Bobcat 863, 863H HIGH-FLOW Skid-Steer Loader Repair Service Manual – 6900648

(S/N: 514425001 & Above – S/N: 514525001 & Above – S/N: 514625001 & Above)
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This workshop repair service manual PDF download for the 863, 863H Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

Bobcat Loader 863, 863H
HIGH FLOW
S/N: 514425001 & Above
S/N: 514525001 & Above
S/N: 514625001 & Above

TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION
PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE
SYSTEM ANALYSIS
SPECIFICATIONS
ADVANCED HAND CONTROL SYSTEM
SERVICE MANUAL REVISIONS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6900648 (7-10)
Total Pages : 570

This 863, 863H Bobcat Loader Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
LOADER SERIAL NUMBER
ENGINE SERIAL NUMBER
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION

PREVENTIVE MAINTENANCE
SERVICE SCHEDULE
LIFTING AND BLOCKING THE LOADER
Procedure
TRANSPORTING THE BOBCAT LOADER
Procedure
TOWING THE LOADER
LIFT ARM SUPPORT DEVICE
To Install The Lift Arm Support Device
To Remove The Lift Arm Support Device
OPERATOR CAB
Raising The Operator Cab
Lowering The Operator Cab
Emergency Exit
SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)
Description
Seat Bar Inspection
Seat Bar Maintenance
SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS)
Description
Seat Bar Inspection
Seat Bar Maintenance
SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)
Description
Seat Bar Maintenance
Seat Bar Inspection
AIR CLEANER SERVICE
Replacing Filter Element
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Fuel Filter
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Replacement Of Oil And Filter
COOLING SYSTEM
Cleaning The Cooling System
ALTERNATOR BELT
Adjusting The Alternator Belt
HYDRAULIC/HYDROSTATIC SYSTEM
Replacing The Hydraulic/Hydrostatic Filter
Checking And Adding Fluid
Replacing The Hydraulic Fluid
TIRE MAINTENANCE
Wheel Nuts
Tire Rotation
Tire Mounting
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
Removing Oil From The Chaincase
LUBRICATION OF THE BOBCAT LOADER
Procedure
FAN GEARBOX
Checking And Maintaining
BOB–TACH
Inspection And Maintenance
REMOTE START SWITCH
Procedure

HYDRAULIC SYSTEM
HYDRAULIC/HYDROSTATIC SCHEMATICS
TROUBLESHOOTING
HYDRAULIC SYSTEM INFORMATION
Tighten Procedures
LIFT CYLINDER(S)
Checking The Lift Cylinder(s)
Removal And Installation
TILT CYLINDER
Checking The Tilt Cylinder
Removal And Installation
Rod End Seal
HYDRAULIC CYLINDER
Lift Cylinder Identification
Tilt Cylinder Identification
Disassembly
Assembly
MAIN RELIEF VALVE
Checking The Main Relief Valve
Checking The Main Relief Valve Without Auxiliaries
Removal And Installation
Adjustment
MAIN RELIEF VALVE (Advanced Hand Control)
Adjustment
SELECT VALVE 863H
Checking The High Flow Pump Relief Valve
Removal And Installation
Disassembly And Assembly
Solenoid Testing
LIFT ARM BY–PASS CONTROL VALVE
Removal And Installation
Disassembly And Assembly
BICS™ CONTROL VALVE
Removal And Installation
BICS™ VALVE ASSEMBLY
Lift Arm By–Pass Orifice
Check Valve
Lock Valve
BICS™ Valve Solenoid
HYDRAULIC CONTROL VALVE
Removal And Installation
Identification Chart
Disassembly And Assembly
Load Check Valve
Lift Base End Restrictor
Main Relief Valve
Port Relief Valve
Anti–Cavitation/Port Relief Valve
Rubber Boot
Lift Spool And Detent
Tilt Spool And Centering Spring
Auxiliary Spool
Auxiliary Electric Solenoid
H Port – Auxiliary Section
Inspection
Spool Seal Installation
HYDRAULIC PUMP
Checking The Output Of The Pump
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
HYDRAULIC PUMP (Double Gear) 863H
Checking The Output Of The High Flow Pump
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
HYDRAULIC FLUID RESERVOIR
Removal And Installation
HYDROSTATIC FILTER HOUSING
Removal And Installation
Hydrostatic Charge Pressure Sender
CONTROL PEDALS
Removal And Installation
Pedal Adjustment
PEDAL INTERLOCK LINKAGE
Removal And Installation
Pedal Interlock Linkage Adjustment
REAR AUXILIARY DIVERTER
Disassembly
Inspection
Solenoid Testing
Assembly

HYDROSTATIC SYSTEM
TROUBLESHOOTING
HYDROSTATIC SYSTEM INFORMATION
Replenishing Valve Function
FRONT PANEL (M46 Pump & AHC)
Removal And Installation
FRONT PANEL (M44 Hydraulic Pump)
Removal And Installation
STEERING LEVERS (M46 Pumps & AHC)
Disassembly And Assembly
STEERING LEVERS (M44 Pumps)
Removal And Installation
Disassembly And Assembly
CONTROL TOWER (M46 Pump & AHC)
Removal And Installation
Disassembly And Assembly
SOLID STEERING LINKAGE NEUTRAL ADJUSTMENT (M46 Pump)
Procedure
STEERING LINKAGE (M44 Pump)
Removal And Installation
Steering Linkage Adjustment
HYDROSTATIC MOTOR (S/N 514427762 & Above; 514525304 & Above; 514625302 & Above)
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
HYDROSTATIC MOTOR (S/N 514427761 & Below; 514525303 & Below; 514625301 & Below)
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
MOTOR CARRIER
Removal And Installation
Parts Identification
Disassembly
Assembly
HYDROSTATIC PUMP (M46)
Removal And Installation
Replenishing/High Pressure Relief Valve
Charge Pressure Relief Valve
Parts Identification (Right Half)
Parts Identification (Left Half)
Hydraulic Pump Removal
Hydrostatic Pump Separation
Charge Pump Disassembly
Disassembly
Inspection
Assembly
Charge Pump Assembly
Hydrostatic Pump Connection
Hydraulic Pump Installation
Swashplate Neutral Adjustment
Displacement Control Servo (Solid Linkage)
HYDROSTATIC PUMP (M44)
Parts Identification (Right Half)
Parts Identification (Left Half)
Replenishing/High Pressure Relief Valve
Charge Pressure Relief Valve
Hydraulic Pump Removal
Hydraulic Pump Separation
Charge Pump Disassembly
Disassembly
Assembly
CHARGE PUMP (M44)
Assembly
DRIVE BELT SHIELD
Removal And Installation
DRIVE BELT
Adjusting The Drive Belt
Replacing The Drive Belt
DRIVE BELT TENSIONER PULLEY
Removal And Installation
Tension Spring
HYDRAULIC/HYDROSTATIC OIL COOLER
Removal And Installation

DRIVE SYSTEM
PARKING BRAKE PEDAL
Removal And Installation
Disassembly And Assembly
PARKING BRAKE DISC
Removal And Installation
FRONT CHAINCASE COVER
Removal And Installation
REAR CHAINCASE COVER
Removal And Installation
AXLE SEAL
Removal And Installation
AXLE, SPROCKET AND BEARINGS
Removal And Installation
DRIVE CHAIN
Removal And Installation
CHAINCASE FLUID
Removing The Fluid From The Chaincase

MAIN FRAME
SEAT BAR
Removal And Installation
Assembling Components
Compression Spring Disassembly And Assembly
OPERATOR CAB GAS CYLINDER
Removal And Installation
Disassembly And Assembly
OPERATOR CAB
Removal And Installation
OPERATOR SEAT
Removal And Installation
BOB–TACH
Bob–Tach Lever And Wedge
Bob–Tach Stops
Removal And Installation
Pivot Pin Bushing And Seal Replacement
LIFT ARMS
Removal And Installation
REAR GRILL
Removal And Installation
REAR DOOR
Removal And Installation
Door Latch And Catch Adjustment
FUEL TANK
Removal And Installation
Fuel Level Sender
Fuel Pick–Up Screen/Check Valve
Inlet Screen

ELECTRICAL SYSTEM
ELECTRICAL SCHEMATICS
TROUBLESHOOTING
ELECTRICAL SYSTEM INFORMATION
Description
Fuse Location
BATTERY
Removal And Installation
Servicing The Battery
Using A Booster Battery
ALTERNATOR
Alternator Output Test
Rectifier (Diode) Test
Alternator Regulator Test
Removal And Installation
Disassembly
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
Rectifier Continuity (Diode) Test
Assembly
STARTER
Removal And Installation
Parts Identification
Disassembly And Assembly
External Pinion
Inspection And Repair
Magnetic Switch Test
No Load Test
STANDARD INSTRUMENT PANEL
Removal And Installation
FRONT LIGHTS
Removal And Installation
RELAY SWITCHES
Location

ENGINE SERVICE
TROUBLESHOOTING
ENGINE SPEED CONTROL
Removal And Installation
Speed Control Cable
Speed Control Linkage
ENGINE MUFFLER
Removal And Installation
AIR CLEANER HOUSING
Removal And Installation
BLOWER HOUSING/FAN GEARBOX
Removal And Installation
FAN DRIVE TENSION PULLEY
Removal And Installation
BLOWER FAN
Removal And Installation
FAN GEARBOX
Parts Identification
Disassembly
Assembly
Checking Backlash
ENGINE
Removal And Installation
Replacement
FLYWHEEL
Removal And Installation
Flywheel Ring Gear
FLYWHEEL HOUSING
Removal And Installation
GLOW PLUG
Checking The Glow Plug
VALVE CLEARANCE
Adjustment
FUEL INJECTION PUMP
Description
Removal
Injection Pump Timing
Installation
FUEL INJECTOR
Removal and Installation
Checking
Disassembly
Assembly
TIMING BELT
Inspection
Removal
Installation
Belt Replacement In Loader
VALVE TIMING
Checking
DEUTZ ENGINE TOOLS
Identification Chart
RECONDITIONING THE ENGINE
Disassembly
Assembly
CYLINDER LINERS
Checking The Cylinder Liners
CAMSHAFT BEARINGS
Checking
Removal And Installation
CONTROL ROD GUIDE BUSHING
Removal
Installation
REAR COVER SEAL
Removal And Installation
CRANKSHAFT
Checking The Crankshaft
CONNECTING ROD
Checking The Connecting Rod
PISTON AND PISTON PIN
Checking the Piston
Installing Piston Rings
CYLINDER HEAD
Disassembly
Checking The Valves
Checking Valve Seats
Valve Spring
Assembly
ROCKER ARM AND BRACKET
Checking
FRONT COVER
Disassembly
Assembly
TURBOCHARGER
Removal and Installation
Disassembly
Inspection
Assembly
ENGINE OIL COOLER
Removal And Installation
CRANKSHAFT GEAR MOUNTING BOLT
Torque Procedure

SYSTEMS ANALYSIS
BICS™ (With Press To Operate Button)
Inspecting The BICS™ Controller (Engine STOPPED– Key ON)
Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
Inspecting The Seat Bar Sensor (Engine RUNNING)
Inspecting The Traction Lock (Engine RUNNING)
Inspecting The Lift Arm By–Pass Control
Additional Inspection For Loaders With Advanced Hand Controls
Troubleshooting Chart
BICS™ (Without Press To Operate Button)
Inspecting The BICS™ Controller (Engine STOPPED– Key ON)
Inspecting Deactivation of the Auxiliary HydraulicsSystem (Engine STOPPED – Key ON)
Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)
Inspecting The Traction Lock (Engine RUNNING)
Inspecting The Lift Arm By–Pass Control
Maintenance
Troubleshooting Chart
SEAT SENSOR OVERRIDE ONLY (If Equipped)
BICS SYSTEM CONTROLLER
Removal And Installation
SEAT BAR SENSOR
Troubleshooting Guide
Seat Bar Sensor Test
Removal And Installation
BICS™ Controller Seat Bar Sensor Circuit Test
SEAT SENSOR
Troubleshooting Guide
Seat Sensor Test
Removal And Installation
BICS™ Controller Seat Sensor Circuit Test
TRACTION LOCK
Troubleshooting Guide
Removal And Installation
TRACTION LOCK CONTROL SYSTEM (S/N 514427600 & Above; 514525300 & Above; 514625300 & Above)
Inspecting The Traction Lock Control System
Maintenance
TRACTION LOCK CONTROL SYSTEM (S/N 514123809 & Below; 514222299 & Below)
Description
Inspection
Maintenance
BOSS® DIAGNOSTIC TOOL
Procedure
SENDER AND SENSOR
Service Checks
RPM SENSOR
Adjustment
MONITOR SERVICE CODES
TROUBLESHOOTING THE BOSS® & LCD DISPLAY
BOSS® UNIT
Removal And Installation
BOSS® INSTRUMENT PANEL
Removal And Installation
PWM MODULE
Description
PWM TROUBLESHOOTING
Chart
PWM CONTROL HANDLE
Handle Testing
PWM ELECTRIC SOLENOID
Solenoid Coil Testing
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE

SPECIFICATIONS
LOADER SPECIFICATIONS
LOADER DIMENSIONS
PERFORMANCE
CONTROLS
ENGINE
HYDRAULIC SYSTEM
ELECTRICAL
DRIVE SYSTEM
CAPACITIES
TIRES
ENGINE SPECIFICATIONS (BF4M1011)
General
Fuel System
Valve And Valve Guide And Seat Insert
Piston And Rings
Connecting Rod
Cylinder Head And Block
Crankshaft And Main Bearings
Camshaft And Bearings
Oil Pump
ENGINE SPECIFICATIONS (BF4M1011F)
General
Fuel System
Valve And Valve Guide And Seat Insert
Piston And Rings
Connecting Rod
Cylinder Head And Block
Crankshaft And Main Bearings
Camshaft And Bearings
Oil Pump
ENGINE TORQUE
Specifications
Torque For General Metric Bolts
TORQUE SPECIFICATIONS FOR LOADER
HYDRAULIC CONNECTION SPECIFICATIONS
O–ring Face Seal Connection
Straight Thread O–ring Fitting
Tubelines And Hoses
Flare Fitting
O–ring Flare Fitting
Port Seal Fitting
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
STANDARD TORQUE SPECIFICATIONS FOR BOLTS
DECIMAL AND MILLIMETER EQUIVALENTS
U.S. TO METRIC CONVERSION

ADVANCE HAND CONTROL SYSTEM (A.H.C)
ADVANCE HAND CONTROL ELECTRICAL SCHEMATICS
A.H.C. COMPONENTS
Identification
TROUBLESHOOTING (A.H.C.)
ACTUATOR VOLTAGE TEST
Procedure
HANDLE CONTROL UNIT TEST
Procedure
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
Troubleshooting Chart
A.H.C./PWM CONTROLLER
Removal and Installation
Test
Description
Conditions
Troubleshooting Chart
Handle Testing
Solenoid Coil Testing
HANDLE CONTROL UNIT
Removal And Installation
Control Unit Connector
SWITCH HANDLE
Removal And Installation
A. H. C. HANDLE
Removal And Installation
Disassembly And Assembly
A.H.C. STEERING LEVER
Removal And Installation
Steering Lever Boot
ACTUATORS
Removal And Installation
Disassembly And Assembly
Mounting Plate
BICS™ VALVE
Lift Arm By–Pass Orifice
Check Valve
Lock Valve
BICS™ Valve Solenoid
Removal And Installation
HYDRAULIC CONTROL VALVE
Removal And Installation
Identification Chart
Disassembly And Assembly
Load Check Valve
Lift Base End Restrictor
Main Relief Valve
Port Relief Valve (Lift)
Anti–Cavitation/Port Relief Valve
Port Relief Valve (Tilt)
Anti–Cavitation Valve
Rubber Boot
Lift And Tilt Spool
Inspection
Auxiliary Spool
Auxiliary Electrical Solenoid
Spool Seal Installation
H–Port Auxiliary Section

SERVICE MANUAL REVISIONS
863/863H–1
863-2

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