 1-18 Wheel Nuts 1-18 TOWING THE LOADER Pee occas TRANSPORTING THE LOADER Procedure J 863, 863H Bobcat Loader Revised Dec. 96 ae ‘Service ManualO SERVICE SCHEDULE ‘Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat loader. Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and Instructions in the SNS TN TINE manual wien making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death. ey aes EreviErs ITEM SERVICE REQUIRED Engine OF ‘Check the oil level and add oll as needed. Engine Air Cleaner Check condition indicator or display panel. Service only when required, | Engine Cooling System Clean debris trom oll coolers & gril Tift Arms, Cyl, Bob=Tach | ~ Lubricate with multi-purpose lithium based grease Pivot Pins and Wedges | _(12 places). Engine Air System. sheck for leaks and damaged components Tires ‘Check for damaged tires and correct ar pressure. ‘Seat Batt, Seat Bar & Pedal] — Check the condition of seat belt. Check the seat bar and Toot Interlock. ‘pedal interlocks for correct operation. Clean dirt and debris from moving part ‘Bobeat interlock Control | Check BICS™ functions. Clean dit, debris or objects from System (BICS™) under or behind seat and around brake pedal as required. Safety Signs and Safely | Check for damaged signs (decals) and safety treads. Replace Treads ‘any signs or safety treads that are damaged or wor. ‘Operator Cab ‘Check the fastening bolts, washers and nuts. Check the ‘condition of cab, Fuel Fiter Remove the trapped water. Hyd. Fluid, Hoses and ‘Check fluid level & add as needed, Chock Tor damage & leaks, Tubelines, Repair or replace as needed. Final Drive Trans [Chainease| — Check oil evel Battery ‘Check battery for damage, hold downs, cables, connections and electrolyte level, Add distilled water as needed. Foot Pedals and Steering | Check for correct operation. Repair or adjust as needed Wheel Nuts [E'Check for loose wheel nuts and tighten to 105-115 R.=Ws. (142156 Nm) torque. Parking Brake ‘Check operation of the brake. ‘Alternator Belt Check tension and adjust as needed. Engine/Hyaro, Drive Bat [+ Check for wear or damage. Check iler arm Sfp. Fuel Filter Replace fiter element Steering Shaft Grease thee ftings. Hydraulic Reservoir Replace the reservoir breather cap. Breather Cap Hiyd Hydro. Fifer [= Replace the Mer element Engine Oil and Filer FF Replace ollanatifer. Use CD or batter grade olandMelroe fier Final Orve Trans. Feplace the olin the chaincase. Hydraulic Reservoir ‘Giean or pace the fi. Hydraulic Motors Giean or replace the case drain Miers ‘Bobcat interlock Conirar | Check if arm by-pass control. System (BICS™) Fan Drive Gearbox Theck gear lube level. Engine Valves = Adjust the engine valves. Engine Timing Beh, [5 eplace the timing bet and belt tensioner assy 2 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. @ Orevery 12 months. * Inspect the new belt after first 50 hours. + After the first 50 ours. ‘Attar the fret 800 hours on new engine, adjust ‘engine valves; 1000 hours thereafter. (See Service Manual for rocedure 0 Breverys years. £863, 863H Bobcat Loader Revised Dec. 96 41-3- ‘Service ManualPREVENTIVE MAINTENANCE, A WARNING Instructions are necessary before operating or servicing machine. Read Operation” & Maintenance Manuals, 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-2003-1269 Read the Removal & Installation, Disassembly & Assembly, etc. completely to become familiar with the procedure before beginning [A]. LIFTING AND BLOCKING THE LOADER Procedure ‘Always park the loader on a level surface. A WARNING Put jackstands under the front axles and rear corners of the frame before running the engine Failure to use jackstands can allow to fall or move and cause injury or w-2017-0286 Put floor jack under the rear of the loader [B]. Lift the rear of the loader and install jackstands [B}. Put the floor jack under the front of the loader [C]. Lift the front of the loader and put jackstands under the axle tubes [C] NOTE: Make sure the jackstands do not touch the tires. Make sure tires clear floor or any obstacles. 57028 1863, 863H Bobcat Loader Service Manual‘TRANSPORTING THE LOADER Procedure oO A WARNING ‘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-2058-0496 Mo=1261 ‘Alloader with an empty bucket or no attachment must be loaded backward onto the transport vehicle [A]. Be sure the transport and towing vehicles are of adequate size and capacity. 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 frontand rearloader tie down positions (Inset) [B]. Fasten each end of the chain to the transport vehicle and tighten the chain with a chain tightener. ‘The Inset [B] shows the decal with attachment points for towing and tie down TOWING THE LOADER Procedure ‘To prevent damage to the loaders hydrostatic system, the loader must be towed only a short distance al 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 Specification, Page 9-1.) * Tum the key switch to ON and press the Traction Lock Override button. ‘+ Tow the Bobeat at 2 MPH (3,2 km/hr.) or less for not more than 25 feet (7,6 meters), 6707867 ifthe electrical system not functioning, part of the brake system must be disassembled to move the loader. See Traction Lock removal and installation procedure. (See Page 8-1.) Mc-1242LIFT ARM SUPPORT DEVICE A WARNING Never work on a machine with the lift arms up unless the lift arms are secured by a 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-2059-0901 To Install the Lift Arm Support Device Maintenance and service work can be done with the lift arms lowered. I the lft arms must be raised for service, use the following procedure: Put jackstands under the rear corners of the loader. Disconnect the spring from the retaining pin (Item 1) [A], hold onto the lift arm support device (Item 2) [A] and remove the retaining pin Lower the lft arm support device on top of the lft cylinder. Hook the free end of the spring (Item 1) [B] to the lit arm ‘support device so there will be no interference with the support device engagement, With the operator in the seat, seat belt fastened and seat, bar lowered, start the engine. Raise the lift arms, until the lift arm support device drops conto the lift cylinder rod [C} Lower the lift arms slowly unti the support device is held between the lft arm and the lift cylinder, Stop the engine. Raise the seal bar and move pedals until both pedals lock Install pin (tem 1) [C] into the rear of the lift arm support device below the cylinder rod. To Remove the Lift Arm Support Device Remove the pin from the lift arm support device (Item 1) (c] Connect the spring (Item 1) [D] from the fift arm support device to the bracket below the lift arms. With the operator in the seat, seat belt fastened and seat bar lowered, start the engine. Raise the lift arms a small amount and the spring will ft the support device off the lift cylinder rod. 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 lit arm support device and bracket [A]. Connect spring to the retaining pin (Item 1) (A). 863 Loader Service ManualOPERATOR CAB Description ‘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 damages. A WARNING Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Melroe Company. Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death. W-2069-1288 ROPSIFOPS ~ Roll-Over Protection Structure per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level I, Level Ii is available. LEVEL | - Protection from falling bricks, small concrete blocks, and hand tools encounteredin operations such as highway maintenance, landscaping, and other construction site services. LEVEL I — Protection from falling trees, rocks: for ‘Machines involved in site clearing, overhead demaition oF forestry. Raising the Operator Cab Stop the loader on a level surface. Lower the lift arms. If the lift arms must be up while raising the operator cab, install the lft arm support device. (See Page 1-6.) Loosen the nut (both sides) at the front corner of the operator cab [A]. Remove the nut and plate (both sides) [B} Lift on the grab handle and bottom of the operator cab. Raise slowly until the cab latching mechanism engages and the cab is all the way up [C] IMPORTANT Use care when raising or lowering the operator cab to prevent damaging the shaft of the lift lock by-pass valve. 2070-0498 863 Loader 17 Service MantOPERATOR CAB (Cont'd) Lowering the Operator Cab Not Make sure the seat bar is fully raised or lowered when lowering the cab. Pull down on the bottom of the operator cab untiit stops at the latching mechanism. ‘Release the latching ‘mechanism and pull the cab all the way down [A] Install the plate and nut (both sides) [B] Tighten the nuts to 40-50 ft—Ibs. (54-68 Nm) torque. Emergency Exit ‘The front opening on the operator cab and rear window provide exits To exit through the rear window, use the following procedure: Pullon the tag on the top of the rear window toremove the, rubber cord (C}. Push the rear window out of the rear of the operator cab. Exit through the rear of the operator cab [D] 863 Loader Service ManualOPERATOR CAB (Cont'd) Emergency Exit (Cont'd) NOTE: When an Operator Cab Enclosure. Kit (optional) is installed, the window of the front door can be used as an emergency exit [A]. Pull the plastic loop at the top of the window in the front door. Push the window out with your foot, ‘SEAT BAR RESTRAINT SYSTEM Description ‘The seat bar restraint system has a pivoting seat bar with arm rests and has spring loaded interlocks for the lift and tilt control pedals. 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 pedals are locked when returned to the neutral position. A WARNING AVOID INJURY OR DEATH The seat bar system must lock the lift and tilt Control pedals in neutral when the seat bar is up. Service the system I pedals do not lock correctly. 2105-1785 Seat Bar Inspection Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Slartthe Engine. Operate each foot pedal to check both the liftand titfunctions. Raise the lift arms until the bucket is about 2 feet (600 mm) off the ground 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 tlt (bucket) when the pedals are pushed. Pull the seat bar down, lower the lift arms. Operate the tft pedals. While the lif arms are going up, raise the seat bar nd the lift arms should stop. Lower the seat bar, lower the lift arms and place the ‘bucket lat on the ground. Stop the engine. Raise the seat bar and operate the foot pedals to be Sure that the pedals are fmiylocked in theneutral postion. nbucke te seat it Seat Bar Maintenance See the Service Schedule, Page 1-3 for correct service interval. Giean any debs ord om te moving pats (8) 8 (6) fnspeet he Inkage ols and nuts for ighinoss. TNS Cect torque is 25-26 fips. (34-38 Nv If the seat bar system does not function correctly, check for free _movernent of each linkage part. Check for excessive wear. Adjust pedal control linkage. Replace parts that are worn or damaged. Use only genuine Melroe Feplacement parts. EMERGENCY 707852 Interlock Shield A WARNING AVOID INJURY OR DEATH Never operate loader without pedal lock shield 6705474 on both interlocks. Shields prevent foot from unlocking interlocks when leaving loader seat. we2162-1194 863, 863H Bobcat Loader ‘Service ManualAIR CLEANER SERVICE Replacing Filter Element WITH CONDITION INDICATOR: Replace the large (outer) iter element only when the red ring shows in the window of the condition indicator (item 1) [A]. NOTE: Before replacing the filter element, push the button on the condition indicator (Item 2) [A]. Start the engine. If the red ring does not show, do not replace the filter element. Replace the inner filter every third time the outer filter is, replaced or when the red ring stil shows in the indicator window after the outer fiter has been replaced WITH BOSS® OPTION: Its important to change the air filter element only when the service codes (on the optional instrument panel) shows the symbols [AF-2] [B] Service the air cleaner as follows: Remove the dust cover clips (Item 1) [C]. Remove the dust cover. Remove the large filler element [D}. NOTE: Make sure all sealing surfaces are free of dirt and debris. Install the new filter element. Install dust cover. Check the air intake hose for damage. Check the air cleaner housing for damage. Check to make sure all connections are tight, Revised Sept. 96 Mc=2042 -1-40- 863, 863H Bobcat Loader Service ManualAIR CLEANER SERVICE (Cont'd) Replacing Filter Element (Cont'd) ‘Only replace the inner flter element under the following conditions [AJ 1, Replace the inner filter element every third time the outer filter is replaced 2. When the service code on the instrument pane! shows symbol AF-2| (See Page 1-10 (B}) during ful engine speed, replace the, ier iter element only affer outer filter element has been replaced, (See Page 1-10.) o 863, 863H Bobcat Loader Revised Sept. 96 att Service ManualFUEL SYSTEM Fuel Specifications Use only clean, high quality diesel fuel, Grade No. 1 or Grade No. 2 The following is one suggested blending guideline which should prevent fuel gelling problems: Temp. F°(C*) No.2 Not #15°(9°) 190% 0% Down to 20: (28°) 80% 50% Below 20° (28°) 0% 700% We recommend an operator contact their fuel supplier for local recommendations. Filling the Fuel Tank A WARNING 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 fil cap (Item 1) [A 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! [8] Install and tighten the fue! fill cap [A]. Fuel Filter See the Service Schedule, Page 1-3 for the Tecommended service interval when to remove the water, from the fuel filler. Loosen the drain (Item 1) [C} at the bottom of the fiter element to drain any water from the filter. See the Service Schedule, Page 1-3 for the Fecommended service interval when to replace the ful filler. To replace the fuel filter element, use a filer wrench to remove the filter element [C]. Clean the area around the filter housing. Put oil on the seal of the new filler element, Install the fuel filter, and hand tighten. Remove the air from the fuel system. Removing Air From the Fuel System After replacing the fue! 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) [C] atthe top ofthe fuel filter. Operate the priming bulb (Item 3) [C] until fuel flows from the vent, Tighten the air vent plug P7646 WRONG 13456 1412- A WARNING 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 863, 863H Bobcat Loader Service ManualENGINE LUBRICATION SYSTEM ‘Checking Engine Oil ‘Check the engine oil level every day. Before starting the engine for the work shift, open the rear door. Remove the dipstick (Item 1) [A]. Keep the oil level between the marks on the dipstick. Use a good quality motor oil that meets API Service Classification of CC, CD or CE. TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE. Use SAE SW-30 for +80°F (+27°C) & Below, Use SAE 10W-30 for +80°F (+27°C) & Above. Replacement of Oil and Filter See the Service Schedule Page 1-3 for the service interval for replacing the engine oil and filter. Run the engine unt it is at operating temperature. Stop the engine, Open the rear door. Remove the drain plug (Item 1) [B). Drain the oil into container. Remove the oil fier (Item 1) [C] Clean the fiter housing surface. Put clean oll on the new oil iter gasket. Install the filter and hand tighten only. Install and tighten the drain plug. Remove the filler cap (Item 2) [A]. Put 10 ats. (9.5 L) of oil in the engine. Start the engine and letit run for several minutes, Stop the engine. Check for leaks and check the oil level. Add oll as. needed if itis not at the top mark on the dipstick. 113. A WARNING 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 Service ManualCOOLING SYSTEM Cleaning the Cooling System Check the cooling system every day to prevent ‘overheating, loss of performance or engine damage. A WARNING 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. w-2019-1285 Raise the rear grill [A] Use air pressure or water pressure to clean the top hydraulic/hydrostatic system oil cooler (Item 1) [A]. Remove the hair pin (Item 1) [B] (both sides) so the oil cooler can be raised Raise the oi cooler, use air pressure or water pressure to, lean the top of the engine oil cooler (Item 1) {C] 14 863 Loader Service ManualALTERNATOR BELT ‘Adjusting the Alternator Belt Stop the engine Loosen the alternator mounting bot (tem 1) [Al Loosen the adjustment bolt (Item 2) [A] Move the alternator unti the belt has 5/16 inch (8,0 mm) ‘movement at the middle of the belt span with 15 Ibs. (66 N) of force [8]. Tighten the adjustment and mounting bolts. 415- 863, 863H Bobcat Loader ‘Service ManualHYDRAULIC/HYDROSTATIC SYSTEM Checking and Adding Fluid Use only recommended fluid in the hydraulic system. (See Specification, Page 9-1.) To check the reservoir, use the following procedure: Put the Bobcat loader on a level surface, Lower the lift arms and tlt the Bob—Tach fully back. Stop the engine. Remove the dipstick (Item 1) [Al. ‘The fluid level must be between the marks on the dipstick {8} ‘Add fluid as needed to bring the level to the top mark on the dipstick [B] Replacing the HydrauliciHydrostatic Filter See the Service Schedule, Page 1-3 for the correct, service interval Raise the operator cab. (See Page 1-7.) Use a filter wrench to remove the filter elements (Items 1 &2) {Cl}. Clean the surface of the filter housing where the element seal contacts the housing. Putclean ollon the rubber seal Of the filter elements. Install and hand tighten the filter elements, Revised Dec. 96 -1-46- 863, 863H Bobcat Loader ‘Service Manual J| HYDRAULICIHYDROSTATIC SYSTEM (Cont'd) Replacing the Hydraulic Fluid ‘See the Service Schedule, Page 1-3 for the service interval Replace the fluid if it becomes contaminated or after ‘major repair Also clean the two hydrostatic motor case drain filters. thoroughly after a major repair. Remove the fill cap. Remove the screen from the reservoir [A]. Wash the screen in clean solvent and air ory. Raise the operator cab. (See Page 1-7.) Disconnect the hose (Iter 1) [B] from the hydraulic fluid reservoir and drain the fluid into a container, Replace the two filter elements, (See Page 1-17.) Remove the case drain fers (Item 1) {C] & [D] and clean. thoroughly with clean solvent. Install the case drain filters and tighten all the hoses. ‘Add the correct fluid to the reservoir until the fluid level is to the top mark on the dipstick. (See Page 1-17.) © A WARNING Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes causing serious injury. 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. wy, 2974-4285 ‘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 explosign or fire which can result in injury or death. w-2103-1285 Lower the operator cab. Start the engine and operate the loader hydraulic controls. Stop the engine. Check for leaks. Check the fluid level in the reservoir-and add as. needed. C Revised Dec. 96 -147— — = =— RIGHT CASE DRAIN FILTER im 863, 863H Bobcat Loader ‘Service ManualTIRE MAINTENANCE ‘Wheel Nuts, See the Service Schedule, Page 1-3 for the service interval to check the wheel nuts. The correct torque is 405-118 fh-Hbs. (142-156 Nm) torque [A] Tire Rotation Check the tires regularly for pressure, wear and damage. Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling capability, Check for the corect pressure before ‘operating the loader. Inflate to maximum pressure shown, on sidewall of tire Rear tires usually wear faster than front ties. To keep tire wear even, move the front tires to the rear and rear tires. to the front [B] Itis important to keep the same size tires on each side of the loader. If different sizes are used, each tire will be tuming al a different rate and cause excessive wear. The tread bars of all the tires must face the same direction, 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 tre 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 10 avoid over inflation. A WARNING 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. ae IMPORTANT Inflate tires to the MAXIMUM pressure shown. on the sidewall of the tire. DO NOT mix brands of tires used on the same loader. 12087-0794 Revised Dec. 96 P7649 8-0976 2 ‘863, 863H Bobcat Loader ‘Service ManualFINAL DRIVE TRANSMISSION (CHAINCASE) Checking and Adding Oil < The chaincase contains the final drive sprockets and chains and uses the same typeof. oll asthe hydraulichhydrostatic system. (See SPECIFICATIONS, Page 9-1.) To check the chaincase oil level, use the following procedure: Drive the loader on a level surface. Stop the engine. Remove the plug (Item 1) [A] from the front of the chaincase housing {foil can be reached with the tip of the your finger through the hole the oil level is correct. Ifthe 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] over the drain plug at the rear of the | chaincase, Remove the drain plug (Item 1) [C] and drain the oil into a container. NOTE: When installing the drain plug into the chaincase, always use a NEW drain plug. © 863, 863H Bobcat Loader Service Manual Revised Dec. 96 st19-LUBRICATION OF THE BOBCAT LOADER Procedure Lubricate the loader as specified in the SERVICE SCHEDULE, Page 1-3 for the best performance ofthe loader. Record the operating hours each time you lubricate the Bobeat loader. Always use @ 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] 2. Base End Lift Cylinder (Both Sides) [B}. 3. Liff Arm Pivot Pin (Both Sides) [C}. 4, Base End Tilt Cylinder [D] Revised Dec. 96 7692 863, 863H Bobcat Loader -1-20- Service ManualLUBRICATION OF THE BOBCAT LOADER (Cont'd) 5. Rod End Tilt Cylinder [A] 6, Bob—Tach Pivot Pin (Both Sides) [A]. 7. Bob—Tach Wedge (Both Sides) [A]. 8. 250 Hours: Steering Lever Shaft (2) [8] 9. 250 Hours: Centering bracket pivot pin (B] O ran ceansox Checking and Maintaining ‘See the SERVICE SCHEDULE, Page 1-3 for the correct service interval Raise the operator cab. (See Page 1-7.) Remove the plug (Item 1) [C] to check the lubricant level When checking 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 ifthe level is low. © Revised Dec. 96 -1-21- 863, 863H Bobcat Loader Service ManualREMOTE START SWITCH Procedure The too! listed will be needed to do the following procedure: MEL1429 A ~ Remote Start Switch The Remote Start Switch is required when the service technician is adjusting the steering linkage, checking the hydraulic/hydrostatic system. Lift and block the loader. (See Page 1-4.) Raise the lft arms and install an approved lift arm support device. (See Page 1-6.) Raise the operator cab, (See Page 1-7.) Disconnect the operator cab wire hamess (Item 1) [A] from the engine wire hamess. Connect the remote start switch to the engine harness connectors (item 1) [B]. A WARNING Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. 2017-0786 A WARNING ‘Never work on a machine with the lift arms up unless the lift arms are secured by a lift arm support dovice. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W-2059-0901 Revised Dec. 96 -1-22- ‘863, 863H Bobcat Loader ‘Service Manual JREMOTE START SWITCH (Cont'd) Procedure (Cont'd) Put the traction lock override switch (Item 1) [A] in the 'ON position so the traction function is locked. The wheels are not able to turn ‘Tum the key to the right and start the engine, Move the traction ock override switch (tem 1) [B] tothe OFF position so the traction function is unlocked. The wheels are now able to turn. ‘The auxiliary mode switch (Item 2) [B] is used to turn the front auxiliary quick couplers ON and OFF during relief pressure and flow tests Revised Dec. 96 p-a719 Paria 2 ‘863, 863H Bobcat Loader ‘Service ManualRevised Dec. 96