Description
Complete Factory Service Information for Bobcat 863 Loaders
This is the comprehensive Bobcat Service Manual for the 863 and 863H High Flow Turbo Skid-Steer Loader. This factory-grade publication provides every procedure, specification, and diagnostic routine needed to properly maintain, repair, and service these versatile machines. It covers all serial number ranges listed, ensuring you have the exact information for your specific loader model.
Document & File Details
- Manual Type: Factory Service Manual
- Brand/Model: Bobcat 863 and 863 High Flow Turbo Loader
- Document Number: 6900942
- Edition / Date: February 2006
- Language: English
- Page Count: Approximately 963 pages (as per PDF)
- File Format: High-quality digital PDF
Chapters & Major Sections Covered
The manual is meticulously organized into the following main sections. Every subsystem is detailed with step-by-step instructions, accurate torque specifications, and clear diagrams.
- Safety & Maintenance: Includes complete service schedules, lift arm support procedures, towing instructions, lubrication points, and safety protocols.
- Hydraulic System: Covers the hydraulic pump (aluminum and cast iron variants), hydraulic control valves (foot, ACS, AHC), lift and tilt cylinders, Power Bob-Tach cylinders, bucket position valve, select valve, and front auxiliary coupler block.
- Hydrostatic System: Contains detailed service for the hydrostatic pump, hydrostatic motors (single and two-speed), charge pressure system, drive belt, and oil cooler.
- Drive System: Covers the brakes (standard and two-speed), chaincase, and all drive components (axles, sprockets, bearings, drive chains).
- Main Frame: Complete disassembly and assembly procedures for the Bob-Tach, lift arms, operator cab, operator seat, control panels, pedals, and fuel tank.
- Electrical System & Analysis: Extensive troubleshooting guides, wiring schematics (for standard and advanced control systems), service codes, starter and alternator rebuild, and BICS™ system diagnostics.
- Engine Service: Full reconditioning guide for the Deutz BF4M1011F engine, including timing belt replacement, fuel system, compression checks, and turbocharger service.
- Heating, Ventilation, & Air Conditioning (HVAC): Covers A/C service, reclamation, component replacement (compressor, condenser, evaporator), and system troubleshooting.
- Specifications: Complete listing of loader specifications, fluid capacities, and standard torque values for bolts and hydraulic connections.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Bobcat 863 / 863H High Flow Turbo Loader Service Manual PDF” are as follows:
MAINTENANCE SAFETYp. 3
ALPHABETICAL INDEXp. 5
+CONTENTSp. 7
FOREWORDp. 8
+SAFETY INSTRUCTIONSp. 11
+SERIAL NUMBER LOCATIONSp. 15
Loader Serial Numberp. 15
Engine Serial Numberp. 15
DELIVERY REPORTp. 16
BOBCAT LOADER IDENTIFICATIONp. 17
+SAFETY AND MAINTENANCEp. 19
+LIFTING AND BLOCKING THE LOADERp. 21
+LIFT ARM SUPPORT DEVICEp. 23
Engaging The Lift Arm Support Devicep. 23
Disengaging The Lift Arm Support Devicep. 24
+OPERATOR CABp. 25
Raising The Operator Cabp. 25
Lowering The Operator Cabp. 26
Emergency Exitp. 27
+TRANSPORTING THE LOADERp. 29
Procedurep. 29
Adjusting The Bumperp. 29
+TOWING THE LOADERp. 31
Procedure For Non-Two-Speedsp. 31
Procedure For Two-Speeds (S/N 51464170, 514540172, 514449389 And Below)p. 32
Procedure (S/N 51451171, 514540173, 514449390 and Above)p. 33
+REMOTE STARTp. 35
Procedure For Loader Without, Attachments Control Harnessp. 35
Procedure For Loader With, Attachments Control Harnessp. 36
Procedurep. 38
+SERVICE SCHEDULEp. 39
+AIR CLEANER SERVICEp. 41
Replacing Filter Elementp. 41
+ENGINE COOLING SYSTEMp. 43
Cleaning The Cooling Systemp. 43
+FUEL SYSTEMp. 45
Fuel Specificationsp. 45
Filling The Fuel Tankp. 45
Fuel Filterp. 46
Fuel Lift Pump Strainerp. 47
Removing Air From The Fuel Systemp. 47
+ENGINE LUBRICATION SYSTEMp. 49
Checking Engine Oilp. 49
Replacing Oil And Filterp. 49
+HYDRAULIC/HYDROSTATIC SYSTEMp. 51
Checking And Adding Fluidp. 51
Replacing The Hydraulic/Hydrostatic Fluidp. 52
Replacing Hydraulic Fluid And Case Drain Filtersp. 52
Breather Capp. 54
+FINAL DRIVE TRANSMISSION (CHAINCASE)p. 55
Checking And Adding Oilp. 55
Replacing The Oilp. 55
+FAN GEAR BOXp. 57
Checking And Adding Oilp. 57
+BOB-TACHp. 59
Inspection And Maintenancep. 59
+POWER BOB-TACH (OPTION)p. 61
Inspection And Maintenancep. 61
+LUBRICATING THE LOADERp. 63
+TIRE MAINTENANCEp. 65
Wheel Nutsp. 65
Tire Rotationp. 65
Tire Mountingp. 65
+HYDRAULIC SYSTEMp. 67
HYDRAULIC/HYDROSTATIC SCHEMATICSp. 73
+HYDRAULIC SYSTEM INFORMATIONp. 113
Tighten Proceduresp. 117
Troubleshooting Chartp. 117
+CYLINDER (LIFT)p. 119
Checkingp. 119
Removal And Installationp. 120
Parts Identificationp. 122
Disassemblyp. 123
Assemblyp. 125
+CYLINDER (TILT)p. 129
Checkingp. 129
Removal And Installationp. 129
Rod End Sealp. 131
Parts Identificationp. 132
Disassemblyp. 133
Assemblyp. 135
+CYLINDER (POWER BOB-TACH)p. 139
Checkingp. 139
Removal And Installationp. 140
Parts Identificationp. 141
Disassemblyp. 142
Assemblyp. 143
+MAIN RELIEF VALVE (FOOT CONTROL)p. 147
Checking The Main Relief Valve At Front Auxiliary Hydraulicsp. 147
Checking The Main Relief Valve Without Front Auxiliariesp. 148
Removal And Installationp. 150
Adjustmentp. 151
+HYDRAULIC CONTROL VALVE (FOOT CONTROL)p. 153
Removal And Installation (S/N 514447863 & Below)p. 153
Removal And Installation (S/N 514447864 & Above)p. 156
BICS™ Valve, Removal And Installationp. 162
BICS™ Valve, Lift arm By-Pass Orifice Disassembly And Assemblyp. 163
BICS™ Valve, Check Valve Disassembly And Assembly (S/N 514450007 & Below)p. 164
BICS™ Valve, Check Valve Disassembly And Assembly (514450007 & Above)p. 165
BICS™ Valve, Lock Valve Disassembly And Assemblyp. 166
BICS™ Valve, Solenoid Disassembly And Assemblyp. 167
BICS™ Valve, Solenoid Testingp. 168
Identification Chartp. 168
Load Check Valvep. 169
Main Relief Valvep. 170
Port Relief Valve, Tilt Spoolp. 171
Port Relief Valve, Lift Spoolp. 171
Anti-Cavitation Valve/Port Relief Valve, Tilt Spoolp. 172
Anti-Cavitation Valve, Lift Spoolp. 172
Rubber Bootp. 173
Lift And Tilt Blockp. 173
Lift Spool And Detentp. 174
Tilt Spool Removal And Installationp. 183
Auxiliary Spool Removal And Installationp. 185
Auxiliary Plug Removal And Installationp. 187
Auxiliary Electric Solenoid Disassemblyp. 188
Port Relief-Auxiliary Section Disassemblyp. 189
Cleaning And Inspectionp. 190
+HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)p. 191
Descriptionp. 191
Actuator Removal And Installation (In Loader)p. 191
Removal & Installation (S/N 514447863 & Below)p. 193
Removal And Installation (S/N 514447864 & Above)p. 197
Actuator Removal And Installation (Out Of Loader)p. 202
BICS™ Valve Removal And Installationp. 203
BICS™ Valve Lift Arm By-Pass Orifice Removal And Installationp. 205
BICS™ Valve Check Valve Removal And Installationp. 206
BICS™ Valve Lock Valve Removal And Installationp. 207
BICS™ Valve Removal Solenoid And Installationp. 208
BICS™ Valve Solenoid Testingp. 209
Identification Chartp. 209
Lift Base End Restrictorp. 210
Load Check Valvep. 210
Main Relief Valvep. 212
Port Relief Valve(s)p. 213
Anti-Cavitation Valve/Port Relief Valvep. 214
Anti-Cavitation Valvep. 215
Lift Spool Removal And Installationp. 216
Tilt Spool Removal And Installationp. 217
Lift And Tilt Spool Disassembly And Assemblyp. 218
Auxiliary Spool Removal And Installationp. 219
Auxiliary Electric Solenoid Disassembly And Assemblyp. 220
Port-Auxiliary Section Disassemblyp. 221
Cleaning And Inspectionp. 222
+LIFT ARM BY-PASS CONTROL VALVEp. 223
Inspectingp. 223
Additional Inspection For Loaders With ACSp. 223
Removal And Installationp. 223
Disassembly And Assemblyp. 224
+HYDRAULIC PUMP (ALUMINUM) (S/N 514449259 & BELOW)p. 225
Checking The Output Of The Pumpp. 225
Removal And Installationp. 226
Parts Identificationp. 227
Disassemblyp. 228
Inspectionp. 230
Assemblyp. 231
+HYDRAULIC PUMP (ALUMINUM HI FLOW) (S/N 514449483 & Below)p. 233
Checking The Output Of The High Flow Pumpp. 233
Removal And Installationp. 234
Parts Identificationp. 236
Disassemblyp. 237
Inspectionp. 241
Assemblyp. 242
+HYDRAULIC PUMP (CAST IRON) (S/N 514449260 & ABOVE)p. 247
Check The Output Of The Hydraulic Pump Without Power Bob-Tachp. 247
Check The Output Of The Hydraulic Pump With Power Bob-Tachp. 249
Removal And Installationp. 250
Identificationp. 252
Disassembly And Assemblyp. 253
+HYDRAULIC PUMP (CAST IRON HIGH FLOW) (S/N 514449484-514450945)p. 259
Check The Output Of The Hydraulic Pump Without Power Bob-Tachp. 259
Check The Output Of The Hydraulic Pump With Power Bob-Tachp. 260
Removal And Installationp. 262
Identificationp. 264
Disassembly And Assemblyp. 265
+HYDRAULIC PUMP (CAST IRON HI FLOW) (514450846 & aBOVE)p. 275
Hydraulic Pump Testp. 275
Inline Hydraulic Pump Test (Standard)p. 276
Inline Hydraulic Pump Test (High Flow)p. 278
High Flow Relief Adjustment Procedurep. 280
High Flow Relief Valve Removal and Installationp. 282
Removal And Installationp. 284
Identificationp. 286
Disassembly And Assemblyp. 287
+HYDRAULIC/HYDROSTATIC FILTERp. 297
Housing Removal And Installationp. 297
+HYDRAULIC FLUID RESERVOIRp. 299
Draining The Fluid Reservoirp. 299
Removal And Installationp. 299
Hydraulic Fluid Screenp. 301
+BUCKET POSITION VALVEp. 303
Solenoid Removal And Installationp. 303
Solenoid Testingp. 304
Removal And Installationp. 304
Disassembly And Assemblyp. 306
+SELECT VALVEp. 309
Checking The High Flow Pump Relief Valve (S/N 514450945 & Below)p. 309
Removal And Installationp. 310
Disassembly And Assemblyp. 312
+REAR AUXILIARY DIVERTER VALVEp. 315
Disassemblyp. 315
Inspectionp. 316
Solenoid Testingp. 316
Assemblyp. 316
+POWER BOB-TACH BLOCK (6676547-ALUMINUM)p. 317
Removal And Installationp. 317
Disassembly And Assemblyp. 319
+POWER BOB-TACH BLOCK (6678554-CAST IRON)p. 327
Removal And Installationp. 327
Disassembly And Assemblyp. 328
+FRONT AUXILIARY HYDRAULIC COUPLER BLOCKp. 337
Removal And Installation (514449564 & Above)p. 337
Disassembly And Assembly (518916011 & Above)p. 337
+HYDROSTATIC SYSTEMp. 339
+HYDROSTATIC SYSTEM INFORMATIONp. 341
Troubleshooting Chartp. 341
Replentishing The Valve Functionp. 342
+HYDROSTATIC MOTORp. 343
Removal And Installationp. 343
Parts Identificationp. 345
Disassemblyp. 346
Inspectionp. 349
Assemblyp. 350
Carrier Removal And Installationp. 353
Carrier Parts Identificationp. 354
Carrier Disassemblyp. 355
Carrier Assemblyp. 356
+HYDROSTATIC MOTOR (TWO-SPEED)p. 359
Removal And Installationp. 359
Parts Identificationp. 361
Disassemblyp. 362
Inspectionp. 369
Assemblyp. 370
+CHARGE PRESSUREp. 377
Hydrostatic Charge Pressure Sender Removal And Installationp. 377
+HYDROSTATIC PUMPp. 379
Replenishing/High Pressure Relief Valvep. 379
Charge Pressure Relief Valvep. 380
Removal And Installationp. 381
Parts Identification (Right Half)p. 383
Parts Identification (Left Half)p. 384
Hydraulic Pump Removal & Installationp. 385
Disassemblyp. 386
Assemblyp. 394
+DRIVE BELTp. 403
Shield Removal And Installationp. 403
Adjustmentp. 403
Replacementp. 404
Tensioner Pulley Removal And Installationp. 404
Tensioner Pulley Tension Springp. 406
+OIL COOLERp. 407
Removal And Installation With STC (Seal Tight Connector)p. 407
+DRIVE SYSTEMp. 409
+BRAKEp. 411
Pedal Removal And Installationp. 411
Pedal Disassembly And Assemblyp. 412
Disc Removal And Installationp. 413
+BRAKE (TWO-SPEED) (S/N 514449389 & Below)p. 417
Block Removal And Installationp. 417
Block Disassembly And Assemblyp. 418
+BRAKE (TWO-SPEED) (S/N 514449390 & Above)p. 423
Block Removal And Installationp. 423
Block Disassembly And Assemblyp. 425
+DRIVE COMPONENTSp. 429
Axle Seal Removal And Installationp. 429
Axle, Sprocket And Bearings Removal And Installationp. 431
Drive Chain Removal And Installationp. 436
+CHAINCASEp. 437
Front Chaincase Cover Removal And Installationp. 437
Rear Chaincase Cover Removal And Installationp. 437
+MAIN FRAMEp. 439
+SEAT BARp. 443
Removal And Installationp. 443
Assembling Componentsp. 444
Compression Spring Assembly And Assemblyp. 446
+OPERATOR CABp. 447
Gas Cylinder Removal And Installationp. 447
Gas Cylinder Bracket Disassembly And Assemblyp. 448
Removal And Installationp. 449
+OPERATOR SEATp. 451
Removal And Installationp. 451
Seat Belt Removal And Installation.p. 451
+OPERATOR SEAT (SUSPENSION)p. 453
Removal And Installationp. 453
Slide Rail Removal And Installationp. 454
Cushion Removal And Installationp. 455
Back Removal And Installationp. 456
Shock Removal And Installationp. 456
+BOB-TACHp. 459
Removal And Installationp. 459
Bob-Tach Lever And Wedgep. 461
Bob-Tach Stopsp. 462
Pivot Pin Bushing And Seal Replacementp. 463
+POWER BOB-TACHp. 465
Removal And Installationp. 465
Power Bob-Tach Lever And Wedgep. 466
Pivot Pin Bushing And Seal Replacementp. 468
+LIFT ARMSp. 469
Removal And Installationp. 469
+REAR GRILLp. 473
Removal And Installationp. 473
+REAR DOORp. 475
Removal And Installation (S/N 514449208 & Below)p. 475
Adjusting The Rear Door Latch (S/N 514449208 & Below)p. 476
Striker Removal And Installation (S/N 514449209 & Above)p. 477
Adjusting The Striker (S/N 514449209 & Above)p. 477
Latch Removal And Installation (S/N 514449209 & Above)p. 478
+FUEL TANKp. 479
Removal And Installationp. 479
Fuel Level Senderp. 480
+CONTROL PEDALSp. 481
Removal And Installationp. 481
Pedal Adjustmentp. 481
Crossbar Linkage Removal And Installationp. 482
Lift Foot Pedal Linkage Removal And Installationp. 483
Tilt Foot Pedal Linkage Removal And Installationp. 484
+CONTROL PEDALS (ACS)p. 485
Foot Sensor Removal And Installationp. 485
Foot Pedal Removal And Installationp. 486
Foot Pedal Linkage Disassembly And Assemblyp. 486
+CONTROL PANELp. 487
Removal And Installationp. 487
+CONTROL HANDLEp. 491
Lever Removal And Installationp. 491
Lever Disassembly And Assemblyp. 491
Linkage Removal And Installationp. 492
Linkage Neutral Adjustmentp. 495
+CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC)p. 501
Components Identificationp. 501
Trouble shooting Guidep. 502
Parts Identificationp. 503
AHC Controller Removal And Installationp. 504
Handle Control Unit Connectorp. 505
Control Handle Removal And Installationp. 506
Actuators Disassembly And Assemblyp. 509
+CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/PUSH BUTTON FLOAT)p. 511
Components Identificationp. 511
Trouble shooting Guidep. 512
Controller Connector and Wire Identificationp. 513
AHC Controller Removal And Installationp. 514
Handle Sensor Removal And Installationp. 515
Handle Sensor Connectorp. 517
Control Handle Removal And Installationp. 518
Actuators Disassembly And Assemblyp. 521
+CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) ADVANCED HAND CONTROLp. 523
Components Identificationp. 523
Handle Sensor Removal And Installationp. 523
Control Handle Removal And Installationp. 527
Control Handle Disassembly and Assemblyp. 528
Control Lever Removal And Installationp. 529
Control Lever Bootp. 530
+CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROLp. 531
Components Identificationp. 531
Handle Sensor Removal And Installationp. 531
Control Handle Removal And Installationp. 535
Control Handle Disassembly and Assemblyp. 536
Control Lever Removal And Installationp. 536
Control Lever Bootp. 538
+ELECTRICAL SYSTEM & ANALYSISp. 539
ELECTRICAL SCHEMATICSp. 543
+ELECTRICAL SYSTEM INFORMATIONp. 554
Troubleshooting Chartp. 556
Descriptionp. 557
Fuse Locationp. 559
Relay Switches Locationp. 559
Solenoid Testp. 560
+BATTERYp. 562
Removal And Installationp. 562
Servicing The Electrical Systemp. 564
Using A Booster Battery (Jump Starting)p. 564
+ALTERNATOR (55 AMP)p. 566
Alternator Output Testp. 566
Rectifier (Diode) Testp. 566
Alternator Regulator Testp. 567
Removal And Installationp. 568
Disassemblyp. 569
Stator Continuity Testp. 569
Stator Ground Testp. 569
Rotor Continuity Testp. 570
Rotor Ground Testp. 570
Rectifier Continuity (Diode) Testp. 570
Assemblyp. 571
+ALTERNATOR (90 AMP)p. 572
Adjusting The Alternator Beltp. 572
Alternator Identificationp. 572
Charging System Checkp. 573
Alternator Voltage Testp. 574
Low Voltage Testp. 575
High Voltage Testp. 575
Removal And Installationp. 576
Rectifier Continuity (Diode) Testp. 577
Alternator Regulator Testp. 578
Disassemblyp. 578
Stator Continuity Testp. 579
Stator Ground Testp. 579
Rotor Continuity Testp. 579
Rotor Ground Testp. 579
Assemblyp. 580
+STARTER (NIPPONDENSO)p. 582
Removal And Installationp. 582
Parts Identificationp. 583
Disassembly And Assemblyp. 584
External Pinionp. 587
Inspection And Repairp. 588
No Load Testp. 592
+STARTER (VALEO)p. 594
Checkingp. 594
Removal And Installationp. 595
Parts Identificationp. 596
Disassembly and Assemblyp. 597
Inspection And Repairp. 600
No Load Testp. 602
+INSTRUMENT PANELp. 604
Left Panelp. 604
Right Panel – Standard Instrument Panel (With Key Switch)p. 605
Right Panel – (Deluxe) (With Keyless Start)p. 606
Right Panel Setup Display Options (Deluxe)p. 607
Deluxe Panel Setupp. 608
Passwordsp. 608
Changing The Passwordp. 608
Option And Field Accessory Panelsp. 610
Standard Panel Removal And Installation (Right Side)p. 611
Deluxe Panel Removal And Installation (Right Side)p. 612
Standard & Deluxe Panel Removal And Installation (Left Side)p. 613
+LIGHTSp. 616
Front Removal And Installationp. 616
Rear Removal And Installationp. 617
+BOBCAT CONTROLLERp. 618
Identification Chart (S/N 514450763 & Below)p. 618
Identification Chart (S/N 514450764 & Above)p. 619
Removal And Installationp. 621
DELUXE INSTRUMENTATION SERVICE CODESp. 624
+BICS™ SYSTEMp. 626
Inspecting The BICS™ Controller (Engine STOPPED – Key ON)p. 626
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)p. 626
Inspecting The Seat Bar Sensor (Engine RUNNING)p. 626
Inspecting The Traction Lock (Engine RUNNING)p. 626
Inspecting The Lift Arm By-Pass Controlp. 626
Additional Inspection For Loaders With Advanced Hand Controlsp. 627
Troubleshooting Chartp. 628
Troubleshooting Guidep. 629
+SEAT BAR SENSORp. 630
Troubleshooting Chartp. 630
Testp. 631
Removal And Installationp. 632
BICS™ Circuit Testp. 633
+TRACTION LOCKp. 634
Troubleshooting Chartp. 634
Removal And Installation (Single Speed)p. 635
Description Of The Control System (Two-Speed)p. 636
Inspecting The Control System (Two-Speed)p. 636
+ADVANCED HAND CONTROL SYSTEM (AHC)p. 638
Components Identificationp. 638
Trouble shooting Guidep. 639
Parts Identificationp. 640
AHC Controller Removal And Installationp. 641
Handle Control Unit Connectorp. 642
Switch Handle Removal And Installationp. 643
Actuators Disassembly And Assemblyp. 646
+ADVANCED HAND CONTROL SYSTEM (AHC) (W/ PUSH BUTTON FLOAT)p. 648
Components Identificationp. 648
Trouble shooting Guidep. 649
Controller Connector and Wire Identificationp. 650
AHC Controller Removal And Installationp. 651
Handle Control Unit Removal And Installationp. 652
Handle Control Unit Connectorp. 654
Switch Handle Removal And Installationp. 655
Actuators Disassembly And Assemblyp. 658
+ADVANCED CONTROL SYSTEM (ACS) ADVANCED HAND CONTROLp. 660
Components Identificationp. 660
Troubleshooting Guidep. 661
Controller, Connector And Wire Identificationp. 662
ACS Controller Removal And Installationp. 663
Handle Sensor Connectorp. 664
Switch Handle Removalp. 665
Switch Handle Installationp. 667
Actuators Disassembly and Assemblyp. 670
+ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND/FOOT CONTROLp. 672
Components Identificationp. 672
Troubleshooting Guidep. 674
Controller, Connector And Wire Identificationp. 675
ACS Controller Removal And Installationp. 676
Handle Sensor Connectorp. 677
Switch Handle Removalp. 678
Switch Handle Installationp. 680
Actuators Disassembly and Assemblyp. 683
Handle Lock Solenoid Removal And Installationp. 684
Handle Lock Solenoid Disassembly And Assemblyp. 685
Handle Lock Solenoid Connectorp. 685
Calibration Of The ACS Systemp. 686
Switchable Hand/Foot Controls Calibration Procedurep. 686
Hand Controls Only Calibration Procedurep. 688
Foot Sensor Disassembly And Assemblyp. 689
Foot Sensor Connectorp. 690
Foot Lock Solenoid Removal And Installationp. 691
Foot Lock Solenoid Connectorp. 691
+ELECTRICAL/HYDRAULIC CONTROLS REFERENCEp. 694
Controls Identification Chartp. 694
+ENGINE SERVICEp. 696
+TROUBLESHOOTINGp. 698
+ENGINE SPEED CONTROLp. 700
Removal And Installationp. 700
Speed Control Cablep. 701
Speed Control Linkagep. 702
+MUFFLERp. 704
Removal And Installationp. 704
+AIR CLEANERp. 706
Housing Removal And Installationp. 706
+RADIATORp. 708
Oil Cooler Removal And Installationp. 708
+COOLING FANp. 710
Drive Tension Pulley Removal And Installationp. 710
Gearbox/Blower Housing Removal And Installationp. 711
Blower Removal And Installationp. 714
Gearbox Parts Identificationp. 715
Gearbox Disassemblyp. 716
Gearbox Assemblyp. 721
Gearbox, Checking Backlashp. 726
+ENGINE COMPONENTS AND TESTSp. 730
Engine Compression, Checkingp. 730
Glow Plug, Checkingp. 731
Fuel Shut-Off Solenoid, Checkingp. 732
Fuel Shut-Off Solenoid Removal and Installationp. 733
Fuel Injection Pump Removalp. 733
Fuel Injection Pump Timingp. 735
Fuel Injection Pump Installationp. 736
Fuel Injector Removal and Installationp. 738
Fuel Injector, Checkingp. 739
Fuel Injector Disassemblyp. 740
Fuel Injector Assemblyp. 741
Timing Belt Inspectionp. 743
Timing Belt Removalp. 743
Timing Belt Installationp. 744
Timing Belt, Replacement In the Loaderp. 748
Valve Clearance Adjustmentp. 753
Valve Timing, Checkingp. 754
Thermostat, Oil Pressure Control Valves And Heater Connectionsp. 756
+ENGINE AND ENGINE MOUNTSp. 760
Removal And Installationp. 760
Engine Mount Replacementp. 766
+FLYWHEEL AND HOUSINGp. 768
Flywheel Removal And Installationp. 768
Ring Gear Removal And Installationp. 768
Flywheel Housing Removal And Installationp. 768
+RPM SENSORp. 770
+RECONDITIONING THE ENGINEp. 772
Deutz Engine Tools Identification Chartp. 772
Disassemblyp. 773
Assemblyp. 777
Cylinder, Checkingp. 793
Camshaft Bearing, Checkingp. 794
Camshaft Bearing, Removal And Installationp. 794
Control Rod Guide Bushing Removalp. 795
Control Rod Guide Bushing Installationp. 797
Rear Cover Seal Removal And Installationp. 801
Crankshaft, Checkingp. 802
Connecting Rod, Checkingp. 804
Piston, Checkingp. 806
Piston Pin, Checkingp. 807
Piston Rings Installationp. 807
Piston Installation On the Connecting Rodp. 808
Cylinder Head Disassemblyp. 810
Valves, Checkingp. 810
Valve Seats, Checkingp. 811
Valve Spring, Checkingp. 812
Cylinder Head Assemblyp. 812
Rocker Arm and Bracket, Checkingp. 813
Front Cover Disassemblyp. 814
Front Cover Assemblyp. 819
Turbo Charger Removal and Installationp. 828
Crankshaft Gear Mounting Bolt Torque Procedurep. 829
+HEATING, VENTILATION, AIR CONDITIONINGp. 832
+AIR CONDITIONING SYSTEM FLOWp. 835
Principalsp. 835
Chartp. 836
+COMPONENTSp. 838
+SAFETYp. 842
+REGULAR MAINTENANCEp. 844
Cleaning The Condenserp. 844
Compressor Drive Belt Inspectionp. 845
Filter Elements Removal And Installationp. 845
+BASIC TROUBLESHOOTINGp. 848
Cleaning The A/C Evaporator Coil & Heater Coilp. 848
Checking The Electrical Systemp. 850
Compressor Drive Belt Inspection:p. 858
Engine Coolant By-Passing The Heater Valvep. 858
Heater Valve Not Opening Or Closingp. 859
Poor A/C Performancep. 860
+GENERAL AIR CONDITIONING SERVICE GUIDELINESp. 862
Compressor Oilp. 862
Compressor Oil Checkp. 862
Component Replacement And Refrigeration Leaksp. 864
+SYSTEM TROUBLESHOOTING CHARTp. 866
Gauge Pressure Related Troubleshootingp. 867
Troubleshooting Treep. 869
+TEMPERATURE/PRESSUREp. 874
+AIR CONDITIONING SERVICEp. 876
+SYSTEM CHARGING AND RECLAMATIONp. 878
Reclamation Procedurep. 878
Charging Procedure With A Manifold Gauge Setp. 880
Charging Procedurep. 881
+COMPRESSORp. 884
Removal And Installationp. 884
Compressor Clutch Disassemblyp. 885
+CONDENSERp. 890
Removal And Installationp. 890
+RECEIVER/DRIERp. 892
Removal And Installationp. 892
+PRESSURE RELIEF VALVEp. 894
Removal And Installationp. 894
+PRESSURE SWITCHp. 896
Removal And Installationp. 896
+EVAPORATOR/HEATER UNITp. 898
Removal And Installationp. 898
Disassembly And Assemblyp. 899
+THERMOSTATp. 900
Removal And Installationp. 900
+EXPANSION VALVEp. 902
Removal And Installationp. 902
+EVAPORATORp. 904
Removal And Installationp. 904
+HEATER COILp. 906
Removal And Installation With A/Cp. 906
Removal And Installation Without A/Cp. 907
+HEATER/AC FANp. 910
Removal And Installationp. 910
Disassmbly And Assemblyp. 911
Wire Connector Removal And Installationp. 913
+HEATER VALVEp. 916
Removal and Installationp. 916
Disassembly And Assemblyp. 917
+SPECIFICATIONSp. 920
+LOADER SPECIFICATIONSp. 922
Loader Dimensionsp. 922
Performancep. 923
Controlsp. 923
Enginep. 923
Hydraulic Systemp. 924
Electricalp. 924
Drive Systemp. 925
Capacitiesp. 925
Tiresp. 925
+ENGINE SPECIFICATIONSp. 926
Generalp. 926
Fuel Systemp. 926
Valve and Valve Guide and Seat Insertp. 927
Piston and Ringsp. 928
Connecting Rodp. 928
Cylinder Head and Blockp. 929
Crankshaft and Main Bearingsp. 929
Camshaft and Bearingsp. 929
Oil Pumpp. 929
+LOADER TORQUEp. 930
+TORQUE SPECIFICATIONS FOR BOLTSp. 934
Torque For General SAE Boltsp. 934
Torque For General Metric Boltsp. 935
+HYDRAULIC CONNECTION SPECIFICATIONSp. 936
O-ring Face Seal Connectionp. 936
Straight Thread O-ring Fittingp. 936
Tubelines And Hosesp. 936
Flare Fittingp. 937
O-ring Flare Fittingp. 938
Port Seal Fittingp. 940
+HYDRAULIC FLUID SPECIFICATIONSp. 942
CONVERSIONSp. 944
+SMRp. 946
Revision No: 863/863H-1p. 946
Revision No: 863/863H-2p. 948
Revision No: 863/863H-3p. 950
Revision No: 863/863H-4p. 952
Revision No: 863-5p. 954
Revision No: 863-6p. 956
Revision No: 863-7p. 958
Revision No: 863-8p. 960
Revision No: 863-9p. 962
This manual empowers the professional technician or owner-operator to handle everything from basic maintenance like checking hydraulic fluids and replacing filters, to complex tasks such as overhauling the hydrostatic transmission, rebuilding hydraulic cylinders, or performing engine timing belt replacement. The Bobcat 863/863H service manual is the same resource used by Bobcat dealerships to ensure repairs meet factory standards.
Why You Need This Manual
Working on a Bobcat 863 without this manual is a risk. Incorrect torque, improper procedures, or mismatched specifications can lead to costly breakdowns and safety hazards. This PDF gives you the confidence to perform precise, factory-authorized repairs and diagnoses.
This is an instant PDF download. After completing your purchase, you will have immediate access to the manual on any device—laptop, tablet, or smartphone. It is fully printable, allowing you to take a physical copy into your workshop without worrying about damaging the original.
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