Bobcat 863 TURBO – HIGH FLOW Skid-Steer Loader Repair Service Manual – 6900942

(S/N: 514440001 & Above – S/N: 514540001 & Above – S/N: 514640001 & Above)
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This workshop repair service manual PDF download for the 863 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
TURBO – HIGH FLOW
S/N: 514440001 & Above
S/N: 514540001 & Above
S/N: 514640001 & Above

TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE
HEATING, VENTILATION, AIR CONDITIONING
SPECIFICATIONS
SERVICE MANUAL REVISION

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6900942 (7-10)
Total Pages : 968

This 863 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
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrestor Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATIONS
Loader Serial Number
Engine Serial Number
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION

SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE LOADER
Procedure
LIFT ARM SUPPORT DEVICE
Engaging The Lift Arm Support Device
Disengaging The Lift Arm Support Device
OPERATOR CAB
Raising The Operator Cab
Lowering The Operator Cab
Emergency Exit
TRANSPORTING THE LOADER
Procedure
Adjusting The Bumper
TOWING THE LOADER
Procedure For Non-Two-Speeds
Procedure For Two-Speeds (S/N 51464170, 514540172, 514449389 And Below)
Procedure (S/N 51451171, 514540173, 514449390 and Above)
REMOTE START
Procedure For Loader Without, Attachments Control Harness
Procedure For Loader With, Attachments Control Harness
Procedure
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Replacing Filter Element
ENGINE COOLING SYSTEM
Cleaning The Cooling System
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Fuel Filter
Fuel Lift Pump Strainer
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Replacing Oil And Filter
HYDRAULIC / HYDROSTATIC SYSTEM
Checking And Adding Fluid
Replacing The Hydraulic / Hydrostatic Fluid
Replacing Hydraulic Fluid And Case Drain Filters
Breather Cap
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
Replacing The Oil
FAN GEAR BOX
Checking And Adding Oil
BOB-TACH
Inspection And Maintenance
POWER BOB-TACH (OPTION)
Inspection And Maintenance
LUBRICATING THE LOADER
Procedure
TIRE MAINTENANCE
Wheel Nuts
Tire Rotation
Tire Mounting

HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Tighten Procedures
Troubleshooting Chart
CYLINDER (LIFT)
Checking
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (TILT)
Checking
Removal And Installation
Rod End Seal
Parts Identification
Disassembly
Assembly
CYLINDER (POWER BOB-TACH)
Checking
Removal And Installation
Parts Identification
Disassembly
Assembly
MAIN RELIEF VALVE (FOOT CONTROL)
Checking The Main Relief Valve At Front Auxiliary Hydraulics
Checking The Main Relief Valve Without Front Auxiliaries
Removal And Installation
Adjustment
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
Removal And Installation (S/N 514447863 & Below)
Removal And Installation (S/N 514447864 & Above)
BICS™ Valve, Removal And Installation
BICS™ Valve, Lift arm Bypass Orifice Disassembly And Assembly
BICS™ Valve, Check Valve Disassembly And Assembly (S/N 514450007 & Below)
BICS™ Valve, Check Valve Disassembly And Assembly (514450007 & Above)
BICS™ Valve, Lock Valve Disassembly And Assembly
BICS™ Valve, Solenoid Disassembly And Assembly
BICS™ Valve, Solenoid Testing
Identification Chart
Load Check Valve
Main Relief Valve
Port Relief Valve, Tilt Spool
Port Relief Valve, Lift Spool
Anti-Cavitation Valve / Port Relief Valve, Tilt Spool
Anti-Cavitation Valve, Lift Spool
Rubber Boot
Lift And Tilt Block
Lift Spool And Detent
Tilt Spool Removal And Installation
Auxiliary Spool Removal And Installation
Auxiliary Plug Removal And Installation
Auxiliary Electric Solenoid Disassembly
Port Relief-Auxiliary Section Disassembly
Cleaning And Inspection
HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)
Description
Actuator Removal And Installation (In Loader)
Removal & Installation (S/N 514447863 & Below)
Removal And Installation (S/N 514447864 & Above)
Actuator Removal And Installation (Out Of Loader)
BICS™ Valve Removal And Installation
BICS™ Valve Lift Arm Bypass Orifice Removal And Installation
BICS™ Valve Check Valve Removal And Installation
BICS™ Valve Lock Valve Removal And Installation
BICS™ Valve Removal Solenoid And Installation
BICS™ Valve Solenoid Testing
Identification Chart
Lift Base End Restrictor
Load Check Valve
Main Relief Valve
Port Relief Valve(s)
Anti-Cavitation Valve / Port Relief Valve
Anti-Cavitation Valve
Lift Spool Removal And Installation
Tilt Spool Removal And Installation
Lift And Tilt Spool Disassembly And Assembly
Auxiliary Spool Removal And Installation
Auxiliary Electric Solenoid Disassembly And Assembly
Port-Auxiliary Section Disassembly
Cleaning And Inspection
LIFT ARM BYPASS CONTROL VALVE
Inspecting
Additional Inspection For Loaders With ACS
Removal And Installation
Disassembly And Assembly
HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 & BELOW)
Checking The Output Of The Pump
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N 514449483 & Below)
Checking The Output Of The High Flow Pump
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
HYDRAULIC PUMP (CAST IRON) (S/N 514449260 & ABOVE)
Check The Output Of The Hydraulic Pump Without Power Bob-Tach
Check The Output Of The Hydraulic Pump With Power Bob-Tach
Removal And Installation
Identification
Disassembly And Assembly
HYDRAULIC PUMP (CAST IRON HIGH FLOW) (S/N 514449484-514450945)
Check The Output Of The Hydraulic Pump Without Power Bob-Tach
Check The Output Of The Hydraulic Pump With Power Bob-Tach
Removal And Installation
Identification
Disassembly And Assembly
HYDRAULIC PUMP (CAST IRON HI FLOW) (514450846 & aBOVE)
Hydraulic Pump Test
Inline Hydraulic Pump Test (Standard)
Inline Hydraulic Pump Test (High Flow)
High Flow Relief Adjustment Procedure
High Flow Relief Valve Removal and Installation
Removal And Installation
Identification
Disassembly And Assembly
HYDRAULIC / HYDROSTATIC FILTER
Housing Removal And Installation
HYDRAULIC FLUID RESERVOIR
Draining The Fluid Reservoir
Removal And Installation
Hydraulic Fluid Screen
BUCKET POSITION VALVE
Solenoid Removal And Installation
Solenoid Testing
Removal And Installation
Disassembly And Assembly
SELECT VALVE
Checking The High Flow Pump Relief Valve (S/N 514450945 & Below)
Removal And Installation
Disassembly And Assembly
REAR AUXILIARY DIVERTER VALVE
Disassembly
Inspection
Solenoid Testing
Assembly
POWER BOB-TACH BLOCK (6676547-ALUMINUM)
Removal And Installation
Disassembly And Assembly
POWER BOB-TACH BLOCK (6678554-CAST IRON)
Removal And Installation
Disassembly And Assembly
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
Removal And Installation (514449564 & Above)
Disassembly And Assembly (518916011 & Above)

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart
Replentishing The Valve Function
HYDROSTATIC MOTOR
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
Carrier Removal And Installation
Carrier Parts Identification
Carrier Disassembly
Carrier Assembly
HYDROSTATIC MOTOR (TWO-SPEED)
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
CHARGE PRESSURE
Hydrostatic Charge Pressure Sender Removal And Installation
HYDROSTATIC PUMP
Replenishing / High Pressure Relief Valve
Charge Pressure Relief Valve
Removal And Installation
Parts Identification (Right Half)
Parts Identification (Left Half)
Hydraulic Pump Removal & Installation
Disassembly
Assembly
DRIVE BELT
Shield Removal And Installation
Adjustment
Replacement
Tensioner Pulley Removal And Installation
Tensioner Pulley Tension Spring
OIL COOLER
Removal And Installation With STC (Seal Tight Connector)

DRIVE SYSTEM
BRAKE
Pedal Removal And Installation
Pedal Disassembly And Assembly
Disc Removal And Installation
BRAKE (TWO-SPEED) (S/N 514449389 & Below)
Block Removal And Installation
Block Disassembly And Assembly
BRAKE (TWO-SPEED) (S/N 514449390 & Above)
Block Removal And Installation
Block Disassembly And Assembly
DRIVE COMPONENTS
Axle Seal Removal And Installation
Axle, Sprocket And Bearings Removal And Installation
Drive Chain Removal And Installation
CHAINCASE
Front Chaincase Cover Removal And Installation
Rear Chaincase Cover Removal And Installation

MAINFRAME
SEAT BAR
Removal And Installation
Assembling Components
Compression Spring Assembly And Assembly
OPERATOR CAB
Gas Cylinder Removal And Installation
Gas Cylinder Bracket Disassembly And Assembly
Removal And Installation
OPERATOR SEAT
Removal And Installation
Seat Belt Removal And Installation.
OPERATOR SEAT (SUSPENSION)
Removal And Installation
Slide Rail Removal And Installation
Cushion Removal And Installation
Back Removal And Installation
Shock Removal And Installation
BOB-TACH
Removal And Installation
Bob-Tach Lever And Wedge
Bob-Tach Stops
Pivot Pin Bushing And Seal Replacement
POWER BOB-TACH
Removal And Installation
Power Bob-Tach Lever And Wedge
Pivot Pin Bushing And Seal Replacement
LIFT ARMS
Removal And Installation
REAR GRILL
Removal And Installation
REAR DOOR
Removal And Installation (S/N 514449208 & Below)
Adjusting The Rear Door Latch (S/N 514449208 & Below)
Striker Removal And Installation (S/N 514449209 & Above)
Adjusting The Striker (S/N 514449209 & Above)
Latch Removal And Installation (S/N 514449209 & Above)
FUEL TANK
Removal And Installation
Fuel Level Sender
CONTROL PEDALS
Removal And Installation
Pedal Adjustment
Crossbar Linkage Removal And Installation
Lift Foot Pedal Linkage Removal And Installation
Tilt Foot Pedal Linkage Removal And Installation
CONTROL PEDALS (ACS)
Foot Sensor Removal And Installation
Foot Pedal Removal And Installation
Foot Pedal Linkage Disassembly And Assembly
CONTROL PANEL
Removal And Installation
CONTROL HANDLE
Lever Removal And Installation
Lever Disassembly And Assembly
Linkage Removal And Installation
Linkage Neutral Adjustment
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC)
Components Identification
Trouble shooting Guide
Parts Identification
AHC Controller Removal And Installation
Handle Control Unit Connector
Control Handle Removal And Installation
Actuators Disassembly And Assembly
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/ PUSH BUTTON FLOAT)
Components Identification
Trouble shooting Guide
Controller Connector and Wire Identification
AHC Controller Removal And Installation
Handle Sensor Removal And Installation
Handle Sensor Connector
Control Handle Removal And Installation
Actuators Disassembly And Assembly
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) ADVANCED HAND CONTROL
Components Identification
Handle Sensor Removal And Installation
Control Handle Removal And Installation
Control Handle Disassembly and Assembly
Control Lever Removal And Installation
Control Lever Boot
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL
Components Identification
Handle Sensor Removal And Installation
Control Handle Removal And Installation
Control Handle Disassembly and Assembly
Control Lever Removal And Installation
Control Lever Boot

ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
Description
Fuse Location
Relay Switches Location
Solenoid Test
BATTERY
Removal And Installation
Servicing The Electrical System
Using A Booster Battery (Jump Starting)
ALTERNATOR (55 AMP)
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
ALTERNATOR (90 AMP)
Adjusting The Alternator Belt
Alternator Identification
Charging System Check
Alternator Voltage Test
Low Voltage Test
High Voltage Test
Removal And Installation
Rectifier Continuity (Diode) Test
Alternator Regulator Test
Disassembly
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
Assembly
STARTER (NIPPONDENSO)
Removal And Installation
Parts Identification
Disassembly And Assembly
External Pinion
Inspection And Repair
No Load Test
STARTER (VALEO)
Checking
Removal And Installation
Parts Identification
Disassembly and Assembly
Inspection And Repair
No Load Test
INSTRUMENT PANEL
Left Panel
Right Panel – Standard Instrument Panel (With Key Switch)
Right Panel – (Deluxe) (With Keyless Start)
Right Panel Setup Display Options (Deluxe)
Deluxe Panel Setup
Passwords
Changing The Password
Option And Field Accessory Panels
Standard Panel Removal And Installation (Right Side)
Deluxe Panel Removal And Installation (Right Side)
Standard & Deluxe Panel Removal And Installation (Left Side)
LIGHTS
Front Removal And Installation
Rear Removal And Installation
BOBCAT CONTROLLER
Identification Chart (S/N 514450763 & Below)
Identification Chart (S/N 514450764 & Above)
Removal And Installation
DELUXE INSTRUMENTATION SERVICE CODES
BICS™ SYSTEM
Inspecting The BICS™ Controller (Engine STOPPED – Key ON)
Inspecting 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 Bypass Control
Additional Inspection For Loaders With Advanced Hand Controls
Troubleshooting Chart
Troubleshooting Guide
SEAT BAR SENSOR
Troubleshooting Chart
Test
Removal And Installation
BICS™ Circuit Test
TRACTION LOCK
Troubleshooting Chart
Removal And Installation (Single Speed)
Description Of The Control System (Two-Speed)
Inspecting The Control System (Two-Speed)
ADVANCED HAND CONTROL SYSTEM (AHC)
Components Identification
Trouble shooting Guide
Parts Identification
AHC Controller Removal And Installation
Handle Control Unit Connector
Switch Handle Removal And Installation
Actuators Disassembly And Assembly
ADVANCED HAND CONTROL SYSTEM (AHC) (W/ PUSH BUTTON FLOAT)
Components Identification
Trouble shooting Guide
Controller Connector and Wire Identification
AHC Controller Removal And Installation
Handle Control Unit Removal And Installation
Handle Control Unit Connector
Switch Handle Removal And Installation
Actuators Disassembly And Assembly
ADVANCED CONTROL SYSTEM (ACS) ADVANCED HAND CONTROL
Components Identification
Troubleshooting Guide
Controller, Connector And Wire Identification
ACS Controller Removal And Installation
Handle Sensor Connector
Switch Handle Removal
Switch Handle Installation
Actuators Disassembly and Assembly
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND / FOOT CONTROL
Components Identification
Troubleshooting Guide
Controller, Connector And Wire Identification
ACS Controller Removal And Installation
Handle Sensor Connector
Switch Handle Removal
Switch Handle Installation
Actuators Disassembly and Assembly
Handle Lock Solenoid Removal And Installation
Handle Lock Solenoid Disassembly And Assembly
Handle Lock Solenoid Connector
Calibration Of The ACS System
Switchable Hand / Foot Controls Calibration Procedure
Hand Controls Only Calibration Procedure
Foot Sensor Disassembly And Assembly
Foot Sensor Connector
Foot Lock Solenoid Removal And Installation
Foot Lock Solenoid Connector
ELECTRICAL / HYDRAULIC CONTROLS REFERENCE
Controls Identification Chart

ENGINE SERVICE
TROUBLESHOOTING
Chart
ENGINE SPEED CONTROL
Removal And Installation
Speed Control Cable
Speed Control Linkage
MUFFLER
Removal And Installation
AIR CLEANER
Housing Removal And Installation
RADIATOR
Oil Cooler Removal And Installation
COOLING FAN
Drive Tension Pulley Removal And Installation
Gearbox / Blower Housing Removal And Installation
Blower Removal And Installation
Gearbox Parts Identification
Gearbox Disassembly
Gearbox Assembly
Gearbox, Checking Backlash
ENGINE COMPONENTS AND TESTS
Engine Compression, Checking
Glow Plug, Checking
Fuel Shut-Off Solenoid, Checking
Fuel Shut-Off Solenoid Removal and Installation
Fuel Injection Pump Removal
Fuel Injection Pump Timing
Fuel Injection Pump Installation
Fuel Injector Removal and Installation
Fuel Injector, Checking
Fuel Injector Disassembly
Fuel Injector Assembly
Timing Belt Inspection
Timing Belt Removal
Timing Belt Installation
Timing Belt, Replacement In the Loader
Valve Clearance Adjustment
Valve Timing, Checking
Thermostat, Oil Pressure Control Valves And Heater Connections
ENGINE AND ENGINE MOUNTS
Removal And Installation
Engine Mount Replacement
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Ring Gear Removal And Installation
Flywheel Housing Removal And Installation
RPM SENSOR
Adjustment
RECONDITIONING THE ENGINE
Deutz Engine Tools Identification Chart
Disassembly
Assembly
Cylinder, Checking
Camshaft Bearing, Checking
Camshaft Bearing, Removal And Installation
Control Rod Guide Bushing Removal
Control Rod Guide Bushing Installation
Rear Cover Seal Removal And Installation
Crankshaft, Checking
Connecting Rod, Checking
Piston, Checking
Piston Pin, Checking
Piston Rings Installation
Piston Installation On the Connecting Rod
Cylinder Head Disassembly
Valves, Checking
Valve Seats, Checking
Valve Spring, Checking
Cylinder Head Assembly
Rocker Arm and Bracket, Checking
Front Cover Disassembly
Front Cover Assembly
Turbo Charger Removal and Installation
Crankshaft Gear Mounting Bolt Torque Procedure

HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW
Principals
Chart
COMPONENTS
Identification
SAFETY
Safety Equipment
REGULAR MAINTENANCE
Cleaning The Condenser
Compressor Drive Belt Inspection
Filter Elements Removal And Installation
BASIC TROUBLESHOOTING
Cleaning The A/C Evaporator Coil & Heater Coil
Checking The Electrical System
Compressor Drive Belt Inspection:
Engine Coolant Bypassing The Heater Valve
Heater Valve Not Opening Or Closing
Poor A/C Performance
GENERAL AIR CONDITIONING SERVICE GUIDELINES
Compressor Oil
Compressor Oil Check
Component Replacement And Refrigeration Leaks
SYSTEM TROUBLESHOOTING CHART
Gauge Pressure Related Troubleshooting
Troubleshooting Tree
TEMPERATURE / PRESSURE
Chart
AIR CONDITIONING SERVICE
Chart
SYSTEM CHARGING AND RECLAMATION
Reclamation Procedure
Charging Procedure With A Manifold Gauge Set
Charging Procedure
COMPRESSOR
Removal And Installation
Compressor Clutch Disassembly
CONDENSER
Removal And Installation
RECEIVER / DRIER
Removal And Installation
PRESSURE RELIEF VALVE
Removal And Installation
PRESSURE SWITCH
Removal And Installation
EVAPORATOR / HEATER UNIT
Removal And Installation
Disassembly And Assembly
THERMOSTAT
Removal And Installation
EXPANSION VALVE
Removal And Installation
EVAPORATOR
Removal And Installation
HEATER COIL
Removal And Installation With A/C
Removal And Installation Without A/C
HEATER / AC FAN
Removal And Installation
Disassembly And Assembly
Wire Connector Removal And Installation
HEATER VALVE
Removal and Installation
Disassembly And Assembly

SPECIFICATIONS
LOADER SPECIFICATIONS
Loader Dimensions
Performance
Controls
Engine
Hydraulic System
Electrical
Drive System
Capacities
Tires
ENGINE SPECIFICATIONS
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
LOADER TORQUE
Specifications
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
Torque For General Metric Bolts
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 FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion

SERVICE MANUAL REVISION
863/863H-1
863/863H-2
863/863H-3
863/863H-4
863-5
863-6
863-7
863-8
863-9
863-10

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