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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