Service

Manual
(S/N 514411001–514424999)
(S/N 514511001–514524999)
HIGH FLOW (S/N 514611001–514624999)

EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICSTM) 6724799 (7-10) Printed in U.S.A. © Bobcat Company 2010
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING 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. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.

CORRECT CORRECT CORRECT

P-90216 B-12365 B-7469

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG

B-11799 B-15231 B-15280

Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG

B-6590 B-6580 B-6589

Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW01-0409
CONTENTS
PREVENTIVE
MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii HYDRAULIC
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 SYSTEM
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 HYDROSTATIC
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 SYSTEM
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
SYSTEMS ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
DRIVE
SYSTEM

CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its MAIN
constituents are known to the State of California FRAME
to cause cancer, birth defects and other
reproductive harm.

ELECTRICAL
SYSTEM

ENGINE
SERVICE

SYSTEMS
ANALYSIS

SPECIFICATIONS

863, 863H Bobcat Loader

Revised Dec. 96 i Service Manual
FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

A general inspection of the following items must be made after the loader has had service or repair:

1. Check that the ROPS/FOPS 9. The parking brake must

(Including sidescreens) is in function correctly.
good condition and is not
modified.

2. Check that ROPS mounting 10. Enclosure door latches must

hardware is tightened and is open and close freely.
Bobcat approved.

3. The seat belt must be correctly 11. Bob–Tach wedges and

installed, functional and in linkages must function
good condition. correctly and be in good
condition.

4. The seat bar and pedal 12. Safety treads must in good
interlocks must be correctly condition.
adjusted, clean and lubricated.

5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps (Optional on
some models).

6. Machine signs must be legible WARNING 14. Check hydraulic fluid level,
and in the correct location. engine oil level and fuel supply.

7. Steering levers and foot pedals 15. Inspect for fuel, oil or hydraulic
must return to neutral. fluid leaks.

8. Check for correct function of 16. Lubricate the loader.

the work lights.

863, 863H Bobcat Loader

Revised Mar. 99 ii Service Manual
17. Check the condition of the
battery and cables.

18. Inspect the air cleaner for

damage or leaks. Check the
condition of the element.

19. Check the electrical charging

system.

20. Check tires for wear and

pressure.

21. Inspect for loose or broken

parts or connections.

22. Operate the loader and check

all functions.

23. Check for any field

modification not completed.

24. Check for correct function of

the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.

Recommend to the owner that all

necessary corrections be made
before the machine is returned to
service.

863, 863H Bobcat Loader

Revised Mar. 99 iii Service Manual
863, 863H Bobcat Loader
iv Service Manual
SAFETY INSTRUCTIONS

Instructions are necessary before operating or servicing machine. Read and understand the Operation &
Maintenance Manual, 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–2003–1298

The following publications provide information on the safe use and maintenance of the loader and attachments:

• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine
is in safe operating condition.

• The Operation & Maintenance Manual delivered with the loader gives operating information as well as routine
maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement
Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.

• The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are
shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.

• The loader has a plastic Operator’s Handbook fastened to the operator cab. Its brief instructions are convenient to the
operator. The Handbook is available from your dealer in an English edition or one of many other languages. See your
Bobcat dealer for more information on translated versions.

• The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and
repair work.

• The Skid–Steer Loader Operator Training Course is available through your local dealer. This course is intended to provide
rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish version.

• The Service Safety Training Course is available from your Bobcat dealer. This course provides information for safe and
correct service procedures for Bobcat Skid–Steer loaders.

• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.

Warnings on the machine and in the This notice identifies procedures

manuals are for your safety. Failure to which must be followed to avoid
obey warnings can cause injury or damage to the machine.
death. I–2019–0284
W–2044–1285

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.

SI05–1298

863, 863H Bobcat Loader

Revised Mar. 99 v Service Manual
SAFETY INSTRUCTIONS (Cont’d)

• Wear tight fitting clothing. Always wear safety glasses when maintaining or servicing loader. Safety glasses, hearing
protection or loader special applications kit are required for some work. See your dealer for Bobcat Safety equipment.

• Know where fire extinguisher and first aid kit are located and how to use them.
• Do not use the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive
dust or gases.

• The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent
fire hazard and overheating.

• Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any
damaged part.

• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check
for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for
cleaning parts. Use commercial nonflammable solvents.

• Follow any environmental safety regulations when disposing of used fluids such as engine oil, grease or anti–freeze.
• Do not use ether or starting fluids on engines which have glow plugs. These starting aids can cause explosion and injure
you or bystanders.

• Always clean the loader and disconnect the battery before doing any welding. Cover rubber hoses, battery and all other
flammable parts. Keep a fire extinguisher near the loader when welding. Have good ventilation when grinding or welding
painted parts. Wear dust mask when grinding painted parts. Toxic dust or gas can be produced.

• Stop the engine and let it cool before adding fuel. No smoking!
• Use the procedure in the Operation & Maintenance or Service Manuals for connecting the battery.
A fire extinguisher is available from your local dealer. The fire extinguisher can be installed in the location shown [A].

P–3705

863, 863H Bobcat Loader

vi Service Manual
SERIAL NUMBER LOCATIONS
Always use the serial number of the loader when
A
requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
LOADER SERIAL NUMBER
The loader serial number plate is located on the inside of
the left upright, above the grill [A].
Explanation of loader Serial Number:
XXXX XXXXX P–07612

Module 2. – Production
Sequence (Series) B
Module 1. – Model/Engine
Combination
The four digit Model/Engine Combination module number
identifies the model number and engine combination.
This number (in parenthesis beside the model number) is
used in the Service Manual to more easily identify the
standard, optional and field accessory equipment
included or available for each specific model.
The five digit Production Sequence Number identifies the
order which the loader is produced.

ENGINE SERIAL NUMBER

P–07619
The serial number is located on the valve cover at the right
side of the engine [B].

DELIVERY REPORT C
The Delivery Report must be filled out by the dealer and
signed by the owner or operator when the Bobcat loader
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [C].

863, 863H Bobcat Loader

vii Service Manual
BOBCAT LOADER IDENTIFICATION
FRONT LIGHTS
(OPTIONAL)
OPERATOR SEAT

GRAB REAR AUXILIARY

HANDLES QUICK COUPLERS
(OPTIONAL)

SEAT BELT

TILT CYLINDER

BUCKET
FRONT AUXILIARY
QUICK COUPLERS
(OPTIONAL)
SAFETY TREAD
BUCKET STEPS
OPERATOR CAB
(ROPS & FOPS)
SEAT BAR

LIFT ARM
REAR GRILL

LIFT ARM
SUPPORT DEVICE

REAR LIGHT
(OPTIONAL)

LIFT CYLINDER
REAR DOOR TAIL LIGHT
(OPTIONAL) B–15016
TIRES* B–15017

* TIRES – Flotation tires are shown. Optional tires are available.

BUCKET – Several different buckets and other attachments are available for the Bobcat loader.
ROPS, FOPS – Roll Over Protective Structure, per SAE J1040 and ISO 3471 and Falling Object Protective
Structure per SAE J1043 and ISO 3449 Level I. Level ll FOPS is available for protection from heavy falling
objects. The Bobcat loader is base–equipped with a standard operator cab as shown. Extra insulated cab is
available as an option (Reduced noise level).
863, 863H Bobcat Loader
Revised Mar. 99 viii Service Manual
OPTIONS AND ACCESSORIES
All 863 Bobcat loaders are equipped with the following standard items:
Bob–Tach Seat Belt
Adjustable Cushion Seat Seat Bar
Spark Arrestor Exhaust System Parking Brake
Lift Arm Support Device Gauges/Warning Lights
Operator Cab (W/ROPS & FOPS Approval) Bobcat Interlock Control System (BICS™)
Glow Plug Pre–Heat System
Below is a listing of the optional equipment which is available through your Bobcat loader dealer.
863
Tires
12 x 16.5, 10 PR Bobcat Heavy Duty Flotation Std.
8.25 x 15, Air Boss Segmented . . . . . . . . . . . . . . FA
12.00 x16.5 , Air Boss Segmented . . . . . . . . . . . FA
8.00 x 16 Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . Opt. & FA
10.00 x 33 Bobcat Solid . . . . . . . . . . . . . . . . . . . . FA
31 x 15.5x15, 8PR Ultra Grip Tread . . . . . . . . . . Opt. & FA
Operator Cab
Sound Cab (85 dBa) . . . . . . . . . . . . . . . . . . . . . . . Opt.
Deluxe Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Opt. & FA
Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . . Opt. & FA
Operating Lights (Front & Rear) . . . . . . . . . . . . . Opt. & FA
Hand Control Kit . . . . . . . . . . . . . . . . . . . . . . . . . . Opt. & FA
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FA
Back–Up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . Opt. & FA
Heated Enclosed Cab . . . . . . . . . . . . . . . . . . . . . . Opt. & FA
Top Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FA
Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FA
Rear Wiper/Washer . . . . . . . . . . . . . . . . . . . . . . . . FA
Cab Enclosure Kit . . . . . . . . . . . . . . . . . . . . . . . . . FA
Vinyl Cab Enclosure . . . . . . . . . . . . . . . . . . . . . . . FA
Cover Kit (Pedals Area) . . . . . . . . . . . . . . . . . . . . FA
Cover Kit (Hydraulic Reservoir Area) . . . . . . . . . FA
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . FA
Flasher Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FA
Strobe or Rotating Beacon Light . . . . . . . . . . . . . FA
3’’ Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FA
Special Applications Kit (Includes Lexan Front
Door, Top & Rear Windows) . . . . . . . . . . . . . . . FA
Hydraulics
Front Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . Opt. & FA
Rear Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . Opt. & FA
Hydraulic Bucket Positioning (Includes On/Off
Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Opt. & FA
Hi–Flow Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . Opt.
Other
Engine Oil Pan Heater . . . . . . . . . . . . . . . . . . . . . Opt. & FA
Single or Four Point Lift . . . . . . . . . . . . . . . . . . . . FA
Locking Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . FA
Radiator Screen Kit . . . . . . . . . . . . . . . . . . . . . . . . FA
Rear Door Bumpers . . . . . . . . . . . . . . . . . . . . . . . FA
Tailgate Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FA
Tool Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FA
Counterweight Kit . . . . . . . . . . . . . . . . . . . . . . . . . Opt. & FA
Catalytic Exhaust Purifier . . . . . . . . . . . . . . . . . . . Opt. & FA
Instrumentation
Bobcat Operation Sensing System (BOSS®) . . Opt. (Std. in Europe)
Keyless Start System . . . . . . . . . . . . . . . . . . . . . . FA
Std. = Standard Equipment
Opt. = Factory Installed Option
FA = Field Installed Accessory
Specifications subject to
change without notice
Revised Jan. 98
863, 863H Bobcat Loader
ix Service Manual
863,863HServiceManual#6724799–ContentsSection

863, 863H Bobcat Loader

x Service Manual
PREVENTIVE MAINTENANCE
PREVENTIVE
Page MAINTENANCE
Number
AIR CLEANER SERVICE
Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
ALTERNATOR BELT
Adjusting the Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16
COOLING SYSTEM
Cleaning the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15
ENGINE LUBRICATION SYSTEM
Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14
Replacing of Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14
FAN GEARBOX
Checking and Maintaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–22
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking and Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20
Removing Oil From the Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20
FUEL SYSTEM
Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
Removing Air From the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
HYDRAULIC/HYDROSTATIC SYSTEM
Checking and Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17
Replacing Hydraulic/Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18
LIFT ARM SUPPORT DEVICE
To Install the Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
To Remove the Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
LIFTING AND BLOCKING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
LUBRICATING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21
OPERATOR CAB
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
Lowering the Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
Raising the Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
REMOTE START SWITCH
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23
SEAT BAR RESTRAINT SYSTEM
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
SERVICE SCHEDULE
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

863, 863H Bobcat Loader

Revised June 98 –1–1– Service Manual
PREVENTIVE MAINTENANCE (Cont’d)
Page
Number
TIRE MAINTENANCE
Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19
Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19
TOWING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5

TRANSPORTING THE LOADER

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5

863, 863H Bobcat Loader

Revised June 98 –1–2– Service Manual
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 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–2003–0797

◊
ITEM SERVICE REQUIRED 8–10 50 250 500 1000 3000
Engine Oil Check the oil level and add oil as needed.
Engine Air Cleaner Check condition indicator or display panel. Service only
when required.
Engine Cooling System Clean debris from oil cooler radiator and grill.
Lift Arms, Cyl., Bob–Tach Lubricate with multi–purpose lithium based grease
Pivot Pins and Wedges (12 places).
Engine Air System Check for leaks and damaged components.
Tires Check for damaged tires and correct air pressure.
Seat Belt, Seat Bar & Pedal Check the condition of seat belt. Check the seat bar and foot
Interlocks pedal interlocks for correct operation. Clean dirt and debris from
moving parts.
Bobcat Interlock Control Check BICS™ functions. Clean dirt, debris or objects from
System (BICSTM) under or behind seat and around brake pedal as required.
Safety Signs and Safety Check for damaged signs (decals) and safety treads. Replace
Treads any signs or safety treads that are damaged or worn.
Operator Cab Check the fastening bolts, washers and nuts. Check the
condition of cab.
Fuel Filter Remove the trapped water.
Hyd. Fluid, Hoses and Check fluid level and add as needed. Check for damage and
Tubelines leaks. Repair or replace as needed.
Final Drive Trans.(Chaincase) Check oil level.
Battery Check 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 Check for loose wheel nuts and tighten to 105–115 ft.–lbs.
(142–156 Nm) torque.
Parking Brake Check operation of the brake.
Alternator Belt Check tension and adjust as needed.
Engine/Hydro. Drive Belt * Check for wear or damage. Check idler arm stop.
Fuel Filter Replace filter element.
Steering Shaft Grease three fittings.
Hydraulic Reservoir Replace the reservoir breather cap.
Breather Cap
Hyd./Hydro. Filter Replace the filter element.
Engine Oil and Filter Replace oil and filter. Use CD or better grade oil and Bobcat filter.
Final Drive Trans. Replace the oil in the chaincase.
Hydraulic Reservoir Clean or replace the fluid.
Hydraulic Motors Clean or replace the case drain filters.
Bobcat Interlock Control Check lift arm by–pass control.
System (BICSTM)
Fan Drive Gearbox Check gear lube level.
Engine Valves ∞ Adjust the engine valves.
Engine Timing Belt ◊ Replace the timing belt and belt tensioner assy.
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.
Or every 12 months.
* Inspect the new belt after first 50 hours.
After the first 50 hours.
∞ After the first 500 hours on new engine, adjust engine valves; 1000 hours thereafter. (See Page 7–1 for
procedure.)
◊ Or every 5 years.
863, 863H Bobcat Loader
Revised Jan. 98 –1–3– Service Manual
A

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–2003–0797

Read the Removal & Installation, Disassembly &

Assembly, etc. completely to become familiar with the
procedure before beginning [A].
B–7023
LIFTING AND BLOCKING THE LOADER
Procedure
Always park the loader on a level surface.

Put jackstands under the front axles and rear

corners of the frame before running the engine B
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.
W–2017–0286

Put floor jack under the rear of the loader [B].

Lift the rear of the loader and install jackstands [B].

P–07703

C
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.

P–07704

863, 863H Bobcat Loader

Revised Apr. 97 –1–4– Service Manual
TRANSPORTING THE BOBCAT LOADER
A
Procedure

Adequately designed ramps of sufficient

strength are needed to support the weight of
the machine when loading onto a transport Support
vehicle. Wood ramps can break and cause P–10458
personal injury.
W–2058–0494

A loader with an empty bucket or no attachment must be B

loaded backward onto the transport vehicle [A].
The rear of the trailer must be blocked or supported when
loading or unloading the loader to prevent the front end of
the trailer from raising up. Some ramps provide support
[A].
Be sure the transport and towing vehicles are of adequate
size and capacity (See SPECIFICATIONS Section Page P–10462 P–10464
9–1, for weight of loader.)
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
front and rear loader tie down positions [B]. Fasten each
end of the chain to the transport vehicle.

TOWING THE LOADER

To prevent damage to the loaders hydrostatic system, the
loader must be towed only a short distance at 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 SPECIFICATIONS
Section, Page 9–1.)
• Turn the key switch to ON and press the Traction
Lock Override button.
• Tow the Bobcat at 2 MPH (3,2 km/hr) or less for not
more than 25 feet (7,6 meters).
If the electrical system is not functioning, part of the brake 6707867 P–10460
system must be disassembled to move the loader.

863, 863H Bobcat Loader

Revised Mar. 99 –1–5– Service Manual
LIFT ARM SUPPORT DEVICE
To Install the Lift Arm Support Device
A

1
P–10829

B 1
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
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–2059–0598

Maintenance and service work can be done with the lift

arms lowered. If the lift arms must be raised for service,
use the following procedure:
Put jackstands under the rear corners of the loader.
P–10830
Disconnect the spring from the retaining pin (Item 1) [A],
hold onto the approved lift arm support device (Item 2) [A]
and remove the retaining pin.
Lower the lift arm support device on top of the lift cylinder.
Hook the free end of the spring (Item 1) [B] to the lift 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.

Service lift arm support device if damaged or if

parts are missing. Using a damaged lift arm
support or with missing parts can cause lift
arms to drop causing injury or death.
W–2271–1197

863, 863H Bobcat Loader

Revised Mar. 99 –1–6– Service Manual
LIFT ARM SUPPORT DEVICE
Raise the lift arms, until the lift arm support device drops
A
onto the lift cylinder rod [A].
Lower the lift arms slowly until the support device is held
between the lift arm and the lift cylinder. Stop the engine.
Raise the seat bar and move pedals until both pedals
lock.
Install pin (Item 1) [A] into the rear of the lift arm support
device below the cylinder rod. 1
To Remove the Lift Arm Support Device
Remove the pin from the lift arm support device (Item 1)
[A]. P–07659

Connect the spring (Item 1) [B] from the lift arm support
device to the bracket below the lift arms.
B
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 lift
the support device off the lift cylinder rod. Lower the lift
arms. Stop the engine. 1

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 lift arm support device and bracket [A]. (Page P–07656
1–6.)

Connect spring to the retaining pin (Item 1) [A]. (Page

1–6.)

863, 863H Bobcat Loader

Revised June 98 –1–7– Service Manual
OPERATOR CAB
Description
A
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 damaged.

Never modify operator cab by welding, P–10887

grinding, drilling holes or adding attachments
unless instructed to do so by Bobcat
Company. Changes to the cab can cause loss
of operator protection from rollover and B
falling objects, and result in injury or death.
W–2069–1285

ROPS/FOPS – 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 I – Protection from falling bricks, small concrete
blocks, and hand tools encountered in operations such as
highway maintenance, landscaping, and other
construction site services.
P–10888
LEVEL II – Protection from falling trees, rocks; for
machines involved in site clearing, overhead demolition
or forestry.
C
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 lift 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].

P–10826
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].

Use care when raising or lowering the operator

cab to prevent damaging the shaft of the lift
lock by–pass valve.
I–2070–0495

863, 863H Bobcat Loader

Revised June 98 –1–8– Service Manual
OPERATOR CAB (Cont’d)
Lowering the Operator Cab
A
NOTE: Make sure the seat bar is fully raised or
lowered when lowering the cab.
Pull down on the bottom of the operator cab until it stops
at the latching mechanism. Release the latching
mechanism and pull the cab all the way down [A].

P–10825

Install the plate and nut (both sides) [B]. B

Tighten the nuts to 40–50 ft.–lbs. (54–68 Nm) torque.

P–10888 P–10887

Emergency Exit C
The front opening on the operator cab and rear window
provide exits.

To exit through the rear window, use the following

procedure:
Pull on the tag on the top of the rear window to remove the
rubber cord [C].

P–00660

Push the rear window out of the rear of the operator cab.
D
Exit through the rear of the operator cab [D].

P–10810

863, 863H Bobcat Loader

Revised June 98 –1–9– Service Manual
OPERATOR CAB (Cont’d)
Emergency Exit (Cont’d)
A
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
6707852
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
B
pedal controls. When the seat bar is up, the lift and tilt
pedals are locked when returned to the neutral position.

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 if pedals do not lock
correctly. W–2105–1285 P–03269 P–03270

Seat Bar Inspection

Sit in the seat and fasten the seat belt. Engage the
C
Interlock
parking brake. Pull the seat bar all the way down. Start the Shield
engine. Operate each foot pedal to check both the lift and
tilt functions. Raise the lift arms until the bucket is about
2 feet (600 mm) off the ground.
Clean
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 tilt (bucket) when the pedals
are pushed.
Pull the seat bar down, lower the lift arms. Operate the lift
pedals. While the lift arms are going up, raise the seat bar
and the lift arms should stop.
P–01640
Lower the seat bar, lower the lift arms and place the
bucket flat on the ground. Stop the engine. Raise the seat
bar and operate the foot pedals to be sure that the pedals
are firmly locked in the neutral position. Unbuckle the seat
belt.
Seat Bar Maintenance
See the SERVICE SCHEDULE Page 1–3 for correct
service interval.
AVOID INJURY OR DEATH
Clean any debris or dirt from the moving parts [B] & [C]. Never operate loader without pedal lock shield
Inspect the linkage bolts and nuts for tightness. The 6705474 on both interlocks. Shields prevent
correct torque is 25–28 ft.–lbs. (34–38 Nm). foot from unlocking interlocks when leaving
loader seat.
If the seat bar system does not function correctly, check W–2162–1194
for free movement of each linkage part. Check for
excessive wear. Adjust pedal control linkage. Replace
parts that are worn or damaged. Use only genuine Bobcat
replacement parts.
863, 863H Bobcat Loader
Revised June 98 –1–10– Service Manual
AIR CLEANER SERVICE
Replacing Filter Element
A 2

Without BOSS®: Replace the outer filter element only

when the red ring shows in the window of the condition
indicator (Item 1) [A].
1

NOTE: Before replacing the filter element, push the

button on the condition indicator (Item 2) [A].
Start the engine, then stop the engine. If the
red ring does not show, do not replace the
filter element. P–10799

Replace the inner filter every third time the outer filter is
replaced or when the red ring still shows in the indicator B
window after the outer filter has been replaced.

With BOSS®: It is important to change the air filter

element only when the service codes (on the BOSS®
option instrument panel) shows the symbols AF.2 [B].

MC–02322

Service the air cleaner as follows:

Release the three dust cover fasteners (Item 1) [C].
C
1
Remove the dust cover.

P–10800

863, 863H Bobcat Loader

Revised June 98 –1–11– Service Manual
AIR CLEANER SERVICE (Cont’d)
Replacing Filter Element (Cont’d)
A
Remove the outer filter element [A].

NOTE: Make sure all sealing surfaces are free of dirt

and debris.

Install the new outer filter element. P–10798

Only replace the inner filter element under the following

conditions [B]:
B
Replace the inner filter every third time the outer filter
is replaced or when the red ring still shows in the
indicator window after the outer filter has been
replaced.
When the service codes on the instrument panel
shows symbol AF.2 during full engine speed, replace
the inner filter element only after the outer filter
element has been changed.
Align the tab on the cover with one of the slots on air
cleaner housing (Item 1) [B]. The evacuator (Item 1) [C]
must be at the bottom.
P–10802
Push dust cover into place and secure with wire
fasteners.
Check the air intake hose for damage. Check the air C
cleaner housing for damage. Check to make sure all
connections are tight.

P–10800

863, 863H Bobcat Loader

Revised June 98 –1–12– Service Manual
FUEL SYSTEM
Fuel Specifications
A
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 No.1
1
+15°(9°) 100% 0%
Down to –20° (–29°) 50% 50%
Below –20° (29°) 0% 100%
We recommend an operator contact their fuel supplier for
local recommendations. P–10819

Filling the Fuel Tank

B WRONG

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 fill 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 B–13456
free movement of air and no open flames or sparks. NO
SMOKING! [B].
Install and tighten the fuel fill cap [A]. C
Fuel Filter
2
See the SERVICE SCHEDULE, Page 1–3 for the
recommended service interval when to remove the water
from the fuel filter.
Loosen the drain (Item 1) [C] at the bottom of the filter
element to drain any water from the filter.
See the SERVICE SCHEDULE, Page 1–3 for the
recommended service interval when to replace the fuel
filter.
To replace the fuel filter element, use a filter wrench to
remove the filter element [C].
1
Clean the area around the filter housing. Put oil on the
seal of the new filter element. Install the fuel filter, and
hand tighten. Remove the air from the fuel system.
Removing Air From the Fuel System
After replacing the fuel filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel 3
system prior to starting the engine.
Loosen the air vent plug (Item 2) [C] at the top of the fuel
filter.
Operate the priming bulb (Item 3) [C] until fuel flows from
the vent.
P–10803
Tighten the air vent plug.
863, 863H Bobcat Loader
Revised June 98 –1–13– Service Manual
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
A
Check the engine oil level every day.
Before starting the engine for the work shift, open the rear 3
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.
RECOMMENDED SAE VISCOSITY NUMBER 1
C° (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)
–40 –34 –29 –23 –18 –13 –7 –1 +4 +10 +15 +21 +27 +32 +38 +43 +49

SAE 40W or 20W–50

SAE 10W–30

SAE 15W–40

SAE 30W

* SAE 5W–30
SAE 20W–20

SAE 10W
2
SYNTHETIC OIL Use recommendation from Synthetic Oil Mfgr.

P–10803
–40 –30 –20 –10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120
F°
TEMPERATURE RANGE ANTICIPATED
BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
CLASSIFICATION CD, CF4, CG4 ) B
* Can be used ONLY when available with appropriate diesel rating.

Replacement of Oil and Filter

See the SERVICE SCHEDULE, Page 1–3 for the service
interval for replacing the engine oil and filter. 1

Run the engine until it is at operating temperature. Stop

the engine.
Open the rear door. Remove the drain plug (Item 2) [A].
Drain the oil into container.
P–10801
Remove the oil filter (Item 1) [B].
Clean the filter housing surface. Put clean oil on the new
oil filter gasket. Install the filter and hand tighten only.
Install and tighten the drain plug.
Remove the filler cap (Item 3) [A].
Always clean up spilled fuel or oil. Keep heat,
Put 10 qts. (9,5 L) of oil in the engine. flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
Start the engine and let it run for several minutes. Stop the combustibles can cause explosion or fire
engine. Check for leaks and check the oil level. Add oil as which can result in injury or death.
needed if it is not at the top mark on the dipstick. W–2103–1285

863, 863H Bobcat Loader

Revised June 98 –1–14– Service Manual
COOLING SYSTEM
Cleaning the Cooling System
A
Check the cooling system every day to prevent
over–heating, loss of performance or engine damage.
1

Wear safety glasses to prevent eye injury when

any of the following conditions exist:
P–07614
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used. B
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 1
cooler can be raised.
Raise the oil cooler, use air pressure or water pressure to
clean the top of the engine oil cooler (Item 1) [C].
P–07618

P–07617

863, 863H Bobcat Loader

Revised June 98 –1–15– Service Manual
ALTERNATOR BELT
Adjusting the Alternator Belt
A S/N 514415609 & Below

Stop the engine.

1
Loosen the alternator mounting bolt (Item 1) [A] or [B].
Loosen the adjustment bolt (Item 2) [A] or [B].

P–10087 P–10094

Move the alternator until the belt has 5/16 inch (8,0 mm)
movement at the middle of the belt span with 15 lbs. (66
N) of force [A] or [B].
B S/N 514415610 & Above

Tighten the adjustment and mounting bolts.

1

P–10357 P–10358

863, 863H Bobcat Loader

Revised June 98 –1–16– Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM
Checking and Adding Fluid
A
Use only recommended fluid in the hydraulic system.
(See SPECIFICATIONS, Page 9–1.)
To check the reservoir, use the following procedure:
2
Put the Bobcat loader on a level surface. Lower the lift
arms and tilt the Bob–Tach fully back.
Stop the engine.
Remove the dipstick (Item 1) [A].
1
P–07671

The fluid level must be between the marks on the dipstick

[B].
B
Add fluid as needed to bring the level to the top mark on
the dipstick [B].

P–07673

Replacing the Hydraulic/Hydrostatic Filter

C
See the SERVICE SCHEDULE, Page 1–3 for the correct
service interval.
2
Raise the operator cab. (See Page 1–7.)
Use a filter wrench to remove the filter elements (Items 1
& 2) [C].
Clean the surface of the filter housing where the element 1
seal contacts the housing. Put clean oil on the rubber seal
of the filter elements.
Install and hand tighten the filter elements.
P–07613

863, 863H Bobcat Loader

Revised June 98 –1–17– Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)
Replacing the Hydraulic Fluid
A
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
dry.
P–7672
Raise the operator cab. (See Page 1–7.)
Disconnect the hose (Item 1) [B] from the hydraulic fluid
reservoir and drain the fluid into a container.
B
Replace the two filter elements. (See Page 1–17.)
Remove the case drain filters (Item 1) [C] & [D] and clean
thoroughly with clean solvent.
1
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.)

P–7690

C LEFT CASE DRAIN

FILTER
Diesel fuel or hydraulic fluid under pressure
can penetrate skin or eyes causing serious 1
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.
W–2074–1285
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
P–7611
which can result in injury or death.
W–2103–1285
RIGHT CASE DRAIN
Lower the operator cab. Start the engine and operate the
D FILTER
loader hydraulic controls. Stop the engine. Check for
leaks. Check the fluid level in the reservoir and add as
needed.

P–7608

863, 863H Bobcat Loader

Revised June 98 –1–18– Service Manual
TIRE MAINTENANCE
Wheel Nuts
A
See the Service Schedule, Page 1–3 for the service
interval to check the wheel nuts. The correct torque is
105–115 ft.–lbs. (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 correct pressure before
operating the loader. Inflate to maximum pressure shown
on sidewall of tire. P–7649

Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires
to the front [B].
B
It is important to keep the same size tires on each side of
the loader. If different sizes are used, each tire will be
turning at 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 tire bead for damage.
The rim flange must be cleaned and free of rust. The tire B–9976
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 to avoid over inflation.

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. W–2078–1285

Inflate tires to the MAXIMUM pressure shown

on the sidewall of the tire. DO NOT mix brands
of tires used on the same loader.
I–2057–0794

863, 863H Bobcat Loader

Revised June 98 –1–19– Service Manual
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking and Adding Oil
A
The chaincase contains the final drive sprockets and 1
chains and uses the same type of oil as the
hydraulic/hydrostatic 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.
P–07610
If oil can be reached with the tip of the your finger through
the hole the oil level is correct.
If the level is low, add oil through the check plug hole until
B
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.
1

P–01616

Remove the drain plug (Item 1) [C] and drain the oil into
a container. C
NOTE: When installing the drain plug into the
chaincase, always use a NEW drain plug.

P–01619

863, 863H Bobcat Loader

Revised June 98 –1–20– Service Manual
LUBRICATION OF THE BOBCAT LOADER
Procedure
A
Lubricate the loader as specified in the SERVICE
SCHEDULE, Page 1–3 for the best performance of the
loader.
1
Record the operating hours each time you lubricate the
Bobcat loader.
Always use a 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:
P–07655
1. Rod End Lift Cylinder (Both Sides) [A].

2. Base End Lift Cylinder (Both Sides) [B]. B

P–10815

3. Lift Arm Pivot Pin (Both Sides) [C]. C

P–07631

4. Base End Tilt Cylinder [D].

D
4

P–07641

863, 863H Bobcat Loader

Revised June 98 –1–21– Service Manual
LUBRICATION OF THE BOBCAT LOADER (Cont’d)
A
5. Rod End Tilt Cylinder [A].

6. Bob–Tach Pivot Pin (Both Sides) [A]. 5

7. Bob–Tach Wedge (Both Sides) [A].

6
7
P–07653

8. 250 Hours: Steering Lever Shaft (2) [B]. B

9. 250 Hours: Centering bracket pivot pin [B]. 8

P–07609

FAN GEARBOX
Checking and Maintaining C
See the SERVICE SCHEDULE, Page 1–3 for the correct
service interval.
Raise the operator cab. (See Page 1–7.)
Gear Lube
Remove the plug (Item 1) [C] to check the lubricant level. Level 1

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 if the level is low.

P–07616

863, 863H Bobcat Loader

Revised June 98 –1–22– Service Manual
REMOTE START SWITCH
Procedure
A
The tool 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.)
1
Raise the lift arms and install an approved lift arm support
device. (See Page 1–6.) P–07101

Raise the operator cab. (See Page 1–7.)

NOTE: On current model loaders, the connector on B
the BICS harness is round (7–pin) connector,
not a rectangular (8–pin) connector. Use the 1
adapter harness (Item 1) [A] to connect the
remote start switch to the loader harness.
Disconnect the operator cab wire harness (Item 1) [B]
from the engine wire harness.
Connect the remote start switch to the engine harness
connectors (Item 1) [C].

P–04732

Put jackstands under the front axles and rear

C
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.
W–2017–0286

1
1

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved
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–2059–0598

P–04758

863, 863H Bobcat Loader

Revised June 98 –1–23– Service Manual
REMOTE START SWITCH (Cont’d)
863,863HServiceManual#6724799–PreventiveMaintenanceSection

A
Procedure (Cont’d) 1
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.
Turn the key to the right and start the engine.

P–04713

Move the traction lock override switch (Item 1) [B] to the

OFF position so the traction function is unlocked. The
wheels are now able to turn.
B
1
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.

2
P–04714

863, 863H Bobcat Loader

Revised June 98 –1–24– Service Manual
HYDRAULIC SYSTEM
Page
Number
BICS™ CONTROL VALVE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–25
HYDRAULIC
BICS™ VALVE ASSEMBLY SYSTEM
BICS™ Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–31
Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–29
Lift Arm By–Pass Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–28
Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–30

CONTROL PEDALS
Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–74
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–74

HYDRAULIC CONTROL VALVE

Anti–Cavitation/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–39
Auxiliary Electric Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–48
Auxiliary Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–47
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–37
H Port – Auxiliary Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–49
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–36
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–49
Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–37
Lift Spool and Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–42
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–37
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–38
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–39
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–32
Rubber Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–41
Spool Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–50
Tilt Spool and Centering Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–46

HYDRAULIC CYLINDER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
Lift Cylinder Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
Tilt Cylinder Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
HYDRAULIC FILTER HOUSING
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–73

HYDRAULIC FLUID RESERVOIR

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–71
HYDRAULIC PUMP
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–57
Checking the Output of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–51
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–54
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–56
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–53
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–52

863, 863H Bobcat Loader

Revised June 98 –2–1– Service Manual
HYDRAULIC SYSTEM (Cont’d)

Page
Number
HYDRAULIC PUMP (Double Gear) 863H
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–68
Checking the Output of the High Flow Pump . . . . . . . . . . . . . . . . . . . . . . 2–59
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–63
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–67
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–62
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–60

HYDRAULIC SYSTEM INFORMATION

Tighten Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
HYDROSTATIC FILTER HOUSING
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–72
Hydrostatic Charge Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–72
LIFT CYLINDER(S)
Checking the Lift Cylinder(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5

LIFT ARM BY–PASS CONTROL VALVE

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–24
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–23

MAIN RELIEF VALVE

Checking the Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–16
Checking the Main Relief Valve Without Auxiliaries . . . . . . . . . . . . . . . . 2–17
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–18
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–18

PEDAL INTERLOCK LINKAGE

Pedal Interlock Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–76
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–75
REAR AUXILIARY DIVERTER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–77
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–77
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–77
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–77

SELECT VALVE 863H

Checking the High Flow Pump Relief Valve . . . . . . . . . . . . . . . . . . . . . . . 2–19
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–21
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–20
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22

TILT CYLINDER
Checking the Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
Rod End Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8

TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE
STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 9)
UNLESS OTHERWISE SPECIFIED.
863, 863H Bobcat Loader
Revised June 98 –2–2– Service Manual
TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are
most common. Many of the recommended procedures
must be done by authorized Bobcat Service Personnel Check for correct function after adjustments,
only. repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W–2004–1285

PROBLEM CAUSE

The hydraulic system will not operate. 1, 2, 3, 5, 8

The transmission warning light comes ON when hydraulics are
operating. 1, 3

Slow hydraulic system action. 1, 3, 4, 6, 8

Hydraulic action is not smooth. 1, 4, 5, 6, 7

Lift arms go up slowly at full engine RPM. 1, 3, 4, 5, 6, 7, 8, 9

The lift arms or Bob–Tach will move when the pedal is in neutral position. 4
The lift arms come down with the pedal in the neutral position. 4, 9, 10, 11

KEY TO CORRECT THE CAUSE

1. The fluid level is not correct.

2. The pedal linkage is disconnected.

3. The hydraulic pump has damage.

4. The pedal linkage is not adjusted correctly.

5. Relief valve is not at the correct pressure.

6. Suction leak on the inlet side of the hydraulic pump.

7. Fluid is cold. Wrong viscosity fluid. (See Section 9.)

8. Using the loader for more than its rated capacity.

9. Internal leak in the lift cylinder(s).

10. External leak from the lift cylinder(s).

11. Damaged lift spool.

863, 863H Bobcat Loader

–2–3– Service Manual
HYDRAULIC SYSTEM INFORMATION

When repairing hydrostatic and hydraulic

systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888

Tighten Procedures
For tightening torques for hydraulic fittings,
tubelines etc., See Section 9. – Hydraulic Connection
Specifications.

863, 863H Bobcat Loader

Revised June 98 –2–4– Service Manual
LIFT CYLINDER(S)
Checking the Lift Cylinder(s)
A
Lower the lift arms. Stop the engine. Raise the seat bar. 1

Diesel fuel or hydraulic fluid under pressure

can penetrate skin or eyes, causing serious
injury or death. Fluid leaks under pressure may
not be visible. Use a piece or cardboard or CD–15067
wood to find leaks. Do not use your bare hand.
Wear safety goggles. If fluid enters skin or eyes,
get immediate medical attention from a
physician familiar with this injury.
W–2072–0496
B
1
Check only one cylinder at a time. Disconnect the hose
(Item 1) [A] which goes to the base end of the lift cylinder.
Install a plug (Item1) [B] in the hose and tighten.
Engage the parking brake. Lower the seat bar. Start the
engine and push the top (toe) of the lift pedal.
If there is any leakage from the open port, remove the lift
cylinder for repair. Repeat the procedure to check the
other lift cylinder.
CD–15068

Removal and Installation

C
Raise the lift arms so the rod end retaining pin will clear
the loader frame for removal.
Have a second person put jackstands under the
Bob–Tach to support the lift arms [C]. Stop the engine.
Raise the operator cab. (See Page 1–1.)

P–7960

Remove the retaining bolt and nut (Item 1) [D] from the
pivot pin on the rod end of the cylinder. D
Installation: Tighten the retainer bolt and nut to 18–20
ft.–lbs. (24–27 Nm) torque.
Remove the pivot pin from the rod end of the cylinder.

CD–15069

863, 863H Bobcat Loader

–2–5– Service Manual
LIFT CYLINDER(S) (Cont’d)
Removal and Installation (Cont’d)
A
Remove the retaining bolt and nut (Item 1) [A] from the
pivot pin on the base end of the cylinder.
Installation: Tighten the retainer bolt and nut to 18–20
ft.–lbs. (24–27 Nm) torque.

CD–15070

Remove the pivot pin from the base end of the cylinder
[B].
B
Slide the cylinder forward for clearance to disconnect the
hoses.

CD–15072

Mark the hoses for correct installation.

C
Disconnect the two hoses (Item 1) [C] from the lift
cylinder. 1
Remove the lift cylinder.

Always clean up spilled fuel or oil. Keep heat,

flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around CD–15073
combustibles can cause explosion or fire
which can result in injury or death.
W–2103–1285

863, 863H Bobcat Loader

–2–6– Service Manual
TILT CYLINDER
Checking the Tilt Cylinder
A
Remove the attachment. Roll the Bob–Tach fully back.
Stop the engine. Raise the seat bar. 2

1
Diesel fuel or hydraulic fluid under pressure
can penetrate skin or eyes, causing serious
injury or death. Fluid leaks under pressure may P–1187
not be visible. Use a piece or 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 from a B
physician familiar with this injury.
W–2072–0496

Disconnect the hose (Item 1) [A] which goes to the base

end of the tilt cylinder.
Put a plug in the hose and tighten.
Install a test hose between cylinder and a drain pan.
Engage the parking brake. Lower the seat bar. Start the
engine and push the bottom (heel) of the tilt pedal. If there
is leakage from the open port, remove the tilt cylinder for
repair. P–7694

Removal and Installation

Remove the attachment. Roll the Bob–Tach fully forward
C
[B]. 1
Stop the engine. Raise the seat bar.
Remove the retainer bolt and nut (Item 1) [C] from the rod
end pivot pin.
Installation: Tighten the retainer nut to 18–20 ft.–lbs.
(24–27 Nm) torque.

P–7693

Remove the rod end pivot pin (Item 1) [D].

D
Engage the parking brake. Lower the seat bar. Start the
engine and push the bottom (heel) of the tilt pedal until rod
end of cylinder is fully retracted.
Disconnect both hydraulic hoses (Items 1 & 2) [A].
Plug fittings on tilt cylinder.

P–7695

863, 863H Bobcat Loader

–2–7– Service Manual
TILT CYLINDER (Cont’d)
Removal and Installation (Cont’d)
A
Remove the retainer bolt and nut (Item 1) [A] from the
base end pivot pin.
Installation: Tighten the retainer nut and bolt to 18–20
ft.–lbs. (24–27 Nm) torque.

P–7678
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 B
which can result in injury or death.
W–2103–1285

Remove the base end pivot pin (Item 1) [B].

Remove the tilt cylinder from the loader.

P–7679

Rod End Seal

C
Remove the old seal (both sides) from the rod end of the
tilt cylinder.
Install the new seals (Item 1) [C] with the lip facing out.

P–3911

Using two pieces of shim stock, install the rod end of the
tilt cylinder into the Bob–Tach [D]. D
Be careful not to damage the new seals during
installation.
Hold the rod end in position and remove the shim stock.

P–3910

863, 863H Bobcat Loader

–2–8– Service Manual
HYDRAULIC CYLINDER
Lift Cylinder Identification

1. Tube 9. O–ring
2. O–ring 10. Spacer
3. Plug 11. O–ring
4. Case 12. Washer
5. O–ring 13. Head
6. Nut 14. Seal
7. Piston 15. Seal
8. Ring 16. Rod

10

7
16
3 6
2
5
15

1 14
3
2 13
4
12

11

TS–1060

863, 863H Bobcat Loader

Revised Jan. 98 –2–9– Service Manual
HYDRAULIC CYLINDER (Cont’d)
Tilt Cylinder Identification

1. Case 11. O–ring

2. Plug 12. O–ring
3. O–ring 13. Washer
4. Tube 14. O–ring
5. Nut 15. Head
6. Clamp 16. Seal
7. Bolt 17. Seal
8. Nut 18. Rod
9. Piston 19. Seal
10. Seal 20. Bushing

MC–1688
3
2

5 1
6

15
9

10 16

11 17

12

18
13

19
MC–1688 20
19
14

TS–1233

863, 863H Bobcat Loader

Revised Jan. 98 –2–10– Service Manual
HYDRAULIC CYLINDERS (Cont’d)
Disassembly
A
Use the following tools to disassemble the cylinder:
MEL1074 – O–ring Seal Hook
Spanner Wrench
The lift and tilt cylinders internal components are similar,
the differences are listed below:
Tilt rod diameter is larger.
Piston relief area is slightly different.
No spacer in the tilt cylinder.
Hold the hydraulic cylinder over a drain pan and move the P–7429
rod in and out slowly to remove the fluid from the cylinder.
Put the base end of the cylinder in a vise. B
Use a spanner wrench to loosen the head [A] & [B].

P–7435

Lift Cylinder: Remove the head and the rod assembly

from the cylinder [C]. Put the rod end in a vise. C 4
3
2
Lift Cylinder: Remove the nut (Item 1) [C], piston (Item 2)
[C], spacer (Item 3) [C] and head (Item 4) [C]. 1

P–7428

Tilt Cylinder: Remove the head and rod assembly from

the cylinder [D]. Put the rod end in a vise. D
2 3
1
Tilt Cylinder: Remove the nut (Item 1) [D], piston (Item 2)
[D] and head (Item 3) [D].

P–7434

863, 863H Bobcat Loader

–2–11– Service Manual
HYDRAULIC CYLINDERS (Cont’d)
Disassembly (Cont’d)
A 3

Standard Piston: Remove the seal (Item 1) [A], and

O–ring (Item 2) [A] from the piston (Item 3) [A]. 2
1

P–7430

Cushion Piston: Remove the seal (Item 1) [B], and O–ring

(Item 2) [B] from the piston (Item 3) [B].
B 3

2
1

P–7439

Remove the thick O–ring (Item 1) [C], and the back–up

washer (Item 2) [C] from the groove in the head. Remove C
the thin O–ring (Item 3) [C].

3
2
1

P–7422

Remove the wiper seat (Item 1) [D], and rod seal (Item 2)
[D]. D
Remove the O–ring (Item 3) [D] from the rod seal.

3 1

P–7426

863, 863H Bobcat Loader

–2–12– Service Manual
HYDRAULIC CYLINDERS (Cont’d)
A
Assembly
Use the following tools to assembly the cylinder:
MEL1396 – Seal Installation Tool
MEL1033 – Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other
damage. Replace any damaged parts.
Always install new O–rings and seals during assembly. P–07424

Lubricate all O–rings and seals with hydraulic oil during

installation. B 3

Install the new seal on the tool and slowly stretch it until
it fits the piston [A]. 2
Allow the seal to stretch for 30 seconds before installing 1
it on the piston.
Standard Piston: Install the seal (Item 1) [B] and O–ring
(Item 2) [B] on the piston (Item 3) [B].

P–07430

Cushion Piston: Install the seal and O–ring on the piston

(Item 1) [C].
C
Use a ring compressor to compress the seal to the correct
size. Leave the piston in the compressor for about three
minutes.
1

P–07438

Install the rod seal on the rod seal tool [D].

D
NOTE: During installation the O–ring side of the seal
must be toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [D].

P–07427

863, 863H Bobcat Loader

–2–13– Service Manual
HYDRAULIC CYLINDERS (Cont’d)
Assembly (Cont’d)
A
Install the rod seal in the head [A].
Install the wiper seal with the wiper toward the outside of
the head.

P–07425

Install the thin O–ring (Item 1) [B]. B

Install the back–up washer (Item 2) [B] and thick O–ring
(Item 3) [B] into the groove on the head.
1

2
3

NOTE: Clean and dry the threads before install the P–07422
nut. Install the new nut from the kit.

Tilt Cylinder: Install the head (Item 1) [C], and the piston C
(Item 2) [C]. The small diameter of the piston goes into the 1
cylinder tube first. 3 2

Tilt Cyllinder: Grease the piston where the nut contacts

the piston. Do not get grease on the threads.
Tilt Cylinder: Install the nut (Item 3) [C].
Tilt Cylinder: Tighten the nut to 100 ft.–lbs. (136 Nm)
torque.

P–07434

Tilt Cylinder: Mark the end of the shaft and nut [D].
Tighten the nut an additional 135 degrees or 2–1/4 flats D
[D].

P–10450 P–10456

863, 863H Bobcat Loader

Revised Jan. 98 –2–14– Service Manual
HYDRAULIC CYLINDERS (Cont’d)
Assembly (Cont’d)
A 1
3 2
NOTE: Clean and dry the threads before install the
nut. Install the new nut from the kit. 4
Lift Cylinder: Install the head (Item 1) [A], and spacer
(Item 2) [A].

Lift Cylinder: Install the piston (Item 3) [A], and the nut
(Item 4) [A].

Lift Cylinder: Tighten the nut (Item 4) [A] to 400 ft.–lbs.

(542 Nm) torque. P–07428

Put the base end of the hydraulic cylinder in a vise.

Tighten the head using a spanner wrench [B] & [C]. B

P–07429

P–07435

863, 863H Bobcat Loader

Revised Jan. 98 –2–15– Service Manual
MAIN RELIEF VALVE
Checking the Main Relief Valve
A
NOTE: This procedure is the same for 863 and 863H
in the standard flow mode.
The 863H is a single pressure (3000 PSI) system with 2
flow modes. There are 2 pumps with a relief valve for each
pump. Only the standard flow (main relief valve) is
adjustable.
The tools listed will be needed to do the following
procedure:
MEL10003 – Hydraulic Tester
MEL10006 – Hydraulic Test Kit
P–05061
Turn the key switch to the OFF position, as the engine
stops running, turn the key switch all the way to the left to
release the hydraulic pressure at the front auxiliary quick
couplers. B
Lift and block the loader. (See Page 1–1.)
AUXILIARY HYDRAULIC CONTROL 1
Connect the IN port of the hydraulic tester to the female
quick coupler on the loader [A].
Connect the OUT port of the hydraulic tester to the male
quick coupler on the loader [A].

2
B–13443
The hydraulic tester must be in the fully open
position before you start the engine.
I–2024–0284 C

Left Right
Steering 1 Steering
Put jackstands under the front axles and rear Lever Lever
corners of the frame before running the engine Control Control
for service. Failure to use jackstands can allow (Optional) (Optional)
the machine to fall or move and cause injury or
death.
W–2017–0286
P–02154 P–02152
Start the engine and run at low engine idle RPM. Push the
mode switch (Item 1) [B] (on the instrument panel) two
times to engage the front auxiliary hydraulics, the light
(Item 2) [B] will come ON.
Push the button (Item 1) [C] for fluid pressure to the quick
couplers.
Watch the flow meter on the hydraulic tester to make sure
the flow is correct. Increase the engine speed to full RPM.
There should be 18.0 GPM (68,1 L/min.) free flow. Turn
the restrictor control, on the tester, until the main relief
valve opens. The correct pressure for the main relief is
3000 PSI (20685 kPa).
Stop the engine. Replace or adjust the main relief valve.
(See Page 2–18.)
863, 863H Bobcat Loader
Revised Sept. 96 –2–16– Service Manual
MAIN RELIEF VALVE (Cont’d)
Checking the Main Relief Valve Without Auxiliaries
A
The tools listed will be needed to do the following 1
procedure:
MEL10003 – Hydraulic Tester
MEL10006 – Hydraulic Test Kit
Stop the engine. 1
Lift and block the loader. (See Page 1–1.)
Disconnect the hydraulic hoses (Item 1) [A] from the tilt
cylinder.
CD–15074
Connect the hydraulic tester to the tilt cylinder hoses [B].
Have a second person in the operator seat, with seat bar
in down position.
B

The hydraulic tester must be in the fully open

position before you start the engine.
I–2024–0284

Start the engine and run at idle RPM. P–01193

Push the tilt pedal at the top (toe) or bottom (heel) until the
hydraulic tester shows the correct fluid flow through the
flow meter.
Increase the engine RPM to maximum.
There should be 18.0 GPM (68,1 L/min.) free flow.
Turn the restrictor control, on the tester, to increase the
pressure until the main relief valve opens.
The correct pressure is 3000 PSI (20685 kPa).
Stop the engine.
Replace or adjust the main relief valve. (See Page 2–18.)

When an engine is running in an enclosed

area, fresh air must be added to avoid
concentration of exhaust fumes. If the engine
is stationary, vent the exhaust outside.
Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W–2050–1285

863, 863H Bobcat Loader

Revised Jan. 98 –2–17– Service Manual
MAIN RELIEF VALVE (Cont’d)
Removal and Installation
A
Raise the operator cab. (See Page 1–1.)

When making repairs on hydrostatic and 1

hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and N–00077
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0284
B
The main relief valve (Item 1) [A] is located at the lower
front of the control valve.
Clean the area around the control valve. 1

2
Loosen and remove the main relief valve (Item 1) [B].
Installation: Tighten the main relief valve to 35–40
ft.–lbs. (47–54 Nm) torque.

P–7745

Remove the O–rings and back–up washers from the main

relief valve [C]. C
Clean the main relief valve in clean solvent. Use air
pressure to dry the valve.
Install new O–rings and backup washers. Install the main
relief valve and tighten [A]. Check the pressure again.
(See Page 2–16 or 2–17.)

CD–15092

Adjustment

If the pressure is not correct, adjust the main relief valve.

D
Remove the end cap (Item 2) [B].
Turn the adjusting screw (Item 1) [D] in or out until the
pressure is correct. Turning screw in will increase
pressure.
NOTE: If the correct pressure can not be reached, 1
replace the main relief valve. Check the
pressure setting of the new relief valve.

P–7746

863, 863H Bobcat Loader

–2–18– Service Manual
SELECT VALVE 863H
A
Checking the High Flow Pump Relief Valve
The tools listed will be needed to do the following 2
procedure:
MEL10003 – Hydraulic Tester
MEL10006 – Hydraulic Test Kit
Lift and block the loader. (See Page 1–1.)
Connect the IN port of the hydraulic tester to the female
quick couplers (Item 1) [A] on the loader. 1
Connect the OUT port of the hydraulic tester to the male
quick coupler (Item 2) [A] on the loader. P–9153

B
3
The hydraulic tester must be in the fully open
position before you start the engine.
I–2024–0284
Left
Steering
Lever 2
Control 1

P–2130 P–0998

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
C
death. W–2017–0286

Start the engine and run at low idle RPM. Push the mode
switch (Item 1) [B] once (on the instrument panel) to
engage the front auxiliary hydraulics momentary, the light
(Item 2) [B] will come ON.
Push the rocker switch (Item 3) [B] for fluid pressure to
the secondary quick couplers. 1

Watch the flow meter on the hydraulic tester to make sure

the flow is correct. Increase the engine speed to full RPM.
P–9164
The free flow should be approximately 10.0 GPM (37,85
L/min.). Turn the restrictor control, on the tester, until the
main relief valve opens. The correct pressure for the main
relief is approximately 3000 PSI (20685 kPa). D
Release the rocker switch (Item 3) [B] to disengage the
flow to the secondary quick couplers.
If the relief pressure is not correct, stop the engine.
Remove and inspect the relief valve (Item 1) [D]. Inspect
the O–rings (Item 2) [D] and back–up ring (Item 3) [D] for 3
damage. 1
Replace the relief valve if required. This relief valve is not
adjustable.

2 2
P–9174 P–9165

863, 863H Bobcat Loader

Revised Sept. 96 –2–19– Service Manual
SELECT VALVE (863H) (Cont’d)
A
Removal and Installation
Raise the operator cab. (See Page 1–1.)
Disconnect the controls harness at the left side steering 3
lever connectors (Item 1) [A].
Disconnect the controls harness at the select valve
connectors (Item 2) [A].
2
Remove the rear bolt on the left side pedal link (Item 3)
[A] and lower the link.
2
NOTE: Steering panel brace is removed for photo 1
P–9164
clarity.

Drain the hydraulic reservoir. (See Page 1–1.) B 1

Loosen the clamp (Item 1) [B] and disconnect the hose.
Disconnect the tubeline (Item 2) [B].
Disconnect the hose (Item 3) [B].
Install caps and plugs on open connections.
3
2

P–9165

Remove the mounting bolts (Item 1) [C] located on the

outside left frame. C
NOTE: The select valve will drop down for wrench
clearance.

P–9166

Disconnect the tubelines (Item 1) [D].

D
Remove the select valve.
Installation: Connect controls harness to select valve 1
solenoids. See Page 2–21 for solenoid identification and
correct controls harness wire color.

P–9167

863, 863H Bobcat Loader

Revised Sept. 96 –2–20– Service Manual
SELECT VALVE 863H (Cont’d)
A
Disassembly and Assembly
2
Clean the select valve to remove dirt before disassembly.
1
3

When repairing hydrostatic and hydraulic 5 4

systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and P–09168
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888
B
Remove the solenoid valve coils in Fig. [A].
NOTE: The controls wiring harness colors are listed
below for identification during select valve 1
assembly installation.
Second aux. male coupler (Item 1) [A] Yellow/Brown
Second aux. female coupler (Item 2) [A] Yellow/Lt. Green
Second aux. pressure relief (Item 3) [A] Dk. Green/Yellow
High Flow (Item 4) [A] Lt. Blue/Red 2
Second aux. diverter (Item 5) [A] Yellow

P–09177
Assembly: The coils largest opening (Item 1) [B] must
position on the valve shoulder (Item 2) [B]. Install the
washer (Item 1) [C] between the double coils. Install the
coils and tighten the nuts (Item 2) [C] to 5 ft.–lbs. (6,7 Nm)
C
torque.

1
2

2
2
2

P–09169

Remove the 4–way solenoid valve (Item 1) [D].

D
Remove the 2–way solenoid valve (Item 2) [D].
Remove the 2–way solenoid valves (Item 3) [D].

Inspect the solenoid valves for contamination or damage.

Washer all parts in clean solvent. Use air pressure to dry 1
them. Install new O–rings and back–up washers.
Assembly: Put oil on O–rings and back–up washers.
Install and tighten the solenoid valves (Items 1 & 3) [D] to
25 ft.–lbs. (33,9 Nm) torque. Tighten the solenoid valve 2
(Item 2) [D] to 20 ft.–lbs. (27,1 Nm) torque. 3
P–09170

863, 863H Bobcat Loader

Revised Jan. 98 –2–21– Service Manual
SELECT VALVE 863H (Cont’d)
Disassembly and Assembly (Cont’d)
A
Remove the relief valve (Item 1) [A]. Remove the check
valve (Item 2) [A]. Remove the pilot piston (Item 3) [A]
located between the check valves (Item 2) [A] and (Item
3) [B].

3
1
2
P–09171

Remove the load shuttle (Item 1) [B]. Remove the fitting

(Item 2) [B]. Remove the check valve (Item 3) [B]. B
Inspect the relief valve, check valves, piston, load shuttle
and fitting for contamination or damage. Wash all parts in
clean solvent. Use air pressure to dry them. Install new
O–rings and back–up washers.
The load shuttle (Item 1) [B] has a ball (Item 5) [B] that 1
must move free inside the shuttle, the plug (Item 4) [B]
can be removed to clean the shuttle and ball. 4
5 2

N–00503 P–09172

The fitting (Item 2) [B] and fig. [C] has a poppet valve. The
poppet valve allows flow out of the select valve only.
Inspect the poppet for smooth opening and closing. C
Assembly: Put oil on O–rings and back–up washers and
pilot piston (Item 3) [A]. Install and tighten the relief valve
(Item 1) [A] to 25 ft.–lbs. 33,9 Nm) torque. Install the pilot
piston (Item 3) [A] in the port between the check valves
(Item 2) [A] and (Item 3) [B]. Install the check valves and
load shuttle (Item 1) [B] and tighten to 20 ft.–lbs. (27,1
Nm) torque. Install the fitting (Item 2) [B] and tighten to 35
ft.–lbs. (47,4 Nm) torque.

P–09176

Solenoid Testing
D
Use a test meter to measure coil resistance [D]. Coil wires
do not have polarity. Correct resistance for the pressure
relief (small) coil is 7–10 ohms and the other coils 5–8
ohms.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.

P–09175

863, 863H Bobcat Loader

Revised Sept. 96 –2–22– Service Manual
LIFT ARM BY–PASS CONTROL VALVE
Removal and Installation
A

1
When making repairs on hydrostatic and
hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always 1
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
1
P–7760
the system.
I–2003–0284

P–7937

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved
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–2059–0598

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
Remove the control panel/steering levers. (See Page
3–1.)
Disconnect the hoses (Items 1) [A].
Remove the two mounting bolts (Item 1) [B].
Installation: Tighten the mounting bolts to 180–200
in.–lbs. (21–23 Nm) torque.
Remove the lift arm by–pass valve.

863, 863H Bobcat Loader

Revised Mar. 99 –2–23– Service Manual
LIFT ARM BY–PASS CONTROL VALVE (Cont’d)
Removal and Installation (Cont’d)
A
Remove the two bolts (Item 1) [A] to replace the by–pass
valve mounting bracket if necessary.
Reverse the removal procedure to install the lift arm
by–pass valve in the loader.

P–7938
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 B
which can result in injury or death.
W–2103–1285

1
Disassembly and Assembly
Remove the by–pass valve (Item 1) [B] from the valve
block. Inspect the by–pass valve for damage and replace
if necessary.
Installation: Tighten the valve to 33–37 ft.–lbs. (45–50
Nm) torque.
Inspect the hydraulic fittings on the valve block for
damage and replace if necessary. P–7939

863, 863H Bobcat Loader

Revised June 98 –2–24– Service Manual
BICS™ CONTROL VALVE
863,863HServiceManual#6724799–HydraulicSystemSectionPart1of4

Removal and Installation

A

When making repairs on hydrostatic and

hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system. I–2003–0284 1
P–07760

P–07748
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
lift arm support device. Failure to use an C
approved lift arm support device can allow the
lift arms or attachment to fall and cause injury 1
or death. W–2059–0598

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
Drain the fluid from the hydraulic reservoir. (See Page
1–1.)
Mark all tubelines for correct installation. P–07761

Disconnect hose at lift arm by–pass control valve (Item 1)

[A]. D
Remove the bolt and nut (Item 1) [B] and remove the
tubeline clamp. 1
Remove the tubelines from hydraulic control valve to
hydrostatic filter head (Item 1) [C].

Disconnect the auxiliary tubelines at hydraulic control

valve (Item 1) [D].

P–07762

863, 863H Bobcat Loader

Revised Mar. 99 –2–25– Service Manual
BICS™ CONTROL VALVE (Cont’d)
A
Removal and Installation (Cont’d)
Disconnect tilt tubelines (Item 1) [A] and lift tubeline (Item
2) [A] at valve. 1

P–07763

Disconnect lift tubelines (Item 1) [B] and hose (Item 2)

[B].
B
NOTE: BICS™ control valve can be removed without
removing hydraulic control valve. Valve
removed for photo clarity [C] and [D]. 2
1

P–07764

863, 863H Bobcat Loader

–2–26– Service Manual
BICS™ CONTROL VALVE (Cont’d)
A
Removal and Installation (Cont’d)
1
Loosen the six mounting bolts (Item 1) [A] at the BICS 1
valve.

Remove the mounting bolts (Item 1) [B]. N–00076

N–00093

Remove the BICS valve assembly from the top of the

control valve [C]. C
1

Installation: Always replace the four large O–rings (Item

1) [C] and small O–ring (Item 2) [C].

The chart below lists the correct torque specifications and 2

tightening sequence when reinstalling the BICS™ valve N–00094
assembly to the hydraulic control valve. Thoroughly clean
and dry bolts and threads in valve. Use liquid adhesive
LOCTITE #242.
D
Step Torque ♦Sequence
1 110–130 in.–lbs.
(12,4–14,7 Nm) 3 6
2 190–210 in.–lbs. 1 2
(21,5–23,7 Nm) 1, 2, 3, 4, 5 & 6
5 4
3* 190–210 in.–lbs.
(21,5–23,7 Nm)

*Torque must be 190–210 in.–lbs. (21,5–23,7 Nm) for

every bolt or the complete ♦sequence must be repeated.
P–09587

863, 863H Bobcat Loader

–2–27– Service Manual
BICS™ VALVE ASSEMBLY
Lift Arm By–Pass Orifice
A
Remove the control valve from the loader. (See Page
2–28.)
1
To remove, replace or check the orifice for the lift arm
by–pass function, use the following procedure.

N–00079

When making repairs on hydrostatic and

hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always B
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0284
1
Remove the fitting (Item 1) [A] from the BICS valve.
The orifice (Item 1) [B] is slotted so a flat blade
screwdriver can be used to remove it.

N–00081

Remove the orifice (Item 1) [C] from the valve.

C
Clean and inspect the orifice. Replace as needed.

N–00084

863, 863H Bobcat Loader

–2–28– Service Manual
BICS™ VALVE ASSEMBLY (Cont’d)
Check Valve
A
Loosen and remove the check valve (Item 1) [A] and [B].
Installation: Tighten the check valve to 20 ft.–lbs. (27 1
Nm) torque.

N–00085

Inspect and clean the screen (Item 1) [B] on the end of

the check valve.
B
Inspect the check valve for damage. Replace the O–rings
and back–up washers before installation.
Replace the check valve if necessary.

P–09057

863, 863H Bobcat Loader

–2–29– Service Manual
BICS™ VALVE ASSEMBLY (Cont’d)
Lock Valve
A
2
There are two lock valves on the BICS valve, lift lock valve
(Item 1) [A] and tilt lock valve (Item 2) [A].

N–00078

Loosen and remove the lock valve(s) (Item 1) [B] & [C]
from the valve.
B
Installation: Tighten the lock valve(s) to 25 ft.–lbs. (34
Nm) torque.
1

N–00091

N–00080

Inspect the lock valve for damage [D].

D
Replace all the O–rings and back–up washers before
installation [D].
Replace the lock valve if necessary.

N–00092

863, 863H Bobcat Loader

–2–30– Service Manual
BICS™ VALVE ASSEMBLY (Cont’d)
BICS™ Valve Solenoid
A
1
Loosen the mounting nut (Item 1) [A] at the solenoid.

N–00077

Remove the mounting nut (Item 1) [B], O–ring (Item 2)

[B], solenoid (Item 3) [B], and O–ring (Item 4) [B].
B

3
1
4 2

N–00087

Loosen and remove the solenoid cartridge (Item 1) [C]

from the valve. C
Installation: Tighten the cartridge to 20 ft.–lbs. (27 Nm)
torque.

N–00088

Inspect the solenoid cartridge for damage [D].

D
Replace all the O–rings and back–up washers before
installation [D].
Replace the cartridge if necessary.

N–00090

863, 863H Bobcat Loader

–2–31– Service Manual
HYDRAULIC CONTROL VALVE
Removal and Installation
A

3
When making repairs on hydrostatic and
hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and 1
ports to keep dirt out. Dirt can quickly damage
the system. 1
I–2003–0284

P–07759

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved
lift arm support device. Failure to use an B
approved lift arm support device can allow the
lift arms or attachment to fall and cause injury
or death. W–2059–0598

Raise the lift arms and install an approved lift arm support 1
device. (See Page 1–1.)
Stop the engine. Raise the seat bar.
Raise the operator cab. (See Page 1–1.)
Remove the steering panel/steering lever assembly. (See
Page 3–1.)
Clean the area around the control valve. P–13471

Disconnect the wire harness connectors (Item 1) [A] from

the auxiliary solenoids connectors.
C
Disconnect the harness connector (Item 2) [A] from the
BICS valve solenoid connector.
Disconnect the hose (Item 3) [A] from the tubeline.
Disconnect the tubeline from the check valve (Item 1) [B].
Disconnect the hose (Item 1) [C] from the lift arm by–pass 1
control valve.
Disconnect the hoses (Items 2 & 3) [C] from the valve. 4
Remove the two mounting bolts and nuts (Item 4) [C] from 3
the valve mounting bracket.
2
Remove the valve/bracket assembly. P–07760

863, 863H Bobcat Loader

Revised Mar. 99 –2–32– Service Manual
HYDRAULIC CONTROL VALVE
Removal and Installation (Cont’d)
A 1

Disconnect the linkage (Items 1 & 2) [A] from the lift and
tilt spools.

P–7756

Remove the crossmember bolt (Item 1) [B]. B 2

Remove the bolt and nut (Item 2) [B] to disconnect the lift
pedal linkage from the crossmember.
Remove the crossmember from the pivot. 1
Installation: Check the nylon bushing for wear and
replace as needed.

P–7757

Remove the bolt and nut (Item 1) [C] and remove the
tubeline clamp. C

P–7748

863, 863H Bobcat Loader

–2–33– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Removal and Installation (Cont’d)
A
1
Remove the tubelines from the hydraulic control valve to
hydrostatic filter head (Item 1) [A].

P–7761

Disconnect the auxiliary tubelines (Item 1) [B] from the

control valve.
B

1 1

P–7762

Disconnect the tilt tubelines (Item 1) [C].

C
Disconnect the lift tubeline (Item 2) [C].
1

P–7763

863, 863H Bobcat Loader

–2–34– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Removal and Installation (Cont’d)
A
Disconnect the lift tubelines (Item 1) [A] at the tee fitting. 2
Disconnect the hose (Item 2) [A] from the valve.

P–07764

Remove the two mounting bolts (Item 1) [B] from the

valve mounting bracket. B 1
Disconnect the hose (Item 2) [B] from the valve.
1

P–07766

Slide the control valve/mounting bracket toward the front

of the loader for clearance at the tubelines, lift the control C
valve assembly out of the loader [C].

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. P–07765
W–2103–1285

863, 863H Bobcat Loader

–2–35– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
A H3 H1
Identification Chart H2

Item 863 Loader

A1 Lift Cylinder Base End/Restrictor C4

A2 Tilt Cylinder Base End G3 B3 A3 D3

A3 Auxiliary Hydraulics C3
B2 A2 D2
G2 E2
B1 Lift Cylinder Rod End
F2 C2
B2 Tilt Cylinder Rod End G1 B1 A1 E1 D1
F1 C1
B3 Auxiliary Hydraulics
MR
C1 Load Check Valve/Lift Function
C2 Load Check Valve/Tilt Function MC–2229
C3 Orificed Load Check Valve/Auxiliary Function
C4 Outlet Fluid Flow
D1 Lift Spool Detent
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool/Centering Springs
E1 Port Relief Valve – 3500 PSI
E2 Anti–Cavitation/Port Relief Valve – 2500 PSI
F1 Anti–Cavitation Valve
F2 Port Relief
G1 Lift Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Springs
H1 Auxiliary Electric Solenoid
H2 Plug/Port Relief (Optional) – 2500 PSI
H3 Auxiliary Electric Solenoid
MR Main Relief Valve – 3000 PSI

863, 863H Bobcat Loader

–2–36– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Disassembly and Assembly
A 1

Remove the BICS valve assembly from the control valve.

(See Page 2–23.)
Remove the four large O–rings (Item 1) [A] and small
O–ring (Item 2) [A]. Always replace these O–rings before
installing the BICS valve assembly. 1
The anti–cavitation valve, port relief valves and plugs are
at different locations in the control valve. Refer to Control
Valve Identification Chart for the correct location of the
parts. (See Page 2–27.) 2
N–00095

B
When making repairs on hydrostatic and
hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0284
1

Mark each valve section, spool and related parts so that

they will be returned to its original valve section during
assembly.
N–00102
Use bolts to fasten the control valve to a work bench for
easier disassembly and assembly procedures.
Load Check Valve
C 4

Loosen the load check valve plug (Item 1) [B].

Installation: Always use new O–ring. tighten the plug to 1
35–40 ft.–lbs. (47–54 Nm) torque.
Remove the load check plug (Item 1) [C].
Remove the spring (Item 2) [C] and poppet (Item 3) [C].
The auxiliary section (Item 4) [C] uses an orifice load
check poppet.
3 2
N–00103

Lift Base End Restrictor D

Remove the restrictor (Item 1) [D] from the lift section
base end port.
Check for damage and replace as needed.

N–00097

863, 863H Bobcat Loader

–2–37– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Main Relief Valve
A
Loosen the main relief valve (Item 1) [A].

1
N–00095

Remove the main relief valve (Item 1) [B]. B

N–00099

Remove the O–rings, sleeve, and glide ring from the main
relief valve [C]. C 2 3 4 5
Installation: Always use new O–rings. sleeve, and glide
ring. Tighten to 35–40 ft.–lbs. (47–54 Nm) torque.
1
B–6764

1. Relief Valve
2. O–ring
3. Sleeve
4. Glide Ring
5. O–ring

CD–15092

863, 863H Bobcat Loader

–2–38– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Port Relief Valve
A
Loosen the port relief valve (Item 1) [A] (Port E1 or F2).
1
Installation: Always use new O–rings and back–up
washers. Tighten to 35–40 ft.–lbs. (47–54 Nm) torque.

P–09134

Remove the port relief valve (Item 1) [B]. B

P–09135

Remove the O–rings and back–up washer from the port

relief valve [C]. C 1 2
3 4

E–1509

1. Relief Valve
2. O–ring
3. Backup Washer
4. O–ring

CD–15101

Anti–Cavitation/Port Relief Valve

D
Loosen the anti–cavitation valve (Item 1) [D].
Installation: Always use new O–rings and back–up
washers. Tighten to 35–40 ft.–lbs. (47–54 Nm) torque.
1

P–09134

863, 863H Bobcat Loader

–2–39– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Anti–Cavitation/Port Relief Valve (Cont’d)
A
Remove the anti–cavitation/port relief valve (Item 1) [A]
from the control valve for the tilt section.
1

P–09136

Remove the O–rings (Item 1) [B] from the

anti–cavitation/port relief valve. B

P–09139

Remove the anti–cavitation valve (Item 1) [C] from the

control valve for the lift section. C

N–00100

Remove the O–rings and back–up washer from the

anti–cavitation valve [D]. D 1 2
3 4

E–1509

1. Anti–Cavitation Valve
2. O–ring
3. Backup Washer
4. O–ring

CD–15102

863, 863H Bobcat Loader

–2–40– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Rubber Boot
A
Remove the two screws (Item 1) [A] on the rubber boot
retainer.
Installation: Tighten the screws to 90–100 in.–lbs.
(10,2–11,3 Nm) torque.

N–00104

Remove the rubber boot and retainer [B]. B

N–00105

Remove the retainer (Item 1) [C] and large O–ring (Item

2) [C]. C

1
2
N–00106

863, 863H Bobcat Loader

–2–41– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Lift Spool and Detent
A
The tool listed will be needed to do the following
procedure:
MEL1278 – Detent Tool 2
Use a screwdriver to remove the snap ring (Item 1) [A].
1
Remove the washer (Item 2) [A].

N–00111

Remove the screws (Item 1) [B] from the detent sleeve. B

Remove the detent sleeve (Item 2) [B].

The detent assembly has small springs and

balls. Do not lose these parts during
disassembly and assembly. 1
I–2012–0284
N–00112

Put a rag around the detent assembly [C]. This will

prevent the detent balls and spring from being lost when C
the detent sleeve is removed.

N–00113

Remove the detent sleeve, detent balls and spring [D].

D

N–00114

863, 863H Bobcat Loader

–2–42– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Lift Spool and Detent (Cont’d)
A
Remove the spool, centering spring, back–up washer,
seal and spool assembly from the control valve [A].

N–00115

At the other end of the spool bore, remove the spool seal
(Item 1) [B].
B

N–00116

Put the linkage end of the spool in the vise [C].

C
NOTE: Be careful when removing the detent adapter,
because there is spring pressure.
Loosen the detent adapter [C].

CD–15045

Remove the detent adapter, cap, and centering spring

[D]. D

CD–15046

863, 863H Bobcat Loader

–2–43– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Lift Spool and Detent (Cont’d)
A
Remove the back–up washer and spool seal [A].

CD–15047

Remove the stud from the end of the spool [B]. B

Removal of the plastic plug:
a. Make a center point in the plug using a 1/16 inch drill.
b. Drill a hole all the way through the plug using a 7/64
inch tap drill.
c. Turn a 6–32 tap into the plug. Pull the tap and plug
out of the spool. Be careful, do not break the tap.
d. Clean all the debris from inside the spool bore.

NOTE: DO NOT USE LOCTITE ON THE STUD

THREADS. CD–15048

Installation: Slide O–ring over nipple on plastic plug.

Install the plastic plug in the spool. Install the stud so that
the end is about 0.60 inch (15,2 mm) from the spool [C].
C O–ring

Plastic
Plug
0.60 inch
(15,2 mm)
B–14712

Put grease on all the detent component surfaces before

assembly [D]. D

CD–15051

863, 863H Bobcat Loader

–2–44– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Lift Spool and Detent (Cont’d)
A
Install the detent balls and spring into the detent adapter.
Hold the detent balls in position with the tool (MEL1278)
and install the detent adapter into the end cap [A].

CD–15050

Install the new spool seal (Item 1) [B] and back–up

washer (Item 2) [B].
B

2
1

CD–15047

Install the centering spring, end cap/detent adapter on the

valve spool. Tighten the detent adapter to 90–100 in.–lbs. C
(10,2–11,3 Nm) torque [C].

CD–15045

Install the detent balls and spring [D].

D

CD–15051

863, 863H Bobcat Loader

–2–45– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Lift Spool and Detent (Cont’d)
A
Hold the detent balls and spring in position with the tool
(MEL1278) [A].

CD–15052

Install the detent sleeve (Item 1) [B] over the balls and
into position.
B

CD–15053

Tilt Spool and Centering Spring

C
Remove the end cap screws (Item 1) [C].
Installation: Tighten the screws to 90–100 in.–lbs.
(10,2–11,3 Nm) torque.
Remove the end cap (Item 2) [C].

2 1
N–00117

Remove the spool, centering spring, back–up washer and

spool seal [D]. D
Installation: If the centering spring bolt is removed,
tighten to 90–100 in.–lbs. (10,2–11,3 Nm) torque. Put
grease on all the centering spring component parts.
Always use new spool seals at both ends of the spool.

N–00118

863, 863H Bobcat Loader

–2–46– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Auxiliary Spool
A
Remove the end cap screws (Item 1) [A] & [B]. 2
5
Installation: Tighten the screws to 90–100 in.–lbs. 3
(10,2–11,3 Nm) torque.

6
4 1
N–00065

Remove the end cap (Item 2) [A] & [B], O–ring (Item 3)
[A] & [B].
B
Remove the large spring (Item 4) [A] & [B] and small
spring (Item 5) [A] & [B]. 2 6
Remove the spring retainer (Item 6) [A] & [B]. 5
3

4 1
N–00121

Remove the auxiliary spool (Item 1) [C].

C

N–00064

863, 863H Bobcat Loader

–2–47– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Auxiliary Electric Solenoid
A
Remove the nut (Item 1) [A] from the end of the solenoid.
Installation: Tighten the nut to 9–12 in.–lbs. (1,02–1,36
Nm) torque.

N–00069

Remove the solenoid metal housing (Item 1) [B]. B

N–00070

Remove the solenoid coil (Item 1) [C] and end plate (Item
2) [C]. C

1
N–00071

Remove the electric solenoid valve (Item 1) [D]. D

Installation: Tighten the electric solenoid valve to
96–144 in.–lbs. (10,8–16 Nm) torque. Always install new
O–rings and back–up washers.

N–00073

863, 863H Bobcat Loader

–2–48– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
H Port – Auxiliary Section
A
Loosen the plug (Item 1) [A].
Installation: Tighten the plug to 35–40 ft.–lbs. (47–54
Nm) torque.

N–00069

Remove the plug from the control valve [B]. B

Replace the O–ring.

N–00067

Depending on the application of the auxiliaries, the control

valve may be equipped with a port relief valve (H port). C
Remove the port relief valve (Item 1) [C].
Installation: Replace the O–rings and back–up washers.
Tighten the port relief valve to 35–40 ft.–lbs. (47–54 Nm)
torque.

Inspection
Check the spools for wear or scratches. 1
Check that the spools are not loose in their bore.
N–00068
Check that the centering springs are not broken.
Check that the load check valve seats are not worn.
Check the load check poppets for damage.
Check the rubber boots and retainers that they are not
worn or damaged.
Replace the parts as needed.

863, 863H Bobcat Loader

–2–49– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
863,863HServiceManual#6724799–HydraulicSystemSectionPart2of4

Spool Seal Installation

A
To install new spool seals when the centering spring (tilt
spool) or the detent assembly (lift spool) are not removed
from the spool, use the following procedure:
Check the seal surface area in the control valve (Item 1)
[A] for rust, corrosion, scratches, etc. Correct any
irregularities before continuing. 1

N–00116

Put plastic material (Example: Plastic food wrap) on the

valve spool [B].
B
Put clean oil on the spool seal. Install the spool seal (Item
1) [B] on the spool. Be careful not to damage the seal on
the sharp edges.
NOTE: Seal must be installed with lip face toward
valve body. Lift face has largest outside
diameter. 1
Remove the plastic material.
Install the spool into the control valve.

CD–15080

Slide the linkage end spool seal over the rubber boot
groove [C]. C
Be careful not to damage the spool seal.
Install the back–up washer [C].
Continue assembling the control valve.

N–00118

863, 863H Bobcat Loader

–2–50– Service Manual
HYDRAULIC PUMP
Checking the Output of the Pump
A
NOTE: This procedure is the same for 863 and 863H 1
in the standard flow mode.
The tools listed will be needed to do the following
procedure:
MEL10003 – Hydraulic Tester
MEL10006 – Hydraulic Test Kit
NOTE: Make sure all the air is removed from the
hydraulic system before beginning the test.
Air in the system can give an inaccurate test.
P–7754
*Relief pressure must be per specification
before the test is done.
Lift and block the loader. (See Page 1–1.) B
Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
Connect the remote start switch. (See Page 1–1.)
Disconnect the OUTLET hose (Item 1) [A] from the
pump.
Connect the INLET hose from the tester to the OUTLET
of the pump. Connect the OUTLET hose from the tester
to the tubeline which was disconnected from the hose [B].
P–7753

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.
W–2017–0286

Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM.
Warm the fluid to 140°F. (60°C.) by turning the restrictor
control on the tester to about 1000 PSI (6895 kPa). DO
NOT exceed system relief pressure. Open the restrictor
control and record the free flow (GPM) at full RPM.
Turn the restrictor down to system operating pressure.
DO NOT EXCEED SYSTEM RELIEF PRESSURE. The
highest pressure flow must be at least 80% of free flow.

HIGH PRESSURE FLOW (GPM)

%= X 100
FREE FLOW (GPM)
A low percentage may indicate a pump problem.

863, 863H Bobcat Loader

Revised June 98 –2–51– Service Manual
HYDRAULIC PUMP (Cont’d)
Removal and Installation
A

1
2
P–7755

B 1

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved
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–2059–0598
2

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
P–7758
Drain the hydraulic reservoir.
Loosen the hose clamp and disconnect the hose (Item 1)
[A] from the pump inlet fitting.
Loosen the hose clamp and disconnect the hose (Item 2)
[A] from the pump inlet fitting.
Disconnect the hose (Item 1) [B] from the pump outlet.
When making repairs on hydrostatic and
Remove the pump mounting bolts (Item 2) [B] (both hydraulic systems, clean the work area before
sides). disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
Installation: Tighten the mounting bolts to 25–27 ft.–lbs. ports to keep dirt out. Dirt can quickly damage
(34–37 Nm) torque. the system.
I–2003–0284
Remove the hydraulic pump.

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

Revised Mar. 99 –2–52– Service Manual
HYDRAULIC PUMP (Cont’d)
Parts Identification

1
2 3
4
5
6 7
8

10
8 6
5

13 14
11 12

TS–1022

Ref. Description
1. BOLT
2. WASHER
3. END HOUSING
4. O–RING SEAL
5. SEAL
6. RING
7. BODY
8. BEARING HOUSING
9. DRIVE GEAR
10. IDLER GEAR
11. BOLT
12. WASHER
13. COVER
14. SEAL

863, 863H Bobcat Loader

Revised June 98 –2–53– Service Manual
HYDRAULIC PUMP (Cont’d)
Disassembly
A
Marks

When making repairs on hydrostatic and

hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system. CD–15160
I–2003–0284

Mark the pump sections for correct assembly [A].

B
Remove the pump housing bolts (Item 1) [B].

1
1

CD–15141

Remove the end housing (Item 1) [C].

C

CD–15142

Remove the mounting flange end housing (Item 1) [D].

D

1
CD–15143

863, 863H Bobcat Loader

Revised June 98 –2–54– Service Manual
HYDRAULIC PUMP (Cont’d)
Disassembly (Cont’d)
A
Remove the gear/bearing housing assembly [A].

CD–15144

Remove the O–rings (Item 1) [B] from the pump housing. B

1
CD–15145

Remove the bearing housing (Item 1) [C] from the gears.

C
Remove the back–up seals/O–ring seals (Item 2) [C]
from the bearing housing. 1

2
2 CD–15146

Remove the drive gear shaft seals (Item 1) [D].

D

1
CD–15150

863, 863H Bobcat Loader

Revised June 98 –2–55– Service Manual
HYDRAULIC PUMP (Cont’d)
Inspection
A
Wash all parts in clean solvent.
Use air pressure to dry them.
Make a visual inspection of all the parts.
After visual inspection, those parts which show wear or
damage must be replaced.
Check the drive and idler gears [A].
If excessive wear is visible on the journals or side or face
of the gears, they must be replaced. If the splines are CD–15148
worn, replace the drive gear.
Check the bushings in the housing [B]. B
If the bushings are worn, scratched, and etc., replace
them as needed.

CD–15147

Check the pump housing [C].

C
Check the surface in the gear area for scratches, wear,
etc.
NOTE: See Parts Microfiche for available parts.

CD–15149

863, 863H Bobcat Loader

Revised June 98 –2–56– Service Manual
HYDRAULIC PUMP (Cont’d)
Assembly
A
Always use new O–rings and seals when assembling the
hydraulic pump.

When making repairs on hydrostatic and

hydraulic systems, clean the work area before 1
disassembly and keep all parts clean. Always CD–15150
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0284 B
Install the two seals (Item 1) [A] into the mounting flange
housing using the correct size driver tool.
Install the inside seal with the lip facing the drive gear and
the outside seal with the lip facing outward.

Install the bearing housing/gears assembly into the pump

housing [B].

CD–15151

Install the back–up seals/O–ring seals (Item 1) [C].

C
Install the large O–ring (Item 2) [C].

1
2

CD–15152

Install the mounting flange housing on the pump housing

[D]. D

CD–15153

863, 863H Bobcat Loader

Revised June 98 –2–57– Service Manual
HYDRAULIC PUMP (Cont’d)
Assembly (Cont’d)
A
Install the back–up seals/O–ring seals (Item 1) [A].
Install the large O–ring (Item 2) [A].

CD–15154

Install the end housing (Item 1) [B]. B

Install the four pump housing bolts [B].

CD–15155

Tighten the bolts to 45–50 ft.–lbs. (61–68 Nm) torque [C].

C

CD–15156

863, 863H Bobcat Loader

Revised June 98 –2–58– Service Manual
HYDRAULIC PUMP (Double Gear) 863H
Checking the Output of the High Flow Pump
A
The tools listed will be needed to do the following
procedure:
MEL10003 – Hydraulic Tester
MEL10006 – Hydraulic Test Kit
1
NOTE: Make sure all the air is removed from the
hydraulic system before beginning the test.
Air in the system can give an inaccurate test.
*Relief pressure must be per specification
before the test is done.
P–9156
Lift and block the loader. (See Page 1–1.)
Remove the right side rear wheel. B
Remove the four bolts and cover (Item 1) [A].
Disconnect the OUTLET hose from the pump fitting
(Item1) [B]. Remove the fitting (Item 1) [B] and install a
90° elbow fitting.
Connect the INLET hose from the tester to the OUTLET 1
of the pump. Connect the OUTLET hose from the tester
to the hose which was disconnected from the pump [C].

P–9157

Put jackstands under the front axles and rear C

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.
W–2017–0286

Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM.
Warm the fluid to 140°F. (60°C.) by turning the restrictor
control on the tester to about 1000 PSI (6895 kPa). DO P–9155
NOT exceed system relief pressure. Open the restrictor
control and record the free flow (GPM) at full RPM.
Push the mode switch (on the remote start switch) to
engage the front auxiliary hydraulics, the light will come
ON. Push the button (on the right steering lever) for fluid
pressure to the quick coupler (fluid pressure will go over
main relief). Record the highest pressure (PSI) and flow
(GPM). The high pressure flow must be at least 80% of
free flow.

%= HIGH PRESSURE FLOW (GPM)

X 100
FREE FLOW (GPM)
A low percentage may indicate a pump problem.

863, 863H Bobcat Loader

Revised June 98 –2–59– Service Manual
HYDRAULIC PUMP (Double Gear) 863H (Cont’d)
Removal and Installation
A

1
When making repairs on hydrostatic and
hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system. P–9156
I–2003–0284

Lift and block the loader. (See Page 1–1.)

B
Remove the right side rear wheel.
Remove the four bolts and cover (Item 1) [A].

Raise the operator cab. (See Page 1–1.)

Drain the hydraulic reservoir. (See Page 1–1.) 1

Disconnect the outlet hose from the small pump fitting

(Item 1) [B].
Remove the fitting (Item 1) [B].
P–9157

1
2

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved P–9160
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–2059–0598 D 3
Loosen the clamp (Item 1) [C] and remove the fuel hose
from fill neck. Position hose away from pump.
Loose the clamps and remove the pump inlet hose (Item
2) [C].
Loosen the clamps and disconnect the pump inlet hose
(Item 1) [D]. 2
Remove the inlet fitting (Item 2) [D].
1
Disconnect the hose (Item 3) [D] from the large pump
outlet fitting. P–9161

863, 863H Bobcat Loader

Revised Mar. 99 –2–60– Service Manual
HYDRAULIC PUMP (Double Gear) 863H (Cont’d)
Removal and Installation (Cont’d)
A
Loosen and remove the two pump mounting bolts (Item
1) [A].
Installation: Install a new gasket (Item 2) [A]. Tighten the 2
mounting bolts (Item 1) [A] to 25–27 ft.–lbs. (34–37 Nm)
torque.

1
P–9163

863, 863H Bobcat Loader

Revised June 98 –2–61– Service Manual
HYDRAULIC PUMP (Double Gear) 863H (Cont’d)
Parts Identification

1 2
3
4
5
6 7
8

10 9
9
6
5 4

12
11

13
14
15 16

17
18

20
15 19
14 13 21

23
22

24
26
25 TS–1078

Ref. Description Ref. Description

1. BOLT 14. SEAL
2. WASHER 15. RING
3. COVER 16. BODY
4. O–RING SEAL 17. BEARING
5. SEAL 18. DRIVE GEAR
6. RING 19. IDLER GEAR
7. BODY 20. BEARING
8. DOWEL 21. COVER
9. BEARING 22. SEAL
10. DRIVE GEAR 23. BOLT
11. IDLER GEAR 24. SEAL
12. COVER 25. WASHER
13. O–RING SEAL 26. BOLT

863, 863H Bobcat Loader

Revised June 98 –2–62– Service Manual
HYDRAULIC PUMP (Double Gear) 863H (Cont’d)
A Mark
Disassembly

When making repairs on hydrostatic and

hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always Mark
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system. CD–15159
I–2003–0284

Mark the pump sections for correct assembly [A]. B

Remove the four pump housing bolts (Item 1) [B] from the
small gear pump end housing.
Remove the small gear pump end housing (Item 2) [B].
1
Remove the small gear pump housing (Item 3) [B] from
the center housing.

2
CD–15017

Remove the O–ring (Item 1) [C] from the end housing.

C
Remove the back–up seal/O–ring seal (Item 2) [C] from
the pump housing.

1
2

CD–15018

Remove the O–ring (Item 1) [D] from the center housing.

D
Remove the back–up seal/O–ring seal (Item 2) [D].

1 CD–15019

863, 863H Bobcat Loader

Revised June 98 –2–63– Service Manual
HYDRAULIC PUMP (Double Gear) 863H (Cont’d)
Disassembly (Cont’d)
A
Remove the bearing housing/gears assembly from the
housing [A].

CD–15020

Remove the drive and idler gear from the bearing housing
[B]. B

CD–15021

Remove the two hex head bolts (Item 1) [C] and two allen
head bolts (Item 2) [C] from the mounting flange housing. C
Remove the mounting flange housing (Item 3) [C].

3
2
CD–15022

Remove the O–ring (Item 1) [D].

Remove the back–up seal/O–ring seal (Item 2) [D]. D

CD–15023

863, 863H Bobcat Loader

Revised June 98 –2–64– Service Manual
HYDRAULIC PUMP (Double Gear) 863H (Cont’d)
Disassembly (Cont’d)
A
Remove the center housing (Item 1) [A] from the large
gear pump housing.

1
CD–15024

Remove the O–ring (Item 1) [B].

Remove the back–up seal/O–ring seal (Item 2) [B].
B

1
2

CD–15025

Remove the bearing housing/gears assembly from the

large pump housing [C].
C

CD–15026

Remove the drive and idler gear from the bearing

housings [D]. D

CD–15027

Revised June 98 863, 863H Bobcat Loader

–2–65– Service Manual
HYDRAULIC PUMP (Double Gear) 863H (Cont’d)
Disassembly (Cont’d)
A
Remove the two seals (Item 1) [A] from the mounting
flange housing.

1
CD–15032

Check the connecting coupler (Item 1) [D] in the center

housing. If worn or damaged, use a press and correct size
driver tool to remove it from the center housing.
B

1
CD–15031

863, 863H Bobcat Loader

Revised June 98 –2–66– Service Manual
HYDRAULIC PUMP (Double Gear) 863H (Cont’d)
Inspection
A
Wash all parts in clean solvent.
Use air pressure to dry them.
Make a visual inspection of all the parts.
After visual inspection, those parts which are of
questionable condition must be replaced.
Check the bushings in the large and small bearing
housings [A].
If the bushings are worn, scratched, and etc., replace CD–15028
them as needed.
Check the drive and idler gears for the large and small
pumps [B].
B
If excessive wear is visible on the journals, side or face of
the gears they must be replaced. If the splines are worn,
replace the drive gear(s).

CD–15029

Check the large and small pump housing [C].

Check the surfaces in the gear area for scratches, wear C
and etc.
Replace all parts as needed.

CD–15030

863, 863H Bobcat Loader

Revised June 98 –2–67– Service Manual
HYDRAULIC PUMP (Double Gear) 863H (Cont’d)
Assembly
A
Always use new O–rings and seals when assembling the
hydraulic pump.

When making repairs on hydrostatic and

hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always 1
CD–15032
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0284 B
Install the two seals (Item 1) [A] into the mounting flange
housing using the correct size driver tool.
Install the inside seal with the lip facing the drive gear and 1
the outside seal with the lip facing outward.

CD–15026

Install the large drive and idler gears into the bearing
housing (Item 1) [B]. C
Install the bearing housing/gears assembly into the large
pump housing [C].
Install the back–up seal/O–ring seal (Item 1) [C].
1
Install the large O–ring (Item 2) [C]. 2

CD–15033

Turn the large pump housing around; install the back–up

seal/O–ring seal (Item 1) [D]. D
Install the large O–ring (Item 2) [D].

2
1

CD–15034

863, 863H Bobcat Loader

Revised June 98 –2–68– Service Manual
HYDRAULIC PUMP (Double Gear) 863H (Cont’d)
Assembly (Cont’d)
A
Install the center housing (Item 1) [A] on the large pump
housing.

CD–15035

Install the mounting flange housing (Item 1) [B] on the

large pump housing. B

CD–15036

Install the hex head bolts (Item 1) [C] and allen head bolts
(Item 2) [C]. Finger tighten only.
C
1

2
CD–15037

Install the drive and idler gears into the bearing housing
(Item 1) [D]. D

CD–15020

863, 863H Bobcat Loader

Revised June 98 –2–69– Service Manual
HYDRAULIC PUMP (Double Gear) 863H (Cont’d)
Assembly (Cont’d)
A
Install the bearing housing/gears assembly into the pump
housing [A].
Install the large O–ring (Item 1) [A].
Install the back–up seal/O–ring seal (Item 2) [A].

2
1

CD–15019

Install pump housing on the center housing [B].

Install the large O–ring (Item 1) [B].
B
Install the back–up seal/O–ring seal (Item 2) [B].
Install the end housing.
Install the four pump housing bolts. 1
2

CD–15017

Tighten the small pump housing bolts to 20–25 ft.–lbs.

(27–34 Nm) torque [C].
C

CD–15084

Tighten the large pump housing bolts (hex head & allen
head) to 33–41 ft.–lbs. (45–56 Nm) torque [D]. D

CD–15038

863, 863H Bobcat Loader

Revised June 98 –2–70– Service Manual
HYDRAULIC FLUID RESERVOIR
Removal and Installation
A
Raise the operator cab. (See Page 1–1.)
Disconnect the hose (Item 1) [A] at the case drain filter
and drain the fluid into a container.

P–7690

Loosen the hose clamp and disconnect the reservoir

outlet hose (Item 1) [B].
B
Disconnect the case drain hose (Item 2) [B] at the 1
reservoir. 2

P–4856

Remove the bolt and plate from the mounting strap (Item
1) [C] (both sides) C
Installation: Tighten the bolt to 16–20 ft.–lbs. (21–27
Nm) torque.
Remove the mounting strap.
Remove the hydraulic reservoir from the loader.

P–7708

863, 863H Bobcat Loader

Revised June 98 –2–71– Service Manual
HYDROSTATIC FILTER HOUSING
Removal and Installation
A
1

2
P–7767

B 1
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
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–2059–0598

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
3
Raise the operator cab. (See Page 1–1.)
Disconnect the wire (Item 1) [A] from the sender.
2
P–7768

Disconnect the wire connector (Item 2) [A] from the

switch.
C
Disconnect the hose (Item 1) [B] from the filter housing.
Disconnect the large tubeline (Item 2) [B].
1
Disconnect the small tubeline (Item 3) [B]

Remove the four mounting bolts (Item 1) [C].

Installation: Tighten the mounting bolts to 25 ft.–lbs. (34
Nm) torque.
Remove the filter housing/filter assembly. P–7770

Hydrostatic Charge Pressure Sender D

To remove and install the charge pressure sender, use the
following procedure.
Disconnect the wire (Item 1) [D] from the sender.
2
Remove the hose clamp (Item 2) [D] from the sender.
Remove the sender from the fitting. 1

P–7749

863, 863H Bobcat Loader

Revised Mar. 99 –2–72– Service Manual
HYDRAULIC FILTER HOUSING
Removal and Installation
A

When making repairs on hydrostatic and

hydraulic systems, clean the work area before 3
disassembly and keep all parts clean. Always 2
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system. P–7769
I–2003–0284

B
1

P–5498

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved
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–2059–0598

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)

NOTE: Hydrostatic filter is removed for photo clarity.

Disconnect the wire (Item 1) [A] from the sender.

Loosen the two hose clamps (Item 2) [A] and disconnect
the hose.
Disconnect the tubeline (Item 3) [A].

Remove the four mounting bolts (Item 1) [B].

Installation: Tighten the mounting bolts to 25 ft.–lbs. (34
Nm) torque.

Remove the filter housing/filter assembly.

863, 863H Bobcat Loader

Revised Mar. 99 –2–73– Service Manual
CONTROL PEDALS
Removal and Installation
A
Remove the bolt and nut (Item 1) [A] from the pedal
linkage.
1
Installation: Tighten the bolt and nut to 21–25 ft.–lbs.
(28–34 Nm) torque.
Check the rubber bushing in the pedal for wear and
replace as needed.

P–5380

Remove the two mounting bolts (Item 1) [B].

Remove the pedal assembly from the loader.
B
1
Pedal Adjustment
After installing the pedal, adjust the pedal so that there is
clearance under the rear of the pedal and the valve spool
must travel full stroke without hitting the floor panel.

P–5383
AVOID INJURY OR DEATH
Adjust locking tabs on pedal control linkage so
that lift and tilt control pedals are locked in
neutral when the seat bar is up.
W–2104–1285

NOTE: See Page 2–55 for correct procedure to

adjust the pedal interlock linkage.

863, 863H Bobcat Loader

Revised June 98 –2–74– Service Manual
PEDAL INTERLOCK LINKAGE
863,863HServiceManual#6724799–HydraulicSystemSectionPart3of4

Removal and Installation

A

1
2

P–1216

B
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
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–2059–0598

Raise the lift arms and install an approved lift arm support 1
device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
P–1210
Remove the interlock shield mounting nuts (Item 1) [A].
Installation: Tighten the shield mounting nuts to 25–28
ft.–lbs. (34–38 Nm) torque. C
Remove the interlock shield (Item 2) [A].

Remove the interlock mounting nuts and plastic washers

from behind the nuts [B].
Remove the interlock (Item 1) [B] and plastic washers
from behind the interlock.

Installation: Hold the inside plastic washer up with an P–1219

O–ring pick or a small screwdriver so the plastic washer
does not become wedged between the side panel and the
interlock nut [C].
D
Installation: Tighten the interlock mounting nuts to
84–95 in.–lbs. (9,5–10,8 Nm) torque.
To install new interlock mounting bolts, remove the top
bolt from the front panel and loosen the two bolts at the
bottom of the panel [D].

P–1213

863, 863H Bobcat Loader

Revised Mar. 99 –2–75– Service Manual
PEDAL INTERLOCK LINKAGE (Cont’d)
Removal and Installation (Cont’d)
A
Remove the panel from the loader frame [A].

P–1215

Install the mounting bolts (Item 1) [B] through the back of

the panel as shown. B

P–1212

Pedal Interlock Linkage Adjustment

Check the pedal interlock linkage so it is free and locks C
both pedals in neutral position.
Check that the tab (Item 1) [C] on the linkage, slides into
the slot on the interlock and holds the pedal in locked
position.
If not, loosen the bolts and adjust the tab for correct 1
engagement.
Tighten the bolts to 25–28 ft.–lbs. (34–38 Nm) torque.

P–1214

D
AVOID INJURY OR DEATH
Adjust locking tabs on pedal control linkage so
that lift and tilt control pedals are locked in
neutral when the seat bar is up.
W–2104–1285

The locking tab should fit into the slot of the interlock as
shown in figure [D], when adjusted correctly.

P–4051

863, 863H Bobcat Loader

Revised June 98 –2–76– Service Manual
REAR AUXILIARY DIVERTER
A
Disassembly
Clean the diverter block to remove dirt before
disassembly. Block ports are labeled for correct
assembly.

1
When repairing hydrostatic and hydraulic
systems, clean the work area before 1
N–00527
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888
B

Remove the logic cartridge valves from block ports LC1

and LC2 (Item 1) [A].
Remove the pilot check valves from block ports PC1 and
PC2 (Item 1) [B].
Remove the shuttle check valve from block port SH1
(Item 2) [B]. 1
Remove the nuts (Item 1) [C], seal washers (Item 2) [C], 2
and solenoid valve coils (Item 3) [C].
N–00529
Remove the diverter control solenoid valve (Item 4) [C]
from port SV1. Remove the pressure relieving solenoid
valve (Item 5) [C] from block port SV2. C 4
Inspection
Inspect cartridges, check valves, solenoid valves and 2
3
sealing washers for contamination or damage. Wash all
parts in clean solvent. Use air pressure for drying them.
Install new O–rings and back–up washers. 5 2

Inspect diverter block cavities for contamination. Wash 2

block in clean solvent. Use air pressure to dry.
Solenoid Testing
3
Use a test meter to measure coil resistance [D]. Coil wires 2 1
do not have polarity. Correct resistance is 6–9 ohms. N–00528

Replace the test meter with 12 volt power. You can see
and hear the spool shift. D
Assembly
Put oil on O–rings and back–up washers.
Tighten the Logic cartridge valves (Item 1) [A] to 65 ft. lbs.
(88 Nm) torque.
Tighten the pilot check valves (Item 1) [B], and shuttle
check valve (Item 2) [B] to 35 ft. lbs. (47 Nm) torque.
Tighten the solenoid valves (Items 4 and 5) [C] to 12 ft.
lbs. (16,3 Nm) torque. Install the sealing washers (Item 2)
[C] and coils (Item 3) [C]. Tighten the nuts (Item 1) [C] to
10 in. lbs. (1,13 Nm) torque. P–9137

863, 863H Bobcat Loader

Revised June 98 –2–77– Service Manual
863,863HServiceManual#6724799–HydraulicSystemSectionPart4of4

863, 863H Bobcat Loader

–2–78– Service Manual
HYDROSTATIC SYSTEM
Page
Number
CABLE STEERING LINKAGE NEUTRAL ADJUSTMENT
Adusting Lever Freeplay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–18
Adjusting The Steering Neutral Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–21
Adjusting The Wheel RPM Forward Compared To Reverse Travel . . . 3–19
Adjusting The Wheel RPM Left Compared To Right Side . . . . . . . . . . . 3–22
Pre–Adjustment Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17

CONTROL TOWER (SOLID STEERING LINKAGE) HYDROSTATIC

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12 SYSTEM
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11
DRIVE BELT
Adjusting the Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–72
Replacing the Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–72
DRIVE BELT SHIELD
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–71

DRIVE BELT TENSIONER PULLEY

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–73
Tension Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–75
FRONT PANEL (CABLE STEERING LINKAGE)
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7

FRONT PANEL (SOLID STEERING LINKAGE)

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5

HYDROSTATIC MOTOR
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–30
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–26
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23
HYDROSTATIC PUMP
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–55
Charge Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–64
Charge Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–43
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–44
Displacement Control Servo (Cable Linkage) . . . . . . . . . . . . . . . . . . . . . 3–69
Displacement Control Servo (Steering Linkage) . . . . . . . . . . . . . . . . . . . 3–68
Hydraulic Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–66
Hydraulic Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–42
Hydrostatic Pump Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–65
Hydrostatic Pump Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–42
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–53
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–38
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–34
Replenishing/High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . 3–36
Swashplate Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–67

Continued On Next Page

863, 863H Bobcat Loader
–3–1– Service Manual
Page
Number
HYDROSTATIC SYSTEM INFORMATION
Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
OIL COOLER
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–76

SOLID STEERING LINKAGE NEUTRAL ADJUSTMENT

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–14
STEERING LEVERS
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9

TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

863, 863H Bobcat Loader

–3–2– Service Manual
TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are
most common. Many of the recommended procedures
must be done by authorized Bobcat Service Personnel Check for correct function after adjustments,
only. repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W–2004–1285

PROBLEM CAUSE

No drive on one side, in one direction. 1, 2

No drive on one side in both directions. 2, 3, 4, 5

The loader does not move in a straight line. 2, 3, 5, 6, 7

The hydrostatic system is overheating. 8, 9, 10, 11

Service code HP 2 appears (Warnings, low charge pressure) or the
warning light comes ON. 8, 11, 12, 13, 14

KEY TO CORRECT THE CAUSE

1. The hydrostatic pump replenishing valves not seating.

2. The steering linkage needs adjustment.

3. The hydrostatic pump has damage.

4. The final drive chains are broken.

5. The hydrostatic motor has damage.

6. The tires do not have the correct tire pressure.

7. The tires are not the same size.

8. The hydrostatic fluid is not at the correct level.

9. The oil cooler has a restriction.

10. The temperature sending switch is not operating correctly.

11. The loader is not being operated at the correct RPM.

12. The sender is defective.

13. Pump is defective or worn hydrostatics.

14. Hydraulic filter is plugged.

863, 863H Bobcat Loader

–3–3– Service Manual
HYDROSTATIC SYSTEM INFORMATION
A CHARGE OIL

When making repairs on hydrostatic and

hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and Valve Moves for Charge
ports to keep dirt out. Dirt can quickly damage
the system. FUNCTION 1 Oil Replacement
I–2003–0284

Replenishing Valve Function

The functions of the replenishing valves are:
• To give replacement fluid to the low pressure side of
the hydrostatic circuit. Replacement fluid is needed
because of normal internal leakage and the controlled
flow to the oil cooler for cooling; Function 1 [A].

• To keep high pressure fluid out of the low pressure side

of the hydrostatic circuitry; Function 2 [A]. Valve Stays on Seat to
Hold High Pressure for Drive
FUNCTION 2
See Page 3–28 for valve location and repair information. B–02804

863, 863H Bobcat Loader

–3–4– Service Manual
FRONT PANEL (SOLID STEERING LINKAGE)
Removal and Installation
A
1

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.
W–2017–0286
P–13477

2 3

P–13478
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
lift arm support device. Failure to use an
approved lift arm support device can allow the C
lift arms or attachment to fall and cause injury
or death. W–2059–0598

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.) 1
Raise the operator cab. (See Page 1–1.)
Remove the engine speed control (Item 1) [A]. (See Page
7–1.)
Hold the lock nut and remove the knob (Item 2) [A] from
the lift arm lock valve. P–07736
Disconnect the wire harness connectors (Item 1) [B] from
the steering lever wire harness.

NOTE: The 863 without front auxiliary hydraulics

does not have electric control handles.
Remove the right side steering shock absorber (Item 2)
[B].
Remove the steering panel brace bolts (Item 1) [C].
Remove the steering panel brace (Item 3) [B].

NOTE: Bolts have a nut on rear side holding panel

brace.

863, 863H Bobcat Loader

Revised Mar. 99 –3–5– Service Manual
FRONT PANEL (SOLID STEERING LINKAGE)
(Cont’d) A 4
Removal and Installation (Cont’d)
Remove the shock absorber mounting bolt (Item 1) [A].
Disconnect the shock absorber panel brace bolt (Item 2) 3
[B]. Remove panel brace and shock. 2
1
Installation: Connect the bottom panel brace (both
sides) prior to connecting shock absorber/panel brace
bolt (Item 2) [A]. Lift upward on rear edge of panel to align
panel and brace.
Disconnect the steering linkage ball joints (Item 3) [A]
from the steering cross shaft. P–13480

Remove the top mounting bolt (Item 4) [A] (both sides).

B
Remove the two mounting bolts (Item 1) [B] at the side
of the front panel (both sides).
1
Remove the mounting bolt (Item 2) [B] on the bottom of 2
the front panel.
Remove the front panel.
Installation: Align pedal linkage grommets in steering
3
panel and lower cover slots (Item 3) [B]. 3

P–07970

863, 863H Bobcat Loader

Revised Apr. 98 –3–6– Service Manual
FRONT PANEL (CABLE STEERING LINKAGE)
Removal and Installation
A
1

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.
W–2017–0286
P–13477

1
P–07738
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
lift arm support device. Failure to use an
approved lift arm support device can allow the
C
lift arms or attachment to fall and cause injury
or death. W–2059–0598

Raise the lift arms and install an approved lift arm support 1
device. (See Page 1–1.) 1

Raise the operator cab. (See Page 1–1.)

Remove the engine speed control. (See Page 7–1.)
Hold the lock nut and remove the knob (Item 1) [A] from
the lift arm manual down valve.
P–07736
Disconnect the wire harness connectors (Item 1) [B] from
the steering lever wire harness.
NOTE: The 863 without front auxiliary hydraulics
does not have electric control handles.
Remove the right side steering shock absorber (Item 2)
[B].

Remove the steering panel brace bolts (Item 1) [C].

NOTE: Bolts have a nut on rear side holding panel
brace.

863, 863H Bobcat Loader

Revised Mar. 99 –3–7– Service Manual
FRONT PANEL (CABLE STEERING LINKAGE)
(Cont’d) A
Removal and Installation (Cont’d) 2
3
Remove the steering panel brace (Item 1) [A].
Remove the steering cable U–bolt (Item 2) [A].
Disconnect the steering cable ball joint (Item 3) [A].

P–07734

Remove the top mounting bolt (Item 1) [B] (both sides). B

Remove the shock absorber mounting bolt (Item 2) [B]. 1
Disconnect the shock absorber panel brace bolt (Item 3) 3
[B]. Remove panel brace and shock. 2
Installation: Connect the bottom panel brace (both
sides) prior to connecting shock absorber/panel brace
bolt (Item 3) [B]. Lift upward on rear edge of panel to align 5
panel and brace.
Remove the steering cable U–bolt (Item 4) [B]. 4
Disconnect the steering cable ball joint (Item 5) [B].
P–04743

Remove the two mounting bolts (Item 1) [C] at the side C

of the front panel (both sides).
Remove the mounting bolt (Item 2) [C] on the bottom of 1
the front panel. 2
Remove the front panel.
Installation: Align pedal link grommets in steering panel
and lower cover slots (Item 3) [C]. 3
3

P–07970

863, 863H Bobcat Loader

Revised Apr. 98 –3–8– Service Manual
STEERING LEVERS
Disassembly and Assembly
A
Remove the front panel/steering lever assembly. (See
Page 3–5 or 3–7.)
Remove the steering shaft centering mechanism bolt and
nut (Item 1) [A] or [B] and spring.
1

P–10858

P–05033

Loosen both U–bolts (Item 1) [C] at the steering lever.

Remove the steering lever. C
1

P–07971
Loosen both U–bolts (Item 1) [D] at the steering lever.
Remove the steering lever.
D 1
Assembly: The steering levers must be mounted flush
with the back of the mounting plate (Item 2) [C].
Remove the steering shaft assembly bolts (Item 2) [D]
(both sides).
Remove the steering shaft. 2

P–05035

863, 863H Bobcat Loader

Revised Apr. 98 –3–9– Service Manual
STEERING LEVERS (Cont’d)
Disassembly and Assembly (Cont’d)
A
Disassemble the right and left steering shaft from the
cross shaft [A].
Install new nylon bushings (Item 1) [A] as needed at the 1
ends of the steering shaft. 1

P–05039

Check the nylon bushing (Item 1) [B] and replace as

needed. B 3 4
Assembly: Make sure the wave washer (Item 2) [B] is
between the nylon bushings.
4 2
Check and replace the cams (Item 3) [B] if worn or
damaged. Tighten the cam jam nuts.

P–05040

Remove the bolts (Item 1) [C] or remove the steering

shaft mounting bracket (item 1) [D] and the steering lever C
stop plate (Item 2) [D]. 1

1
P–05037

2
P–05036

863, 863H Bobcat Loader

Revised Apr. 98 –3–10– Service Manual
CONTROL TOWER (SOLID STEERING LINKAGE)
Removal and Installation
A

1
1
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.
W–2017–0286 P–13473

P–13483
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
lift arm support device. Failure to use an C
approved lift arm support device can allow the
lift arms or attachment to fall and cause injury
or death. W–2059–0598 1

Raise the lift and install an approved lift arm support

device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
Disconnect the steering linkage ball joints (Item 1) [A]
from the control tower.
Disconnect the short steering linkage ball joints (Item 1) P–13474
[B] & [C] from the control tower.

D
Remove the four mounting bolts (Item 1) [D] from the
control tower mounting bracket.
Installation: Tighten the four mounting bolts to 25 ft.–lbs.
(34 Nm) torque.
1
Remove the control tower assembly from the loader.
Installation: See Page 3–14 to adjust neutral at the 1
steering linkage.

P–13482

863, 863H Bobcat Loader

Revised Mar. 99 –3–11– Service Manual
CONTROL TOWER (SOLID STEERING LINKAGE)
(Cont’d) A 1
Disassembly and Assembly
Remove the bolt (Item 1) [A] from the top linkage arm.
NOTE: Mark the top linkage arm so it will be returned
to its original position. The top linkage arm
has a offset and must be installed with the
offset in the right direction.
Assembly: Tighten the bolt to 30 ft.–lbs. (41 Nm) torque.
Remove the top linkage arm from the tower shaft.

P–13489

Remove the second linkage arm (Item 1) [B] from the

tower shaft. B 1

P–13487

Remove the bushings (Item 1) [C] from the second

linkage arm. Check the bushings for wear and replace as C
needed. 1

P–13490

863, 863H Bobcat Loader

Revised Apr. 98 –3–12– Service Manual
CONTROL TOWER (SOLID STEERING LINKAGE)
(Cont’d) A
Disassembly and Assembly (Cont’d)
Remove the clip (Item 1) [A] from the bottom of the
control tower shaft.

P–13484

Remove the control tower shaft (Item 1) [B] from the

mounting bracket.
B
1

P–13486

Remove the bushings (Item 1) [C] from the control tower

tube. Check the bushings for wear and replace as C
needed.

P–13492

863, 863H Bobcat Loader

–3–13– Service Manual
SOLID STEERING LINKAGE NEUTRAL
ADJUSTMENT A
Procedure

Put jackstands under the front axles and rear

corners of the frame before running the engine 1
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.
W–2017–0286 P–13483

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved
lift arm support device. Failure to use an B
approved lift arm support device can allow the
lift arms or attachment to fall and cause injury
or death.
W–2059–0598

The following tool will be needed to do the following

procedure:
MEL1429A – Remote Start Switch
1
Lift and block the loader. (See Page 1–1.)
Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.) P–13474

Raise the operator cab. (See Page 1–1.)

Connect the remote start switch. (See Page 1–1.)
C
Read the adjustment procedure completely to become
familiar with the procedure.
NOTE: See Page 3–67 for hydrostatic pump neutral
adjustment before beginning the linkage
adjustment. 1
1
The short steering linkage (Item 1) [A] & [B] at the
hydrostatic pump pintle levers must be of equal length.
If not, disconnect the long steering linkage (Item 1) [C] at
the control tower.
Disconnect the ball joint at the linkage (Item 1) [A] or [B]. P–13473

Loosen the lock nuts on the linkage and adjust until both
short steering linkages are the same length. D
Install the short steering linkage and tighten the nuts on
the ball joints.
1.000’’ 1
Adjust the short steering linkage (Item1) [A] & [B] by (25,4 mm)
turning each equal amounts to reach a distance of 1.000
inch (25,4 mm) between the center mounting holes of the
short steering linkage (Item 1) [D] in the top and bottom
linkage arms. 1
Tighten the lock nuts on the short steering linkage.
Connect the long steering linkage (Item 1) [C] at the
control tower.
TS–01641

863, 863H Bobcat Loader

Revised Mar. 99 –3–14– Service Manual
SOLID STEERING LINKAGE NEUTRAL
ADJUSTMENT (Cont’d) A
Procedure (Cont’d)
Disconnect the long steering linkage (Item 1) [A] ball
joints at the steering lever cross shaft brackets.

The following procedure will adjust the steering cross

shaft cams so both steering levers have no free play
against the cam. P–13478

Only the right side cam is adjustable in a slotted hole in

the bellcrank (Item 1) [B]. The left side cam is fixed and
will not require adjustment.
B

P–10858

The cam should not rotate on the mounting bolt. If the cam
rotates, tighten the jam nut (Item 1) [C] against the cam
while holding cam mounting bolt (Item 2) [C]. C 1
Push the left steering lever forward and move the right
steering lever cam (Item 1) [C], to the rear of the slot to 3
get free play in the left steering lever. Tighten the nut (Item
1) [B].
2

P–10873

Use a punch and hammer, hit the right cam nut (cam
mounting bolt is still tight) until free play is removed from D
the left steering lever [D].
Check the torque at the cam bolt again to be sure it is still
tight. Check again to be sure there is no free play in the
cams.

NOTE: If there is any free play the neutral setting can

not be obtained.

P–10872

863, 863H Bobcat Loader

Revised Apr. 98 –3–15– Service Manual
SOLID STEERING LINKAGE NEUTRAL
ADJUSTMENT (Cont’d) A
Procedure (Cont’d)
The cam must be centered in the pocket in the detent
bracket [A].

Connect the long steering linkage ball joints (Item 1) [B] Cam
at the steering cross shaft. Detent
Bracket
Loosen the lock nuts (Item 2) [B] (both ends). Pocket
Start the engine. WHEN THE ENGINE IS RUNNING
THE WHEELS MAY BE TURNING. MC–01944

Adjust the steering linkage, by turning the linkage rod to

the right or left until the wheels stop turning. Tighten the
lock nuts (Item 2) [B].
B 1
Increase the engine speed to full RPM. Move the steering
1
lever forward and let it return to neutral and the wheels
should stop. Move the steering lever backward and let it 2
return to neutral and the should stop. If not re–adjust the
steering linkage rod again.
Repeat the above procedure for the other side of the 2
loader.

NOTE: The following procedure is for MINOR

adjustment in full forward travel only.
Steering neutral setting must be correctly
adjusted before doing this procedure. P–13475

Loosen the bolts (Item 1) [C] at the stop and lower the
lever stops (both sides). C
Start the engine. Increase engine speed to full RPM.
1 1

P–07970

Check the wheel RPM left and right side [D].

They should be the same. If not, the stop can used for
D
minor adjustment.
Bring the stop up on the faster side until the wheel RPM
is equal. Tighten the stop bolt (Item 1) [C].
Tighten the other stop in the down position.
Re–check the wheel RPM and make adjustment as
necessary.

P–07959

863, 863H Bobcat Loader

Revised Apr. 98 –3–16– Service Manual
CABLE STEERING LINKAGE NEUTRAL
ADJUSTMENT A
Pre–Adjustment Checks
Read this adjustment completely to become familiar with
the procedure before beginning the adjustment.
The loader should not creep (slow wheel movement)
when the steering levers are at rest in the neutral position.
The following special tool will be needed to do the
following procedure:
MEL1429A – Remote Start Switch
Lift and block the loader. (See Page 1–1.) P–02865

Raise the operator cab. (See Page 1–1.)

Connect the remote start switch. (See Page 1–1.)
B

When working on the left side of the hydrostatic

pump, BE CAREFUL to keep your fingers and
tools clear of the cooling fan belt.
W–2184–0395

Check the following items (Steps 1, 2 & 3) before making P–02866

any adjustments on the steering linkage:

1. Always check tire pressure and tire size before

making any adjustments. Inflate tires to maximum
C
pressure shown on the sidewall of the tire. Be sure
the tires do not vary more than 1 inch (25,4 mm) in
circumference [A] which could cause different rate
of travel and the loader drifting to one side with both
steering levers at equal travel. Socket

2. To be sure the hydrostatic pump is in neutral, block

the neutral spring bracket out with a deep socket
(approximately 7/16 inch) so you can no longer feel
the linkage neutral setting [B] & [C].
Detent
Bracket
3. Start the engine. Move the levers while observing
the neutral position on the pump servo spool valve. MC–01944
You can feel and see the spring (Item 1) [D] of the
pump neutral adjustment. If the wheels do not move
when the pump is in the neutral position, then the
pump is correctly adjusted. Only linkage adjustment D
will be necessary for neutral position. If the wheels
move when the pump levers are in neutral position,
see Page 3–59 for the pump neutral adjustment.

4. Stop the engine. Remove the socket [B].

1

P–07927

863, 863H Bobcat Loader

Revised Apr. 98 –3–17– Service Manual
CABLE STEERING LINKAGE NEUTRAL
ADJUSTMENT (Cont’d) A
Adjusting Lever Freeplay
Read this adjustment completely to become familiar with
the procedure before beginning the adjustment. 1

Use the following procedure to adjust the steering linkage

so both steering levers have no free play against the
cam. To remove the free play, move the right cam to 3
match the left cam so there is no free play between the
two cams in the pocket of the detent bracket [C]. Use the
following procedure to adjust the the cam free play.
2
1. Only the right side cam is adjustable in slotted hole P–02867
in bellcrank (Item 1) [B]. The left side cam is fixed
and will not require adjustment. The cam should not
rotate on the mounting bolt. If cam rotates, tighten
the jam nut (Item 1) [A] against the cam while B
holding cam mounting bolt (Item 3) [A].
2. Loose the cam mounting bolt nut (Item 2) [A] and
move the cam to the rear to get free play in the left
hand lever.

3. Tighten the cam bolt. Use a punch and hammer, hit

the cam nut (cam mounting bolt is still tight) until the
free play is removed from the left hand lever [B].
The cam must be centered in the detent bracket
pocket [C]. 1

4. Recheck the torque at the cam bolt to be sure it is

still tight. Check again to be sure there is no free play P–02868
in the cams. If there is any free play the neutral
setting can not be obtained.
C

Detent Cam
Bracket
Pocket

MC–01944

863, 863H Bobcat Loader

Revised Apr. 98 –3–18– Service Manual
CABLE STEERING LINKAGE NEUTRAL
ADJUSTMENT (Cont’d) A
1
Adjusting the Wheel RPM Forward Compared to
Reverse Travel
Read this adjustment completely to become familiar with
the procedure before beginning the adjustment.
NOTE: This procedure adjusts the position of the
steering levers in the panel when in neutral.
Levers centered in steering panel give equal
travel forward compared to reverse.
1. Disconnect the two bolts of the pintle links (both
sides) (Item 1) [A].
P–07927

2. Fully lower steering lever stop and tighten (both

sides) (Item 1) [B]. B
NOTE: Before measuring, move the steering lever a
small amount to be sure the cam is in the
detent pocket with no freeplay.

P–02875

3. Move the lever to full forward, measure the distance

from the U–bolt to the lock nut. Record this C FORWARD
measurement [C].
EXAMPLE ONLY: 3.66 inch (93 mm)

3.66 inch
(93 mm)

MC–01944

4. Move the lever to full reverse, measure the distance

from the U–bolt to the lock nut. Make a record of this D REVERSE
measurement [D].
EXAMPLE ONLY: 2.76 inch (70 mm)

2.76 inch
(70 mm)

MC–01943

863, 863H Bobcat Loader

Revised Apr. 98 –3–19– Service Manual
CABLE STEERING LINKAGE NEUTRAL
ADJUSTMENT (Cont’d) A NEUTRAL
Adjusting the Wheel RPM Forward Compared to
Reverse Travel (Cont’d)

5. Move the lever to the neutral position. Measure the

distance from the U–bolt to the lock nut [A]. Neutral
must be adjusted to 3.21 inch (82 mm) per example.

EXAMPLE:
3.21 inch
Forward 3.66 inch (93 mm) (82 mm)
Reverse – 2.76 inch (70 mm)
0.90 inch (23 mm) Total Travel* MC–01943

Divided by Two = 0.45 inch (11 mm) Half the Travel

+ 2.76 inch (70 mm) Reverse Travel
3.21 inch (82 mm) Is Neutral B
If adjustment is required, loosen the mounting bolts (Item
1) [B].
Moving the neutral spring bracket up will allow more
forward stroke and more forward wheel RPM. Moving it
down will allow more rearward stroke and more reverse CD–11204
wheel RPM.
1

P–02875

Use a screwdriver to move the neutral spring bracket C

(Item 1) [C] down or a large pliers to move it up in its
slotted holes.

NOTE: Keep the bracket vertical to be sure that the

cams make full contact in the pocket of the
detent bracket.
Tighten the mounting bolts on the spring bracket (Item 1) 1 1
[B].
Neutral to forward cable travel must be within 0.010 inch
(0,25 mm) left compared to right side.

N–00301 N–00302

Install pintle link bolts (Item 1) [D] (both sides).

D 1

P–07927

863, 863H Bobcat Loader

Revised Apr. 98 –3–20– Service Manual
CABLE STEERING LINKAGE NEUTRAL
ADJUSTMENT (Cont’d) A
Adjusting the Steering Neutral Setting
Read this adjustment completely to become familiar with
the procedure before beginning the adjustment.

NOTE: This procedure adjusts the creep (wheel 1 2

movement in neutral) and dead–band (lever
travel before wheels start to turn). Adjusting
steering cable length will match lever neutral
and pump neutral.
NOTE: The following adjustments (Steps a, b, c & d) P–07721
are not necessary if the thread engagement
in the ball joint is equal on both ends of the
cable (Item 1) [A] & [B].
B
a. Disconnect the cable ball joint from the steering
lever shaft (Item 2) [A].
b. Loosen the jam nut and turn the ball joint all the
way to the end of the threads (toward cable 1
housing).
c. At the pumps, loosen the jam nut and turn the
inner cable until the ball joint is all the way to the
end of the threads (toward the cable housing).
d. Connect the steering cable ball joint.

1. Start the engine. WHEN THE ENGINE IS P–07723

RUNNING, THE WHEELS WILL BE TURNING.

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.
W–2017–0286

2. The steering cable ends have right and left hand

threads. By turning the inner cable, it will shorten or
lengthen the cable. Turn the inner cable until the P–02869
wheels stop turning [C].
NOTE: Before measuring, move the steering lever a
small amount to be sure the cam is in the D
detent pocket with no freeplay.
3. Use a straight edge for a measuring reference point
positioned against the pedal lock links (Item 1) [D].
Put a ruler between reference and steering lever to
measure lever travel from neutral until wheel starts
to travel forward. Then measure from neutral until
wheel starts to travel reverse [D].
1
4. Adjust cable length by turning the inner cable until
the two measurements are equal [C]. Tighten the
jam nut (both ends).

5. Repeat the procedure for the other side of the P–07724

loader.
863, 863H Bobcat Loader
Revised Apr. 98 –3–21– Service Manual
CABLE STEERING LINKAGE NEUTRAL
ADJUSTMENT (Cont’d) A
Adjusting the Wheel RPM Left Compared to Right
Side

NOTE: This procedure is for MINOR adjustment in

full forward travel only. Steering neutral
setting must be correctly adjusted before
this procedure.
1. Loosen the bolts at the stop (Item 1) [A] and lower 1
the lever stops (both sides).
2. Start the engine. P–02875

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.
W–2017–0286

3. Check wheel RPM left and right side [B]. They

should be the same. If not, the stop (Item 1) [A] can
be used for MINOR adjustment. Bring the stop up
on the faster side until RPM is equal. (Tighten stop P–07959
before re–checking) tighten remaining side in down
position.

863, 863H Bobcat Loader

Revised Apr. 98 –3–22– Service Manual
HYDROSTATIC MOTOR
A
Removal and Installation
Lift and block the loader. (See Page 1–1.)

1
1

When making repairs on hydrostatic and

hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always P–07793
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0284 B 1

P–07788

C
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
lift arm support device. Failure to use an
approved lift arm support device can allow the 1
lift arms or attachment to fall and cause injury
or death. W–2059–0598

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
Remove the four mounting bolts for the motor cover (Item P–07795
1) [A].
Remove the motor cover.
D
Mark the hoses for correct installation. 1

Disconnect the high pressure hoses (Item 1 & 2) [B].

Disconnect the case drain hose (Item 1) [C].

1
Remove the four mounting bolts (Item 1) [D] from the
motor.
Installation: Tighten the bolts to 210–230 ft.–lbs. 1
(285–310 Nm) torque.
Remove the hydrostatic motor from the carrier. P–07792

863, 863H Bobcat Loader

Revised Mar. 99 –3–23– Service Manual
HYDROSTATIC MOTOR (Cont’d)
A
Removal and Installation (Cont’d)
Installation: Always replace the large O–ring (Item 1)
[A] before installing the hydrostatic motor into the carrier.

NOTE: To prevent damage to the balance plate,

never lift or support the motor by the center 1
shaft.

P–07796

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

Revised Apr. 98 –3–24– Service Manual
HYDROSTATIC MOTOR (Cont’d)
863,863HServiceManual#6724799–HydrostaticSystemSectionPart1of3

Parts Identification

21
20
17
19
18
19
17
24 20
25 22
26 23

27
1

3
4
3
5
6
3 7
3
2

6
12

8
9 16
10
11

14
13 15 C–03402

Ref. Description Ref. Description

1. HOUSING 15. SHAFT, drive
2. O–RING 16. BOLT
3. SEAL, square 17. SPRING
4. VALVE, plate 18. PISTON
5. GEROLER 19. POPPET
6. BALL 20. SLEEVE
7. PLATE, balance 21. PLUG
8. RING, back–up 22. PLUG
9. SEAL 23. O–RING
10. RING, back–up 24. PLUG
11. O–RING 25. SPRING
12. PLUG, 26. SHIM
13. FLANGE, mounting 27. POPPET
14. SEAL, face

863, 863H Bobcat Loader

Revised Apr. 98 –3–25– Service Manual
HYDROSTATIC MOTOR (Cont’d)
A
Disassembly

When making repairs on hydrostatic and

hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system. N–00124
I–2003–0284

B
Put a mark across the motor sections for correct
assembly.
Loosen and remove the nine bolts (Item 1) [A] from the
motor mounting flange.

Remove the mounting flange from the balance plate [B].

NOTE: DO NOT scratch or damage the surfaces of

the motor sections, always put them on a soft
surface.
N–00125

Remove the seal (Item 1) [C] from the mounting flange

bore. C
1

N–00126

Turn the mounting flange over, remove the large O–ring,

seal, small O–ring and back–up seal [D]. D

N–00128

863, 863H Bobcat Loader

Revised Apr. 98 –3–26– Service Manual
HYDROSTATIC MOTOR (Cont’d)
A
Disassembly (Cont’d)
Remove the center shaft [A].

N–00136

Remove the balance plate [B].

Remove the large O–ring (Item 1) [B] from the gerolor.
B 1

N–00137

Remove the two steel balls (Item 1) [C] from the gerolor.
C
1
1

N–00140

Remove the gerolor from the valve plate [D].

Remove the O–ring from the gerolor. D
Do not disassemble the gerolor.

N–00141

863, 863H Bobcat Loader

Revised Apr. 98 –3–27– Service Manual
HYDROSTATIC MOTOR (Cont’d)
A
Disassembly (Cont’d)
Remove the valve plate from the end housing [A].
Remove the large and small O–ring from the end housing.

N–00143
Remove the plug (Item 1) [B], spring (Item 2) [B], shims
(Item 3) [B] and shuttle relief piston (Item 4) [B].
B
NOTE: The relief pressure is factory set with shims 1
and must not be changed.
2

3
4

P–9140

Remove the plug (Item 1) [C], dash pot sleeve (Item 2)

[C], spring (Item 3) [C], poppet (Item 4) [C] and shuttle
piston (Item 5) [C].
C 1

2
3
4
5

P–9141

Use a punch, through the end housing and remove the

poppet (Item 1) [D], spring (Item 2) [D], dash pot sleeve
(Item 3) [D] and plug (Item 4) [D].
D

3
2

4 1
N–00074

863, 863H Bobcat Loader

Revised Apr. 98 –3–28– Service Manual
HYDROSTATIC MOTOR (Cont’d)
A
Inspection
Clean all the parts in solvent and use air pressure to dry
them. DO NOT use cloth or paper because small pieces
of material can get into the system and cause damage.
Before the motor is assembled, check the following items.
Check the gerolor rollers and rotor for wear and scratches
[A].

NOTE: Do not disassemble the geroler. If rollers

come out, put them back in their original
bore. N–00098

Check the valve plate surface for scratches (both sides)

[B]. B

N–00096

Check the balance plate surface for scratches (both

sides) [C]. C
Check the center shaft for wear.

N–00107

Check the end plate surface for scratches [D].

Replace parts as needed. See Parts Micro–Fiche for D
availability of parts.

NOTE: Inspect and clean motor case drain filters

during motor repair or replacement.

N–00083

863, 863H Bobcat Loader

Revised Apr. 98 –3–29– Service Manual
HYDROSTATIC MOTOR (Cont’d)
A
Assembly

3
When making repairs on hydrostatic and
2
hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and 4
ports to keep dirt out. Dirt can quickly damage 1
the system. N–00074
I–2003–0284

B 5
NOTE: Always use new O–rings and seals when
assembling the motor. Put a small amount of
grease on all the O–rings and seals for easier 4
installation. 3
Install the poppet (Item 1) [A], spring (Item 2) [A], and 2
dash pot sleeve (Item 3) [A] into the gerolor side of the
end plate housing. 1

Install the plug (Item 4) [A] until it is flush with the end
plate housing surface.

Install the shuttle piston (Item 1) [B], into the opposite P–09141
side of the end plate housing. Install the poppet (Item 2)
[B], spring (Item 3) [B], and dash pot sleeve (Item 4) [B]
onto the piston.
C
Install the plug (Item 5) [B] and tighten to 30 ft.–lbs. (41
Nm) torque. 4

3
Install the shuttle relief piston (Item 1) [C], shims (Item 2)
[C] and spring (Item 3) [C]. 2
Install the plug (Item 4) [C] and tighten to 20 ft.–lbs. (27
Nm) torque. 1

P–09140

Install the small O–ring (Item 1) [D] on the end plate

housing. D

N–00145

863, 863H Bobcat Loader

Revised Apr. 98 –3–30– Service Manual
HYDROSTATIC MOTOR (Cont’d)
Assembly (Cont’d)
A
Install the large O–ring (Item 1) [A] on the end plate
housing.
1

N–00144

Install the valve plate (Item 1) [B] onto the end housing.
Align the case drain hole (Item 2) [B] in the valve plate
B
with the case drain hole in the end plate housing.
1
Install the large O–ring (Item 3) [B] on the gerolor.

3
N–00141

Install the gerolor (Item 1) [C] on the valve plate.

C
Align the case drain hole (Item 2) [C] in the gerolor with
the case drain hole in the valve plate.
1
Install the large O–ring (Item 3) [C] on the gerolor.

3 2

N–00138

Install the two steel balls (Item 1) [D] into the gerolor.
D
1
1

N–00140

863, 863H Bobcat Loader

Revised Apr. 98 –3–31– Service Manual
HYDROSTATIC MOTOR (Cont’d)
Assembly (Cont’d)
A 1

Install the balance plate (Item 1) [A] on the gerolor.

Align the case drain hole (Item 2) [A] in the balance plate
with the case drain hole in the gerolor. 3
Install the center shaft (Item 3) [A] into the gerolor splines.
2

N–00136

Install the O–ring (Item 1) [B] and back–up seal (Item 2)

[B] into the mounting flange. B

2
1

N–00131

Install the rubber gasket (Item 1) [C] and back–up ring

(Item 2) [C] into the mounting flange.
C

1
N–00132

Install the large O–ring (Item 1) [D] on the mounting

flange. D

N–00135

863, 863H Bobcat Loader

Revised Apr. 98 –3–32– Service Manual
HYDROSTATIC MOTOR (Cont’d)
A
Assembly (Cont’d)
1
Carefully turn the mounting flange over, install the seal
(Item 1) [A].

N–00126

Install the mounting flange (Item 1) [B] on the balance

plate. B
Be careful not to displace the seals and back–up rings. 2

Install the nine bolts (Item 2) [B] into the motor. Make sure
all the parts are in correct alignment.

N–00124

Step One: Tighten the bolts to 50 ft.–lbs. (68 Nm) torque

as shown in Figure [C]. C 9 1

Step Two: Tighten the bolts to 105 ft.–lbs. (142 Nm)

torque as shown in Figure [C]. 6 4

NOTE: To prevent damage to the balance plate,

never lift or support the motor by the center
shaft.
3 7

2
8
5 MC–02230

863, 863H Bobcat Loader

Revised Apr. 98 –3–33– Service Manual
HYDROSTATIC PUMP
Removal and Installation
A 1

Remove the hydrostatic pump/engine assembly from the

loader. (See Page 7–1.)
Remove the belt shield clips (Item 1) [A] and belt shield
(Item 2) [A]. 2

1
P–05552

Loosen the stop mounting bolts (Item 1) [B]. B

Loosen the spring tension bolt (Item 2) [B].
Remove the drive belt (Item 3) [B].
2 1

P–05554

Remove the washer and nut (Item 1) [C] from the

hydrostatic pump drive shaft. C
Installation: Tighten the nut to 175–200 ft.–lbs.
(237–271 Nm) torque.

P–05557

Install the nut on the end of the pump drive shaft (without
washer). D
Use a puller (Item 1) [D] to remove the pulley from the
pump drive shaft.

P–05657

863, 863H Bobcat Loader

Revised Apr. 98 –3–34– Service Manual
HYDROSTATIC PUMP (Cont’d)
Removal and Installation (Cont’d)
A
2
Remove the two mounting bolts (Item 1) [A] and nuts
(Item 1) [B].
Installation: Tighten the mounting bolts and nuts to
65–70 ft.–lbs. (88–95 Nm) torque. Make sure the key
(Item 2) [A] is installed.

P–05658

P–05660

Remove the mounting bolt (Item 1) [C] at the hydraulic

pump end of the pump.
C
Remove the hydrostatic pump from the mounting bracket
and drive belt housing.

1
P–05547

863, 863H Bobcat Loader

Revised Apr. 98 –3–35– Service Manual
HYDROSTATIC PUMP (Cont’d)
Replenishing/High Pressure Relief Valve
A
There are four replenishing/high pressure relief valves
(Item 1) [A] in the hydrostatic pump. Two are located at
the front of the pump and two at the rear of the pump.
See Page 3–4 for valve function. 1

P–04936

Remove the plug spring and high pressure relief valve

from the pump [B]. B 2 1
Check for damage and replace as needed.
3
Ref. Description
4
1. PLUG
2. O–RING
3. SPRING
4. HIGH PRESSURE RELIEF

P–04938

863, 863H Bobcat Loader

Revised Apr. 98 –3–36– Service Manual
863, 863H Bobcat Loader
–3–37– Service Manual
HYDROSTATIC PUMP (Cont’d)
Parts Identification

21
13 30

12 22 31
14
11 15 32
20 23
10 16 33
1 2
17 19 34
3 9
4 18 24 35
5 25 36
8 26
27 37
28 29 36
7 35
6
46
41
40
47 39
48 9 38
49 34
50 52 10
51 53 11
54 42
55 43
56
32
12
58 57 44 31
59 30
51 45
19

61 62 64
60
66
63 67
TOP OF PUMP 68
72
65
73
72
70 69 67 68
71 76
74
75 77
74 76
78

E–2012

863, 863H Bobcat Loader

Revised Apr. 98 –3–38– Service Manual
HYDROSTATIC PUMP (Cont’d)
Parts Identification (Cont’d)

Ref. Description Ref. Description

1. O–RING 40. BEARING
2. O–RING 41. GASKET
3. O–RING 42. PIN
4. COVER 43. SERVO COVER
5. ROTOR ASSY. 44. NUT
6. PIN 45. COVER
7. COUPLER 46. HOUSING
8. PIN 47. O–RING PLATE
9. RELIEF VALVE 48. ADAPTER
10. SPRING 49. BOLT
11. O–RING 50. ORIFICE
12. PLUG 51. PLUG
13. PLUG 52. SLEEVE
14. O–RING 53. O–RING
15. SHIM 54. O–RING
16. SPRING 55. SPOOL
17. CHARGE RELIEF VALVE 56. O–RING
18. O–RING 57. SPRING
19. RING 58. BRACKET
20. BYPASS VALVE 59. BOLT
21. BOLT 60. NUT
22. GUIDE 61. WASHER
23. SPRING 62. HANDLE
24. STOP 63. SHAFT
25. GUIDE 64. KEY
26. SNAP RING 65. PIN
27. NUT 66. SWASH PLATE
28. LOCKING NUT 67. PIN
29. BOLT 68. JOURNAL BEARING
30. PLUG 69. PIN
31. BOLT 70. SLEEVE
32. WASHER 71. FRONT COVER
33. SERVO COVER 72. BOLT
34. GASKET 73. PIN
35. SEAL 74. SNAP RING
36. RING 75. BEARING
37. SERVO PISTON 76. SNAP RING
38. ROTATING GROUP ASSY. 77. SEAL
39. VALVE PLATE 78. NUT

863, 863H Bobcat Loader

Revised Apr. 98 –3–39– Service Manual
HYDROSTATIC PUMP (Cont’d)
Parts Identification (Cont’d)

22
21

23

24

25

1 26
2
5 6 27
7
8 26
3 9 25
4
28
10
11 29
15
30
16
11 36
17
37
31
13
12 14 19 38
32
39
33
18 34 35
51 40
50
53
54 20
55
56 41
57
44 49
42
58
60 59
52 24 42
39
51
48 38 43
61
37 44
21
45
62 63 47
46 36
22

TOP OF PUMP

E–2011

863, 863H Bobcat Loader

Revised Apr. 98 –3–40– Service Manual
HYDROSTATIC PUMP (Cont’d)
Parts Identification (Cont’d)

Ref. Description Ref. Description

1. O–RING 33. LOCKING NUT
2. SNAP RING 34. NUT
3. BEARING 35. RING
4. SNAP RING 36. PLUG
5. BOLT 37. O–RING
6. BOLT 38. SPRING
7. PIN 39. RELIEF VALVE
8. COVER 40. PLUG
9. GASKET 41. HOUSING
10. JOURNAL BEARING 42. O–RING
11. PIN 43. O–RING
12. SLEEVE 44. RING
13. PIN 45. BYPASS VALVE
14. PIN 46. COVER
15. SWASH PLATE 47. NUT
16. ROTATING GROUP ASSY. 48. COVER
17. VALVE PLATE 49. STUD
18. PIN 50. NUT
19. SHAFT 51. PLUG
20. BEARING 52. ORIFICE
21. BOLT 53. SLEEVE
22. PLUG 54. O–RING
23. SERVO COVER 55. O–RING
24. GASKET 56. SPOOL
25. SEAL 57. O–RING
26. RING 58. SPRING
27. SERVO PISTON 59. BRACKET
28. BOLT 60. BOLT
29. GUIDE 61. NUT
30. SPRING 62. WASHER
31. STOP 63. HANDLE
32. GUIDE

863, 863H Bobcat Loader

Revised Apr. 98 –3–41– Service Manual
HYDROSTATIC PUMP (Cont’d)
Hydraulic Pump Removal
A

When making repairs on hydrostatic and

hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system. CD–00048
I–2003–0284

Remove the two hydraulic pump mounting bolts [A]. B

Remove the hydraulic pump and O–ring [B].

CD–00049

Hydrostatic Pump Separation

C
Remove the bolt from both sides of the pump assembly
[C].

CD–00050

Remove the nut and lift bracket [D].

D

CD–00051

863, 863H Bobcat Loader

Revised Apr. 98 –3–42– Service Manual
HYDROSTATIC PUMP (Cont’d)
Hydrostatic Pump Separation (Cont’d)
A
Separate the two pumps [A].
Remove the large O–ring (Item 1) [A] and two small
2
O–rings (Item 2) [A] from the rear pump.
1

2
CD–00052

Charge Pump Disassembly B

Remove the two O–rings from the gerotor cover [B].

CD–00053

Remove the gerotor pump assembly and splined coupler

from the pump [C]. C

CD–00054

Remove the splined coupler and drive pin (Item 1) [D]. D

CD–00055

863, 863H Bobcat Loader

Revised Apr. 98 –3–43– Service Manual
HYDROSTATIC PUMP (Cont’d)
Charge Pump Disassembly (Cont’d)
A
Remove the gerotor assembly from the gerotor cover [A].
Check all charge pump components for wear or damage.
Replace parts as necessary.

CD–00056

Disassembly B

When making repairs on hydrostatic and

hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0284
CD–00057

Use the following procedure to disassemble both front

and rear hydrostatic pumps. Procedures to be performed C
on the front or rear pump only are marked.

NOTE: Keep left and right pump parts separate

during disassembly and assembly.

Remove the plug, shims (if equipped), spring and high

pressure relief valve cartridge from each side of the pump
[B].

♦ Remove the plug, shims (if equipped), spring and

charge pressure relief valve [C].

CD–00059

♦ Remove the bypass valve [D].

D

◊ Right Pump
♦ Left Pump CD–00060

863, 863H Bobcat Loader

Revised Apr. 98 –3–44– Service Manual
HYDROSTATIC PUMP (Cont’d)
A
Disassembly (Cont’d)
♦ Remove the three bolts at the adapter housing [A].

CD–00061

♦ Remove the adapter housing and plate (Item 1) [B].

B

1
CD–00062

Remove the plug at the control inlet orifice port [C].

C

CD–00063

Remove the screened orifice plug (Item 1) [D].

D

◊ Right Pump
♦ Left Pump CD–00064

863, 863H Bobcat Loader

Revised Apr. 98 –3–45– Service Manual
HYDROSTATIC PUMP (Cont’d)
Disassembly (Cont’d)
A
Mark the position of the neutral bracket for reference
during assembly [A].

NOTE: Removal of any part of the mechanical

control will result in the loss of the neutral
setting and will require neutral adjustment.
Refer to Page 3–67 for the correct neutral
adjustment procedure. The neutral
adjustment procedure must be performed
with the pump installed and engine running.

CD–00065

Remove the flange head screw [B].

B

CD–00066

Remove the control lever and spool assembly [C].

C

CD–00067

If necessary, remove the spring from the control lever and

spool assembly [D]. D

CD–00111

863, 863H Bobcat Loader

Revised Apr. 98 –3–46– Service Manual
HYDROSTATIC PUMP (Cont’d)
Disassembly (Cont’d)
A
1
If disassembly of the control lever and spool assembly is
necessary, locate the notch (Item 1) [A] in the end of the
spool. Mark the control lever and neutral bracket on the
same side as the spool notch.

CD–00112

Disassembly as shown in Figure [B]: B 3

Remove the nut (Item 1), lock washer (Item 2), control 4
lever (Item 3), neutral bracket (Item 4), backup washer
(Item 5) and O–ring (Item 6) from the spool (Item 7). 1 7
6

5
2
CD–00113

Hold the outside of the control sleeve with a pliers,

remove the control sleeve [C]. C
NOTE: Do not hold the inside diameter of the control
sleeve, damage will occur.

CD–00068

Remove the seven end housing bolts [D].

D

CD–00070

863, 863H Bobcat Loader

Revised Apr. 98 –3–47– Service Manual
HYDROSTATIC PUMP (Cont’d)
A
Disassembly (Cont’d)
Remove the end housing with the shaft assembly [A].
Remove the gasket [A].

CD–00071

Remove the swashplate journal bearings from the end

housing [B]. B

CD–00090

♦ Remove the snap ring at the seal [C].

C

CD–00092

♦ Drill a small hole in the seal [D].

D
NOTE: Be careful not to damage the bearing behind
the seal.

◊ Right Pump
♦ Left Pump CD–00093

863, 863H Bobcat Loader

Revised Apr. 98 –3–48– Service Manual
HYDROSTATIC PUMP (Cont’d)
Disassembly (Cont’d)
A
♦ Install a seal puller and remove the seal [A].

CD–00094

Remove the large snap ring at the bearing [B].

B

CD–00088

Remove the shaft and bearing assembly [C].

C

CD–00089

Remove the swashplate from the housing [D].

D

◊ Right Pump
♦ Left Pump CD–00072

863, 863H Bobcat Loader

Revised Apr. 98 –3–49– Service Manual
HYDROSTATIC PUMP (Cont’d)
863,863HServiceManual#6724799–HydrostaticSystemSectionPart2of3

Disassembly (Cont’d)
A
Remove the guide from the swashplate [A].

CD–00099

Using a snap ring pliers, remove the rotating group

assembly [B]. B

CD–00074

To remove the valve plate, use an O–ring pick tool to lift

the valve plate up. Remove the valve plate from the
housing [C]. C

CD–00073

♦ Remove the five bolts and bracket (Item 1) [D] from

the end cap. D

◊ Right Pump
♦ Left Pump CD–00076

863, 863H Bobcat Loader

Revised Apr. 98 –3–50– Service Manual
HYDROSTATIC PUMP (Cont’d)
Disassembly (Cont’d)
A
Remove the end cap and gasket [A].

CD–00077

Measure and record the distance between the piston and

housing [B].
B

CD–00078

While holding the centering screw stationary, remove the

neutral adjustment lock nut [C]. C

CD–00079

Remove the five bolts from the end cap [D]. D

CD–00081

863, 863H Bobcat Loader

Revised Apr. 98 –3–51– Service Manual
HYDROSTATIC PUMP (Cont’d)
Disassembly (Cont’d)
A
Turn the end cap off the centering screw. Remove the
gasket [A].

CD–00083

Push the end of the piston into the housing and remove
the seal [B].
B
Remove the piston from the housing by pulling on the
centering screw [B].

CD–00085

Disassembly of the piston as shown in Fig. [C]:

C
Remove the seal (Item 1) from the centering screw end
of the piston. Remove the O–ring (Item 2) and bearing
ring (Item 3) from both ends of the spool.
2

1 2 3 3
CD–00109

If it is necessary to disassemble the piston, use the

following procedure: D
Loosen the jam nut (Item 1) [D]. Tighten the nut at the
piston to release spring tension on the snap ring.

CD–00107

863, 863H Bobcat Loader

Revised Apr. 98 –3–52– Service Manual
HYDROSTATIC PUMP (Cont’d)
Disassembly (Cont’d)
A
Remove the snap ring and centering spring assembly
from the piston [A].

CD–00106

Disassemble the centering spring assembly as shown in

Figure [B]: B
Remove the lock nut (Item 1), nut (Item 2), short spring
guide (Item 3), spring (Item 4), stop (Item 5) and long 6
spring guide (Item 6) from the centering screw (Item 7). 3 4 5
1

7
2

CD–00105

Inspection
C 1
Clean all parts in solvent and use air pressure to dry them.
DO NOT use cloth or paper because small pieces of
material can get into the system and cause damage.
Lubricate all internal pump parts with clean hydraulic oil
before assembly.
Check the two bearing locater pins (Item 1) [C] in the end
housing. The pins must measure 0.0625–0.080 inch 1
(1,65–2,03 mm) from the end housing surface to the end
of the pins.

CD–00098

Check the shaft for wear or damage in the splined and D

bearing areas [D].
Check the bearing for correct operation. Remove from the
shaft only if necessary to replace [D].

CD–00110

863, 863H Bobcat Loader

Revised Apr. 98 –3–53– Service Manual
HYDROSTATIC PUMP (Cont’d)
Inspection (Cont’d)
A
Check the needle bearing (Item 1) [A] in the housing for
proper operation.
If the bearing must be replaced, use the correct driver to
remove and install the bearing. The numbered end of the
bearing must be installed toward the inside of the pump
housing. When installed correctly, the end of the bearing
must measure 0.08–0.10 inch (2,0–2,5 mm) above the 1
machined housing surface. 2
Check the locating spring pin (Item 2) [A].
The pin must measure 0.165–0.185 inch (4,19–4,70 mm) CD–00075
from the housing to the end of the pin.

Check the swashplate (Item 1) [B] and valve plate (Item

B 1
2) [B]. 2
4
The surface finish must be smooth and free of scratches.
If scratches can be felt with a fingernail, replace the parts.
Check the four small holes in the swashplate surface to
make sure they are open.
Check the guide pin (Item 3) [B].
The guide pin must measure 0.29–0.31 inch (7,4–7,9 3
mm) from the swashplate surface to the end of the pin.
Check the spring pin (Item 4) [B]. CD–00100

The spring pin must be installed with the split toward the
center of the swashplate. The spring pin must measure
0.33–0.5 inch (8,4–8,9 mm) from the swashplate to the C
end of the pin.

Check the end of the piston block. The surface must be

smooth and free of scratches [C].

CD–00101

Check that each piston moves freely in its bore [D].

D
Check each piston and piston shoe for wear or scratches.
Check the cylinder bores in the piston block for wear or
scratches.
Check the shoe plate. The shoe plate must be flat with no
sign of cracks or wear.

CD–00102

863, 863H Bobcat Loader

Revised Apr. 98 –3–54– Service Manual
HYDROSTATIC PUMP (Cont’d)
Inspection (Cont’d)
A
Check the spherical washer for wear or damage [A].

CD–00103

Check the three pins [B].

The pins must not be bent. All pins must be the same
B
length.
NOTE: If there is any defect in the rotating group, the
complete rotating group must be replaced.

CD–00104

Assembly
C
If disassembled, assemble as shown in Fig. [C]:
Apply oil to and install the long spring guide (Item 1), stop 4 3 2 1
(Item 2), spring (Item 3), short spring guide (Item 4), nut 6
(Item 5) and lock nut (Item 6) onto the centering screw
(Item 7).

7
5

CD–00105

Hold the centering screw from turning and tighten the nut
to compress the spring. D
Install the centering spring assembly and snap ring into
the piston [D].

CD–00106

863, 863H Bobcat Loader

Revised Apr. 98 –3–55– Service Manual
HYDROSTATIC PUMP (Cont’d)
Assembly (Cont’d)
A
To seat the snap ring, loosen the nut until the centering
screw is loose [A].
Tighten the nut until all axial looseness is removed
between the centering screw and spring guides but stop
tightening the nut before the spring assembly becomes
loose in the piston [A].
NOTE: It will be impossible to set the pump neutral
position if there is any free play between the
piston and spring assembly or between the
spring assembly and centering screw.
CD–00107
While holding the nut, tighten the jam nut to 18–27 ft.–lbs.
(24–37 Nm) torque.
B
Install the rings, O–rings and seals as shown in Figure
[B]:
Apply oil to two new bearing rings (Item 1) [B], two new 1 2 3
O–rings (Item 2) [B] and two new seals (Item 3) [B]. 2 1

Install a bearing ring (Item 1) [B] and O–ring (Item 2) [B]

onto each end of the piston.
Install a seal (Item 3) [B] over the O–ring on the end
opposite the centering screw.

CD–00108

Apply oil to the spool. Carefully install the spool, centering

screw first, into the housing toward the outlet port side of C
the housing [C].
With the centering screw toward the front it makes neutral
adjustment easier.

CD–00087

Push the piston through the housing just far enough to

install the new seal over the O–ring [D]. D
Carefully push the piston back into the housing.

CD–00086

863, 863H Bobcat Loader

Revised Apr. 98 –3–56– Service Manual
HYDROSTATIC PUMP (Cont’d)
A
Assembly (Cont’d)
Install a new gasket. Install the end cap over the centering
screw. Turn the end cap up to the housing [A].

CD–00084

Install the five bolts into the end cap [B]. B

Tighten the bolts to 10–13 ft.–lbs. (14–18 Nm) torque.

CD–00081

Center the piston using the measurement recorded

during disassembly [C].
C
NOTE: The approximate distance between the
piston and housing edge is 0.5 inch (12,7
mm). Any measured adjustment is
approximate. The final neutral adjustment
must be performed with the pump installed
and engine running.

CD–00080

While holding the centering screw stationary, install the

neutral adjustment lock nut [D]. D

CD–00079

863, 863H Bobcat Loader

Revised Apr. 98 –3–57– Service Manual
HYDROSTATIC PUMP (Cont’d)
Assembly (Cont’d)
A
Install a new gasket and the end cap [A].

CD–00077

Install the five bolts into the end cap [B]. B

Tighten the bolts to 10–13 ft.–lbs. (14–18 Nm) torque.

CD–00076

Apply oil to the valve plate.

C
Install the valve plate, bronze side up, into the housing
[C]. 1
The notch (Item 1) [C] in the valve plate must engage the
locating spring pin in the housing.
Apply oil to the needle bearing at the base of the housing.

CD–00073

Apply oil to all parts and surfaces in the rotating group.

Using a snap ring pliers, lower the rotating group into the D
housing [D].

CD–00074

863, 863H Bobcat Loader

Revised Apr. 98 –3–58– Service Manual
HYDROSTATIC PUMP (Cont’d)
Assembly (Cont’d)
A
Apply oil to the guide and swashplate. Install the guide
onto the swashplate with the guide offset positioned to
provide clearance for the journal bearing [A].

CD–00099

Install the swashplate into the housing [B]. B

Adjust the swashplate so that the guide engages the
piston.
Center the rotating group and swashplate over the needle
bearing.
Check that the spherical washer is on top of the three
pins.

CD–00072

Apply oil to the bearing and shaft. Install the shaft and
bearing assembly into the end housing [C]. C

CD–00089

Install the snap ring [D]. D

CD–00088

863, 863H Bobcat Loader

Revised Apr. 98 –3–59– Service Manual
HYDROSTATIC PUMP (Cont’d)
Assembly (Cont’d)
A
♦ Apply a light coating of grease to the lips of a new
seal. Using a correct size driver tool, install the new
seal [A].

CD–00095

♦ Install the snap ring [B].

B

CD–00092

Apply oil to both journal bearings. Install the journal

bearings on the end housing [C].
C
Check that the journal bearings are seated on the bearing
locater pins.
NOTE: Petroleum jelly can be applied between the
journal bearings and end housing to retain
the journal bearings during installation on
the pump.

CD–00090

Install a new gasket. Carefully install the end housing and

shaft assembly [D]. D
When the shaft and end housing are properly installed,
the rotating group spring will hold the end housing. A
maximum distance of 0.125 inch (3,2 mm) away from the
housing.

◊ Right Pump
♦ Left Pump CD–00071

863, 863H Bobcat Loader

Revised Apr. 98 –3–60– Service Manual
HYDROSTATIC PUMP (Cont’d)
Assembly (Cont’d)
A
Install the seven end housing bolts [A].
Evenly tighten the six 7/16 inch bolts to 60–74 ft.–lbs.
(81–100 Nm) torque and 3/8 inch bolt to 39–47 ft.–lbs.
(53–64 Nm) torque.
Rotate the shaft periodically while tightening the bolts to
assure the correct pump assembly. When fully
assembled a torque of 4–8 ft.–lbs. (5,4–10,8 Nm) will be
required to turn the shaft.

CD–00070

Apply petroleum jelly to a new O–ring and back–up

washer. Install the O–ring (Item 1) [B] and back–up
washer (Item 2) [B] on the control sleeve.
B 1 2

Apply oil to the control sleeve. Install the sleeve into the
housing [B]. 3
The notch (Item 3) [B] in the control sleeve must be
installed toward the end housing and engage the spring
pin in the swashplate.

CD–00069

Apply petroleum jelly to a new O–ring and back–up

washer. Install the O–ring (Item 1) [C] and back–up C 4
washer (Item 2) [C] onto the spool.
Install the neutral bracket (Item 3) [C] and control lever 6 8
(Item 4) [C] on the spool aligning the marks made during
1
disassembly with the notch (Item 7) [C] in the end of the
spool (Item 8) [C].

NOTE: The notch (Item 7) [C], on either spool must

face the servo during assembly.

Install the lock washer (Item 5) [C] and nut (Item 6) [C] 2 7
onto the spool. 5
3
Tighten the nut to 10–12 ft.–lbs. (13,6–16,3 Nm) torque. CD–00113

Install the spring on the control lever and spool assembly

[D].
D

CD–00111

863, 863H Bobcat Loader

Revised Apr. 98 –3–61– Service Manual
HYDROSTATIC PUMP (Cont’d)
Assembly (Cont’d)
A
Apply oil to the spool. Install the control lever and spool
assembly into the housing [A].

CD–00067

NOTE: Be sure the notch (Item 1) [B] in the servo

spool faces toward the servo piston during
assembly.
B
Align the neutral bracket with the reference mark made
during disassembly. Install the flange head screw [B].
1
NOTE: Removal of any part of the mechanical
control will result in the loss of the neutral
setting and will require neutral adjustment.
Refer to Page 3–67 for the correct neutral
adjustment procedure. The neutral
adjustment procedure must be performed
with the pump installed and engine running.

CD–00066

Install the screened orifice plug [C].

C
Tighten the plug to 8–12 ft.–lbs. (10,8–16,3 Nm) torque.

CD–00064

Apply thread sealant to the plug threads. Install the plug

into the housing [D]. D

CD–00063

863, 863H Bobcat Loader

Revised Apr. 98 –3–62– Service Manual
HYDROSTATIC PUMP (Cont’d)
A
Assembly (Cont’d)
♦ Apply oil to the three molded O–rings on the plate
(Item 1) [A]. Install the plate onto the housing.
Install the adapter housing [A].

1
CD–00062

♦ Install the three bolts into the adapter housing [B]. B

Evenly tighten the bolts to 16–21 ft.–lbs. (22–28 Nm)
torque.

CD–00061

♦ Apply petroleum jelly to a new O–ring and back–up

washer. Install the back–up washer (Item 1) [C] and
C
O–ring (Item 2) [C] onto the by–pass valve.
Install the by–pass valve [C].
Tighten the valve to 7–10 ft.–lbs. (9,5–13,6 Nm) torque.

CD–00060

♦ Apply petroleum jelly to a new O–ring. Install the

O–ring on the plug [D]. D
Apply oil to the charge pressure relief valve. Install the
charge pressure relief valve, spring, shims (if equipped)
and plug [D].
Tighten the plug to 30–70 ft.–lbs. (41–95 Nm) torque.

◊ Right Pump
♦ Left Pump CD–00059

863, 863H Bobcat Loader

Revised Apr. 98 –3–63– Service Manual
HYDROSTATIC PUMP (Cont’d)
Assembly (Cont’d)
A
Apply petroleum jelly to a new O–ring. Install the O–ring
on the plug [A].
Apply oil to the high pressure relief valve cartridge. Install
the high pressure relief valve cartridge, spring, shims (if
equipped) and plug [A].
Tighten the plug to 70–170 ft.–lbs. (95–230 Nm) torque.

CD–00057

Charge Pump Assembly

Apply oil to the gerotor assembly and gerotor cover.
B
Install the gerotor assembly into the gerotor cover [B].

CD–00056

Apply oil to the splined coupler (Item 1) [C] and drive pin
(Item 2) [C].
C
Install the splined coupler and drive pin into the gerotor
assembly [C].
1
The drive pin must be engaged in the gerotor slot.

CD–00055

Install the gerotor assembly into the rear pump [D].

D
Make sure to install the gerotor assembly for the correct
rotation. The pin (Item 1) [D] must be installed in the
bottom hole (Item 2) [D] in the housing.
NOTE: DO NOT align the gerotor pin with the top 2
matching hole in the housing.

1
P–05747

863, 863H Bobcat Loader

Revised Apr. 98 –3–64– Service Manual
HYDROSTATIC PUMP (Cont’d)
Charge Pump Assembly (Cont’d)
A
Apply petroleum jelly to two new O–rings. Install the
O–rings on the gerotor cover [A].

CD–00053

Hydrostatic Pump Connection B

Apply petroleum jelly to two new small O–rings (Item 1)
[B] and a large O–ring (Item 2) [B]. Install the O–rings on
the rear pump.
1
Connect the two hydrostatic pumps [B].
2

1
CD–00052

Install the lift bracket and nut [C].

C

CD–00051

Install a bolt on both sides of the pump assembly [D].

D
Evenly tighten the two bolts and nuts to 67–82 ft.–lbs.
(91–111 Nm) torque.
Rotate the tandem pump input shaft to check for proper
assembly.

CD–00050

863, 863H Bobcat Loader

Revised Apr. 98 –3–65– Service Manual
HYDROSTATIC PUMP (Cont’d)
Hydraulic Pump Installation
A
Apply petroleum jelly to a new O–ring. Install the O–ring
on the hydraulic pump [A].
Install the hydraulic pump on the tandem pump assembly
[A].

CD–00049

Install the two bolts [B]. B

Tighten the bolts evenly to 25–27 ft.–lbs. (34–37 Nm)
torque.

CD–00048

863, 863H Bobcat Loader

Revised Apr. 98 –3–66– Service Manual
HYDROSTATIC PUMP (Cont’d)
Swashplate Neutral Adjustment
A
After the hydrostatic pump has been rebuilt, the neutral 1
for the swashplate servo will have to adjusted. The
hydrostatic pump must be installed for this procedure.
The following tool will be needed to do the following 3
procedure:
MEL1429A – Remote Start Switch
Lift and block the loader. (See Page 1–1.) 2

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.) P–13474

Raise the operator cab. (See Page 1–1.)

Connect the remote start switch. (See Page 1–1.)
B 1

Disconnect the linkage (Item 1) [A] or [B] from the

displacement control servo.
Remove the plug (Item 2) [A] or [B] from both sides of the
swashplate servo end cap.

2
3

P–07927

Connect a hose (Item 1) [C] between the two ports.

Loosen the servo lock nut (Item 3) [A] or [B] while holding C
the servo adjustment screw in position.
Start the engine. WHEN THE ENGINE IS RUNNING 1
THE WHEELS MAY BE TURNING.
Turn the servo adjustment screw clockwise until the
wheels start to turn. Noting the amount of rotation, turn
the adjustment screw counter–clockwise until the wheels
turn in the other direction. Turn the adjustment screw
clockwise half the amount of the turns noted.
While holding the servo adjustment screw from turning,
torque the lock nut to 13–18 ft.–lbs. (18–24 Nm) torque.
P–13495
Repeat the procedure for the other side of the hydrostatic
pump.
Stop the engine.
Remove the hose and install the plugs.
Adjust the displacement control sevro. (See Page 3–68
or 3–69.)

863, 863H Bobcat Loader

Added Apr. 98 –3–67– Service Manual
HYDROSTATIC PUMP (Cont’d)
Displacement Control Servo (Solid Linkage)
A
1

When working on the left side of the hydrostatic

pump, Be Careful to keep your fingers and tools
clear of the cooling fan belt.
W–2185–0395

P–13474
The folloiwng tool will be needed to do the following
procedure:
MEL1429A – Remote Start Switch B
Lift and block the loader. (See Page 1–1.)
Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
1
Connect the remote start switch. (See Page 1–1.) 2
Disconnect the steering linkage (Item 1) [A] from the
displacement servo.
Loosen the bolt (Item 1) [B] for the neutral adjustment
bracket. P–13491

NOTE: Loosen the rear bolt, on the neural

adjustment bracket, just enough so there is
some tension on the adjustment bracket.

Clamp the control lever to the neutral adjustment bracket

with a small locking pliers (Item 2) [B].
Increase engine speed to full RPM.
Move the control lever forward until the wheel just begin
to move. Marka the position on the bracket [B].
Move the control lever in reverse until the wheels just
begin to move. Mark this position [B].
Position the netural adjustment bracket between the two
marks and tighten the holddlown front bolt (Item 1) [B]
and rear bolt.
Remove the locking pliers. Check the pump in both
directions to be sure the pump will return to neutral.
Adjust the steering linkage for neutral position. (See Page
3–14.)

863, 863H Bobcat Loader

Added Apr. 98 –3–68– Service Manual
HYDROSTATIC PUMP (Cont’d)
A
Displacement Control Servo (Cable Linkage)

When working on the left side of the hydrostatic

pump, Be Careful to keep your fingers and tools
clear of the cooling fan belt.
W–2185–0395

After the hydrostatic pump has been rebuilt, the neutral P–02866
for the servo valve spool will have to be adjusted. Use the
following procedure:

NOTE: The hydrostatic pump must be installed in

B
the loader for this procedure.
The following tool will be needed to do the following
procedure:
Socket
MEL1429A – Remote Start Switch
Lift and block the loader. (See Page 1–1.)
Raise the lift arms and install an approved lift arm support
devise. (See Page 1–1.) Cam
Raise the operator cab. (See Page 1–1.)
MC–1944
Connect the remote start switch. (See Page 1–1.)
1. Block the neutral spring bracket out with a large
socket (1–1/8 inch) so you can feel and see the C
linkage neutral setting [A] & [B].

The pump neutral adjustment bracket (Item 1) [C]

controls the position of the spool lever arm (Item 2) [C] 2
with a centering spring (Item 1) [D].
Inspect centering spring ends for damage or wear.
Replace the spring if there is excessive freeplay between
spool lever arm (Item 2) [C] and spring ends (Item 1) [D]. 1

P–07927

2. Loosen the bolt (Item 2) [D] for the neutral

adjustment bracket. D
1

2
P–07928

863, 863H Bobcat Loader

Added Apr. 98 –3–69– Service Manual
HYDROSTATIC PUMP (Cont’d)
Displacement Control Servo (Cable Linkage)
A
(Cont’d)

3. Clamp the control lever to the neutral adjustment

bracket with a small locking pliers [A].

P–07929

4. Start the engine. With the engine running at full

RPM, move the control lever forward until the
B
wheels just begin to move. Mark the position on the
bracket (felt tip pen) [B].

5. Move the control lever in reverse until the wheels

just begin to move. Mark this position.

6. Stop the engine.

P–07930

7. Position the neutral adjustment bracket between

the two marks and tighten the holddown bolt [C]. C
Remove the locking pliers. Start the engine and
check in both directions to be sure the pump will
return to neutral.

P–07931

8. Remove the socket from blocking the neutral spring

bracket [D]. D
9. Adjust the steering neutral setting. (See Page
3–12.)

P–02866

863, 863H Bobcat Loader

Added Apr. 98 –3–70– Service Manual
DRIVE BELT SHIELD
Removal and Installation
A
Stop the engine.
Open the rear door.
Remove the three belt shield holddown clips (Item 1) [A].
1

P–07881

Remove the belt shield (Item 1) [B] from the drive belt
housing.
B

P–07889

863, 863H Bobcat Loader

Added Apr. 98 –3–71– Service Manual
DRIVE BELT
Adjusting the Drive Belt
A 2

The drive belt idler arm stop is located on the left side of
the engine below the air cleaner [A].
Loosen the two bolts (Item 1) [A] and slide the stop
against the idler arm. Tighten the bolts. 1
There is no adjustment for the spring, just make sure the
spring bolt (Item 2) [A] is tight.
P–05554

1
2

P–04681

Replacing the Drive Belt

B
Remove the belt shield. (See Page 3–61.)
Loosen the two stop mounting bolts (Item 1) [A].
Loosen the spring tension bolt (Item 2) [A].
Remove the fan drive belt from the tensioner pulley.
Remove the drive belt from the hydrostatic pump pulley
and flywheel pulley.
Remove the drive belt [B].

P–07894

863, 863H Bobcat Loader

Added Apr. 98 –3–72– Service Manual
DRIVE BELT TENSIONER PULLEY
Removal and Installation
A 1

Remove the belt shield clips (Item 1) [A]. 1

Remove the belt shield (Item 2) [A].

P–05552

Remove the two stop mounting bolts (Item 1) [B].

Remove the stop.
B 2

Remove the spring tension bolt (Item 2) [B].

P–05554

Remove the end cap (Item 1) [C] from the tensioner

pulley arm. C
1

P–05548

Remove the mounting bolt (Item 1) [D] from the tensioner

pulley arm. D

P–05555

863, 863H Bobcat Loader

Added Apr. 98 –3–73– Service Manual
DRIVE BELT TENSIONER PULLEY (Cont’d)
Removal and Installation (Cont’d)
A 1

Remove the pulley/arm assembly (Item 1) [A] from the

engine housing.
Remove the arm bushing (Item 2) [A]. Check for wear and
replace as needed.
2

P–05560

Check the arm seal (Item 1) [B]. Replace the seal as

needed.
B

P–05553

Remove the pulley mounting bolt [C].

C

P–05561

Disassembly the pulley and bearings as shown in figure

[D]. D
Check the parts for wear and replace as needed.

P–05559

863, 863H Bobcat Loader

Added Apr. 98 –3–74– Service Manual
DRIVE BELT TENSIONER PULLEY (Cont’d)
A
Tension Spring
Remove the base end bolt (Item 1) [A] from the spring
block.
Remove the tension spring from the engine housing.

P–05551

Remove the end block (Item 1) [B] (both ends) from the
spring.
B
Check the spring for wear and etc. Replace the spring as 1
needed.
Check the spring end blocks for wear and replace as
needed.

P–05563

863, 863H Bobcat Loader

Added Apr. 98 –3–75– Service Manual
OIL COOLER
863,863HServiceManual#6724799–HydrostaticSystemPart3of4

Removal and Installation

A
Open the rear door.
1
Raise the rear grill.
Disconnect the tubeline (Item 1) [A] from the oil cooler. 2
Remove the cotter pin (Item 2) [A].

P–07870

Remove the hose (Item 1) [B].

B
Remove the cotter pin (Item 2) [B].

1
2

P–07618

Lift the oil cooler to unhook the front tabs from the loader
frame [C]. C
Remove the oil cooler from the loader [C].

P–07887

863, 863H Bobcat Loader

Added Apr.98 –3–76– Service Manual
DRIVE SYSTEM
1. Page
Number
AXLE SEAL
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–9

AXLE, SPROCKET AND BEARINGS

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–11
CHAINCASE FLUID
Removing the Fluid From the Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . 4–26

DRIVE CHAIN
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–25

FRONT CHAINCASE COVER DRIVE

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8 SYSTEM
MOTOR CARRIER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–21
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–19
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–18
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–16
Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–15
PARKING BRAKE DISC
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5

PARKING BRAKE PEDAL

Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3

REAR CHAINCASE COVER

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8

863, 863H Bobcat Loader

–4–1– Service Manual
863, 863H Bobcat Loader
–4–2– Service Manual
PARKING BRAKE PEDAL
Removal and Installation
A
Raise the loader operator cab. (See Page 1–1.)
1
Remove the two mounting bolts (Item 1) [A] for the foot
rest (both sides).
Remove the foot rest (both sides)–4–1.

P–7737

Remove the five lower mounting bolts from the lower

panel (Item 1) [B].
B 1

P–7741

Pull the lower panel toward the front of the loader, lay the
lower panel (Item 1) [C] flat and slide it under the steering C
panel.
1
Disconnect the wire harness connector (Item 2) [C] for
the parking brake. 2

P–4769

Remove the mounting bolts (Item 1) [D] for the parking

brake pedal. D
Remove the parking brake pedal assembly.

1
P–4768

863, 863H Bobcat Loader

–4–3– Service Manual
PARKING BRAKE PEDAL (Cont’d)
Disassembly and Assembly
A 5
6
Loosen and remove the mounting bolt (Item 1) [A] and nut
from the spring mounting bracket (Item 2) [A].
Remove the brake pedal spring (Item 3) [A] from the
tension spring mounting bracket (Item 2) [A] and from the
brake pedal mounting bracket (Item 4) [A].
1
Remove the two mounting bolts, washers and nuts (Item 4
5) [A] from the brake pedal sensor.

2
3
P–4189

Remove the harness mounting clamp (Item 1) [B] from

the pedal mounting bracket (Item 2) [B].
B
1
Remove the sensor harness from the pedal mounting
bracket.
Remove the pedal mounting bolt (Item 6) [A], plastic
spacers and bushing nut from the brake pedal.
2
Remove the pedal from the pedal mounting bracket.
Photo [B] shows the parking brake disassembled to
identify the existing parts in the brake assembly.

P–4156

863, 863H Bobcat Loader

–4–4– Service Manual
PARKING BRAKE DISC
Removal and Installation
A
2

P–7743

B
Never work on a machine with the lift arms up 1
unless the lift arms are secured by an approved
lift arm support device. Failure to use an 4
approved lift arm support device can allow the
lift arms or attachment to fall and cause injury
or death. W–2059–0598
3 2

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Raise the loader operator cab. (See Page 1–1.)
Remove the bolts (Item 1) [A] from traction lock solenoid. P–7797

Remove the traction lock solenoid (Item 1) [B], spring, C

and spring cup (Item 2) [B].
Remove the wedge assembly (Item 3) [B] from the guides 1

Installation: Inspect the solenoid mount gasket (Item 4)

[B], replace if damaged.
See Page 8–1 for complete disassembly and assembly
procedures for the traction lock assembly.

Remove the crossmember pivot bolt (Item 2) [A].

Remove the bolt and nut (Item 1) [C] to disconnect the lift
pedal linkage from crossmember. P–7744

Remove the hairpin clip and cross–pin from the control

valve lift spool (Item 1) [D].
D
Disconnect the crossmember from the control valve.

P–7739

863, 863H Bobcat Loader

Revised Mar. 99 –4–5– Service Manual
PARKING BRAKE DISC (Cont’d)
Removal and Installation (Cont’d)
A
Remove the crossmember from the pivot [A].
Installation: Check the nylon bushing (Item 1) [A] for
wear and replace as needed.
1

P–7740

Remove the center cover mounting bolts (Item 1) [B]. B

Remove the center chaincase cover/guides assembly.
Installation: Replace the chaincase cover gasket.
Tighten the bolts to 190–240 in.–lbs. (21,5–27,1 Nm)
torque. 1

P–7798

Remove the two nuts (Item 1) [C] from the disc bolts.
C

1 1

P–7799

Remove the two disc bolts (Item 1) [D] from the disc.
D

1
1

P–7801

863, 863H Bobcat Loader

–4–6– Service Manual
PARKING BRAKE DISC (Cont’d)
Removal and Installation (Cont’d)
A
A snap ring pliers with 90° tips are needed for removing
the brake disc snap ring.
Pull the disc away from snap ring.
1
Remove the snap ring (Item 1) [A] from the end of the
carrier shaft.

P–07800

Remove the disc (Item 1) [B] from the shaft. B

1

P–07865

Installation: Bolting the disc to the snap ring provides

proper disc alignment. Disc and shaft are shown removed C 3 3
for photo clarity. The snap ring end gap (Item 1) [C] must
be between the disc bolts (Item 2) [C] and sprocket
teeth(Item 3) [C] after the brake disc is installed on the
shaft.

P–13003

863, 863H Bobcat Loader

Revised Apr. 98 –4–7– Service Manual
FRONT CHAINCASE COVER
Removal and Installation
A
Remove the parking brake pedal. (See Page 4–3.)
Remove the mounting bolts from the front chaincase
cover (Item 1) [A].
Remove the cover.

P–04800

REAR CHAINCASE COVER B

Removal and Installation

1
2

P–07934

C
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
lift arm support device. Failure to use an
approved lift arm support device can allow the 1
lift arms or attachment to fall and cause injury
or death. W–2059–0598

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
P–07935
If so equipped, remove the solid steering linkage and
control tower. (See Page 3–1.)
Disconnect the hose from hydrostatic filter head (Item 1)
[B].
Disconnect the four hydrostatic hoses (Item 2) [B].

Remove the eight mounting bolts from the rear chaincase

cover (Item 1) [C].

NOTE: The auxiliary tubeline at the rear port of

hydraulic control valve may need to be
disconnected to provide clearance for cover
front bolt removal.

863, 863H Bobcat Loader

Revised Mar. 99 –4–8– Service Manual
AXLE SEAL
Removal and Installation
A
Lift and block the loader. (See Page 1–1.) 2
Remove the tire/wheel assembly.
Installation: Tighten the wheel nuts to 105–115 ft.–lbs.
(142–155 Nm) torque.
Remove the bolts (Item 1) [A] and plate.
1
Installation: Tighten the bolts to 175–190 ft.–lbs.
(240–260 Nm) torque. 2
Remove the two wheel studs (Item 2) [A] across from P–04850
each other.
Install puller (Item 1) [B] on the wheel hub. B

NEVER STAND IN–LINE OF THE HUB WHEN

REMOVING A HUB FROM AN AXLE. The hub
has a tapered fit on the axle end and can come
off the axle with great force and cause serious
injury. 1
W–2186–0395

P–04849

Remove the hub from the axle.

Remove the key (Item 1) [C] from the axle.
C
1

P–04848

863, 863H Bobcat Loader

–4–9– Service Manual
AXLE SEAL (Cont’d)
Removal and Installation (Cont’d)
A
Install a slide hammer (Item 1) [A] with a screw tip end into
the axle seal.
Remove the axle seal.
The tool listed will be needed to do the following
procedure:
MEL1407 – Seal Installation Tool
1
If the axle is damaged or worn, an axle repair sleeve kit
is available from Bobcat Parts Sales in Chicago.
P–4817
NOTE: If a new wear ring is being installed with new
seal, put LOCTITE sealant on the inside
diameter of the wear ring. B
Place the taper on the wear ring so it faces the outside [B].
Place the seal with the lip facing in [B].

Taper

B–13493

Use a hammer, install the new axle seal until the tool is
flush with the edge of the axle tube [C]. C

P–04814

NOTE: S/N 514416546 & Above the axle (Item 1) [D]

finish specification was changed to provide
the correct surface for the axle seal (Item 2)
D
[D]. These loaders MAY or MAY NOT have a 2
wear ring installed. When ordering the axle
seal, check to see if the axle uses a wear ring.

P–10553

863, 863H Bobcat Loader

Revised Jan. 98 –4–10– Service Manual
AXLE, SPROCKET AND BEARINGS
Removal and Installation
A
The tools listed will be needed to do the following
procedure:
MEL1242 – Port–a–Power 2
MEL1202B – Axle Bearing Service Set
NOTE: The procedure shown for removal and
installation of the axle, sprocket and
bearings is for a front axle. This procedure
will be the same for the rear axle. 1

P–4810

B
2

Never work on a machine with the lift arms up 1

unless the lift arms are secured by an approved
lift arm support device. Failure to use an
approved lift arm support device can allow the 2
lift arms or attachment to fall and cause injury P–4850
or death. W–2059–0598
NEVER STAND IN–LINE OF THE HUB WHEN
REMOVING A HUB FROM AN AXLE. The hub
has a tapered fit on the axle end and can come
C
off the axle with great force and cause serious
injury.
W–2186–0395

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Lift and block the loader. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
Remove the front panel/steering lever assembly. (See
Page 3–1.) 1
Remove the front cover. (See Page 4–8.)
P–4849
Remove the fluid from the chaincase. (See Page 4–26.)
Remove the axle sprocket bolt (Item 1) [A] and backing
washer (Item 2) [A]. D
Installation: Tighten the axle sprocket bolt to 475–525
ft.–lbs. (644–710 Nm) torque.
Remove the bolts (Item 1) [B] and plate.
Installation: Tighten the bolts to 175–190 ft.–lbs.
(240–260 Nm) torque.
Remove the two wheel studs (Item 2) [B] across from
each other.
Install a puller (Item 1) [C] on the wheel hub.
Remove the hub from the axle.
Install a Port–a–Power ram between the two sprockets P–4809
[D].
863, 863H Bobcat Loader
Revised Mar. 99 –4–11– Service Manual
AXLE, BEARINGS AND SPROCKET (Cont’d)
Removal and Installation (Cont’d)
A
Push the axle out until the ram is at the end of the stroke.
Add a spacer and push the axle out again. Repeat this
procedure until the axle is out of the sprocket. 2

Remove the drive chain from the sprocket.

Remove the sprocket (Item 1) [A] and inner bearing (Item
2) [A].
Installation: Pack the inner and outer bearing with
grease before installing them.
1
P–4808

A bearing puller (Item 1) [B] is needed to do the following

procedure:
B
Be sure the bearing puller makes good contact with the 1
inner race and press the bearing off the mounting surface
of the axle [B].
NOTE: Hold onto the axle during removal as it will
slide freely after the bearing is removed from
the mounting surface.

P–4171

Press the splined end of the axle free from the bearing
[C]. C

P–4171

Installation: Put the spline end of the axle shaft into the
bearing and press the bearing onto the axle. D
NOTE: Hold onto the axle during installation as it
will slide freely after the bearing is pressed
over the splined end of the shaft.
1
Put a piece of tubing (Item 1) [D] that contacts inner race
of the bearing only.
Press the bearing onto the mounting surface until the
bearing is fully seated [D].

P–4175

863, 863H Bobcat Loader

–4–12– Service Manual
AXLE, BEARINGS AND SPROCKET (Cont’d)
Removal and Installation (Cont’d)
A
Use the tools provided in the MEL1202B Axle Bearing
Service Set for bearing cup removal and installation. A
slide hammer is also needed.
Use the long rod and bearing cup tool to remove the inner
bearing cup [A].

P–4812

To remove the outer bearing cup, install a bearing cup tool

on the slide hammer.
B
Leave the bearing cup tool loose until the tool is installed
inside the tube [B].
Pull the tool against the bearing cup and tighten the nut.

P–4818

Use the slide hammer and remove the bearing cup from
the axle tube [C]. C

P–4816

863, 863H Bobcat Loader

–4–13– Service Manual
AXLE, BEARING AND SPROCKET (Cont’d)
A 1
Removal and Installation (Cont’d)
Use the bearing cup installation tools (Item 1) [A] and
(Item 1) [B].
Put the inner cup (Item 2) [A] in the axle tube.
Install the long treaded rod (Item 2) [B] into the axle tube
and through the installation tool (Item 1) [A].
3
Install the nut (Item 3) [A].
2

P–4807

Install the installation tool (Item 1) [B] on the threaded

rod. Install the nut.
B
Hold the inside nut (Item 3) [A] with a wrench and tighten
the outside nut [B].
Tighten the nut until the bearing cup is seated. 2

Remove the installation tools and threaded rod.

P–4811

To install the outer bearing cup, install the bearing cup tool
on the driver handle.
C
Install the bearing cup into the axle tube, and put the tool
into the bearing cup.
Hit the driver handle with a hammer until the bearing cup
is seated inside the axle tube [C].

P–4813

863, 863H Bobcat Loader

–4–14– Service Manual
MOTOR CARRIER
Shaft Seal Replacement
A
The tool listed will be needed to do the following
procedure:
MEL1517 – Motor Carrier/Installer
Use a slide hammer (with puller end) and remove the seal
from the motor carrier [A].

P–07941

Put oil on the seal lips and outside diameter. Install the
new seal onto the alignment tool [B].
B

B–07942

Install the alignment tool/seal assembly onto the carrier

shaft [C]. C

P–07943

Install the seal driving tool over the alignment tool and
drive seal into the carrier until the tool seats on the carrier D
housing [D].

P–07944

863, 863H Bobcat Loader

Revised Aug. 96 –4–15– Service Manual
MOTOR CARRIER (Cont’d)
Removal and Installation
A
1
Lift and block the loader. (See Page 1–1.)
Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
Remove the front panel assembly. (See Page 3–1.) 1
Remove the fluid from the chaincase. (See Page 4–26.)
Remove the parking brake disc. (See Page 4–5.)
P–07866
Remove the front axle. (See Page 4–11.)
Remove the hydrostatic motor. (See Page 3–1.) B
If the motor carrier is removed from the right side, remove
the lift arm by–pass control valve and hydraulic control
valve. (See Page 2–1.)
Remove the six mounting bolts (Item 1) [A] from the
motor carrier.
Installation: Replace carrier gasket (Item 1) [B]. Tighten
the mounting bolts to 330 ft.–lbs. (447 Nm) torque.
Slide the motor carrier toward the rear remove the rear 1
drive chain.

NOTE: For easier access for the motor carrier

coming out and going into the chaincase, tie
front drive chain to the chaincase with a wire
[B].

Slide the motor carrier out of the chaincase far enough to

install a chain and chain hoist to the carrier [B].

P–07867

863, 863H Bobcat Loader

Revised Jan. 98 –4–16– Service Manual
MOTOR CARRIER (Cont’d)
Removal and Installation (Cont’d)
A
Pull the motor carrier out of the chaincase [A].
Lift the motor carrier out of the loader [A].

P–7868

863, 863H Bobcat Loader

–4–17– Service Manual
MOTOR CARRIER (Cont’d)
Parts Identification

1
2 3

5
6
7
8 9

TS–1326

Ref. Description
1. SHAFT
2. BEARING
3. RACE
4. HOUSING
5. RACE
6. BEARING
7. WASHER
8. SNAP RING
9. SEAL

863, 863H Bobcat Loader

–4–18– Service Manual
MOTOR CARRIER (Cont’d)
A 3.75 inch O.D.
(95,3 mm)
Disassembly
A tool will be needed to do the following procedure, use
the dimensions shown in figure [A] and make the tool. 3.375 inch I.D.
(85,7 mm)
Also a hydraulic press, slide hammer with puller end,
bearing puller, snap ring pliers and driver tools.
4.5 inch
Length
(114 mm)

MC–2102

Use a slide hammer (with puller end) and remove the seal
from the motor carrier [B].
B

P–7873

Remove the snap ring (Item 1) [C] & [D] and back–up
washer (Item 2) [C] & [D] from the motor carrier.
C

P–7876

2
P–7875

863, 863H Bobcat Loader

–4–19– Service Manual
MOTOR CARRIER (Cont’d)
A
Disassembly (Cont’d)
Put the motor carrier in a hydraulic press [A].
Use a 2–5/8 inch driver tool and press the carrier shaft out
of the housing [A].

NOTE: The carrier shaft and outer bearing cone will

now be free from the carrier housing.

P–7874

Install the bearing puller (Item 1) [B] on the carrier shaft.

Put the shaft in the press. B
Use the 2–5/8 inch driver tool and press the shaft out of
the bearing [B].

P–7877

863, 863H Bobcat Loader

–4–20– Service Manual
MOTOR CARRIER (Cont’d)
Disassembly (Cont’d)
A
Remove the bearing cups from the carrier housing using
a hammer and a brass punch. Drive the cup out placing
the punch against the shoulder of the cup (Item 1) [A].
Turn the housing over to remove the other bearing cup.
1
Be careful not to damage the housing bore.
Inspect all parts for wear and damage. Always replace
bearing cups when replacing the bearing.

P–7879

Assembly
B
The tool listed will be needed to do the following
procedure:
MEL1517 – Motor Carrier/Installer
MEL1517–1 – Motor Carrier Seal Protector
MEL1517–2 – Motor Carrier Seal Installer
Put the carrier housing in a hydraulic press. Use a 5–1/4
inch driver tool and press the bearing cup into the housing
[B]. Turn the housing over and press the cup into the
other side.

P–7880

Put the carrier shaft in press. Use the tool (Page 4–20, C
[A]) (Item 1) [C] and a 3–3/4 inch driver tool to install the
inner bearing on the shaft.

P–7878

863, 863H Bobcat Loader

–4–21– Service Manual
MOTOR CARRIER (Cont’d)
A
Assembly (Cont’d)
Put oil on the two bearing cups and on the carrier shaft
bearings.
Put the motor carrier housing over the shaft as shown in
Figure [A].
Use the tool (Item 1) [A] and driver tool and install the
outer bearing on the shaft.
1

Press the bearing on while slowly rotating the carrier

housing. Stop pressing when resistance is felt in turning
the housing.

P–7882

Install the back–up washer (Item 1) [B] and snap ring

(Item 2) [B] on the shaft. Snap ring must completely fit
B
into the shaft groove.

P–7883

863, 863H Bobcat Loader

–4–22– Service Manual
MOTOR CARRIER (Cont’d)
Assembly (Cont’d)
A
Put the motor carrier in the press and lightly press on the
carrier shaft to remove the end play from the snap ring
[A].

NOTE: The back–up washer must not turn freely

after the end play is removed.

P–7874

Install a dial indicator as shown in Photo [B].

B
Use a pry bar (Item 1) [B] to lift the carrier shaft and read
the end play on the dial indicator.
The carrier shaft must turn freely with end play not to
exceed 0.0115 inch (0,29 mm).

1
P–7885

863, 863H Bobcat Loader

–4–23– Service Manual
MOTOR CARRIER (Cont’d)
A
Assembly (Cont’d)
1
Put the carrier assembly in a press.
Install the alignment tool (Item 1) [A] for the carrier seal.
Put oil on the tool and the carrier seal lips.
Install the seal (Item 2) [A] on the tool.
2

P–7884

Install the seal tool (Item 1) [B] on the seal and the
alignment tool.
B
Use a driver tool and press the carrier seal into the
housing until the tool bottoms against the housing.
Remove the seal tool and alignment tool from the shaft.

P–7886

863, 863H Bobcat Loader

–4–24– Service Manual
DRIVE CHAIN
863,863HServiceManual#6724799–DriveSystemPart1of2

Removal and Installation

A Rear Chain

Front Chain

P–7866

B
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
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–2059–0598

Raise the loader lift arms and install an approved lift arm
support device. (See Page 1–1.)
Lift and block the loader. (See Page 1–1.)
B–13504
Raise the loader operator cab. (See Page 1–1.)
Drain the fluid from the chaincase. (See Page 4–26.)
Remove the front (or rear) chaincase cover. (See Page
4–8.)
Remove the front (or rear) axle and sprocket. (See Page
4–11.)
Remove the front (or rear) drive chain from the chaincase.
DO NOT exceed the recommended torque of
The tool listed is needed for the following procedure: 130 ft.–lbs. (176 Nm). The tool may fail under too
much torque. Put cloth around the tool to
MEL1037 – Chain Link Tool protect yourself from flying debris.
W–2233–0296
Installation: If a new chain is installed, a connector link
must be used to connect the chain together.
Install the new chain around the carrier shaft.
Use MEL1037 Chain Link Tool and #100 chain adapter.
Secure the tool and place the connector link and chain in
the tool as shown [B].
Turn the threaded rod of the tool and press the connector
link together on the chain [B]. Tighten the threaded rod of
the chain link tool to 130 ft.–lbs. (176 Nm) torque.

863, 863H Bobcat Loader

Revised Mar. 99 –4–25– Service Manual
CHAINCASE FLUID
863,863HServiceManual#6724799–DriveSystemPart2of2

Removing the Fluid From the Chaincase

A
To drain the oil from the chaincase, remove the cover
(Item 1) [A] which is installed over the drain plug at the
rear of the chaincase.

P–1616

Remove the drain plug (Item 1) [B] and drain the oil into
a container.
B
Check the drain plug and replace if necessary.

P–1619

863, 863H Bobcat Loader

–4–26– Service Manual
MAIN FRAME
Page
Number
BOB–TACH
Bob–Tach Lever and Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–17
Bob–Tach Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–18
Pivot Pin Bushing and Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . 5–21
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–19

FUEL TANK
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–31
Fuel Pick–Up Screen/Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–31
Inlet Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–32
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–30

LIFT ARMS
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–22

OPERATOR CAB
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14
OPERATOR CAB GAS CYLINDER MAIN
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13 FRAME
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12

OPERATOR SEAT
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16
REAR DOOR
Bumper Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–29
Door Latch and Catch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–29
Door Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–29
Hood Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–29
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–28

REAR DOOR (ONE PIECE)

Door Latch and Catch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–27
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–26
REAR GRILL
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–25

SEAT BAR (W/GAS SPRING)

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7
Compressing the Gas Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
Seat Bar Pivot Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
SEAT BAR (W/COMPRESSION SPRING)
Assembling Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11
Compression Spring Disassembly and Assembly . . . . . . . . . . . . . . . . . . 5–11
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8

Revised Jan. 98 863, 863H Bobcat Loader

–5–1– Service Manual
863, 863H Bobcat Loader
–5–2– Service Manual
SEAT BAR (W/GAS SPRING)
Removal and Installation
A
The tool listed is needed for the following procedure:
MEL1426 – Gas Spring Retainer Tool 2

Lower the seat bar.

Install the gas spring retainer tool on the gas cylinder
(Item 1) [A].
Seat bar should be positioned so that the tool will easily 1
slip into place.
P–03978

Install the end of the tool that is bent at a 90° angle in the
clevis of the cylinder as shown [B].
B
Install the curved end of the tool on the base end of the
gas cylinder.
1
Secure the tool to the gas cylinder with a hose clamp
(Item 2) [A].
Remove the cotter pin (Item 1) [B] from the clevis pin.

P–03248

Reposition the seat bar to remove pressure of gas spring

on clevis pin.
C
Remove the clevis pin (Item 1) [C] from the gas cylinder.
1

Use a 17/32 inch tappet wrench (thin wrench) (Item 1) [D]

to hold the ball joint on the gas cylinder.
Remove the mounting nut from the ball joint [D].
Installation: Be careful not to overtighten the mounting
nut on the ball joint.
Remove the gas cylinder from the seat bar. P–03979

Cylinder contains high pressure gas. Do not

open. Opening cylinder can release rod and
cause injury or death.
W–2113–0288

Replace the gas cylinder if it malfunctions.

Installation: If the tool is removed, or a new gas cylinder
1
is installed. (See Page 5–6 to compress the gas cylinder
and install the tool.)
P–03249

863, 863H Bobcat Loader

Revised Feb. 97 –5–3– Service Manual
SEAT BAR (W/GAS SPRING) (Cont’d)
Removal and Installation (Cont’d)
A
Disconnect the seat bar sensor connector (Item 1) [A].

P–03981

Remove the seat bar mounting bolt (Item 1) [B] (both

sides).
B
Installation: Tighten the seat bar mounting bolts to
25–28 ft.–lbs. (34–38 Nm) torque.
Remove the seat bar sensor mounting bolt (Item 2) [B]
1
and nut.
Installation: Tighten the sensor mounting bolt to 80–90
in.–lbs. (9,0–10,2 Nm) torque.
Remove the sensor assembly from the magnetic bushing
on the seat bar. 2

P–03246

Installation: Be sure the two tabs on the pivot bushing

are located in the slot on the cab as shown [C]. C

P–03247

Pull both ends of the seat bar which are mounted to the
operator cab, back from the mounting positions on the D
operator cab [D].
Remove the magnetic bushing mounting bolt, washer,
magnetic bushing, plastic bushing and pivot bushing from
the seat bar [D]. Refer to Page 8–1 for correct assembly
procedure of the seat bar sensor assembly.
Remove the mounting bolt, gas cylinder mounting
bracket, plastic bushing and pivot bushing from the seat
bar [D]. Refer to Page 5–6 for correct assembly
procedure of the gas cylinder mounting assembly.

P–03982 P–03983

863, 863H Bobcat Loader

Revised Feb. 97 –5–4– Service Manual
SEAT BAR (W/GAS SPRING) (Cont’d)
A
Removal and Installation (Cont’d)
To remove the seat bar from the operator cab, the seat bar
needs to be put in the correct location.
Use the squares in the right side of the operator cab side
screen to locate the seat bar correctly [A].
Put the padded corner of the seat bar five squares back
from the front and four squares up from the bottom of the
screen [A].

P–03984

The arm of the seat bar (Item 1) [B] should also be located
outside of the operator cab, just below the bottom edge
B
of the cab.
Hold both ends of the seat bar as shown and pull the left
side of the seat bar out of the operator cab until the seat
bar is free [B].
Remove the seat bar from the operator cab.
Reverse removal procedure to install the seat bar.

1
P–04065

Seat Bar Pivot Assembly C

Assemble the parts as shown for the left side of the seat
bar pivot assembly [C]: 7 6 3 2 1
Mounting Bolt – (Item 1)
Washer – (Item 2)
Keyed Plastic Bushing – (Item 3)
Magnetic Bushing Assembly (Item 4)
Sensor Bracket – (Item 5)
Pivot Bushing – (Item 6) Left Side
8 5 4 of Seat Bar
Mounting Bolt – (Item 7) 9
Sensor Mounting Bolt (Item 8)
Sensor Mounting Nut (Item 9) P–03284

863, 863H Bobcat Loader

Revised Feb. 97 –5–5– Service Manual
SEAT BAR (W/GAS SPRING) (Cont’d)
Seat Bar Pivot Assembly (Cont’d)
A 3 2 1

Assemble the parts as shown for the right side of the seat
bar pivot assembly [A]:
Mounting Bolt (Item 1)
Pivot Bushing (Item 2)
Keyed Plastic Bushing (Item 3)
Gas Spring Mounting Bracket (Item 4) 5
Mounting Bolt (Item 5) Right Side
4 of Seat Bar
Install the right side pivot assembly as shown. Tighten the
mounting bolt (Item 1) [B] to 180–200 in.–lbs. (21–23 Nm)
torque.
P–03289
NOTE: Be sure the bend in the gas spring bracket
faces in toward the operator when installing
the gas spring bracket. Slide the bracket all
the way forward so the front edge of the B 1
bracket fits tightly against the operator cab.

Compressing the Gas Cylinder

To compress the seat bar gas spring, it is necessary to
use the gas spring retainer tool MEL1426.
Use the following procedure to compress the gas spring:

P–03319

Cylinder contains high pressure gas. Do not

open. Opening cylinder can release rod and
cause injury or death.
C
W–2113–0288

Install the gas spring on the seat bar. Install the clevis pin
and cotter pin in gas spring.
Securely clamp a locking pliers to the cab one inch below
the gas spring mounting bracket [C].

P–07953

Put the clevis under the locking pliers and against the cab
[D]. D
Install the gas spring retainer tool (Item 1) [D] with the 90°
bend in the clevis of the rod end of the gas cylinder. Install
the hose clamp to hold the tool. Do not tighten the hose
clamp.

1
P–07954

863, 863H Bobcat Loader

Revised Feb. 97 –5–6– Service Manual
SEAT BAR (W/GAS SPRING) (Cont’d)
Assembly
A
Pull the seat bar down and compress the gas cylinder.
Install the curved end of the tool around the base end of
the gas spring. Tighten the hose clamp [A].

P–07955

Remove locking pliers. Remove clevis pin and cotter pin.

Install gas spring to mounting bracket with clevis pin [B].
B

P–03979

Install cotter pin in the clevis pin [C].

C

P–03248

Remove the hose clamp and tool (Item 1) [D].

D
Rotate seat bar so that tool can be easily removed.

P–03978

863, 863H Bobcat Loader

Revised Feb. 97 –5–7– Service Manual
SEAT BAR (W/COMPRESSION SPRING)
Removal and Installation
A
Lower the seat bar (Item 1) [A] so the compression
springs (Item 2) [A] will be in a down position.
1

2 2
P–09543

Loosen the adjustment lock nut (Item 1) [B] (both sides). B

P–09542

Turn the bolt (Item 1) [C] into the clevis five turns (both
sides). C
Installation: The compression spring is adjusted
correctly when the bolt is flush with the clevis (Item 2) [B].

P–09544

Remove the retaining pin (Item 1) [D] and clevis pin (both
sides). D

P–09541

863, 863H Bobcat Loader

Revised Feb. 97 –5–8– Service Manual
SEAT BAR (W/COMPRESSION SPRING) (Cont’d)
Removal and Installation (Cont’d)
A
Disconnect the wiring harness connector (Item 1) [A] (left
side). 1

Remove the seat bar mounting bolt (Item 2) [A] (both

sides).
2
Remove the sensor mounting bolt (Item 3) [A] (left side).

3
P–09548

Installation: Make sure the two tabs (Item 1) [B] are

located in the slot on the operator cab. B

P–09547

Installation: Tighten the mounting bolt and nut (Item 1)

[C] to 180 – 200 in.–lbs. (21 – 23 Nm) torque. C

P–09554

To protect the paint on the operator cab from getting

scratched, install cardboard (Item 1) [D] on the right side. D 1
2
Wrap tape around the left pivot end (Item 2) [D] of the seat
bar.
Wrap tape around the cab grab handle (Item 3) [D] and
the front edge of the cab (Item 4) [D].

3
4

P–09546

863, 863H Bobcat Loader

Revised Feb. 97 –5–9– Service Manual
SEAT BAR (W/COMPRESSION SPRING) (Cont’d)
A 3 2
Removal and Installation (Cont’d)
Position the seat bar in the recess on the left side of the
cab (Item 1) [D]. Position the left side pivot end of the seat
bar between the cab and the grab handle (Item 2) [A].
1

Lift straight up on the right side (Item 3) [A] of the seat bar.

P–09549

Continue to lift on the right side of the seat bar and allow
the left side of the seat bar to rotate between the cab and
B
1
the grab handle (Item 1) [B].

P–09552

Lift the right side of the seat bar until it clears the right side
screen of the cab [C]. C

P–09553

Remove the left side of the seat bar pivot from between
the cab and grab handle and remove the seat bar from the D
cab [D].
Reverse the above procedure to install the seat bar into
the operator cab.

P–09950

863, 863H Bobcat Loader

Revised Feb. 97 –5–10– Service Manual
SEAT BAR (W/COMPRESSION SPRING) (Cont’d)
A 6
3
1
Assembling Components
4
Assemble the parts as shown for the left side of the seat
bar pivot assembly [A]:
Mounting Bolt (Item 1)
Washer (Item 2)
Keyed Plastic Bushing (Item 3)
Magnetic Bushing Assembly (Item 4) 2
Sensor Mounting Nut (Item 5)
Sensor Bracket (Item 6)
Sensor Mounting Bolt (Item 7) 8
9 5
Pivot Bushing (Item 8) 7
Mounting Bolt (Item 9)
P–09555

Assemble the parts as shown for the right side of the seat
bar pivot assembly [B]: B 3
2
Mounting Bolt (Item 1) 1
Pivot Bushing (Item 2)
Mounting Bracket (Item 3)
Keyed Plastic Bushing (Item 4)
Washer (Item 5)
Mounting Bolt (Item 6)
6 5 4

P–09551

Compression Spring Disassembly and Assembly C

Loosen the lock nut (Item 1) [C] and turn the bolt (Item 2)
[C] out of the clevis.
Assembly: Adjust the compressin spring as shown on
Page 5–8; Fig. [B]. 2

P–09542

Disassemble and assemble the seat bar compression

spring and parts as shown in Fig. [D]: D 2
1

Pin (Item 1)
Retaining Pin (Item 2)
Clevis (Item 3)
Lock Nut (Item 4)
Washer (Item 5) 3
Spring (Item 6) 4
Bushing (Item 7)
Bolt (Item 8) 5
8
6

7
P–09586

863, 863H Bobcat Loader

Revised Feb. 97 –5–11– Service Manual
OPERATOR CAB GAS CYLINDER
A
Removal and Installation
2

Cylinder contains high pressure gas. Do not

open. Opening cylinder can release rod and 1
cause injury or death.
W–2113–0288

P–07711
Remove the operator cab stop (Item 1) [A] (both sides).

NOTE: If the operator cab is equipped with a rear

window, the rear grill and rear grill mounts B
(Item 2) [A] must be removed to prevent
window damage.
Raise the operator cab. (See Page 1–1.)
Install a chain (Item 1) [B] from the operator cab to the
loader main frame to prevent the cab from tipping forward
when the gas cylinder(s) are removed.
1
NOTE: Model 873 shown. Procedure is the same.

N–15244

Remove the bolts and nuts (Item 1) [C] from the gas
cylinder mounting bracket. C

P–07705

863, 863H Bobcat Loader

Revised Mar. 99 –5–12– Service Manual
OPERATOR CAB GAS CYLINDER (Cont’d)
Removal and Installation (Cont’d)
A
Use a pliers to unlock cotter pin (Item 1) [A].
1

P–07710

NOTE: Cotter pin (Item 1) [B] is shown in locked

position. B
Remove the cotter pin, pivot pin and bushing.
Remove the gas cylinder.
Installation: Twist the ends of cotter pin to re–lock it.

P–07712

Disassembly and Assembly

C
Remove the clevis (Item 1) [C] and washer (Item 2) [C]
from the end of the gas cylinder.
Remove the gas cylinder from the outer housing.
2
1

P–01008
Assembly: Install a replacement cylinder inside the
cylinder housing.
D
Apply a small amount of LOCTITE on the threads of the
cylinder rod [D].
Reinstall the washer and clevis on the cylinder rod.

P–01006

863, 863H Bobcat Loader

Revised Mar. 99 –5–13– Service Manual
OPERATOR CAB
Removal and Installation
A
Remove the cab nut and holddown plate (Item 1) [A] (both
sides).
Installation: Tighten the nut to 40–50 ft.–lbs. (54–68 Nm)
torque.

1
1

P–10888

Disconnect the wiring harness connectors (Item 1) [B]. B

Disconnect the operator cab ground wire (Item 2) [B].

1 2

P–07707
Install a sling (Item 1) [C] on the grab handles of the
operator cab. Connect a chain hoist to the sling.
Remove both gas cylinders. (See Page 5–12.) C
After the gas cylinders are removed, lower the operator
cab using the chain hoist.

P–07718

863, 863H Bobcat Loader

Revised Feb. 97 –5–14– Service Manual
OPERATOR CAB (Cont’d)
Removal and Installation (Cont’d)
A
Remove the nut (Item 1) [A] from the pivot bolt (both
sides).
Installation: Tighten the pivot bolt and nut to 25–35
ft.–lbs. (34–47 Nm) torque.
Remove the pivot bolt (both sides).

1
P–07709

Move the operator cab forward a small amount for

clearance at the pivot mounting brackets [B].
B
Install the pivot bolt, washer (one on each side) and nut
(Item 1) [B] (both sides).
Install the sling under the pivot bolt and pivot of the
operator cab [B].

1
P–07713

Connect the slings to a chain hoist and remove the

operator cab from the loader [C]. C

P–07717

863, 863H Bobcat Loader

Revised Feb. 97 –5–15– Service Manual
OPERATOR SEAT
A
Removal And Installation
Use the following procedure to remove the operator seat
from the operator cab: 2
2
Raise the operator cab. (See Page 1–1.) 1
Locate the operator seat sensor (Item 1) [A] on the
bottom of the seat pan.
Disconnect the seat sensor connector and remove the 2
seat sensor assembly. (See Page 8–1.)
Remove the three seat mounting nuts (Item 2) [A] and
washers from the operator seat mounting studs. N–00959

Lower the operator cab and remove the operator seat

from the cab. B 5 5

Remove the spring (Item 1) [B], the two steel strips (Item
2) [B] (one strip on each side of the seat), the two foam 3
3
covers (Item 3) [B] (if equipped) and the two spaces (Item
4) [B]. 2
Installation: Use duct tape (Item 5) [B] to hold the ends
of the spring and steel strips to secure parts for seat
1
installation. 4 4

5 5
N–00457

Remove the bushing (Item 1) [C] from the right rear seat
rail stud. C
Installation: The bushing (Item 1) [C] should be
centered in the seat spring slot [C]. Tighten the bushing
to 105–130 in.–lbs. (11,9–14,6 Nm) torque.
1
NOTE: The bushing (Item 1) [B] has precoated
adhesive patch locking material. If adhesive
is not present use liquid adhesive LOCTITE
#242 blue on threaded area of both ends of
bushing.

N–00459

Installation: Make sure the seat spring (Item 1) [D] is

installed with the bend of the seat spring in the position D Operator
Seat
shown.
Inspect the seat adjustment track.
Remove the mounting bolt from each end of the track and Seat Seat
replace the adjustment track if necessary. 1 Spring
Sensor
Reverse the removal procedure to install the operator
seat. Seat Rail
Cover
Check for correct seat sensor operation. (See BICS™
inspection procedure in your Operation & Maintenance
Manual.
MC–02043

863, 863H Bobcat Loader

Revised Jan. 98 –5–16– Service Manual
BOB–TACH
A
Bob–Tach Lever and Wedge
Use the following procedure to remove and install the
Bob–Tach lever, spring, and wedge.
With the lift arms fully down, tilt the Bob–Tach forward so
it is parallel with the floor.

P–07694

Remove the lever mounting nut (Item 1) [B], washer (Item

2) [B] and spring (Item 3) [B].
B
Installation: Tighten the nut to 25–28 ft.–lbs. (34–38 Nm)
torque.

1
2
P–07680

Remove the Bob–Tach lever (Item 1) [C].

C

1
P–07681

Remove the roll pin (Item 1) [D] from the Bob–Tach

wedge assembly. D

P–07682

863, 863H Bobcat Loader

Revised Feb. 97 –5–17– Service Manual
BOB–TACH (Cont’d)
Bob–Tach Lever and Wedge (Cont’d)
A
Remove the spring, bolt and clevis assembly (Item 1) [A].
Remove the wedge from the Bob–Tach frame.
Always replace bent or broken wedges.

P–07683

If the bolt (Item 1) [B], handle pivot (Item 2) [B], spring

(Item 3) [B] or clevis (Item 4) [B] are damaged, put the
B
assembly in the vise for disassembly. Loosen and remove 5
the bolt (Item 1) [B] with a 5/16 inch allen wrench.
Replace the worn or damaged parts as needed.
2
Before installation of the parts, put grease on the handle
pivot (Item 2) [B], Bob–Tach handle pivot (Item 5) [B], and 1
bolt (Item 1) [B].
Reverse the removal procedure to install the Bob–Tach
lever and wedge assembly.
4
3
P–07684

Bob–Tach Stops C
Remove and replace the Bob–Tach stop (Item 1) [C] 1
(both sides) if worn or damaged.

NOTE: The Bob–Tach stop (Item 1) [C] must contact

the lift arm at the same time the tilt cylinder
reaches full extension. Use available shims
to adjust the Bob–Tach stop and tilt cylinder
sequence as closely as possible.

P–07952

863, 863H Bobcat Loader

Revised Feb. 97 –5–18– Service Manual
BOB–TACH (Cont’d)
Removal and Installation
A
With the lift arms all the way down, tilt the Bob–Tach
forward so it is parallel to the floor [A].

P–07694

Remove the retainer bolt (Item 1) [B] from the pivot pin. B
Installation: Tighten the retainer bolt to 18–20 ft.–lbs.
(24–27 Nm) torque.
1

P–07693

Remove the rod end pivot pin (Item 1) [C].

C

P–07695

Remove the tilt cylinder rod end.

D
Remove the seals (Item 1) [D].

P–03911

863, 863H Bobcat Loader

Revised Feb. 97 –5–19– Service Manual
BOB–TACH (Cont’d)
A
Removal and Installation (Cont’d)
Installation: Use two pieces of shim stock (light
cardboard), install the rod end of the tilt cylinder into the
Bob–Tach [A].
Be careful not to damage the seals during installation.

P–03910

NOTE: Removal procedure is shown for the right

side. Left side procedure is the same. B 1
Remove the retainer bolt and nut (Item 1) [B] from the
Bob–Tach pivot pin.
Installation: Tighten the bolt and retainer nut to 25
ft.–lbs. (34 Nm) torque.

P–07697

Install an adapter (Item 1) [C] into the Bob–Tach pivot pin.

C
Install the slide hammer into the adapter and pull the pivot
pin from the lift arms/Bob–Tach.

NOTE: Always inspect Bob–Tach pivot pin bushings

and seals in lift arm for wear or damage.
Replace as needed.

P–03008

863, 863H Bobcat Loader

Revised Feb. 97 –5–20– Service Manual
BOB–TACH (Cont’d)
Pivot Pin Bushing and Seal Replacement
A
1
Use a seal pick to remove seals (Item 1) [A] on both sides
of pivot bushing.

P–07948

Remove and replace bushing with a driver tool and

hammer [B]. B

P–07949

Use a driver to install new seals. The pivot pin can be used
to locate seal [C]. C

P–07950

863, 863H Bobcat Loader

Revised Feb. 97 –5–21– Service Manual
LIFT ARMS
Removal and Installation
A
The items listed are necessary for the following
procedure:
Three Lifting Straps – 7 ft. in length (with looped ends)
Chain Hoist
Install jackstands under the rear corners of the loader. 1

Remove the Bob–Tach from the lift arms. (See Page 1

5–19.)
Remove the two auxiliary tubeline clamps (Item 1) [A]
from the left lift arm (if so equipped). P–07729

Remove the two mounting bolts (Item 1) [B] from the front
auxiliary quick coupler mounting bracket (if so equipped).
B

P–07956

Remove the tilt tubeline mounting clamp (Item 1) [C] from

the back of the lift arm crossmember. C
Raise the operator cab. (See Page 1–1.)

P–07725

863, 863H Bobcat Loader

Revised Feb. 97 –5–22– Service Manual
LIFT ARMS (Cont’d)
Removal and Installation (Cont’d)
A
Wrap the lifting strap around the lift arm crossmember as
shown in Figure [A]. Connect both loops of the lifting strap
to a chain hoist.
2

P–07726

Raise the lift arms enough to remove the auxiliary

tubelines (if so equipped) from the lift arms [B]. B
Remove the nut and retainer bolt (Item 1) [A] from the
pivot pin for the base of the tilt cylinder.
Remove the pivot pin from the base end of the tilt cylinder
(Item 2) [A].
Remove the tilt cylinder (Item 1) [B] from the lift arms.
Remove the tilt tubelines from the lift arms and put the tilt
cylinder on the floor.

1
P–07730

Remove the lift arm support device mounting bolt and nut
(Item 1) [C]. C
Installation: Tighten the mounting bolt and nut to 15–17
ft.–lbs. (20–23 Nm) torque. 2 1
Remove the nut and retainer bolt (Item 2) [C] from the
pivot pin for the lift cylinder rod end (both sides).
Installation: Tighten the retainer bolt and nut to 15–17
ft.–lbs. (20–23 Nm) torque. 3
Remove the pivot pin for the lift cylinder (both sides).
NOTE: Drive out all pivot pins from the opposite side
that the retainer bolt was removed from. P–07728

Remove the lift arm support device (Item 3) [C].

Lower the lift arms with the chain hoist. D
Install the lift strap on the lift arm as shown in Figure [D]
(both sides).
Install the pivot pin (Item 1) [D] retainer bolt and nut (both
sides). 1
Connect the loops of the lifting straps to the chain hoist
(both lift straps).

P–07731

863, 863H Bobcat Loader

Revised Feb. 97 –5–23– Service Manual
LIFT ARMS (Cont’d)
Removal and Installation (Cont’d)
A
Remove the nut and retainer bolt (Item 1) [A] from the lift 1
arm pivot pin (both sides).
Installation: Tighten the retainer bolt and nut to 15–17
ft.–lbs. (20–23 Nm) torque.
Remove the pivot pin (Item 2) [A] from the lift arms (both
sides). 2

P–07732

Raise the lift arms with the chain hoist so the lift arms are
free from the loader.
B
Pull the lift arms away from the loader [B].
Lower the lift arms slowly and put them on the floor.

P–07733

863, 863H Bobcat Loader

Revised Feb. 97 –5–24– Service Manual
REAR GRILL
863,863H Service Manual #6724799 – Main Frame Part 1 of 2

A
Removal and Installation
1
Raise the rear grill.
Support the rear grill.
Remove the nut (Item 1) [A] to disconnect the gas
cylinder from the rear grill.

P–07618

Lower the rear grill. B

Remove the cotter pin and the pivot pin (Item 1) [B] (both 1
sides).

P–07946

Remove the rear grill from the loader [C]. C

P–07947

863, 863H Bobcat Loader

Revised Feb. 97 –5–25– Service Manual
REAR DOOR (ONE PIECE)
Removal And Installation
A
2
Open the rear door.
Disconnect the light harness connector (Item 1) [A] from
the engine harness.
Remove the light bulbs from the light housing and remove
the light housing (Item 2) [A] from the rear door (both
sides).
1

N–10889

Install a nylon sling (Item 1) [B] through the holes for the
light housings.
B 2

Connect a chain hoist (Item 2) [B] to the nylon sling.

N–15410

863, 863H Bobcat Loader

Revised Jan. 98 –5–26– Service Manual
REAR DOOR (ONE PIECE) (Cont’d)
Removal and Installation (Cont’d)
A
Remove the nuts from the top and bottom hinge bolts
(Item 1) [A] and remove the hinge bolts.
1
Installation:Tigthen the mounting bolts and nuts to
25–28 ft.–lbs. (34–38 Nm) torque. The door stop (Item 2)
[A] is installed in the top hinge bolt.
Remove the rear door from the loader frame and lay it flat
on the floor. 2

P–10892

Door Latch and Catch Adjustment

The door catch (Item 1) [B] can be adjusted side to side B
for alignment with the door latch.

P–10891

The door latch (Item 1) [C] can be adjusted forward or

backward for alignment with the door catch.
C

P–10890

863, 863H Bobcat Loader

Revised Jan. 98 –5–27– Service Manual
REAR DOOR
A
Removal and Installation
Connect a 1/4 inch chain to the rear door using two bolts
(Item 1) [A]. One bolt holding rear door weights will have
to be removed.
Inside the rear door, secure the chain with washers and
nuts.
Connect a chain hoist to the chain.

P–07963

Open the rear door, disconnect the wiring harness

connector (Item 1) [B]. B
Remove the nuts (Item 2) [B] from the pivot bolts.
Installation: Tighten the bolts and nuts to 25–28 ft.–lbs.
(34–38 Nm) torque.
2
Remove the rear door pivot bolts.
Lift the rear door away from the loader frame and put the
door flat on the floor.
1

P–07715

863, 863H Bobcat Loader

Revised Jan. 98 –5–28– Service Manual
REAR DOOR (Cont’d)
Hood Removal and Installation
A
Remove the mounting bolts from the rear door hood (Item
1) [A].
1
Installation: Tighten the hood mounting bolts to 25–28
ft.–lbs. (34–38 Nm) torque.
Remove the rear lights harness from the rear door hood
(if so equipped).
Remove the hood from the rear door.

P–05043

Bumper Removal and Installation B

Remove the rear bumper mounting bolts (Item 1) [B] with
a 7/32 inch allen wrench.
Installation: Tighten the mounting bolts to 180–200
in.–lbs. (21–23 Nm) torque.
2
Remove the bumper (Item 2) [B] from the rear door.
1

P–04281

Door Latch Removal and Installation

C
Remove the door latch mounting bolts (Item 1) [C] from
the door latch mechanism.
Installation: Tighten the mounting bolts to 80–90 in.–lbs.
(9–10 Nm) torque.
Remove the latch and handle mechanisms from the rear
door.

Door Latch and Catch Adjustment 1

P–05044

D
1

AVOID INJURY
Never service or adjust the machine when the
engine is running unless instructed to do so in
the manual.
W–2012–0290

The door catch (Item 1) [D] can be adjusted side to side

for alignment with the door latch.
The door latch mechanism (Item 1) [C] can be adjusted
forward or backward for alignment with the door catch. P–07961

863, 863H Bobcat Loader

Revised Jan. 98 –5–29– Service Manual
FUEL TANK
Removal and Installation
A
Remove the cover (Item 1) [A] which is installed over the
drain plug.

P–01616

Remove the drain plug (Item 1) [B]. B

Drain the fuel into a container.
Check the drain plug and replace if necessary.
Remove the engine/hydrostatic pump assembly from the
loader. (See Page 7–1.)
1

P–01619

Disconnect the fuel fill hose (Item 1) [C].

C
Disconnect the tank vent hose (Item 2) [C]. 2

P–04855

Remove the bolts (Item 1) [D] from the battery holddown

plate. D
Remove the battery holddown plate from the loader.

P–07918

863, 863H Bobcat Loader

Revised Jan. 98 –5–30– Service Manual
FUEL TANK (Cont’d)
Removal and Installation (Cont’d)
A
Remove the mounting plate (Item 1) [A] for the battery
holddown plate.
1
Lift the fuel tank and remove it from the loader frame.

P–07923

Fuel Level Sender B 2

Remove the fuel level sender (Item 1) [B].

3
3

P–07921

Check the fuel level sender with an ohmmeter as follows

[C]: C
Fuel Level – 30 Seconds Delay
Full – 30 ohms
Empty – 270 ohms
Short – 0 ohms
Open – 300+ ohms
Fuel float and magnet must slide freely on the shaft [C].

P–07922

Fuel Pick–Up Screen/Check Valve

D
The fuel pick–up screen/check valve (Item 1) [D] is 2
located in the fuel tank, connected to the fitting (Item 2)
[B].
Inspect the screen/check valve, hose and grommets.
Inspect the clamp (Item 3) [B] and (Item 2) [D]. Replace
the parts as needed. 1

P–07919

863, 863H Bobcat Loader

Added Jan. 98 –5–31– Service Manual
FUEL TANK (Cont’d)
863,863H Service Manual #6724799 – Main Frame Part 2 of 2

Inlet Screen
A
1
The inlet screen (Item 1) [A] is located at fuel tank fill
neck.
Disconnect the fuel fill hose.
Remove the inlet screen (Item 1) [A].
Wash the screen in clean solvent.
Dry the screen and check for damage. Replace as
needed.
P–05509

863, 863H Bobcat Loader

Added Jan. 98 –5–32– Service Manual
ELECTRICAL SYSTEM
Page
Number
ALTERNATOR
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
Rectifier (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10

BATTERY
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
Servicing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
Using a Booster Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7

ELECTRICAL SYSTEM INFORMATION

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
FRONT LIGHTS
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–25 ELECTRICAL
SYSTEM
RELAY SWITCHES
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–26

STANDARD INSTRUMENT PANEL

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–24

STARTER
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–15
External Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–19
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–20
Magnetic Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–23
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–23
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13

TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

863, 863H Bobcat Loader

Revised Dec. 96 –6–1– Service Manual
863, 863H Bobcat Loader
–6–2– Service Manual
TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for
assistance in locating and correcting problems. Many of
the recommended procedures must be done by
authorized Bobcat Service Personnel only. 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–2003–0797

PROBLEM CAUSE

Battery will not take a charge. 2, 3, 4

Alternator will not charge. 1, 4

Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9

KEY TO CORRECT THE CAUSE

1. Alternator belt is loose or damaged.

2. Battery connections are dirty or loose.

3. Battery is damaged.

4. The cable & wire connection are not making a good contact.
5. The alternator is damaged.

6. The engine is locked.

7. The starter is damaged.

8. The wiring or the solenoid is damaged.

9. Check the fuses.

863, 863H Bobcat Loader

–6–3– Service Manual
ELECTRICAL SYSTEM INFORMATION
Description
A
The loader has a 12 volt, negative ground alternator
charging system. The electrical system is protected by 1
fuses (Item 1) [A] located in the engine compartment. The
fuses will protect the electrical system when there is an
electrical overload. The reason for the overload must be
found before starting the engine again.

P–7627

Fuse Location B
The electrical system is protected by eight fuses located
in the fuse block (Item 1) [B]. Remove the fuse block
cover to check or replace the fuses.

P–7625

The decal (Item 2 ) [B] inside the rear door specifies the
fuse sizes used in loader circuits [C].
C

P–7626

863, 863H Bobcat Loader

Revised Dec. 96 –6–4– Service Manual
BATTERY
A 1
Removal and Installation

Batteries contain acid which burns eyes and

skin on contact. Wear goggles, protective
clothing and rubber gloves to keep acid off
body.
In case of acid contact, wash immediately with
water. In case of eye contact get prompt medical P–10811
attention and wash eye with clean, cool water
for at least 15 minutes.
If electrolyte is taken internally drink large
quantities of water or milk! DO NOT induce
B
vomiting. Get prompt medical attention.
1
W–2065–1296

Open the rear door.

Disconnect the negative (–) cable (Item 1) [A] from the
battery.
Remove the bolt from the cable clamp (Item 2) [A] and
loader frame.
Remove the battery holddown clamp (Item 1) [B].
P–10809

Disconnect the positive (+) cable (Item 1) [C] from the

battery. C 1
Remove the battery from the loader.

P–10806

863, 863H Bobcat Loader

Revised Jan. 98 –6–5– Service Manual
BATTERY (Cont’d)
Removal and Installation (Cont’d)
A
Installation: Always clean the terminals and cable ends
when installing a new battery as shown in figure [A] and
[B].
When installing the battery in the loader, do not touch any
metal parts with the battery terminal posts.

P–09589

Installation: The short negative cable must be

connected at the cable clamp and ground bolt (Item 1) [C]
to insure proper system ground and cable routing.
Connect and tighten the battery cables. Connect the
negative (–) cable last to prevent sparks.

Servicing the Battery P–09590

Batteries contain acid which burns eyes and

skin on contact. Wear goggles, protective 1
clothing and rubber gloves to keep acid off
body.
In case of acid contact, wash immediately with
water. In case of eye contact get prompt medical
attention and wash eye with clean, cool water
for at least 15 minutes.
If electrolyte is taken internally drink large P–10811
quantities of water or milk! DO NOT induce
vomiting. Get prompt medical attention.
W–2065–1296 D
The battery cables must be clean and the connections
tight. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate (baking soda) and
water solution as shown in figure [D].
Clean the terminals and cable ends as shown in figure [A]
and [B].
Check the electrolyte level in the battery. Add distilled
water as needed.
Put Battery Saver P/N 6664458 or grease on the battery
terminals and cable ends to prevent corrosion. P–09588

863, 863H Bobcat Loader

Revised Jan. 98 –6–6– Service Manual
BATTERY (Cont’d)
A
Using a Booster Battery

2
Batteries contain acid which burns eyes and 4
skin on contact. Wear goggles, protective
clothing and rubber gloves to keep acid off
body. P–10813

In case of acid contact, wash immediately with

water. In case of eye contact get prompt medical
attention and wash eye with clean, cool water
for at least 15 minutes.
If electrolyte is taken internally drink large
quantities of water or milk! DO NOT induce
vomiting. Get prompt medical attention.
W–2065–1296

Keep arcs, sparks, flames and lighted tobacco 3

away from batteries. When jumping from
booster battery make final connection
(negative) at engine frame.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F. (16°C.) before
connecting to a charger. Unplug charger before P–07661
connecting or disconnecting cables to battery.
Never lean over battery while boosting, testing
or charging.
Battery gas can explode and cause serious
injury.
W–2066–1296

If it is necessary to use a booster battery to start the

engine, BE CAREFUL! There must be one person in the
operator’s seat and one person to connect and Damage to the alternator can occur if:
disconnect the battery cables.
• Engine is operated with battery cables
The Key switch must be in the OFF position. The booster disconnected.
battery to be used must be 12 volt. • Battery cables are connected when using a
fast charger or when welding on the loader
Connect the end of the first cable (Item 1) [A] to the (Remove both cables from the battery).
positive (+) terminal of the booster battery. Connect the • Extra battery cables (booster cables) are
other end of the same cable (Item 2) [A] to the positive
terminal on the starter. connected wrong.
I–2023–1285

Connect the end of the second cable (Item 3) [A] to the

negative (–) terminal of the booster battery. Connect the
other end of the same cable (Item 4) [A] to the engine.
Keep cables away from moving parts. Start the engine.
After the engine has started, remove the ground (–) cable
(Item 4) [A] first.
Remove the cable from the starter.

863, 863H Bobcat Loader

Revised Jan. 98 –6–7– Service Manual
ALTERNATOR
Alternator Output Test
A

Put jackstands under the front axles and rear

corners of the frame before running the engine
for service. Failure to use jackstands can allow 1
the machine to fall or move and cause injury or
death.
W–2017–0286
P–07897
Lift and block the loader. (See Page 1–1.)
Disconnect the negative (–) cable from the battery. B Output
Terminal
Disconnect the red wire (Item 1) [A] from the alternator.
Connect the wire to the negative (–) side of the ammeter.
Connect the positive (+) side of the ammeter to the output
terminal on the alternator (Item 1) [A].
Disconnect the fuel stop solenoid connector. 1
Connect the negative (–) cable to the battery.
Turn on the lights for 3 minutes to discharge the battery. Regulator
Terminal
Connect the fuel stop solenoid, start the engine and run
at 2600 RPM. P–01304

If ammeter reading is between 45–55 amps. @ 2600

RPM the alternator is good and no further testing is
needed.
If the reading is low, remove the screws and pull the
regulator cover away from the alternator and continue
testing (below).
Rectifier (Diode) Test
NOTE: The alternator is removed from the loader for
clarity purposes.
Disconnect the negative (–) cable from the battery.
Install the wires in their original location on the back of the
alternator.
Connect a jumper wire (Item 1) [B] to the alternator output
terminal and the regulator terminal.
Connect the battery negative (–) cable.
Start the engine and run at 2600 RPM.
If the reading is within 45–55 amps. @ 2600 RPM replace
the rectifier (diode) assembly or replace the alternator.
If the reading is low, do the Alternator Regulator Test.

863, 863H Bobcat Loader

Revised Dec. 96 –6–8– Service Manual
ALTERNATOR (Cont’d)
A
Alternator Regulator Test

When an engine is running in an enclosed

area, fresh air must be added to avoid
concentration of exhaust fumes. If the engine
is stationary, vent the exhaust outside.
Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W–2050–1285

Connect the positive (+) voltmeter lead to the positive (+)

battery terminal [A].
Connect the negative (–) voltmeter lead to the negative
(–) battery terminal [A].
Start the engine and run at 1500–2000 RPM.
The voltmeter should read between 13.9–14.7 volts.
If the reading is low, stop the engine and disconnect the
battery negative (–) cable.
NOTE: The alternator is removed from the loader for
clarity purposes.
P–07716
Remove the wires from the back of the alternator.
Remove the regulator cover from the back of the
alternator. B
Install the wires on the back of the alternator.
Connect a jumper wire (Item 1) [B] from the brush
terminal to the ground stud. Ground
Stud
Connect the negative (–) battery cable and start the
engine. Run at 1500 RPM.
If the voltmeter reading is 14.5 or above, replace the Brush
regulator. Terminal
If the voltmeter reading is below 14.5, repair or replace the 1
alternator.
P–01364

863, 863H Bobcat Loader

Revised Dec. 96 –6–9– Service Manual
ALTERNATOR (Cont’d)
Removal and Installation
A

Damage to the alternator can occur if:

• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a
fast charger or when welding on the loader
(Remove both cables from the battery).
• Extra battery cables (booster cables) are
connected wrong.
I–2023–1285

Open the rear door.

Disconnect the negative (–) cable at the battery. 1
If So Equipped: Remove the bolts (Item 1) [A] and nuts
from the alternator belt shield (Item 2) [A]. Remove the
belt shield.

P–07715

Disconnect the red wire (Item 1) [B] at the alternator.

B
Disconnect the wiring harness connectors (Item 2) [B].

2 1

P–07896

Loosen the adjustment bolt (Item 1) [C].

C
Remove the alternator belt. 2
Remove the adjustment bolt (Item 1) [C]. 1
Remove the mounting bolt (Item 2) [C] and nut.
Remove the alternator.

P–07714

863, 863H Bobcat Loader

Revised Jan. 98 –6–10– Service Manual
ALTERNATOR (Cont’d)
Disassembly
A 1.
2.
Nut
Pulley
9.
10.
Rectifier (Diode)
Case Half (Rear)
3. Fan 11. Condenser Assy.
Disassemble the alternator (See Parts Identification) [A]. 4. Bolt 12. Strap
5. Case Half (Front) 13. Regulator
Remove the regulator cover and regulator. 6. Bearing 14. Brush
7. Rotor 15. Cover
Remove the four bolts holding halves together. 8. Stator

Pry the halves apart.

Use a soft jaw vise to hold rotor while removing pulley nut.
2 3
Remove front case half from the rotor using a plastic 1
hammer.
Unsolder the stator leads from the rectifier. Remove the 4 8
stator.

6 7
12

13

11 14
10
9

15 C–3312

Stator Continuity Test

B
Use an ohmmeter to test the stator.
Touch the probes to two of the bare stator wires [B].
Move one of the probes to the third wire.
The readings should be the same.
If there is no continuity, replace the stator.

P–1369

Stator Ground Test

C
Touch one probe to a bare stator lead and the other probe
to the bare metal surface of the stator [C].
There should be no continuity.
Replace the stator if there is continuity.

P–1386

863, 863H Bobcat Loader

Revised Dec. 96 –6–11– Service Manual
ALTERNATOR (Cont’d)
A
Rotor Continuity Test
Touch the probes to the slip rings [A].
The ohmmeter should read between 3.0–33.0 ohms.
If there is no continuity replace the rotor.

P–1365

Rotor Ground Test

Touch one probe to one of the slip rings and the other
B
probe to the rotor shaft [B].
There should be no continuity.
Replace the rotor if there is continuity.

P–1378

Rectifier Continuity (Diode) Test

NOTE: In the diode tests there should be continuity

C
in one direction only. If the diode being
tested shows no continuity or continuity in
both directions, replace the rectifier
assembly.
Touch the probes to the terminals of each diode and read
the meter [C].
Reverse the probes to check the diode in the other
direction.
There should be continuity in one direction only.

P–1373

Touch one probe to the diode and the other probe to the
connected heat sink and read the meter [D]. D
Reverse the probes to check the diode in the other
direction.
There should be continuity in one direction only.

P–1370

863, 863H Bobcat Loader

Revised Dec. 96 –6–12– Service Manual
ALTERNATOR (Cont’d)
Assembly
A
Reverse the order of disassembly.
Place the rotor in soft jaws when tightening the shaft nut.
Tighten to 50 ft.–lbs. (68 Nm) torque [A].
Install the rear case half and the remaining parts.

P–01808

STARTER
Removal and Installation
B
Open the rear door.
Disconnect the negative (–) cable (Item 1) [B] from the
battery.
1

P–09591

Disconnect the wires and positive (+) cable (Item 1) [C]

from the starter solenoid. C

P–07893

Remove the three starter mounting bolts (Item 1) [D].

D
Disconnect the ground wires.
1
Remove the starter.

P–07895

863, 863H Bobcat Loader

Revised Dec. 96 –6–13– Service Manual
STARTER (Cont’d)
Parts Identification

1 Felt Washer
2. Bearing 8
3. Armature
4. Bearing 6 9 10
5. Field Windings 7
Housing Assy.
6. Cover
7. Brush Holder 5
8. Cover 11. Brushes
9. Bolt 12. Cover
10. Bolt 4 13. Gasket
3 14. Screw
15. Pinion Shaft
16. Nut
17. Washer
1 18. Nut
19. Washer
20. Roller

2
11
17 13
16 12

18 14

20 19 15
21 11
22

18
25 16
24
17
23

35

34
33 21. Retainer
22. Pinion
23. Ball
31
24. Spring
25. Housing
28
27 26. Screw
30 27. Washer
26 32
28. O–ring
29. Housing
30. Gear
31. Spring
32. O–ring
33. Drive
34. Spring
29 35. Shaft

D–2297

863, 863H Bobcat Loader

–6–14– Service Manual
STARTER (Cont’d)
Disassembly and Assembly
A
Disconnect the wire from the magnetic switch [A].
Assembly: Tighten the nut to 52–86 in.–lbs. (5,9–9,7
Nm) torque. Securely put the rubber boot over the
terminal.

B–14441

Remove the through bolts from the drive end frame [B]. B
Assembly: Tighten the through bolts to 60–104 in.–lbs.
(6,8–11,8 Nm) torque.

B–14474

Remove the field windings housing from the magnetic

switch [C]. C

B–14442

Assembly: When installing the field windings housing to D 1

the magnetic switch, engage the tab (Item 1) [D] on the
field windings housing with the notch in the magnetic
switch.

B–14468

863, 863H Bobcat Loader

–6–15– Service Manual
STARTER (Cont’d)
Disassembly and Assembly (Cont’d)
A
Remove the screws from the cover over the brushes.
Remove the cover over the brushes.
Use a long nose pliers, to remove the brushes from the
brush holder [A].
Remove the brush holder.

B–14443

Assembly: Install the negative brushes (brush holder

side) to the brush holders (not insulated), and the positive
B Positive Brush

brushes to the brush holders (separated from plate with

Insulator
insulator). Make sure that the positive brush wires are not Negative
grounded when assembling the brush holder to the field Brush
windings, take care not to damage and get oil on the
brushes [B].

Positive Brush
Holder Hole

Negative Brush Holder Hole B–14466

Remove the armature from the field windings [C].

C
NOTE: Use a plastic hammer to tap the field
windings housing, when necessary to
remove the armature.

B–14444

Remove the screws from the drive end frame [D].

Assembly: Tighten the screws to 60–104 in.–lbs.
D
(6,8–11,8 Nm) torque.

B–14445

863, 863H Bobcat Loader

–6–16– Service Manual
STARTER (Cont’d)
Disassembly and Assembly (Cont’d)
A
Remove the drive end frame from the magnetic switch
[A].

B–14446

Remove the overrunning clutch from the drive end frame

[B].
B
NOTE: If the pinion is installed on the drive end
frame (externally attached to the overrunning
clutch shaft), it will be necessary to remove
the pinion before removing the overrunning
clutch. (See Page 6–19.)

B–14447

Remove the steel ball from the overrunning clutch [C]. C

B–14448

Remove the pinion (Item 1) [D] from the drive end frame.
D

B–14449

863, 863H Bobcat Loader

–6–17– Service Manual
STARTER (Cont’d)
Disassembly and Assembly (Cont’d)
A
Remove the retainer and rollers from the drive end frame
[A].

B–14450

Remove the return spring from the magnetic switch [B]. B

Assembly: Reverse the order of disassembly. Before
reassembling, put grease on the following parts:
Overrunning Clutch
Retainer and Rollers
Steel Ball
Return Spring
Armature Bearing
Felt Washer

B–14451

863, 863H Bobcat Loader

–6–18– Service Manual
STARTER (Cont’d)
External Pinion
A
If the pinion is installed on the drive end frame (externally
attached to overrunning clutch shaft), it will be necessary
to remove the pinion prior to removing the overrunning
clutch.
Push down on the drive end frame [A].

B–14452

While pressing down on the starter pinion, tap the collar

using a pipe (Item 1) [B].
B 1

Collar

B–14453

Remove the snap ring (Item 1) [C].

C 1
After the snap ring is removed, the pinion, overrunning
clutch, shaft, washer, and spring can be removed.

B–14454

863, 863H Bobcat Loader

–6–19– Service Manual
STARTER (Cont’d)
Inspection and Repair
A
ARMATURE:
Armature Short–Circuit Test: Use a growler tester, put the
armature on the growler and hold a hack saw blade
against the armature core while slowly rotating the
armature [A]. A short circuited armature causes the blade
to vibrate and be attracted to the core. An armature which
is short–circuited must be replaced.

B–14455

Armature Winding Ground Test: Use a circuit tester, touch

one probe to a commutator segment and the other probe
B
to the armature core [B]. There should be no continuity.
If there is continuity, the armature is grounded and must
be replaced.

B–14456

Armature Winding Continuity Test: Use a circuit tester,

touch the probes to two commutator segments [C]. There C
should be continuity at any point. If there is no continuity,
the winding is open–circuited, replace the armature.

B–14457

Commutator Run–Out Test: Check the commutator

run–out as shown in [D]. D
Service Limit – 0.02 inches (0,5 mm)
If the commutator exceeds the service limit, repair as
needed.

B–14458

863, 863H Bobcat Loader

–6–20– Service Manual
STARTER (Cont’d)
Inspection and Repair (Cont’d)
A
ARMATURE (Cont’d)
Measure the commutator outer diameter [A].
Service Limit – 1.38 inches (35 mm)
If it is worn, replace the armature.

B–14459

Measure the segment mica depth (Item 1) [B]. B

Service Limit – 0.008 inches (0,2 mm)
If it is worn, undercut the segment mica.
1
Check the commutator surface for burned spots which
usually indicates an open–circuit, and correct it using
#400 sand paper.

B–14460

Check the bearings for wear and damage [C].

C
If the bearings are worn or damaged, they should be
replaced.

B–14461

Use a press as shown in [D], replace the worn or

damaged bearing(s). D Press

Bearing

Armature

B–14439

863, 863H Bobcat Loader

–6–21– Service Manual
STARTER (Cont’d)
Inspection and Repair (Cont’d)
A
FIELD WINDINGS:
Check the field windings for wear and damage.
Check all the connections for clean and tight solder joints.
Field Winding Ground Test: Use a circuit tester, touch one
probe to the field winding end of the brush and the other
probe to the surface of the field windings housing [A].
There should be no continuity. If there is continuity, the
field windings are grounded.
Replace the field windings. B–14462

Field Windings Continuity Test: Use a circuit tester, touch

one probe to the wire and the other probe to the brush [B].
There should be continuity. If there is no continuity, the
B
field windings are open–circuited.
Replace the field windings.

B–14463

BRUSH AND BRUSH HOLDER:

Measure the brush length. C
Service Limit – 0.512 inches (13 mm)
If it exceeds the limit, replace the brush holder or field
windings assembly.
Check brush springs, for damage or rust. Replace as
needed.
Brush Holder Insulation Test: Use a circuit tester, touch
one probe to the positive brush holder plate and the other
probe to the holder plate [C]. There should be no
continuity. If there is continuity, replace or repair.
B–14464

OVERRUNNING CLUTCH:
Inspect the pinion, it must rotate freely in the direction of D
the starter rotation and locked in the opposite rotation [D].

B–14465

863, 863H Bobcat Loader

–6–22– Service Manual
STARTER (Cont’d)
Magnetic Switch Test
A 50

C
The following tests should be done without the armature
assembly:

NOTE: Each test should be performed a short time

(3 to 5 seconds) to prevent the magnetic
switch winding from burning. Each test
should be performed with 12 volts.

Pull–In Test: Connect the wires as shown in [A]. When M.T.

connecting Terminal C and M.T. are closed, the pinion
should engage.
B–14471

Hold–In Test: With the same conditions as in the pull–in

test, open the connecting Terminal C [B]. The pinion
B 50
should remain in the engaged position. C

M.T.

B–14470

Return Test: With the same conditions as in the hold–in

test, open the connecting Terminal 50 [C]. The pinion C 50
should return immediately.
C
M.T. . . . Main Terminal to which the main cable from the
battery is connected.
C . . . . . . C–Terminal to which the wire from the field
windings is connected.
50 . . . . . 50–Terminal to which the wire from the starting
switch or stator relay is connected.
M.T.

B–14469

No Load Test D Ammeter

The following test should be done after reassembling the

starter: 50
M.T.
Clamp the starter in a vise. Use a 12 volt battery and C
ammeter, connect the positive wire of the battery, and the
ammeter to the 50 Terminal [D]. Connect the negative
wire to the starter body.
The starter should show smooth and steady rotation
immediately after the pinion is engaged, it should draw
less than the specified current.
Service Limit – 200 Amp. Maximum Draw Starter
B–14440

863, 863H Bobcat Loader

–6–23– Service Manual
STANDARD INSTRUMENT PANEL
A
Removal and Installation
Pry the rubber light mount loose from the operator cab
(both sides) [A].

P–3995

Lower the light from the operator cab and locate the three
instrument panel mounting bolts (Item 1) [B] (both sides). B
Remove the three mounting bolts (Item 1) [B]. 1
Installation: Be careful not to overtighten the instrument
panel mounting bolts to prevent stripping the threaded
holes in the panels.
NOTE: Before any wires are disconnected, make 1
sure you have the correct wiring schematic
for the loader.

P–3955

Pull the left instrument panel down and disconnect the

wire harness connectors from the panel. Remove the C
panel [C].

P–3951

Repeat steps [A] & [B]. Pull the right instrument panel
down and disconnect the wire harness connectors from
the panel. Remove the panel [D].
D
Reverse the removal procedure to install the instrument
panel.

P–3953

863, 863H Bobcat Loader

–6–24– Service Manual
FRONT LIGHTS
863,863HServiceManual#6724799–ElectricalSystemPart1of2

Removal and Installation

A
The front lights are mounted in the upper corners of the
operator cab [A].

P–3956

Pry the rubber light mount free from the operator cab [B]. B

P–3995

Pull the light down and remove the three mounting bolts
(Item 1) [C] from the instrument panel. C
Disconnect the front light connector from the instrument 1
panel. Remove the front light from the operator cab.
Reverse the removal procedure to install the front light.

P–3955

863, 863H Bobcat Loader

–6–25– Service Manual
RELAY SWITCHES
863,863HServiceManual#6724799–ElectricalSystemPart2of2

Location
A
The engine harness has relay switches located below the
air cleaner [A].
The switches are for the starter, switch power, glow plug,
brake and engine shutdown.
Remove the screw from the mounting tab on the switch
and replace if the switch malfunctions.

P–7896

863, 863H Bobcat Loader

–6–26– Service Manual
ENGINE SERVICE
Page
Number
AIR CLEANER HOUSING
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7
BLOWER FAN
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11
BLOWER HOUSING/FAN GEARBOX
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8
CAMSHAFT BEARINGS
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–76
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–76
CYLINDER HEAD
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–92
Checking the Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–91
Checking the Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–92
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–91
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–92
CYLINDER LINERS
Checking the Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–75
CONNECTING ROD
Checking the Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–86
CONTROL ROD GUIDE BUSHING
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–80
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–78
CRANKSHAFT
Checking the Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–85
CRANKSHAFT GEAR MOUNTING BOLT
Torque Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–124
DEUTZ ENGINE TOOLS
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–55
ENGINE
Engine Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–32
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–26
ENGINE MUFFLER ENGINE
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6 SERVICE
ENGINE SPEED CONTROL
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
Speed Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
Speed Control Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
FAN DRIVE TENSION PULLEY
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10
FAN GEARBOX
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–18
Checking Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–23
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–12
FLYWHEEL
Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–33
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–33
FLYWHEEL HOUSING
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–33
FRONT COVER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–100
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–95
FUEL INJECTOR
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–43
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–42
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–40

Continued On Next Page

Revised Jan. 98 863, 863H Bobcat Loader
–7–1– Service Manual
ENGINE SERVICE (Cont’d)
Page
Number
FUEL INJECTION PUMP
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–36
GLOW PLUGS
Checking the Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–34
OIL COOLER
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–123
POSITIVE CRANKCASE VENTILATION SYSTEM (S/N 514415609,
514611152, 514511106 & Below)
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–121
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–121
Module Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–122
PISTON AND PISTON PIN
Checking the Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–89
Installing Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–90
REAR COVER SEAL
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–84
RECONDITIONING THE ENGINE
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–60
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–56
ROCKER ARM AND BRACKET
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–94
TIMING BELT
Belt Replacement In Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–49
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–45
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–45
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
TURBOCHARGER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–116
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–111
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–115
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–110
VALVE CLEARANCE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–35
VALVE TIMING
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–54

863, 863H Bobcat Loader

Revised Jan. 98 –7–2– Service Manual
TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most common.
Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.

PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 4
Engine will not start. 2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29
Difficult to start. 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
No power for engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is mis–firing. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue/white exhaust. 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 47, 46
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 39, 48
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 49
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 49
Vibration. 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure warning. 4, 33, 36
Overheating. 10, 12, 13, 15, 16, 20, 21, 32, 40, 44, 47
Too much crankcase pressure. 22, 27, 29, 46
Poor compression. 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 49
Start and stop. 9, 10, 11

KEY TO CORRECT THE CAUSE

1. Battery capacity low. 28. Worn valve and seats.
2. Bad electrical connections. 29. Broken, worn or sticking piston rings.
3. Faulty starter motor. 30. Worn valve stems or guides.
4. Incorrect grade of oil. 31. Worn or damaged bearings.
5. Low cranking speed. 32. Not enough oil in the oil pan.
6. Fuel tank empty. 33. Switch/sensor is defective.
7. Faulty stop control operation. 34. Oil pump worn.
8. Plugged fuel line. 35. Pressure relief valve is sticking open.
9. Plugged fuel filter. 36. Pressure relief valve is sticking closed.
10. Restriction in the air cleaner. 37. Broken relief valve spring.
11. Air in the fuel system. 38. Faulty suction pipe.
12. Faulty fuel injection pump. 39. Plugged oil filter.
13. Faulty fuel injectors. 40. Piston seizure.
14. Broken injection pump drive. 41. Incorrect piston height.
15. Incorrect injection pump timing. 42. Faulty engine mounting.
16. Incorrect valve timing. 43. Incorrect alignment of flywheel.
17. Poor compression. 44. Faulty thermostat.
18. Plugged fuel tank vent. 45. Plugged oil cooler
19. Incorrect grade of fuel. 46. Plugged PCV system.
20. Exhaust pipe restriction. 47. Damaged valve stem oil deflectors.
21. Cylinder head gasket leaking. 48. Plugged oil pump pipe strainer.
22. Overheating. 49. Broken valve spring.
23. Cold running.
24. Incorrect tappet adjustment.
25. Sticking valves.
26. Incorrect high pressure fuel pipes.
27. Worn cylinder bores.
863, 863H Bobcat Loader
Revised Sept. 96 –7–3– Service Manual
ENGINE SPEED CONTROL
A
Removal and Installation

1
P–4731

B 1

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved
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–2059–0598 2

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
P–5368
Remove the two mounting bolts (Item 1) [A].

C 1 2
Mark the front of the stop bracket (Item 1) [B] and remove
the stop bracket
Installation: It is important for the front and rear stop on
the bracket to be located correctly.
Remove the bolts (Item 2) [B].
Installation: Tighten the bolts evenly until the speed
control lever moves backward and forward at a
comfortable tension.

Remove the speed control lever (Item 1) [C] and

P–5375
mounting bracket (Item 2) [C].

Remove the retainer pin (Item 1) [D] and pivot pin (Item
D
2) [D] from the speed control arm (Item 3) [D] to
disconnect the speed control cable clevis.

NOTE: Do not lubricate the speed control parts 3

when assembling.

1 2
P–5378

863, 863H Bobcat Loader

Revised Mar. 99 –7–4– Service Manual
ENGINE SPEED CONTROL (Cont’d)
Speed Control Cable
A 1

P–7940

B
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
lift arm support device. Failure to use an
approved lift arm support device can allow the 2
lift arms or attachment to fall and cause injury
or death. W–2059–0598

Raise the lift arm and install an approved lift arm support
device. (See Page 1–1.)
3 1
Raise the operator cab. (See Page 1–1.)
4
Remove the speed control lever assembly. (See Page
7–4.) P–5545

NOTE: The front panel/steering levers are shown

removed for clarity. C
Remove the u–bolt (Item 1) [A] from the cable.
Open the rear door. 2
NOTE: Engine is shown removed from loader for
clarity. 3
Remove the u–bolt (Item 1) [B] from the cable.
5
NOTE: The throttle mount bracket bolts (Item 2) [B]
can be removed to assist u–bolt removal. 4

Remove the nut (Item 3) [B] to disconnect the cable from 1

the linkage. P–5544

Remove the speed control cable.

Speed Control Linkage

Loosen the bolt (Item 1) [C] to remove the linkage rod
(Item 2) [C].
Disconnect the cable nut (Item 3) [C].
Remove the nut (Item 4) [C] from the pivot bolt (Item 4)
[B].
Remove the bellcrank linkage (Item 5) [C] and spring.

863, 863H Bobcat Loader

Revised Mar. 99 –7–5– Service Manual
ENGINE MUFFLER
Removal and Installation
A
Open the rear door. 1

Raise the rear grill.

Remove the four bolts and nuts (Item 1) [A] from the
engine muffler mounting bracket.
Remove the bracket. 1

P–7898

Remove the three bolts and nuts (Item 1) [B] from the
muffler exhaust flange. B

P–7900

Remove the two bolts and nuts (Item 1) [C] from the
muffler mounting bracket. C
Remove the muffler.

P–7899

863, 863H Bobcat Loader

–7–6– Service Manual
AIR CLEANER HOUSING
A
Removal and Installation
Remove the PCV module. (See Page 7–122.) 1
Loosen the hose clamp (Item 1) [A] and disconnect the
inlet hose from the air cleaner.
2
Remove the two mounting bolts (Item 2) [A].

P–7901

BOSS® option loader:

Disconnect the sensor wire connector (Item 1) [B].
B

P–7902

Loosen the lose clamp (Item 1) [C] and disconnect the

hose from the turbocharger inlet.
C
Remove the air cleaner housing from the loader.

P–7779

863, 863H Bobcat Loader

Revised June 98 –7–7– Service Manual
BLOWER HOUSING/FAN GEARBOX
A
Removal and Installation

P–7966

B 1
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
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–2059–0598

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.) 2
P–4860
Remove the mounting bolts (Item 1) [A] from the gas
cylinder mounting bracket.
Installation: Tighten the mounting bolts to 80–90 in.–lbs. C
(9–10 Nm) torque. 2
Remove the hydraulic fluid reservoir. (See Page 2–1.)

Disconnect the wiring harness connectors (Item 1) [B].

Remove the harness clamp (Item 2) [B]. 1

Move the electrical harness down for clearance at the

blower housing. Oil Level

Remove the clamp and belt shield (Item 1) [C] for the fan
drive. P–7772

Disconnect the breather hose from the fan drive housing

(Item 2) [C]. D
Installation: When checking the fan gearbox oil level,
make sure the level does not go above the top of the shaft
in the gearbox [C]. Use 90W gear lube oil if the level is low.

Remove the fan drive belt (Item 1) [D].

P–7774

863, 863H Bobcat Loader

Revised Mar. 99 –7–8– Service Manual
BLOWER HOUSING/FAN GEARBOX (Cont’d)
Removal and Installation (Cont’d)
A 1

Remove the sealant from the blower housing and loader

frame (Item 1) [A].
Remove fuel fill hose (Item 2) [A] and the fuel vent hose.

P–07936

Remove the four mounting bolts (Item 1) [B] and spacer

tubes (two outside housing and two inside housing).
B
NOTE: Remove the two rear mounting bolts first.
Installation: Use sealant on each end of the inside
spacer tubes to prevent the tubes from falling out of the
housing during installation. Tighten the mounting bolts to
25–28 ft.–lbs. (34–38 Nm) torque.

P–07775
Slide the blower housing forward and remove the fan/fan
gearbox assembly. Remove the blower housing [C].
Installation: Use R.T.V. sealant to re–seal the blower
C
housing to the loader frame (Item 1) [A].
See Page 7–13 for Disassembly of the Fan Gearbox.

P–07773

D
The blower housing must be moved away from the loader
frame if the side grills need to be replaced [D].
To replace the side grill, remove the four mounting screws
(Item 1) [D] from the blower housing. 1

Install the new grill and replace the screws.

P–07776

863, 863H Bobcat Loader

–7–9– Service Manual
FAN DRIVE TENSION PULLEY
A
Removal and Installation
Remove the fan drive belt (Item 1) [A].
Remove the idler pulley bolt (Item 2) [A]. 1

P–05550

Remove the spacers, bolt and washers from the arm [B]. B 1
Installation: Put a small amount of grease around the
outside edge on the grease rings (Item 1) [B] between
ring and bearing.
P–00581

P–04956

Remove the bolt (Item 1) [C] & [D]. C

P–05551

Remove the thrust washer (Item 2) [D], O–rings (Item 3)

[D] and spring (Item 4) [D].
D
Check all parts for damage or wear and replace them as 3
needed.
NOTE: When making any repairs, replace the bronze
bushing (Item 5) [D] with a new style nylon 3
bushing. Clean all parts and assemble dry. 2
Do not lubricate. (See Parts Mircofiche for
correct part numbers.) 4 1

N–00303

863, 863H Bobcat Loader

Revised Jan. 98 –7–10– Service Manual
BLOWER FAN
A
Removal and Installation
Remove the lock nut and spacer [A].
Installation: Tighten the nut to 45–55 ft.–lbs. (61–75 Nm)
torque.

CD–9952

Use the following procedure to remove the fan from the

shaft: B 2
Install the nut (Item 1) [B] on the tapered shaft to protect
the shaft and threads.
Install the puller on the fan as shown [B].
As the center bolt (Item 2) [B] is tightened, periodically
strike the bolt head to loosen the fan from the shaft .

P–3006

Remove the fan from the tapered shaft [C].

C

CD–9953

To remove the blower housing mounting plate, remove

the six bolts (Item 1) [D]. D
1

1
CD–9954

863, 863H Bobcat Loader

–7–11– Service Manual
FAN GEARBOX
Parts Identification

1. Seal
2. Snap Ring (Small)
3. Shims (1.0 inch O.D.)
4. Bearing
5. Shaft (Long)
6. Shims (2.0 inch O.D.) 1
7. Long Key
8. Shaft (Short)
9. Short Key
10. Long Housing
11. Nut 18
12. Gear
13. Washer
14. Screw
15. Square Shim 1 6
*16. Short Housing 2 3
17. Bolt 4
18. Snap Ring (Large) 7 4
19. Cap 5
20. Long Housing Assy.
21. Short Housing Assy.
22. Fill Plug
8

22

2
4
12 9
13 12
14
10
*16
21
11

15
17
20 12

20
3

13

14

18

19
* Individual Part not available TS–1002
863, 863H Bobcat Loader
–7–12– Service Manual
FAN GEARBOX (Cont’d)
A
Disassembly 3
NOTE: When repairing the gearbox order the
following as needed:
1. Complete Assembly
2. Long Housing Assembly
3. Long Housing
4. Short Housing Assembly (See Note 1
Below)
5. Internal Parts 2
NOTE: The short housing is only available as an
assembly. See the parts identification Page
7–12 for reference. (Order parts from Bobcat P–3005
Parts Sales.)
NOTE: Be sure to count the number and thickness of
shims during disassembly. Install the shims B
in the original location during assembly.
Remove the fan and blower housing mounting plate. (See
Page 7–11.)
Long Housing Part Number
Tag
Loosen the set screws (Item 1) [A] and remove the pulley
(Item 2) [A].
Remove the long key (Item 3) [A].
Remove the four mounting bolts and the part number tag
[B].
P–2983
Remove the oil from the gearbox.

AVOID INJURY OR DEATH

Wear safety goggles to prevent eye injury
when drilling or grinding.
W–2108–1186

Drill an 1/8 inch (13 mm) hole in the seal. Use a slide
hammer tool to remove the seal [C].
P–2999

Remove the small snap ring [D].

D

P–2964

863, 863H Bobcat Loader

–7–13– Service Manual
FAN GEARBOX (Cont’d)
A
Disassembly (Cont’d)
Remove the small shims [A].

P–2963

Remove the screw and washer from the shaft [B].

B

P–2966

Support the lower flange and press the shaft from the
bearing [C]. C
NOTE: The gear and the other bearing (pulley end)
will be removed with the shaft.

P–3004

Support the bearing and press the shaft from the bearing
[D]. D

P–3298

863, 863H Bobcat Loader

–7–14– Service Manual
FAN GEARBOX (Cont’d)
Disassembly (Cont’d)
A
Short Housing
Remove the end cap [A].
Use care not to damage the housing.

P–2997
AVOID INJURY OR DEATH
Wear safety goggles to prevent eye injury
when drilling or grinding.
W–2108–1186
B

Drill an 1/8 inch (3 mm) hole in the seal. Use a slide

hammer tool to remove the seal [B].

P–2996

Remove the large snap ring from the flange end of the
housing [C].
C

P–2970

Remove the large shims from the housing [D].

D
NOTE: Use the same size and thickness of shims
during assembly.

P–2969

863, 863H Bobcat Loader

–7–15– Service Manual
FAN GEARBOX (Cont’d)
Disassembly (Cont’d)
A
Remove the screw and washer (Item 1) [A] from the
shaft.

P–2978

Remove the snap ring from the cap end of the housing
[B].
B

P–2973

Press the shaft from the housing [C].

C
NOTE: Both bearings may come out of the housing
with the shaft. If one bearing remains in the
housing, use a non metal object to tap the
bearing from the housing.

P–2998

Press the bearing from the tapered end of the shaft [D].
D

P–3088

863, 863H Bobcat Loader

–7–16– Service Manual
FAN GEARBOX (Cont’d)
Disassembly (Cont’d)
A
Press the bearing, shims and gear from the shaft [A].

P–3001

Remove the key (Item 1) [B] from the shaft. B

P–2972

863, 863H Bobcat Loader

–7–17– Service Manual
FAN GEARBOX (Cont’d)
A
Assembly
NOTE: See Note Page 7–13 when ordering parts for
the Fan Gearbox. Always replace seals
during assembly. Replace the parts in the
gearbox as needed.
NOTE: Do not install the seals and cap in the
housing until after the backlash has been
checked.
NOTE: Use care when pressing the bearings into the
aluminum housing. The housing can be
damaged if too much pressure is used.
P–2961
NOTE: For procedures requiring the use of #242
LOCTITE adhesive, thoroughly clean and dry
affected parts before the application of #242
LOCTITE.
B
Long Housing
Press a bearing on the short keyed end of the long shaft
[A].
Install the long housing on the shaft [B].
Be sure the bearing is seated in the bore at the lower end
of the housing.

P–2960

Install a bearing on the long keyed end of the shaft [C].

Support the lower bearing and press the other bearing in
C
the housing until the bearings seat in the housing [C].

P–2962

Install on the bearing, the same number and size shims

that were removed during disassembly [D]. D

P–2963

863, 863H Bobcat Loader

–7–18– Service Manual
FAN GEARBOX (Cont’d)
A
Assembly (Cont’d)
Install the small snap ring in the groove above the shims
[A].

P–2964

Install the gear key in the flange end of the shaft [B].
B

P–2965

Align the key and gear. While supporting the bearing on

the other end, press the gear on the shaft until it seats
against the bearing [C].
C

P–2967

Install the washer [D].

Put liquid adhesive (LOCTITE #242) on the screw D
threads. Install and tighten the screw [D].

P–2966

863, 863H Bobcat Loader

–7–19– Service Manual
FAN GEARBOX (Cont’d)
Assembly (Cont’d)
A
Short Housing
Install a bearing in the flanged end of the housing [A].

P–2968

Install the large shims on the bearing (flanged end) [B]. B

P–2969

Install the large snap ring in the groove above the shims
[C]. C

P–2970

Install the short key (Item 1) [D].

D
Align and press the gear on the shaft (teeth toward the
tapered end of the shaft) [D].

P–2971

863, 863H Bobcat Loader

–7–20– Service Manual
FAN GEARBOX (Cont’d)
A
Assembly (Cont’d)
After the gear is seated, drive the key down inside the
gear key way [A].

NOTE: This will prevent damage to the shims when

the bearing is installed later.

P–2975

Install the shaft in the housing, tapered end in the bearing

at the round flange end of the housing [B]. B

P–2976

Install on the shaft, the same number and size shims that
were removed during disassembly [C]. C

P–2977

Install a bearing on the gear end of the shaft [D]. D

P–2974

863, 863H Bobcat Loader

–7–21– Service Manual
FAN GEARBOX (Cont’d)
A
Assembly (Cont’d)
Install the snap ring in the groove above the bearing [A].

P–2973

Install the washer (Item 1) [B] on the shaft. Put liquid

adhesive (LOCTITE #242) on the screw threads and
install the screw [B].
B

P–2978

863, 863H Bobcat Loader

–7–22– Service Manual
FAN GEARBOX (Cont’d)
A
Checking Backlash
NOTE: For procedures requiring the use of #242
LOCTITE adhesive, thoroughly clean and dry
affected parts before the application of #242
LOCTITE.
The backlash tolerance between the gears should be
0.005–0.008 inch (0,127–0,203 mm).
To check the gear backlash use the following procedure:
Put the short housing in a vise, square flange facing up
as shown [A].
P–2987

Install the same size and number of square shims (if

present during disassembly) between the two housings B
[B].
Set the long housing on the short housing with a small
amount of liquid adhesive (LOCTITE #242) between the
mounting surfaces.

NOTE: If square shims are used, put a small amount

of the liquid adhesive on both sides of all
shims.

P–2981

Install the four mounting bolts through the flange holes

[C]. C
Install the part number tag [C].
Install and tighten the nut to 25–28 ft.–lbs. (34–38 Nm)
torque.

Part Number
Tag

P–2983

Install the long key (Item 1) [D] and the pulley (Item 2) [D].
Install a bolt in the set screw hole to maintain a 1.000 inch
D
(25,4 mm) distance from the shaft center to the bolt head 1.000 inch
(to be used with a dial indicator) [D].
(25,4 mm)

P–2984

863, 863H Bobcat Loader

–7–23– Service Manual
FAN GEARBOX (Cont’d)
Checking Backlash (Cont’d)
A
Put the fan nut (Item 1) [A] on the shaft and tighten snugly.
Install a locking pliers on the fan nut and support the
handle against the long housing [A].

P–2982

Using a magnetic based dial indicator mounted on a

bench vise, touch the dial stem on the bolt (Item 1) [B]. B
Hold the locking pliers against the long housing and rotate 1
the pulley back and forth to read the dial gauge [B].
If the backlash is GREATER than 0.008 inch (0,203 mm),
do the following:
1. Remove a square shim(s) (if present) between the
two housings.
2. Remove a large shim(s) from the tapered end of the
short shaft and add a small shim(s) of the same
thickness between the bearing and the gear on the
screw end of the shaft.
P–2979
If the backlash is LESS than 0.005 inch (0,127 mm) do the
following:
1. Add a square shim(s) between the two housings.
2. Remove a small shim(s) between the bearing and
the gear on the screw end of the short shaft and add
a large shim(s) of the same thickness between the
snap ring and the bearing on the tapered end of the
shaft.

863, 863H Bobcat Loader

–7–24– Service Manual
FAN GEARBOX (Cont’d)
863,863HServiceManual#6724799–EngineServicePart1of5

A
Checking Backlash (Cont’d)
When the backlash is correct, install the seals, cap and
gear oil as follows:
Remove the bolts from the flanges and separate the two
housings.
Put liquid adhesive (LOCTITE #242) on the outside
diameter of the seal(s) [A].

P–3089

Install the seal(s) flush with the housing surface [B] & [C].
Clean any oil from the flange surface.
B LONG HOUSING

Install the long housing on the short housing flange.

Install the four bolts and part number tag.
Install and tighten the nuts to 25–28 ft.–lbs. (34–38 Nm)
torque.

P–2985

C SHORT HOUSING

P–2986

863, 863H Bobcat Loader

–7–25– Service Manual
ENGINE
Removal and Installation
A
NOTE: The engine and hydrostatic pumps will be
removed as an assembly.

2
1
P–5496

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved
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–2059–0598
2 1

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
P–7774 P–7772
Raise the operator cab. (See Page 1–1.)
Drain the fluid from the hydraulic reservoir. C
Remove the hydraulic reservoir. (See Page 2–1.)
Disconnect the fuel fill hose from the fuel fill neck (Item 1)
[A].
Disconnect the air vent hose (Item 2) [A] from the fuel fill
neck. 1

Remove fan belt shield (Item 1) [B].

2
Remove the fan drive belt (Item 2) [B].
Disconnect the engine wiring harness (Item 1) [C] from P–4860
the operator cab wiring harness.
Remove the bolt (Item 2) [C] from the harness mounting
clamp.
D
NOTE: The electrical harness will be removed with 2
the engine.

Remove the u–bolt (Item 1) [D] from the steering cable

(both sides).
Disconnect the steering cable end (Item 2) [D] from the
hydrostatic pump lever (both sides). 1
Installation: See Page 3–1 for transmission neutral
adjustment.
P–5499

863, 863H Bobcat Loader

Revised Mar. 99 –7–26– Service Manual
ENGINE (Cont’d)
Removal and Installation (Cont’d)
A

When making repairs on hydrostatic and

hydraulic systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system. P–7784
I–2003–0284

Disconnect the outlet hose (Item 1) [A] from the hydraulic B

pump.

Disconnect BICS™, auxiliary, and filter assembly

electrical harness from engine harness [B].
Disconnect filter assembly electrical harness. Remove
hydrostatic and hydraulic filter assembly. (See Page
2–1.)
Disconnect the fuel level sender wiring connector at the
fuel tank.

P–7781

Disconnect the small hose (Item 1) [C] from the

hydrostatic pump. C
Disconnect the two larger hoses (Item 2) [C] from the 1
hydrostatic pump.

P–5507

Disconnect the four high pressure hoses (Item 1) [D] from

the hydrostatic pumps. D 1

1
P–7787

863, 863H Bobcat Loader

–7–27– Service Manual
ENGINE (Cont’d)
A
Removal and Installation (Cont’d)
Disconnect pump case drain hose (Item 1) [A].

P–7782

Remove the bolt and nut (Item 1) [B] at the right front
engine mount.
B

P–7786

Remove the bolt (Item 1) [C] at the left front engine

mount. C
NOTE: The nut is held in the housing and will not
turn.

Installation: Tighten the mounting bolts and nuts to

61–69 ft.–lbs. (83–94 Nm) torque.
Remove the battery. (See Page 6–1.)
Remove the engine muffler. (See Page 7–6.) 1
Remove the air cleaner housing. (See Page 7–7.)

P–7785

863, 863H Bobcat Loader

–7–28– Service Manual
ENGINE (Cont’d)
A
Removal and Installation (Cont’d)
Disconnect the hose (Item 1) [A] at the tubeline and plug
the line.
NOTE: If the oil cooler is drained, measure the
amount of oil removed from the oil cooler 1
and/or engine. Add the same amount of oil to
the engine crankcase when adding engine
oil.

P–7911

Disconnect the fuel hose (Item 1) [B] from the fuel pump.
B
1

P–7621

Disconnect the fuel return hose (Item 1) [C]. C

Remove the three bolts (Item 2) [C] from the engine 2
muffler bracket. Remove the bracket.

P–7912

863, 863H Bobcat Loader

Revised Sept. 96 –7–29– Service Manual
ENGINE (Cont’d)
Removal and Installation (Cont’d)
A
1
Remove the alternator belt shield.
1
At the right side of the engine, remove the two throttle
bracket mount bolts (Item 1) [A].
Disconnect the throttle rod connector (Item 2) [A].
2

P–5545

Remove the left and right rear engine mounting bolts

(Item 1) [B] and nuts.
B
Installation: Tighten the bolts and nuts to 61–69 ft.–lbs.
(83–94 Nm) torque.

P–7914

Use the dimensions from (Figure ([A] Page 7–31) to

make engine removal and installation brackets. C 1
Install the lift bracket (Item 1) [C] on the engine. 2 2

Tighten the bolts (Item 2) [C] until the lift bracket is held
firmly against the valve cover.

NOTE: Bolts required are two 12x80 mm x 1.75

thread.

P–7917

863, 863H Bobcat Loader

–7–30– Service Manual
A 13.0
(330)

2.5
INCHES (64)
(MM) 1–1/2’’ I.S. Dia.
2–1/2’’ O.S. Dia.

2.5 (64)

1–1/2’’ Square Tubing 1/4’’ (4)

Thick Gusset

1.0
(25) 16.0
(406)

4.0
2.0 (102)
(51)
4.0
(102)
0.5 1.0 (25)
(12,7)
0.375 2.0 (51)
0.3125 Dia. (2) (9,5) 9.0
(229) 1.375 0.66 (16,8)
Use Two 3/8’’ x 1–1/4’’ Bolts (35,0) 4.5
for Drilled and Tapped Holes 1.0 (114) 8.525
(25) (218)
1.125
(28,6)
1.125
4.25 (28,6) 1.75
(108) (44,5)
0.775
0.5 0.6875 (2) 2 x 2 x 1/4 (19,7)
(12,7) (17,5) Gusset
45° 17.750
9/16 3/8 Dia. Hole (4)
Dia. Hole (2) Gusset

2–1/2 x 2–1/2 x 22
1.75 1/4’’ Thick MC–1801
(44,5)
MC–1799

ENGINE (Cont’d)
Removal and Installation (Cont’d)
B
Connect a chain hoist to the ring (Item 1) [B] on the lift 1
bracket.
Remove the engine/hydrostatic pump assembly from the
loader [B].
NOTE: Residue remaining in the engine oil cooler
may contaminate the engine oil and damage
the engine. In the event of severe engine oil
contamination, oil cooler replacement is
recommended. Drain and flush the cab heater
and plumbing thoroughly.

P–07915

863, 863H Bobcat Loader

–7–31– Service Manual
ENGINE MOUNTS
Replacement
A 1
2

3
Use the following procedure to install new engine mounts:
Remove the existing mount from the engine. Refer to 4
engine removal and installation for engine mount
locations.
5
Replace all four engine mounts (two front and two rear).
Use the parts shown to install the new engine mounts [A]. 6
Item 1 – Square Nut – Used on left side engine mounts
7
Item 2 – Hex Nut – Used on right side engine mounts MC–01771

Item 3 – Mount Washer

HEAVY DUTY
Item 4 – Engine Mount
B ENGINE
Engine
Mounting
MOUNT Bracket
Item 5 – Tube Spacer Washer

Item 6 – Snubbing Washer

Loader Engine
Item 7 – Mounting Bolt Frame Mount

Install the new engine mount as shown in the cut away

side view [B] or [C].
Tighten the mounting bolts to 61–69 ft.–lbs. (83–94 Nm)
torque.
Snubbing Spacer
Washer TS–01520

863, 863H Bobcat Loader

Revised June 98 –7–32– Service Manual
FLYWHEEL
Removal and Installation
A
Remove the drive belt. (See Page 3–1.)
Remove the bolts (Item 1) [A] from the flywheel.
Installation: Tighten the flywheel bolts as follows:
Initial Torque . . . . . . . . . . . . . . . . . . . 22 ft.–lbs. (30 Nm) 1
1st. Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
2nd. Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°

P–5558

Remove the flywheel from the engine crankshaft [B]. B

Flywheel Ring Gear
NOTE: The lead chamfer on ring gear tooth must 1
face the starter.
The ring gear (Item 1) [B] on the flywheel is an
interference fit. Heat the ring gear enough to expand it
and hit it with a hammer to remove it evenly.
Clean the outer surface of the flywheel to give it a smooth
fit.
Clean the new ring gear and heat it to a maximum
temperature of 428°F (220°C). P–5564

Fit the ring gear over the flywheel. Make sure the gear is
on the seat correctly.
C
FLYWHEEL HOUSING
Removal and Installation
Remove the drive belt. (See Page 3–1.)
1
1
Remove the hydrostatic pump. (See Page 3–1.)
Remove the belt tension pulley assembly. (See Page
3–1.)
Remove the starter. (See Page 6–1.)
P–5562
Remove the flywheel housing mounting bolts (Item 1) [C].
Remove the flywheel housing from the engine.

863, 863H Bobcat Loader

–7–33– Service Manual
GLOW PLUG
Checking the Glow Plug
A
Early S/N Loaders:
Early S/N loaders use a intake manifold heater (Glow
Plug). Figure [A] shows the two mounting locations
possible. Locate the glow plug on your loader. 1

Location one: On the front side of engine facing the right

side of loader. Raise the operator cab. (See page 1–1.)
1
Location two: On the top of engine facing the rear of
loader. Remove the engine muffler. (See page 7–6.)
Disconnect the wire to the glow plug. P–05542 P–09450

Use a testmeter to measure the resistance of the glow

plug. B
Connect the testmeter lead to the terminal of the glow
plug as shown in figure [B].
Touch the other lead from the testmeter to the intake
manifold as shown in figure [B].
The reading must be approximately 0.4 ohms.
If the resistance is zero ohms the glow plug has a short
circuit.
If the resistance is infinite, the coil of the glow plug is
broken.
P–05541
Replace the glow plug if needed. Tighten the glow plug to
15–18 ft.–lbs. (20–24 Nm) torque.
C
Late S/N Loaders:
Late S/N loaders use four glow plugs, one for each 1
cylinder. The glow plugs are located on the rear side of
engine in the cylinder head as shown in figure [C].
Unplug the wire from the glow plug (Item 1) [C].

P–09451
Use a testmeter to measure the resistance of each glow
plug.
Connect the testmeter lead to the terminal of the glow D
plug as shown in figure [D].
Touch the other lead from the testmeter to the base of the
glow plug as shown in figure [D].
The reading must be approximately 0.2 ohms.
If the resistance is zero ohms the glow plug has a short
circuit.
If the resistance is infinite, the coil of the glow plug is
broken.
Replace the glow plug(s) if needed. P–09452

863, 863H Bobcat Loader

Revised Dec. 96 –7–34– Service Manual
VALVE CLEARANCE
Adjustment
A
Make the valve clearance adjustment with engine 1
stopped and cold.
Remove the valve cover (Item 1) [A].
When installing the valve cover bolts, tighten them to 75
in.–lbs. (8,5 Nm) torque.

P–5297

Use the following sequence as shown in figure [B] to set

the valve clearance.
B CRANKSHAFT POSITION
ONE
Turn crankshaft
CRANKSHAFT POSITION
TWO
Turn crankshaft further by
until valves one complete revolution
Turn the crankshaft until the valves of cylinder No. 1 of cylinder No. 1 Overlap (360°)
over–lap [B].
Turn the crankshaft by one complete revolution (360°) DO NOT ADJUST ADJUST
and set the other valves.

MC–2174

Loosen the locknut and turn the set screw until the
clearance is correct. C
Intake – 0.012 inch (0,3 mm)
Exhaust – 0.020 inch (0,5 mm)
Tighten the locknut to 13–16 ft.–lbs. (18–22 Nm) torque.

P–5633

863, 863H Bobcat Loader

Revised June 98 –7–35– Service Manual
FUEL INJECTION PUMP
Description
A 3 3
The injection pump(s) contain parts which have a very
close tolerance and its operation has a direct effect on the
performance of the engine.

2 2
1

Do not attempt to maintain or adjust unless

you are trained and have the correct P–5282
equipment.
I–2028–0289

Removal B
Remove the fuel tubeline (Item 1) [A] to the fuel injection
pumps (Item 2) [A].
Disconnect the respective high pressure fuel line (Item 3)
[A] from the injection pump to be removed and fuel
injector.
Use a flare nut wrench (Item 1) [B] to loosen the high 1
pressure fuel line nut.

P–5280

Do not bend the high pressure fuel injection

C
tubes when removing or installing them.
I–2029–0289

Remove the two mounting nuts (Item 1) [C] from the

injection pump.

P–5281

Remove the fuel injection pump (Item 1) [D].

D
Remove the shim (Item 2) [D].
1
2
NOTE: The shim(s) are used to time the injection
pump, keep the same thickness for each
injection pump.

P–5283

863, 863H Bobcat Loader

–7–36– Service Manual
FUEL INJECTION PUMP (Cont’d)
Removal (Cont’d)
A
Use a magnet to remove the injection pump tappet [A].
Inspect the tappet for wear or damage, replace as
needed.

P–05279

Install the tappet into its respective bore [B]. B

Injection Pump Timing
The fuel injection pump does not need to be timed if the
tappet, shim(s) and the camshaft are not changed.

P–05278

Install a depth micrometer (Item 1) [C].

C 1

Measure the distance between the engine block surface

(without shim) and surface of the tappet [D].
Installation dimension of the injection pump is 2.28 inch
(58 mm).
EXAMPLE: P–05284

Specifications (BF4M1011)
Installation Depth . . . . . . . . . . . 2.28 inch (58 mm) D
Measured Depth a . . . . . . . . . . 2.25 inch (57,55 mm) Tappet
Difference . . . . . . . . . . . . . . . . . 0.030 inch (0,76 mm)
Specifications (BF4M1011F)
Installation Depth . . . . . . . . . . . 2.32 inch (59 mm)
Measured Depth a . . . . . . . . . . 2.25 inch (57,55 mm)
Difference . . . . . . . . . . . . . . . . . 0.070 inch (1,78 mm)
Determine the number of shim(s) needed to get the
correct installation height.
Install the appropriate number of shims(s) on the engine a
block surface. MC–02175

863, 863H Bobcat Loader

Revised Mar. 99 –7–37– Service Manual
FUEL INJECTION PUMP (Cont’d)
Installation
A
Remove the plug from the engine block. Install control
rack locating pin (Item 1) [A]. (See Page 7–55, for correct
tool.)

P–05287

Move the control rack until the slot (Item 1) [B] is in the
center of the injection pump bore.
B
Tighten the locating pin (Item 2) [B].

P–05286

Use the centering pin (Item 1) [C] to remove the press–in

plug (Item 2) [C] from the injection pump. (See Page C 2
7–55, for correct tool.) 1

P–05288

Install the centering pin (Item 1) [D] into the injection

pump and into the control lever (Item 2) [D]. Align the D 2 3
marks (Item 3) [D] on the pump body and the control 1
lever. Make sure the control lever is in the center position.

P–05289

863, 863H Bobcat Loader

Revised June 98 –7–38– Service Manual
FUEL INJECTION PUMP (Cont’d)
Installation (Cont’d)
A
Install the injection pump into the engine block. Make sure
the control lever goes into the slot on the fuel control rack.
1
Install the two nuts (Item 1) [A].
Tighten the mounting nuts to 15 ft.–lbs. (21 Nm) torque
[B].

1
P–05294

Remove the fuel control rack locating pin (Item 1) [B] and
install the plug.
B
Remove the centering pin (Item 2) [B] and install the
press–in plug (Item 2) [A].

1
P–05291

Install the high pressure fuel line.

Tighten the fuel line nut to 10–12 ft.–lbs. (13,5–16,5 Nm) C
torque [C].

P–05280

Install new washers (Item 1) [D] on the fuel line fastening

bolt.
D
Install the fuel line on the injection pumps and tighten to
20–23 ft.–lbs. (27–31 Nm) torque.

P–05285

863, 863H Bobcat Loader

Revised June 98 –7–39– Service Manual
FUEL INJECTOR
Removal and Installation
A
Disconnect the respective high pressure fuel line from
fuel injector to be removed and fuel injection pump.
Use a flare nut wrench (Item 1) [A] to loosen the high
pressure fuel line nut.

Do not bend the high pressure fuel injection P–5280

tubes when removing or installing them.
I–2029–0289
B
Remove the high pressure fuel line.
Installation: Tighten the fuel line nut to 10–12 ft.–lbs.
(13,5–16,5 Nm) torque.
Remove the bolt (Item 1) [B] and holddown clamp from
the fuel injector.
1
Installation: Tighten the bolt to 15.5 ft.–lbs. (21 Nm)
torque.

P–5293

Remove the fuel injector (Item 1) [C] and washer (Item 2)

[C] from the cylinder head. C

P–5290

863, 863H Bobcat Loader

Revised June 98 –7–40– Service Manual
FUEL INJECTOR (Cont’d)
Checking
A

Do not disassemble or test the fuel injector

nozzles unless you have the correct service
and testing tools.
I–2027–0284

B–8971
The tools listed will be needed to do the following
procedure:
OEM1064 – Injection Nozzle Tester B
OEM1065 – Accessory Set
Connect the nozzle to the test pump, in a down position
[A].
Operate the test pump until the nozzle valve opens:
Injection Pressure: (BF4M1011) . 3045 PSI. (210 bar)
Injection Pressure: (BF4M1011F) 3625 PSI. (250 bar)

MC–2177

Diesel fuel or hydraulic fluid under pressure

can penetrate skin or eyes, causing serious
injury or death. Fluid leaks under pressure may
not be visible. Use a piece or 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 from a
physician familiar with this injury.
W–2072–0496

Check nozzles spray pattern [B]:

The spray pattern must be uniform from all four holes of
the nozzle.
The nozzles are dirty or defective:
• If the spray pattern is not uniform.
• If fuel drips from the end of the nozzle.
• If the spray is a solid stream instead of a mist.

863, 863H Bobcat Loader

Revised June 98 –7–41– Service Manual
FUEL INJECTOR (Cont’d)
A
Disassembly

Remove the nozzle cap nut [A].

CD–15332

Disassembly the parts as shown in Fig. [B].

1. Nozzle Cap Nut
B
2. Injector Nozzle
3. Adapter 1
4. Thrust Pin
5. Spring 2
6. Shim(s) 3
5 4
Wash all the parts in clean diesel fuel and blow dry using
compressed air. 6

CD–15333

The nozzle needle and body [C] are lapped together and
can not be exchanged with other nozzle parts. C
DO NOT touch the nozzle needle with your fingers.

When the nozzle body is held in the upright position, the

needle should by its own weight slide slowly and smoothly
on its seat [C].
NOTE: If the nozzle needle does not slide smoothly,
wash the injector nozzle parts again in clean
diesel fuel. Blow dry with compressed air.
Re–do the procedure again. Replace the
injectors as needed. Wash all new injectors
in clean diesel fuel before installation.
CD–15334

Check the seat surface of the adapter for wear. Make sure
the centering pins are in place [D]. D

CD–15335

863, 863H Bobcat Loader

Revised Sept. 96 –7–42– Service Manual
FUEL INJECTOR (Cont’d)
A
Assembly
Install the shim(s) [A].
The injector opening pressure is adjusted by selecting the
correct amount of shim(s). A thicker shim will increase the
opening pressure at the injector nozzle.

CD–15336

Install the compression spring [B].

B

CD–15337

Install the thrust pin with the centering collar facing toward
the compression spring [C]. C

CD–15338

Install the adapter with the centering pins toward the

thrust pin [D].
D

CD–15339

863, 863H Bobcat Loader

–7–43– Service Manual
FUEL INJECTOR (Cont’d)
A
Assembly (Cont’d)
Install the injector nozzle, make sure the center bore fits
over the centering pins of the adapter [A].

NOTE: Be careful that the nozzle needle does not fall

out of the nozzle body.

CD–15340

Install the nozzle cap nut [B].

B

CD–15341

Tighten the cap nut to 35 ft.–lbs. (47 Nm) torque [C].

C
Check the injector nozzle on the nozzle tester before
installation. (See Page 7–41.)

CD–15342

863, 863H Bobcat Loader

–7–44– Service Manual
TIMING BELT
Inspection
A
NOTE: The timing belt is maintenance free. Timing
belts that have been in operation do not need 2
to be re–tensioned (unless removal was
necessary). The timing belt, belt tensioner, 1
and mounting bolt must be replaced every
3000 operating hours or every 5 years. A
repair kit is available.
NOTE: If the timing belt has to be removed before P–13683
200 hours of engine operation, the timing belt
can be re–used and re–tensioned according
to the procedure listed. 3
P–05292
To do the following procedure on the BF4M1011F engine
only, you need the following tool:
MEL1552 – Torx Bit B
Remove the bolts (Item 1) [A] from the timing belt
inspection cover.
Remove the torx bolt (Item 2) [A]. (BF4M1011F only.)
Remove the cover (Item 3) [A].
Check the timing belt, sprockets and tensioner for wear,
cracks or damage [B].
Check the timing belt in detail for the following conditions,
replace as needed.
1. Oil deposits P–05298
2. Hardened back rubber surfaces
3. Cracked
4.
5.
Badly worn teeth
Missing tooth
C 3
6. Side of belt badly worn
7. Side of belt cracked
4
Removal
Remove the bolts (Item 1) [A] from the timing belt 1
inspection cover.
Remove the torx bolt (Item 2) [A]. (BF4M1011F only.)
1
Remove the cover (Item 3) [A]. 2

Remove the bolts (Item 1) [C] from the v–belt pulley (Item
2) [C]. P–05295

Remove the v–belt pulley.

Remove the bolts (Item 3) [C] from the timing belt cover.
D
Remove the cover (Item 4) [C].

Loosen the belt tensioner mounting bolt (Item 1) [D].

Loosen the belt tensioner.
Remove the timing belt.

1
P–05299

863, 863H Bobcat Loader

Revised Mar. 99 –7–45– Service Manual
TIMING BELT (Cont’d)
Installation
A
NOTE: Remove the fuel injectors and rocker
brackets from the cylinder head. (See Page 2
7–40.) This will let the crankshaft turn easier
for timing belt installation. 1

The camshaft plug is located at the rear of the engine

block (Item 1) [A] on the fuel injection pump side. (See
Page 7–55, for the correct tool.)
Remove the plug.
Rotate the camshaft until the notch in the camshaft can
B–14402
be seen through the plug hole.
Install the timing tool (Item 2) [A] and tighten.
B
The crankshaft plug is located at the front of the engine
block (Item 1) [B] on the exhaust manifold side.
Remove the plug. 1
Rotate the crankshaft until the flat spot on the crankshaft
throw can be seen through the plug hole. Turn the
crankshaft back a small amount. Install the timing tool
(Item 2) [B] and tighten.
Rotate the crankshaft until it hits the timing tool and stops. 2

B–14401

Loosen the nut at the camshaft gear [C]. (See Page 7–55,
for correct tool.)
C

P–05301

Install the new timing belt.

D
Measure the distance from the edge of the belt to the front
cover surface [D].

P–05630

863, 863H Bobcat Loader

Revised Feb. 97 –7–46– Service Manual
TIMING BELT (Cont’d)
Installation (Cont’d)
A
Using the dimensions from figure [D]; Page 7–46. Align
the timing belt to make sure it is an equal distance from
the mounting surface for the front cover [A].

P–05632

Install the belt tension tool (Item 1) [B]. (See Page 7–55,
for correct tool.)
B
Turn the idler tensioner pulley in counterclockwise
direction to obtain a scale reading of 3.0–3.5. Tighten the
idler tensioner pulley nut to 33 ft.–lbs. (45 Nm) torque [B].

P–05631

Initially tighten camshaft bolt to 22 ft.–lbs. (30 Nm) [A].

C
Mark camshaft bolt and tighten an additional 210° [A].
Remove the belt tension tool (Item 1) [C].
Remove the camshaft and crankshaft locating pins (Fig.
[A] & [B]; Page 7–43).

P–05635

Mark the crankshaft pulley [D].

D
Make four complete crankshaft revolutions in the
direction of engine rotation. Bring the mark on the
crankshaft pulley back to the same position.

P–05636

863, 863H Bobcat Loader

Revised Feb. 97 –7–47– Service Manual
TIMING BELT (Cont’d)
Installation (Cont’d)
A
Install the belt tension tool (Item 1) [A].
Measure belt tension and the reading should be 6.5–9.5.
NOTE: If the specified scale reading is not obtained,
repeat the installation procedure starting
with Figure [A]; Page 7–46.
1
Remove the belt tension tool.

NOTE: See Valve Timing, Page 7–57 before installing P–05296

the timing belt cover.

Install the belt cover (Item 1) [B] and tighten the bolts. B
1
Install the v–belt pulley (Item 2) [B] and tighten the bolts
to 30–36 ft.–lbs. (41–49 Nm) torque.
2

P–05295

Install the timing belt inspection cover (Item 1) [C] and C

tighten the bolts.

1
P–05292

863, 863H Bobcat Loader

Revised June 98 –7–48– Service Manual
TIMING BELT (Cont’d)
A
Belt Replacement In Loader

Use the following procedure to replace the timing belt,

tensioner and tensioner bolt. If the belt is broken,
additional procedures are required and noted.
♦ For Broken Belt Replacement Only
♦ Remove the engine muffler. (See Page 7–6.) 2

♦ Remove the valve cover. Remove and inspect the

rocker arms/brackets and push rods. (See Page
7–35.)
1
NOTE: The rear door is removed for photo clarity
only. 2
Disconnect the negative (–) battery cable.
Loosen the screw and unplug the fuel solenoid connector
(Item 1) [A].

NOTE: Do not lose the rubber seal gasket on the

solenoid connector.
Remove the bolts (Item 2) [A] holding the belt shield.
Move the shield away from the work area.

P–09566

Loosen the alternator adjustment bolt (Item 1) [B] and

remove the alternator belt.
B
1
Remove the crankshaft pulley bolts (Item 2) [B]. Remove
the pulley.

P–09563

863, 863H Bobcat Loader

Revised Feb. 97 –7–49– Service Manual
TIMING BELT (Cont’d)
863,863HServiceManual#6724799–EngineServicePart2of5

A 2
Belt Replacement In Loader (Cont’d)

Remove the throttle linkage bolts (Item 1) [A]. Lower the

throttle linkage.
Remove the four belt cover bolts (Item 2) [A]. Remove the
front and rear belt covers.
2

P–09564

Remove the camshaft access plug (Item 1) [B].

B

P–09575

Remove the crankshaft access plug (Item 1) [C].

NOTE: The plug is located on the front of crankcase,
C
below the turbocharger and just above the 1
right side front engine mount.

P–09577

Rotate the crankshaft in correct rotation as shown in

figure [D] until the notch in the camshaft can be seen
through the access hole.
D
NOTE: The crankshaft must be turned in correct
rotation. Turn clockwise as viewed from the
timing belt end of engine as shown.

P–09570

863, 863H Bobcat Loader

Revised Feb. 97 –7–50– Service Manual
TIMING BELT (Cont’d)
A
Belt Replacement In Loader (Cont’d)

Install the camshaft timing tool (Item 1) [A] and tighten. 1

(See Page 7–55 for correct tool.)

P–09573

♦ For Broken Belt Replacement Only

B
♦ Remove the number four cylinder fuel injector. (See
Page 7–40)
1
♦ Rotate the crankshaft and use a wire (Item 1) [B] in the
fuel injector hole to indicate piston is moving upward,
to top dead center (T.D.C.).

NOTE: The crankshaft must be turned in correct

rotation. Turn clockwise as viewed from the
timing belt end of engine.

♦ Install the crankshaft timing tool (Item 1) [C] and

tighten. (See Page 7–55 for correct tool.)
P–09605
♦ Rotate crankshaft against timing tool.

Install the crankshaft timing tool (Item 1) [C] and tighten. C

(See Page 55 for the correct tool.)
1

P–09578

Remove the tensioner bolt (Item 1) [D] and the tensioner.

Remove the timing belt. D
NOTE: The timing belt, belt tensioner and mount
bolt must be replaced as a set. A repair kit is
available.
Install the new timing belt, belt tensioner and mount bolt.
Do not tighten the mount bolt.
NOTE: Align the timing belt on gears to obtain equal
distance between the belt and front cover to 1
insure belt runs straight on gears.

P–09565

863, 863H Bobcat Loader

Revised Feb. 97 –7–51– Service Manual
TIMING BELT (Cont’d)
A
Belt Replacement In Loader (Cont’d)

Install the camshaft gear tool (Item 1) [A]. (See Page

7–55 for correct tool.)
Loosen the camshaft gear [A].

P–09571

Install the belt tension tool as shown in Figure [B]. (See

Page 7–55 for the correct tool.) B

P–09576 P–09574

Use a hex wrench to turn the idler tension pulley in

counterclockwise direction as shown in figure [C]. Obtain C
a scale reading of 3.0–3.5. Tighten the idler tension pulley
mount bolt to 33 ft.–lbs. (45 Nm) torque.

P–09579

Remove the belt tension tool, hex wrench and torque

wrench. D
Install the camshaft gear tool.
Tighten camshaft bolt to 22 ft.–lbs. (30 Nm) torque as
shown in figure [D]. Mark the camshaft bolt and tighten an
additional 210°.

P–09569

863, 863H Bobcat Loader

Revised Feb. 97 –7–52– Service Manual
TIMING BELT (Cont’d)
A
Belt Replacement In Loader (Cont’d)

Remove the camshaft and crankshaft timing tools (Item 1

1) [A] & [C]; Page 7–51).
Mark the crankshaft pulley hub (Item 1) [A].

P–09565

Make four complete crankshaft revolutions in the B

direction of engine rotation. Bring the mark on the
crankshaft pulley back to the same position as before [B].
Install the belt tension tool. Check the belt tension
reading. It should be 6.5–9.5.
NOTE: If the specified scale reading is not obtained,
repeat the procedure.

Remove the belt tension tool.

♦ For Broken Belt Replacement Only
♦ Install the push rods and rocker arms/brackets.
Replace all damaged parts. (See Page 7–72.) P–09570

♦ Set the valve clearance. (See Page 7–35.)

♦ Install the valve cover and gasket. Tighten the bolts
to 75 in.–lbs. (8,5 Nm) torque.
Install the crankshaft and camshaft access plugs.
Install the belt covers and four mounting bolts.
Install the throttle linkage and bolts.
Install the crankshaft pulley and bolts. Tighten the bolts to
30–36 ft.–lbs. (41–49 Nm) torque.
Install the alternator belt. Adjust the belt tension.
Install the belt shield and bolts.
Plug in the fuel solenoid connector and tighten the screw.
Reconnect the negative (–) battery cable.

863, 863H Bobcat Loader

Revised June 98 –7–53– Service Manual
VALVE TIMING
A
Checking
Remove the camshaft access plug (Item 1) [A].
1

P–09575

Rotate the crankshaft/camshaft until the notch in the

camshaft can be seen through the plug hole. B
Install the timing tool (Item 1) [B].
1

P–09573

At the crankshaft pulley bolt, install a torque wrench and

turn the engine in the direction of rotation to 30 ft.–lbs. (40
Nm) torque [C].
C
Remove the torque wrench, DO NOT change the
crankshaft position.

Remove the crankshaft access plug (Item 1) [D].

NOTE: The access plug is located on the front of the

crankcase, below the turbocharger and just
above the right side front engine mount. P–09563

Turn the crankshaft timing tool (Item 2) [D] into the

crankcase until it makes slight contact with the
crankshaft.
D
Mark the position of the timing tool. 1
2
The valve timing is correct if the timing tool can be turned
into the crankcase another 3/4 to 2–1/4 turns until it stops.
If the timing tool can not be turned into the crankcase the
required turns, the camshaft (valve timing) setting will
have to be redone.

P–09577 P–09578

863, 863H Bobcat Loader

Revised Feb. 97 –7–54– Service Manual
DEUTZ ENGINE TOOLS
Identification Chart

Part No. Description Illustration Part No. Description Illustration

MEL1433 Compression MEL1460 Belt Tension

Test Adapter Tool for
Toothed Belt

MEL1453 Socket 60 JMP MEL1461 Crankshaft

Seal
Tool (Front)

MEL1454 Depth Gauge MEL1462 Crankshaft

w/Spacers Seal
Tool (Rear)

MEL1455 Spanner MEL1463 Camshaft

Seal Tool

MEL1456 Valve Spring MEL1464 Valve Stem

Assembly Seal Tool
Lever

MEL1457 Torx Tool Kit MEL1465 Crankshaft

Gasket
Removing
Tool

MEL1458 Timing Pin for MEL1466 Camshaft

Crankshaft Gear
and Wrench
Camshaft

Centering Pin
MEL1459 Adjusting Pin MEL1467 Injection Pump
for Control Lever
Injection Pump
Control

863, 863H Bobcat Loader

Revised Feb. 97 –7–55– Service Manual
RECONDITIONING THE ENGINE
Disassembly
A
Remove the starter. (See Page 6–1.)
Remove the alternator. (See Page 6–1.)
Drain the oil from the engine oil pan.
Remove the turbocharger. (See Page 7–110.)
Remove the exhaust manifold.
Remove the intake manifold.
Remove the fuel injection pumps. (See Page 7–36.) CD–15486

Remove the fuel injectors. (See Page 7–40.)

Remove the oil filter.
B
Remove the fuel filter & fuel lift pump [A].
Remove the valve cover.

Remove the rocker arms and brackets [B].

CD–15481

Remove the push rods [C].

C

CD–15480

Remove the cylinder head bolts [D].

D
Remove the cylinder head.

CD–15513

863, 863H Bobcat Loader

Revised Feb. 97 –7–56– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
Disassembly (Cont’d)
A
Remove the oil pressure control valve [A].
Remove the plugs or fittings from the engine block.

CD–15515

Remove the belt pulley (Item 1) [B].

Remove the front cover and timing belt. (See Page 7–45.)
B
Remove the crankshaft gear.

P–05292

Remove the oil pump [C].

C
Remove the oil pump relief valve (Item 1) [C].

CD–15471

Remove the oil pan [D].

D

CD–15518

863, 863H Bobcat Loader

Revised Feb. 97 –7–57– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
A
Disassembly (Cont’d)
Remove the oil suction pipe [A].

CD–15519

Remove the connecting rod bolts [B].

Remove all the piston/connecting rod assembly from the
B
engine block.
To check the piston/connecting rod assembly. (See Page
7– 86.)

CD–15520

Remove the front cover [C]. C

To disassembly, assembly and repair the front cover.
(See Page 7– 95.)
Remove the flywheel. (See Page 7–33.)

CD–15521

Remove the rear cover [D].

D
To install a new rear seal and inspect the cover. (See
Page 7–84.)

CD–15524

863, 863H Bobcat Loader

Revised Feb. 97 –7–58– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
Disassembly (Cont’d)
A
Install the timing tool (Item 1) [A] for the camshaft.
Remove the thrust washer from the camshaft [A].
Remove the timing tool.
1

CD–15525

Remove the camshaft [B]. B

CD–15541

Mark the location of each main bearing cap so it will be

returned to original position. C
Remove the main bearing caps bolts [C].
Remove the main bearing caps.
Remove the crankshaft.
To check the crankshaft specifications. (See Page 7–85.)
Remove the upper half of the main bearings.

CD–15526

Remove the tappets from the engine block [D].

D

CD–15527

863, 863H Bobcat Loader

Revised Feb. 97 –7–59– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
Assembly
A
Install the thermostat and compression spring [A].
Install the plug and tighten to 82 ft.–lbs. (111 Nm) torque.

CD–15528

Install the oil pressure control valve and compression

spring [B].
B
Install the plug.

CD–15531

Install new seals on the fittings and/or plugs.

Install all the fittings and/or plugs and tighten to 82 ft.–lbs. C
(111 Nm) torque [C].

CD–15532

Install the plug and tighten to 37 ft.–lbs. (50 Nm) torque

[D]. D

CD–15537

863, 863H Bobcat Loader

Revised Feb. 97 –7–60– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
A
Assembly (Cont’d)
Install the oil pressure switch and tighten to 115 in.–lbs.
(13 Nm) torque [A].

CD–15538

Install a new seal on the plug and install in the block.

Tighten the plug to 21 ft.–lbs. (28 Nm) torque [B]. B

CD–15539

Install the tappets [C]. C

CD–15540

Before installing the new piston cooling oil nozzle, check

that the bores in the block are clean and free of oil. Press D
in the piston cooling nozzle as far as it will go [D].

CD–15435

863, 863H Bobcat Loader

Revised Feb. 97 –7–61– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
A
Assembly (Cont’d)
Install the camshaft [A].

CD–15541

Install the thrust washer with the lubricating groove

toward the crankcase [B]. B

CD–15542

Install the camshaft timing tool (Item 1) [C].

Tighten the camshaft thrust washer bolt to 15 ft.–lbs. (21
C
Nm) torque [C].
Remove the timing tool. 1

CD–15543

Install the upper main bearing halves [D].

D

CD–15544

863, 863H Bobcat Loader

Revised Feb. 97 –7–62– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
A
Assembly (Cont’d)
Install the other main bearing half into the main bearing
caps [A].

CD–15545

Install the thrust bearings halves on the main bearing cap

[B]. B
Measure the width of the thrust washers/main bearing
cap [B].

CD–15546

Measure the bearing journal width at the crankshaft

(inset) [C] C
Specifications:
Journal Width Std. . . . . . . . . . . . . . . . . 1.378–1.379 inch
(35,0–35,04 mm)
Limit for O/S . . . . . . . . . . . . . . . . 1.395 inch (35,44 mm)
Determine the end play for the crankshaft [C]. CD–15547

Specifications:
Std. End Play . . . . . . . . . . . . . . . . . . . . 0.004–0.010 inch
(0,1–0,273 mm)
Wear Limit . . . . . . . . . . . . . . . . . . . . . 0.016 inch (0,4 mm)
CD–15548
Use new thrust washer as needed to get the correct end
play.
D
Install the main bearing locating sleeves [D].

CD–15549

863, 863H Bobcat Loader

Revised Feb. 97 –7–63– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
Assembly (Cont’d)
A
Install the crankshaft into the engine block [A].

CD–15550

Lubricate the thrust washer with grease and install them

on the main bearing cap [B]. B

CD–15551

Install the main bearing/thrust washer assembly [C].

C
NOTE: The main bearing cap No. 1, at the flywheel
end, the chamfer must be towards the
flywheel end.

CD–15552

Install the main bearing caps/main bearing assembly [D]. D

Make sure they are returned to their original location.

CD–15553

863, 863H Bobcat Loader

Revised Feb. 97 –7–64– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
A
Assembly (Cont’d)
Tighten the main bearing cup bolts as follows [A]:
Initial Torque . . . . . . . . . . . . . . . . . . . . . 37 ft–lbs. (50 Nm)
1st Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
2nd Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°

CD–15554

Put sealing compound on the rear cover [B].

B

CD–15555

Install the rear cover complete with a new rear seal [C]. C
NOTE: Make sure the rear cover oil pan surface
aligns with the engine block surface.

Tighten the bolts to 15 ft.–lbs. (21 Nm) torque [C].

CD–15556

Measure the distance between the top edge of the

crankpin (TDC) and cylinder head sealing surface at ever D
cylinder [D].

CD–15557

863, 863H Bobcat Loader

Revised June 98 –7–65– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
A
Assembly (Cont’d)
Compare actual dimension with the dimension listed [A]:
Specifications:
Piston Class A . . . . . . . . . . . . . . . . . . . 7.732–7.736 inch
(196,39–196,49 mm)
NOTE: If the crankshaft is undersize, 0.005 inch
(0,125 mm) must be added to the dimension
listed.

CD–15558

Install the connecting rod bearing halves into the

connecting rod [B].
B

CD–15559

Before installing piston/connecting rod assembly, make

sure the piston ring gaps are staggered as shown in Fig.
C
[C].

CD–15560

Install a piston ring compressor on the piston rings. D

Install the piston/connecting rod assembly into the engine
block [D].

NOTE: The flywheel symbol on the piston must be

toward the flywheel.

CD–15561

863, 863H Bobcat Loader

Revised Feb. 97 –7–66– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
A
Assembly (Cont’d)
Install the connecting rod cap on the connecting rod,
make sure the numbers are aligned [A].

CD–15562

Tighten the connecting rod bolts as follows [B]:

Initial Torque . . . . . . . . . . . . . . . . . . . . 22 ft.–lbs. (30 Nm)
B
1st Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
2nd Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°

CD–15563

Check that the connecting rods can be easily moved back

and forth on the crankpin [C].
C

CD–15564

Put sealing compound on the front cover sealing surface

[D]. D
NOTE: Make sure the camshaft/centrifugal governor
connecting is clean and free of oil.

CD–15565

863, 863H Bobcat Loader

Revised Feb. 97 –7–67– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
Assembly (Cont’d)
A
Install the front cover with the new shaft seals on the
engine block [A].

NOTE: Make sure the oil pan sealing surface on the

front cover aligns with the sealing surface on
the block [A].

CD–15566

Tighten the front cover bolts to 15 ft.–lbs. (21 Nm) torque

[B]. B

CD–15567

Install the crankshaft gear on the crankshaft [C]. Make

sure the mating surfaces are clean and free of oil. C
Install the bolt and tighten to 243–295 ft.–lbs. (330–400
Nm) torque. (See Page 7–126 for the correct procedure):

Install the camshaft gear [D]. CD–15568

Make sure all mating surfaces are clean and free of oil.
Install the camshaft bolt [D].
D

CD–15468

863, 863H Bobcat Loader

Revised June 98 –7–68– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
A
Assembly (Cont’d)
Tighten the camshaft bolt finger tight only [A]. Camshaft
gear must still turn freely.

CD–15469

Install a new gasket on the oil pump [B]. B

CD–15470

Install the oil pump on the engine block [C].

C

CD–15471

Tighten the oil pump bolts to 16 ft.–lbs. (22 Nm) torque

[D]. D
Install the engine timing belt. (See Page 7–46.)

CD–15472

863, 863H Bobcat Loader

Revised Feb. 97 –7–69– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
Assembly (Cont’d)
A
Put spacers on sealing surface of the engine block and
set dial indicator gauge to 0 [A]. (See Page 7–55, for
correct tool.)

CD–15473

Position the dial gauge on the piston [B]. B

CD–15474

Measure at the gauge points (Item 1) [C].

C
To determine maximum piston projection measure all the
pistons. 1
1

Piston pin axis B–14695

Compare the measurements with the specifications to

determine the correct cylinder head gasket.
D
Specifications:
Marking of Cylinder
Piston Projection Head Gasket [D]
0.023–0.027 inch (0,59–0,69 mm) . . . . . . . . . . . 1 Notch
0.027–0.030 inch (0,69–0,76 mm) . . . . . . . . 2 Notches
0.030–0.033 inch (0,76–0,83 mm) . . . . . . . . 3 Notches

CD–15475

863, 863H Bobcat Loader

Revised June 98 –7–70– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
A
Assembly (Cont’d)
Make sure the dowel pins are installed in the engine block
[A].

CD–15476

Install the cylinder head gasket [B]. Gasket is marked

TOP. B
Make sure the sealing surfaces of the cylinder head
gasket is free of oil.
Install the cylinder head.

CD–15477

Measure the cylinder head bolts. C

Specifications: (BF4M1011)
Std. Length . . . . . . . . . . 5.90 ± 0.03 inch (150±0,8 mm)
Specifications: (BF4M1011F)
Std. Length . . . . . . . . . . 7.28 ± 0.03 inch (185±0,8 mm)
Put a light coat of oil on the head bolts [C].
Install the head bolts.

CD–15478

D 8 6 4 5 9

10 3 1 2 7
Tighten the cylinder head bolts to the correct torque in the
correct sequence [D].
Initial Torque . . . . . . . . . . . . . . . . . . . . 22 ft.–lbs. (30 Nm)
1st Stage Torque . . . . . . . . . . . . . . . . 59 ft.–lbs. (80 Nm)
2nd Stage Torque . . . . . . . . . . . . . 118 ft.–lbs. (160 Nm)
3rd Stage Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90°

CD–15479

863, 863H Bobcat Loader

Revised June 98 –7–71– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
A
Assembly (Cont’d)
Install the push rods [A].

CD–15480

Install the rocker arms/bracket assembly [B]. B

CD–15481

Tighten the rocker arm bracket bolts to 15 ft.–lbs. (21 Nm)

torque [C]. C
Set the valve clearance. (See Page 7–35.)

CD–15482

Install the valve cover gasket [D]. Install the valve cover.
Tighten the bolts to 75 in.–lbs. (8,5 Nm) torque.
D
Install new intake manifold gasket.
Install the intake manifold and tighten the bolts to 15
ft.–lbs. (20 Nm) torque.
Install new exhaust manifold gaskets.
Install the exhaust manifold and tighten the bolts to 30
ft.–lbs. (40 Nm) torque.

CD–15483

863, 863H Bobcat Loader

Revised Feb. 97 –7–72– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
A
Assembly (Cont’d)
Install a new seal on the fuel lift pump [A].

CD–15484

Turn the camshaft so the fuel lift pump lobe is at B.D.C.

(bottom dead center) [B]. B

CD–15485

Install the fuel lift pump [C].

C

CD–15486

Tighten the lift pump bolts to 15 ft.–lbs. (21 Nm) torque

[D].
D
Install a new oil filter.
Install the fuel injectors. (See Page 7–40.)
Install the fuel injector pumps. (See Page 7–36.)

CD–15487

863, 863H Bobcat Loader

Revised Feb. 97 –7–73– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
863,863HServiceManual#6724799–EngineServicePart3of5

Assembly (Cont’d)
A
Put sealing compound on the sealing surface of the oil
suction pipe [A].

CD–15488

Install the oil suction pipe and tighten the bolts to 16

ft.–lbs. (22 Nm) torque [B].
C

CD–15489

Put sealing compound on the sealing surface of the oil

pan [C].
C
Install the oil pan

CD–15490

Initially install the corner bolts first and tighten to 5 in.–lbs.

(0,5 Nm) torque. D
Install the oil pan bolts and tighten to 15 ft.–lbs. (21 Nm)
torque as shown in the Figure [D].
Install the oil pan plug and tighten to 40 ft.–lbs. (55 Nm)
torque.
Install the flywheel. (See Page 7–33.)
Install the turbocharger. (See Page 7–110.)
Install the starter. (See Page 6–1.)
Install the alternator. (See Page 6–1.) B–14696

863, 863H Bobcat Loader

Revised Feb. 97 –7–74– Service Manual
CYLINDER LINERS
Checking the Cylinder Liners
A
Clean the engine block and inspect for damage.
Install the main bearing caps [A].
Tighten the main bearing cap bolts as follows:
Initial Torque . . . . . . . . . . . . . . . . . . . . 37 ft.–lbs. (50 Nm)
1st Stage Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
2nd Stage Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°

CD–15319

Using a dial indicator gauge check the cylinders [B].

B

CD–15421

Check the cylinders with engine block longitudinal (a) and

transverse (b) axis and in three planes [C].
C
Specifications: b
1
Cylinder Bore . . . . . . . . . . . . . . . . . . . 3.58 + 0.0008 inch
(91 + 0,02 mm)
Wear Limit . . . . . . . . . . . . . . . . . . . . . 3.59 inch (91,1 mm) a 1 2 2

3
b

B–14697

863, 863H Bobcat Loader

Revised Feb. 97 –7–75– Service Manual
CAMSHAFT BEARINGS
Checking
A
Check the camshaft bearing bushings at points (1) and (2)
in the planes of (a) and (b) [A]. b
a
1 2

B–14698

Check the camshaft bushings using a gauge [B].

Inner Diameter . . . . . . . . . . . . . . . . . . 2.126 + 0.002 inch
B
(54 + 0,054 mm)
Wear Limit . . . . . . . . . . . . . . . . . . 2.129 inch (54,08 mm)

CD–15350

Removal and Installation

C
Remove all the camshaft bearing bushings using a
camshaft bushing removal tool as needed [C].

CD–15361

Use the dimensions in figure [D] to install the camshaft

D
0.098+0.012 inch

4.681+0.012 inch

0.019+0.012 inch
(118,9+0,3 mm)

8.98 +0.012 inch

bushings.
4.61+0.012 inch
(228,1+0,3 mm)

(117,1+0,3 mm)
(2,5+0,3 mm)

(0,5+0,3 mm)
0

A B

B–14699

863, 863H Bobcat Loader

Revised Feb. 97 –7–76– Service Manual
CAMSHAFT BEARINGS (Cont’d)
Removal and Installation (Cont’d)
A
When installing the new camshaft bushings make sure
the oil lube hole aligns with the oil hole in the engine block
[A].

CD–15383

Install the new camshaft bushings using a camshaft

bushing installation tool [B]. B

CD–15404

863, 863H Bobcat Loader

Revised Feb. 97 –7–77– Service Manual
CONTROL ROD GUIDE BUSHING
Removal
A
Remove the parallel pin [A].

CD–15409

Remove the control rod and spring [B].

B

CD–15411

Remove the cover [C].

C

CD–15412

Drill a 7/32 inch (5,5 mm) hole on one side of the pipe [D].
D
NOTE: Carefully clean the engine block after
drilling.

CD–15413

863, 863H Bobcat Loader

Revised Feb. 97 –7–78– Service Manual
CONTROL ROD AND GUIDE BUSING (Cont’d)
Removal (Cont’d)
A
Install the puller into the bore until the pin engages [A].

CD–15414

Install the spacer tool in position. Pull the pipe from the
lower press fit [B]. B
NOTE: Do Not pull pipe completely out.

Remove the spacer tool.

CD–15415

Press pin in until it does not project beyond the pipe [C].
Pull the pipe out completely. C

CD–15416

Using the tool, drive the guide bushing out [D].

D

CD–15417

863, 863H Bobcat Loader

Revised Feb. 97 –7–79– Service Manual
CONTROL ROD AND GUIDE BUSHING (Cont’d)
Installation
A
Install the new bushing into the center of the arbor
assembly [A].

CD–15418

Install the guide on the arbor assembly with the chamfer

pointing toward the crankcase [B].
B

CD–15419

Fasten the arbor assembly and bushing on the engine

block [C].
C

CD–15420

Drive the bushing into the engine block as far as it will go

[D]. D

CD–15422

863, 863H Bobcat Loader

Revised Feb. 97 –7–80– Service Manual
CONTROL ROD AND GUIDE BUSING (Cont’d)
Installation (Cont’d)
A
Remove the arbor assembly [A].

CD–15423

Remove the guide bushing at the flywheel end of the

engine block [B]. B

CD–15424

Assemble the arbor without the spacer [C].

C

CD–15425

Install the guide bushing on the arbor assembly with the

chamfer pointing toward the crankcase [D]. D

CD–15426

863, 863H Bobcat Loader

Revised Feb. 97 –7–81– Service Manual
CONTROL ROD AND GUIDE BUSHING (Cont’d)
Installation (Cont’d)
A
Fasten the arbor assembly and guide bushing to the
engine block [A].

CD–15427

Drive in the guide bushing as far as it will go, at the

flywheel end [B].
B

CD–15428

Remove the arbor assembly [C].

C

CD–15429

Install the new pipe in the block as far as it will go with the
arbor assembly [D]. D

CD–15430

863, 863H Bobcat Loader

Revised Feb. 97 –7–82– Service Manual
CONTROL ROD AND GUIDE BUSING (Cont’d)
Installation (Cont’d)
A
Put sealing compound on the new cover [A].

CD–15431

Install the new cover flush with the engine block [B]. B

CD–15432

Install the control rod with starter spring into the guide
bushings [C].
C

CD–15433

Compress the starter spring. Install the parallel pin into

the recess for the control rod travel limitation [D]. D
Check to make sure it is flush with the surface.

CD–15434

863, 863H Bobcat Loader

Revised Feb. 97 –7–83– Service Manual
REAR COVER SEAL
Removal and Installation
A
Remove the rear cover shaft seal [A].

CD–15438

Clean the seal seating surface [B]. Inspect the cover for
damage, replace as needed. B

CD–15439

When installing the new shaft seal, use the dimension

C

0.803+0.008 inch
(20,4+0,2 mm)
shown in Figure [C].

B–14700

Use the seal driver tool and install to the correct depth [D].
(See Page 7–55, for correct tool.) D

CD–15441

863, 863H Bobcat Loader

Revised Feb. 97 –7–84– Service Manual
CRANKSHAFT
A
Checking The Crankshaft
Put the crankshaft on v–blocks.
Check the main bearing journals:
Specifications:
– 0.0004
Journal Dia. . . . . . . . . . . . . . . . . . . . . 2.755 – 0.0012 inch
– 0.0001
(70 – 0.03
mm)

Each Undersize . . . . . . . . . . . . . . . 0,010 inch (0,25 mm)

CD–15443
– 0.0004
Undersize Limit . . . . . . . . . . . . . . . . . 2.736 – 0.0012 inch
– 0.01
69,51 – 0.03 mm) B
Wear Limit
Journal Oval . . . . . . . . . . . . . . 0.0003 inch (0,008 mm)

Check the thrust bearing width [A].

Specifications:
Journal Width . . . . . . . . . . . . . . . . . . 1.378 + 0.0016 inch
(35 + 0.04 mm)
Each Oversize . . . . . . . . . . . . . . . . . 0.016 inch (0,4 mm)
Oversize Limit . . . . . . . . . . . . . . 1.395 inch (35,44 mm) CD–15444

Check the connecting rod journals [B].

– 0.0004
C
Pin Dia. . . . . . . . . . . . . . . . . . . . . . . . . . 2.16 – 0.0012 inch
– 0.01
(55 – 0.03 mm)

– 0.0004
Undersize Limit . . . . . . . . . . . . . . . . . 2.146 – 0.0012 inch
– 0.01
(54,5 – 0.03
mm)
Wear Limit
Pin Oval . . . . . . . . . . . . . . . . . . 0.0004 inch (0,01 mm)

Use a dial indicator and check crankshaft for out of CD–15445

roundness [C].
Specification:
D
Out of Roundness Max. . . . . . . . . 0.002 inch (0,05 mm)

Check the surface of the crankshaft seal area [D].

Recondition the crankshaft as needed.

CD–15446

863, 863H Bobcat Loader

Revised June 98 –7–85– Service Manual
CONNECTING ROD
Checking the Connecting Rod
A b

When checking the connecting rod large and small end,

measure at the points (1) and (2) and in planes (a) and (b)
[A].

1 2 a

B–14701

Check the small end bushing [B]. B

Specifications:
+ 0.00014
I.D. of Small End Bushing . . . . . . . . 1.181 + 0.00009 inch
+ 0,035
(30 + 0,025 mm
Wear Limit Bushing
Clearance . . . . . . . . . . . . . . . . . . . 0.003 inch (0,08 mm)

CD–15447

Replace small end busing as needed [C].

C
Bore for Small End Bushing . . . . . . 1.299 + 0.0008 inch
(33 + 0,02 mm)
+ 0.004
O.D. of Small End Bushing . . . . . . . 1.299 + 0.0027 inch
+ 0,110
(33 + 0,070
mm)

CD–15448

Press in the small end bushing, make sure the lubrication

holes are in alignment [D]. D

CD–15449

863, 863H Bobcat Loader

Revised June 98 –7–86– Service Manual
CONNECTING ROD (Cont’d)
Checking the Connecting Rod (Cont’d)
A
After pressing in the small end bushing, bore the bushing
to the following dimensions [A].
Specifications:
+ 0.00014
I.D. of Small End Bushing . . . . . . . . 1.181 + 0.00009 inch
+ 0,035
(30 + 0,025 mm)

CD–15450

Install the correct cap on the correct rod [B].

B

CD–15451

Tighten the connecting rod cap nuts as follows [C].

C
Initial Torque . . . . . . . . . . . . . . . . . . . . 22 ft.–lbs. (30 Nm)
lst Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
2nd Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°

Measure the big end bore [D]. If the measurement is the

same as the specific valve, the necessary preload on the
bearing halves will be obtained.
Specifications:
Big End I.D. . . . . . . . . . . . . . . . . . . . 2.303 + 0.0008 inch CD–15452
(58,5 + 0,02 mm)
Remove connecting rod cap. Install new bearing halves.
Tighten the connecting rod cap nuts and tighten as listed D
above.
Measure the bearing halves:
Big End Bearing I.D. . . . . . . . . . . . . . 2.1655–2.167 inch
(55,004–55,04 mm)
Each Undersize . . . . . . . . . . . . . . . 0.010 inch (0,25 mm)
Limit For Undersize . . . . . . . . . . . . . . 2.148–2.1472 inch
(54,504–54,54 mm)
Radial Clearance
Wear Limit . . . . . . . . . . . . . . . . . . 0.005 inch (0,12 mm) CD–15454

863, 863H Bobcat Loader

Revised June 98 –7–87– Service Manual
CONNECTING ROD (Cont’d)
Checking the Connecting Rod (Cont’d)
A
Check the connecting rod, without bearing halves, on a
connecting rod tester.
Specifications:
Parallel Check–Tolerance . . . . . . . 0.004 inch (0,10 mm)
Over a Distance of . . . . . . . . . . . . . 3.94 inch (100 mm)
Squareness Check–Tolerance . . . 0.002 inch (0,05 mm)
See Page 7–89 to check the piston specifications.
CD–15456
Install the snap ring into the piston [A].

NOTE: The snap ring gap must be towards the B

piston crown [B].

CD–15457

Install the piston on the connecting rod [C].

C
The flywheel symbol (Item 1) [C] on the piston must point
toward the flywheel.

CD–15458

Install the other side snap ring [D]. D

CD–15459

863, 863H Bobcat Loader

Revised June 98 –7–88– Service Manual
PISTON AND PISTON PIN
Checking the Piston
A
Remove the piston rings from the piston [A].
Remvoe the piston from the connecting rod.
See Page 7–86 to check connecting rod specifications.

B–08194

Clean and inspect piston and piston ring grooves [B]. B

B–08231

Measure the ring gap with a feeler gauge in the cylinder

[C]. C
Specifications (BF4M1011):
Wear Limit
1st Ring Gap . . . . . . . 0.011–0.019 inch (0,3–0,5 mm)
2nd Ring Gap . . . . . 0.031–0.041 inch (0,8–1,05 mm)
3rd Ring Gap . . . . . 0.018–0.028 inch (0,45–0,7 mm)
Specifications (BF4M1011F):
Wear Limit
1st Ring Gap . . . . . . . 0.012–0.020 inch (0,3–0,5 mm)
2nd Ring Gap . . . . . . 0.031–0.039 inch (0,8–1,0 mm)
3rd Ring Gap . . . . . 0.018–0.028 inch (0,45–0,7 mm B–08229

Using new rings, measure the ring grooves using a feeler

gauge [D]. D
Specifications:
Wear Limit 1st Ring . . . . . . . . 0.008 inch (0,2 mm)
2nd Ring . . . . . . . 0.006 inch (0,16 mm)
3rd Ring . . . . . . . 0.005 inch (0,12 mm)

B–08228

863, 863H Bobcat Loader

Revised June 98 –7–89– Service Manual
PISTON AND PISTON PIN (Cont’d)
Checking Piston Pin
A
Check piston pin for wear [A].
Specifications (BF4M1011):
Piston Pin O.D. 1.023 –0.0002 inch (26,0 –0,005 mm)
Specifications (BF4M1011F):
Piston Pin O.D. 1.118 –0.0002 inch (30,0 –0,005 mm)

B–08230

Installing Piston Rings

B
When installing the piston rings position them as listed
below [B]:
lst Ring – Key stone Ring, top facing combustion
chamber.
2nd Ring – Tapered compression ring, top facing
combustion chamber.
3rd Ring – Bevelled edge slotted oil control ring.
The gap of each ring must be offset by 180° to the other
ring.

B–08194

863, 863H Bobcat Loader

Revised June 98 –7–90– Service Manual
CYLINDER HEAD
Disassembly
A
NOTE: Do not grind the cylinder head surface, if its
damaged, replace the cylinder head.
Using a valve spring tool, remove the spring locks, valve
spring cap, valve spring and valve [A]. (See Page 7–55,
for correct tool.)
Repeat the procedure for all the valves.
Remove the valve seals.
Clean the cylinder head and inspect for damage.
CD–15461
Checking the Valves
Measure the valve stem clearance [B].
B
Specifications:
Wear Limits:
Intake Valve . . . . . . . . . . . 0.005 inch (0,12 mm)
Exhaust Valve . . . . . . . . . 0.006 inch (0,15 mm)

B–08205
Measure the valve stem diameter [C].
Std. Intake Valve . . . . . . . . . 0.314 –0.0006 inch
(7,98 –0,015 mm) C
Std. Exhaust Valve . . . . . . 0.313 – 0.0006 inch
(7,96 –0,15 mm)
Measure the valve rim thickness [D].
Specifications (BF4M1011):
Intake Valve . . . . . . . . . . . . . . . . . . 0.03 inch (0,8 mm)
Exhaust Valve . . . . . . . . . . . . . . . . . 0.05 inch (1,2 mm)
Specifications (BF4M1011F):
Intake Valve . . . . . . . . . . . . . . . . . 0.055 inch (1,4 mm)
Exhaust Valve . . . . . . . . . . . . . . . . . 0.05 inch (1,2 mm)
Measure the valve head diameter [D]. B–08204

Specifications (BF4M1011):
Intake Valve . . . 1.579 ± 0.004 inch (40,1 ± 0,1 mm)
Exhaust Valve . . 1.374 ± 0.004 inch (34,9 ± 0,1 mm) D
Specifications (BF4M1011F):
Intake Valve . . . 1.594 ± 0.004 inch (40,5 ± 0,1 mm)
Exhaust Valve . . 1.374 ± 0.004 inch 34,9 ± 0,01 mm)
Valve seat angle [D]. Angle
Specifications (BF4M1011)
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Thickness
Specifications (BF4M1011F) Diameter
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° B–08202

863, 863H Bobcat Loader

Revised June 98 –7–91– Service Manual
CYLINDER HEAD (Cont’d)
A
Checking Valve Seats
Measure the valve seat width [A].
Specifications (BF4M1011):
Width . . . . . . . . . . 0.067 ± 0.016 inch (1,7 ± 0,4 mm)
Specifications (BF4M1011F):
Width (Intake) . . 0.062 ± 0.016 inch (1,58 ± 0,4 mm)
(Exhaust) . 0.067 ± 0.016 inch (1,7 ± 0,4 mm)

CD–15463

Measure the valve clearance between the valve head and

cylinder head sealing surface [B]. B
Valve penetration into cylinder head:
Specifications (BF4M1011):
Wear Limit . . . . . 0.039 ± 0.005 inch (1,0 ± 0,13 mm)
Specifications (BF4M1011F):
Wear Limit . . . 0.0512 ± 0.0051 inch (1,3 ± 0,13 mm)
Recondition the valve seats and valve guides if worn.

Valve Spring CD–15464

Measure valve spring free length [C].

Specifications:
C Inclination
Valve Spring Dia. . . . . . . . . . . . 0.132 inch (3,35 mm)
Free Length . . . . . . . . . . . . . . . . 1.74 inch (44,3 mm)
Valve Spring Dia. . . . . . . . . . . . 0.134 inch (3,40 mm)
Free Length . . . . . . . . . . . . . . . 1.547 inch (39,3 mm)
Inclination . . . . . . . . . . . . . . . . . . . 0.126 inch (3,2 mm)
Free Length

Square

B–08208

Assembly
Install the valve into the cylinder head [D]. D
Install the protective sleeve or masking tape on the valve
stem grooves [D].

CD–15322

863, 863H Bobcat Loader

Revisded June 98 –7–92– Service Manual
CYLINDER HEAD (Cont’d)
Assembly (Cont’d)
A
Install the valve seal on the protective sleeve and push
the seal down [A].
Remove the protective sleeve.

CD–15323

Use the tool and press the valve stem as far as it will go
[B]. (See Page 7–55, for correct tool.)
B

CD–15324

Install the valve spring and cap [C].

C

CD–15325

Use the valve spring tool, install the valve spring lock [D].
D
Repeat the above procedure to install all the valves.

CD–15461

863, 863H Bobcat Loader

Revised Feb. 97 –7–93– Service Manual
ROCKER ARM AND BRACKET
Checking
A
Disassembly the rocker arms from the bracket [A].

CD–15327

Check for wear at the following locations and replace as

needed [B]: B
Journals
Adjusting Bolt
Rocker Arm Contact Face
Bore

CD–15328

Check the oil passages that they are open and clean [C].
C

CD–15330

Install the rocker arms on the bracket.

Install the snap ring [D]. D

CD–15331

863, 863H Bobcat Loader

Revised Feb. 97 –7–94– Service Manual
FRONT COVER
Disassembly
A
NOTE: Dynamometer testing is recommended if the
governor assembly is re–built.
Remove the engine shut–down solenoid [A].

CD–15343

Disconnect the governor spring [B].

B

CD–15344

Remove the governor lever shaft [C].

C

CD–15345

Remove the shims below the governor lever shaft [D].

D

CD–15346

863, 863H Bobcat Loader

Revised Feb. 97 –7–95– Service Manual
FRONT COVER (Cont’d)
Disassembly (Cont’d)
A
Remove the centrifugal governor [A].

CD–15347

Remove the camshaft seal [B].

B

CD–15348

Remove the crankshaft seal [C].

C

CD–15349

Disconnect the spring [D].

D

CD–15351

863, 863H Bobcat Loader

Revised Feb. 97 –7–96– Service Manual
FRONT COVER (Cont’d)
Disassembly (Cont’d)
A
Remove the dowel pin [A].

CD–15352

Remove the shut–down lever with spacer bushings [B]. B

CD–15353

Remove the shaft, spacer bushing and spring [C].

C

CD–15354

Remove the O–ring [D].

D

CD–15355

863, 863H Bobcat Loader

Revised Feb. 97 –7–97– Service Manual
FRONT COVER (Cont’d)
Disassembly (Cont’d)
A
Remove the cover [A].

CD–15356

Remove the dowel pin [B]. B

CD–15357

Remove the pin from the lever [C].

Do not damage the cover sealing surface. C

CD–15358

Remove the speed control lever and spacer bushing [D].

D

CD–15359

863, 863H Bobcat Loader

Revised Feb. 97 –7–98– Service Manual
FRONT COVER (Cont’d)
Disassembly (Cont’d)
A
Remove the O–ring [A].

CD–15360

Before removing the torque control assembly, measure

the height from the cover [B] and make a record of this
for assembly.
B

CD–15373

Remove the nut and clamp [C]. C

Remove the torque control assembly.

CD–15363

D
Remove the breather vent [D].

NOTE: On later model Deutz engines the breather is

located in the valve cover. The breather vent
shown in photo [D] is used in both engines.

CD–15364

863, 863H Bobcat Loader

Revised June 98 –7–99– Service Manual
FRONT COVER (Cont’d)
863,863HServiceManual#6724799–EngineServicePart4of5

Assembly
A
Inspect the front cover for damage [A].
Replace the front cover as needed.

CD–15365

Inspect the individual parts of the torque control assembly

[B].
B
Replace the parts as needed.

B–14703

If the torque control was disassemble, do the following

procedure to assemble:
C 1
2
3
Turn (Item 1) [C] into (Item 2) [C] to leave a protrusion of
0–0.039 inch (0–1 mm). 6
Tighten the lock nut (Item 3) [C] to 12 ft.–lbs. (16 Nm)
torque.
Turn (Item 4) [C] as far as it will go into (Item 5) [C]. Turn
back one full turn.
Tighten the lock nut (Item 6) [C] to 53 in.–lbs. (6 Nm) 0–0,39 inch
torque. (0–1 mm)
5 4
B–14704

863, 863H Bobcat Loader

Revised Feb. 97 –7–100– Service Manual
FRONT COVER (Cont’d)
Assembly (Cont’d)
A
Install the torque control into the front cover [A].

CD–15371

Install the torque control assembly to the dimensions

taken (Page 100; Fig. [B]) or use the procedure below:
B
Measure the thread reach [C].
Specification:
Thread Reach . . . . . . . . . . . . . . . . . 0.252 ± 0.019 inch
(6,4 ± 0,5 mm)

NOTE: Dynamometer testing may be necessary

depending on engine performance.

CD–15373

Install the clamp and nut [C].

C

CD–15374

Tighten the clamp nut to 88 in.–lbs. (10 Nm) torque [D].

D

CD–15375

863, 863H Bobcat Loader

Revised Feb. 97 –7–101– Service Manual
FRONT COVER (Cont’d)
Assembly (Cont’d)
A
Put a light coat of oil on the camshaft seal.
Press the camshaft seal into the front cover [A]. (See
Page 7–55, for correct tool.)

CD–15376

Do Not put oil on the crankshaft seal. B

Press the crankshaft seal into the front cover [B].

CD–15377

Adjust the distance of the shut–down stop screw to 0.236

± 0.039 inch (6 ± 1 mm) [C].
C 0.236±0.039 inch
(6±1 mm)
Tighten the lock nut to 40 in.–lbs. (4,5 Nm) torque.

B–14705

863, 863H Bobcat Loader

Revised Feb. 97 –7–102– Service Manual
FRONT COVER (Cont’d)
Assembly (Cont’d)
A 0.79±0.039 inch
(20±1 mm)
Adjust the minimum speed screw to 0.79 ± 0.039 inch (20
± 1,0 mm) [A].
Tighten the lock nut to 40 in.–lbs. (4,5 Nm) torque.

B–14706

Install the spacer bushing and spring on the shut down

shaft [B]. B

CD–15380

Install the shut down shaft [C].

C

B–14707

Put grease on the O–ring and install on the shaft [D].

D

CD–15382

863, 863H Bobcat Loader

Revised Feb. 97 –7–103– Service Manual
FRONT COVER (Cont’d)
Assembly (Cont’d)
A
Install the spacer bushing [A].

CD–15384

Install the shut down lever and dowel pin [B].

B

CD–15385

Put grease on the O–ring and install in the front cover [C].
C

CD–15386

Install the spacer bushing on the speed control lever [D].

Install the speed control lever into the front cover [D]. D

CD–15387

863, 863H Bobcat Loader

Revised Feb. 97 –7–104– Service Manual
FRONT COVER (Cont’d)
Assembly (Cont’d)
A
When installing the speed control lever, make sure it is
installed in the correct direction [A].

B–14708

Install the dowel pin into the speed control lever [B].
B

CD–15389

Drive the pin into the lever [C].

C
The groove in the speed control shaft must be in line with
the dowel pin bore.

CD–15390

Inspect the centrifugal governor for wear [D]. Replace as

needed. D

CD–15391

863, 863H Bobcat Loader

Revised Feb. 97 –7–105– Service Manual
FRONT COVER (Cont’d)
Assembly (Cont’d)
A
Inspect the governor plate for wear [A].
Replace as needed.

CD–15392

Assemble the governor plate with the centrifugal

governor [B]. B

CD–15393

Install centrifugal governor assembly into the front cover

[C].
C
Be careful not to damage the shaft seal.

CD–15394

Inspect roller lever, shaft and idling lever wear [D].

D
Replace the parts as needed.

CD–15395

863, 863H Bobcat Loader

Revised Feb. 97 –7–106– Service Manual
FRONT COVER (Cont’d)
Assembly (Cont’d)
A
Install shims of at least 0.011 inch (0,3 mm) thickness at
points (Items 1 & 2) [A].
1

CD–15396

Install the governor lever shaft without the idling lever [B].
Tighten the bolts to 81 in.–lbs. (9,2 Nm) torque. B

CD–15397

Measure the ball bearing (Item 1) [C], by lightly pressing

the roller lever. C
Set the dial gauge to zero.

1
CD–15398

Place dial indicator on ball bearing (Item 1) [D].

D
Make record of the two readings.
The required tolerance is 0.0019 inch (0,05 mm).
It is possible to install extra shims at (Items 1 & 2) [A] to
get the required measurement.

CD–15399

863, 863H Bobcat Loader

Revised Feb. 97 –7–107– Service Manual
FRONT COVER (Cont’d)
Assembly (Cont’d)
A
Assemble the roller lever with the idling lever and shaft [A]

CD–15400

Install the complete governor lever shaft assembly into

the front cover. B
Tighten the bolts to 81 in.–lbs. (9,2 Nm) torque [B].

CD–15401

Connect the governor spring [C].

C

CD–15402

Install the cover with new gasket. Tighten the bolts to 40

in–lbs. (4,5 Nm) torque [D]. D

CD–15403

863, 863H Bobcat Loader

Revised Feb. 97 –7–108– Service Manual
FRONT COVER (Cont’d)
Assembly (Cont’d)
A
Install a greased O–ring on the shut down solenoid [A].

CD–15405

Install the shut down solenoid into the front cover [B]. B
Tighten the bolts to 79 in.–lbs. (9 Nm) torque.

CD–15406

Install new O–ring on the breather vent [C].

C

CD–15407

Install the breather vent into the front cover. Tighten the
bolts to 75 in.–lbs. (8,5 Nm) torque [D]. D

CD–15408

863, 863H Bobcat Loader

Revised Feb. 97 –7–109– Service Manual
TURBOCHARGER
Removal and Installation
A
Remove the exhaust pipe (Item 1) [A].

P–07780

Disconnect the air cleaner hose (Item 1) [B]. B

Disconnect the oil tubeline (Item 2) [B].

3 1
4

P–07779

Disconnect the oil tubeline (Item 1) [C]. C

Remove the exhaust manifold nuts (Item 3) [B].
Installation: Tighten the nuts to 22 ft.–lbs. (30 Nm)
torque.
Remove the hose clamps (Item 4) [B].
Remove the turbocharger from the intake manifold hose.

P–07343

863, 863H Bobcat Loader

Revised Feb. 97 –7–110– Service Manual
TURBOCHARGER (Cont’d)
Disassembly
A
Mark the turbine housing, bearing housing and back plate
so they will be assembled correctly [A].

CD–15292

Clamp the turbine housing in a vise [B].

Remove the nuts from the compressor and turbine
B
housing [B].
Remove the turbine housing.
Remove the compressor housing.

CD–15293

Clamp the hub of the shaft and turbine wheel assembly

in the vice [C].
C
NOTE: Use vice jaw guards.

CD–15294

863, 863H Bobcat Loader

Revised Feb. 97 –7–111– Service Manual
TURBOCHARGER (Cont’d)
Disassembly (Cont’d)
A
Remove the shaft nut [A].

NOTE: Use a hot air blower to heat the nut. When the
nut was installed, LOCTITE #640 was used on
the threads, do not bend the shaft when
removing the nut.

CD–15295

Heat the compressor wheel to a maximum temperature

of 130°F. (55°C.) using a hot air blower [B]. B
Protect the rotor threads from overheating.

CD–15296

863, 863H Bobcat Loader

Revised Feb. 97 –7–112– Service Manual
TURBOCHARGER (Cont’d)
A
Disassembly (Cont’d)
Carefully push out the shaft and turbine wheel assembly
[A].

CD–15297

Remove the piston rings from the shaft and turbine wheel
assembly [B].
B
Remove the heat shield.

CD–15298

863, 863H Bobcat Loader

Revised Feb. 97 –7–113– Service Manual
TURBOCHARGER (Cont’d)
Disassembly (Cont’d)
A
Clamp the bearing housing in a vise, use jaw guards [A].
Remove the screws [A].

NOTE: The screws are secured with LOCTITE #640.

CD–15299

Remove the back plate from the bearing housing.

B
Remove the sleeve from the back plate.
Remove the O–rings from the back plate.
Remove the piston rings from the backplate [B].

CD–15307

Remove the oil deflector ring, oil deflector and thrust

bearing from the bearing housing. C
Remove the spacer sleeve and thrust ring from the
bearing housing [C].

CD–15312

863, 863H Bobcat Loader

Revised Feb. 97 –7–114– Service Manual
TURBOCHARGER (Cont’d)
A
Inspection
Carefully clean the following parts:
Housings
Shaft and turbine wheel assembly
Compressor wheel
Back plate
Heat shield
Remove LOCTITE from threads.
Visual check the housings, heat shield, turbine and
compressor wheels for cracks, any foreign material and
scratches. Inspect oil feed holes in the bearing housing.
Inspect piston ring sealing surfaces and bearing areas for
damage.
Examine the turbine housing for scaling.
CD–15303
Examine the gas inlet and outlet flanges of the turbine
housing for distortion.
Examine the turbine and compressor wheels, for bent or B
broken, and the shaft for scoring at bearing seats.

NOTE: Wear parts which have excessive wear, as

well as rotating parts with cracks must be
replace [A].

Radial cracks up to 0.39 inch (10 mm) long are

permissible in the areas of the torque and partitioning wall
[B].
Replace the shaft and turbine wheel assembly with
scratches, cracks or any bent blades.
Place the shaft and turbine wheel assembly in twin
v–blocks. Use a dial indicator 0.20 inch (5 mm) from the
compressor wheel end of the shaft.
Measure the out–of–round. When it is more than 0.0003
inch (0,008 mm) out–of–round, replace the assembly.

CD–15304

863, 863H Bobcat Loader

Revised Feb. 97 –7–115– Service Manual
TURBOCHARGER (Cont’d)
Assembly
A
Make sure all the parts are clean. Put oil on the following
parts before assembling:
Bearing seat of the shaft
Bearings
Thrust bearing
Finger sleeve
Oil deflector ring
Thrust ring
Piston rings
Spacer sleeve
Install the bearings and snap rings in the bearing housing CD–15305
[A] & [B].

CD–15307

Clamp the shaft and turbine wheel assembly in a vice

using jaw plates. Install the two piston rings on the shaft.
C
Position the ring gaps at 180° to each other [C].

CD–15308

Install the heat shield on the shaft and turbine wheel

assembly [D]. D
NOTE: Install a piece of shim, 0.039 inch (1,0 mm)
thick between the heat shield end turbine
wheel to make sure that the piston rings are
guided inside the bearing housing bore.

CD–15309

863, 863H Bobcat Loader

Revised Feb. 97 –7–116– Service Manual
TURBOCHARGER (Cont’d)
Assembly (Cont’d)
A
Install the bearing housing carefully onto the rotor shaft
[A].

NOTE: Make sure the piston rings are seated, and

the heat shield and bearing housing turn
freely.

CD–15310

Install the thrust ring and spacer onto the rotor shaft [B].
B

CD–15311

Install the thrust bearing in bearing housing [C].

C

CD–15312

863, 863H Bobcat Loader

Added Feb. 97 –7–117– Service Manual
TURBOCHARGER (Cont’d)
Assembly (Cont’d)
A
Install a new oil deflector plate on the thrust bearing [A].
Install the oil deflector ring onto the rotor shaft with the
large collar at the top.
Install the piston rings onto the finger sleeve. Position the
piston ring gaps at 180° to each other.

CD–15313

Install finger sleeve, complete with piston rings into back

plate [B]. When necessary press piston rings together
B
using a screwdriver.

CD–15314

Put seal compound on backplate [C].

C

CD–15315

863, 863H Bobcat Loader

Added Feb. 97 –7–118– Service Manual
TURBOCHARGER (Cont’d)
Assembly (Cont’d)
A
Install back plate on bearing housing.
Put LOCTITE #640 on the screws.
Tighten the screws to 88 in.–lbs. (10 Nm) torque.
Heat compressor wheel to maximum 130°F (55° C.) using
a hot air blower.
Put oil on the compressor wheel seat on the shaft.
Push the warm compressor wheel onto the shaft and
turbine wheel assembly.

CD–15316

Pre–heat the shaft nut. Install and tighten to 44 in–lbs. (5

Nm) torque [D].
B
Cool the assembly for 10 minutes. Loosen the shaft nut
1–2 turns. Put LOCTITE #640 on the shaft nut. Tighten
to 44 in.–lbs. (5 Nm) + 60°.

CD–15317

863, 863H Bobcat Loader

Added Feb. 97 –7–119– Service Manual
TURBOCHARGER (Cont’d)
Assembly (Cont’d)
A
Put sealing compound on compressor housing back plate
O–ring groove.
Install the O–ring
Install the compressor housing on the back plate.
Coat the bolts with heat resistant lubricating paste.
Tighten the bolts to 62 in.–lbs. (7 Nm) torque [A].

CD–15318

Install dial indicator at the shaft end (Item 1) [B]. Press

shaft and turbine wheel assembly against the dial
indicator. Set to Zero. Release the shaft.
B 1

Axial End Play – Max. . . . . . . . . . . 0.006 inch (0,16 mm)

B–14709

Check radial play at turbine side (Item 1) [C] only.

C
Install the dial indicator touching the cone on the turbine
wheel.
Pull turbine wheel down using about 11 lbs. (50 N) of
1
force. Set to zero. Release the shaft.
Radial Play – Max. . . . . . . . . . . . 0.018 inch (0,4 6 mm)

B–14710

863, 863H Bobcat Loader

Revised Feb. 97 –7–120– Service Manual
POSITIVE CRANKCASE VENTILATION SYSTEM CLOSED
(S/N 514415609, 514611152, 514511106 & Below) A OPEN

Description
The positive crankcase ventilation system performs two
important functions for the engine. 1
1
1. To regulate crankcase negative pressure to 0.06 2
PSI (0,41 kPa) in the engine crankcase. 2
2. To provide an oil air mixture from the crankcase area
for lubrication of the engine valves and seats.
The crankcase breather valve [A] located in the front
engine cover controls the combustion blow–by gasses in 3
3
the crankcase. The gasses flow through the air cleaner
housing and into the intake manifold. The vacuum B–14795
(suction) created in the manifold is working on the
diaphragm (Item 1) [A] and against the spring (Item 2)
[A]. If the air filter becomes restricted the vacuum
increases and the diaphragm closes the connection to the
B
intake manifold preventing oil to be drawn into the air
cleaner housing.
3
During normal operation the breather valve [A] opens and
closes rapidly. The gasses flow from the breather valve
through the hose (Item 1) [B] into the PCV module (Item 2
2) [B] and [D]. Air continues out the module through the
hose (Item 3) [B] to the air cleaner housing. If the loader
is operated at a 30 angle or greater to the right side, a ball 1
inside the PCV module will close the outlet of the module.
This prevents oil from the engine crankcase from entering
the air cleaner housing. When the PCV outlet is closed the
check valve (Item 1) [C] and [D] opens allowing
temporary ventilation to the engine compartment. P–09052

C 1

Inspection
2
The breather valve vent hole (Item 3) [A] must be open
to allow correct valve operation.
The PCV module (Item 2) [D] can be rotated to verify the
ball is free to close the outlet passage. When rotating the
module you can feel and hear the ball movement. P–09053
Replace the module if the ball is not free. Module
disassembly and cleaning is not recommended.
The check valve (Item 1) [D] has a ball and spring to allow D 2
air to flow out the hose end of fitting only. A small punch
may be used in the threaded end of the check valve to
make sure the ball and spring open and close. The spring
pressure is very light. The check valve can be cleaned
with solvent or air pressure.
Routing of the hose is important for correct function. The
module inlet hose (Item 1) [B] must be installed as shown.
If the hose is replaced the correct length must be used to
prevent any loop or sag in the hose. The check valve hose
outlet (Item 2) [C] must be routed to the bottom of the 1
engine compartment as shown. Check all connections
and hoses for leaks or damage.
P–09056

863, 863H Bobcat Loader

Revised Jan. 98 –7–121– Service Manual
+ POSITIVE CRANKCASE VENTILATION SYSTEM (S/N
514415609, 514611152, 514511106 & Below) (Cont’d) A
Module Removal and Installation
Release the three dust cover clips (Item 1) [A]. 2

Remove the dust cover. 1

Remove both filter elements.
Disconnect the hose (Item 2) [A] at the tubeline.

1
P–07903

Loaders without BOSS: Remove the indicator bracket

bolt (Item 1) [B]. B 2
Loosen the hose clamps (Item 2) [B] and disconnect the
hoses from module.

1
P–07908

Loosen the bolt (Item 1) [C]. Slide the module rearward

and remove from the loader.
C
NOTE: The module mounting bracket is slotted to
allow removal or installation of module
without removing air cleaner housing mount
bolts.
1

P–07910

863, 863H Bobcat Loader

Revised Jan. 98 –7–122– Service Manual
OIL COOLER
A
Removal and Installation
Open the rear door.
1 1
Raise the rear grill.
Remove the hydraulic oil cooler. (See Page 3–1.)
Remove the four mounting bolts (Item 1) [A] from the oil
cooler. 2 1 1 2
Disconnect the tubelines (Item 2) [A] from the bulkhead
fittings.
P–07904

Loosen the tubeline fittings (Item 1) [B] and raise the

tubelines (Item 2) [B] (both sides) as shown and tighten
the fittings so they can be used as handles when
B
removing or installing the oil cooler.

1
1

2
2

P–07907

Lift the oil cooler from the loader frame [C]. C

P–07906

Before installing the oil cooler, check the seals (Item 1)

[D] at both sides of the oil cooler mounting frame. D
Replace the seals as needed.
1

P–07909

863, 863H Bobcat Loader

Added Apr. 97 –7–123– Service Manual
CRANKSHAFT GEAR MOUNTING BOLT
863,863HServiceManual#6724799–EngineServicePart5of5

A
Torque Procedure
The tool listed will be needed to do the following
procedure:
MEL 1522 Torque Multipiler Support Device
MEL 1526 Torque Multipiler 1

If the v–belt pulley is installed, remove the four bolts and

remove the pulley (Item 1) [A].

P–05292

Install the tool (Item 1) [B] on the crankshaft hub using the
v–belt pulley bolts. B
1
Install the bolt (Item 2) [B] and tighten to 95 ft.–lbs. (130
Nm) toruqe.

P–13135

Install the torque mulitpower tool (Item 1) [C], with the

socket, into the tool. C
1

P–13136

Tighten the gear bolt to 243–295 ft.–lbs. (330–440 Nm)

torque [D].
D

P–13137

863, 863H Bobcat Loader

Revised June 98 –7–124– Service Manual
SYSTEMS ANALYSIS
Page
Number
BICS™ SYSTEM CONTROLLER
Controller Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–11
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–10
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
Inspecting the BICS™ System Controller
(Engine STOPPED – Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Inspecting the Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Inspecting the Seat and Seat Bar Sensors (Engine RUNNING) . . . . . . 8–3
Inspecting the Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . . . . 8–3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
BOSS® DIAGNOSTIC TOOL
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–17

BOSS® INSTRUMENT PANEL

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–23
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
Controls Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–27
MONITOR SERVICE CODES
Alphabetic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–18
Numeric Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–18
Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–19
OPERATION SENSING SYSTEM UNIT
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–22
PWM CONTROL HANDLE
Handle Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–27
PWM ELECTRIC SOLENOID
Solenoid Coil Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–27
PWM MODULE
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–24 SYSTEMS
ANALYSIS
PWM TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–26
Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–25
RPM SENSOR
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–17
SEAT BAR SENSOR
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–12
Seat Bar Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–13

863, 863H Bobcat Loader

Revised June 98 –8–1– Service Manual
SYSTEMS ANALYSIS (Cont’d)
Page
Number

SEAT SENSOR
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–14
Seat Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–15
SENDER AND SENSOR
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–17
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–17
TRACTION LOCK
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–16
TROUBLESHOOTING THE BOSS® & L.C.D. DISPLAY . . . . . . . . . . . . . 8–21

863, 863H Bobcat Loader

Revised June 98 –8–2– Service Manual
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
Inspecting the BICS™ Controller (Engine STOPPED A
– Key ON) 1
1. Sit in the operator’s seat. Turn key ON, lower the seat 2
bar and disengage the parking brake. The four BICS
Controller lights should be ON (Items 1, 2, 3 & 5) [A], 3
the traction light (Item 4) [A] should be OFF.
4
2. Engage the parking brake and raise the seat bar fully.
Seat bar light (Item 2) [A], valve light (Item 3) [A] and
traction light (Item 4) [A] should be OFF.
5
3. Raise up slightly off the seat. Seat light (Item 1) [A]
should be OFF.
NOTE: Record what lights are blinking (if any) and
number of blinks. Refer to Page 8–4.
4. Exit the loader and press traction lock override P–3760
button. Traction light (Item 4) [A] should be ON.
Press override button again and traction light (Item 4)
[A] should be OFF. B Clean area behind
and under seat.
Inspecting Deactivation of the Auxiliary Hydraulics
System (Engine STOPPED – Key ON)
Machine S/N’s 514411603 &Above
514511003 &Above
514611002 &Above
5. Sit in the operator’s seat. Lower the seat bar. Press
the auxiliary hydraulics mode switch. The mode
switch light will come ON. Raise the seat bar. The 1
light should be OFF.
Inspecting the Seat and Seat Bar Sensors (Engine
RUNNING)
6. Sit in the operator’s seat. Lower the seat bar. Engage
the parking brake. Fasten the seat belt. P–3763
7. Start the engine and operate at low idle. While raising
the lift arms, raise the seat bar fully. The lift arms
should stop. Repeat using the tilt function. C Operator
Seat
Inspecting the Traction Lock (Engine RUNNING)
8. Fasten the seat belt, disengage the parking brake,
and raise the seat bar fully. Move the steering levers
slowly forward and backward. The traction lock Seat
should be engaged. Lower the seat bar. Seat 1 Spring
Sensor
9. Engage the parking brake pedal and move the
steering levers slowly forward and backward. The
traction lock should be engaged. Seat Rail
Cover
Inspecting the Lift Arm By–Pass Control
10. Raise the lift arms six feet (2 m) off the ground. Stop
the engine. Turn the Lift Arm By–Pass Control Knob
clockwise 1/4 turn. Then pull up and hold the Lift Arm
MC–2043
By–Pass Control Knob until the lift arms slowly lower.
Maintenance
Clean any debris, dirt or objects from under or behind the
operator seat [B] & [C]. The rear of the seat must move
up and down.
Inspect both Seat Rail Covers [C] for wear or damage.
Replace if necessary.
AVOID INJURY OR DEATH
Clearance is necessary under the seat spring (Item 1) [C] The Bobcat Interlock Control System (BICS™)
and the seat, to allow the seat to move up and down must deactivate the lift, tilt and traction drive
freely. With adequate clearance, the seat sensor will be functions. If it does not, contact your dealer for
allowed to function correctly. service. DO NOT modify the system.
W–2151–0394
Inspect seat bar pivot area for tightness of linkage bolts.
Replace parts that are damaged. Use only genuine
Bobcat replacement parts.
863, 863H Bobcat Loader
Revised Mar. 99 –8–3– Service Manual
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
Troubleshooting Chart
The following list shows the effects which can happen to the loader, and the probable causes when the BICS Controller
lights are off or flashing. Have the service procedure performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL.

Flashing Indicator Means System Problem

Effect on Operation (See Your Bobcat Dealer for Service)
of Loader
Indicator When Light Is Number of
Light Light ON Light OFF OFF Flashes Cause
Seat Operator in Seat No Operator in Seat Lift and tilt functions 2 Seat sensor circuit shorted to battery
will not operate. voltage*.
3 Seat sensor circuit shorted to ground
Seat Bar Seat Bar Down Seat Bar Up Lift, tilt and traction 2 Seat bar sensor circuit shorted to
functions will not battery voltage*.
operate. 3 Seat bar sensor circuit shorted to
ground.
Valve Control Valve Can Control Valve Lift and tilt functions 1 Valve output circuit is open.
Be Used Cannot Be Used will not operate. 2 Valve output circuit shorted to battery
voltage*.
3 Valve output circuit shorted to ground.
3 Valve output circuit is not grounded.
Traction Loader can be Loader cannot be Loader cannot be 1 Traction lock hold coil circuit is open.
moved forward & moved forward and moved forward and 2 Traction lock hold coil circuit shorted
backward. backward. backward. to battery voltage*.
3 Traction lock hold coil circuit shorted
to ground.
4 Traction lock pull coil circuit is open.
5 Traction lock pull coil circuit is shorted
to battery voltage*.
6 Traction lock pull coil circuit is shorted
to ground.
Power BICS Controller BICS Controller is Lift, tilt and traction
is operating not operating functions will not
correctly. correctly. operate.

SEAT SENSOR OVERRIDE ONLY (If Equipped)

Indicator Light Flashing Effect on Loader Operation
Light Continuously When Light is Flashing Cause
Seat Operator in Seat with Seat Bar Lift , tilt and traction Seat Sensor Override has been
down and Seat Sensor Override functions will operate. activated. Seat Sensor maintenance
has been activated is required.

NOTES:
(1) If the seat and/or seat bar sensor circuits are open, the corresponding lights will be OFF. If one of the lights
stay OFF, check the circuit for continuity. See Inspection & Maintenance Instruction. (See Page 8–1.)
(2) If all five lights flash repeatedly, the voltage supply is greater than 16 volts or less than 9 volts.
(3) Flashing patterns will repeat every 3.25 seconds.
(4) If seat indicator light does not go ON, check for debris, dirt or objects under or behind the seat. The Seat
Sensor Override♦ can be used if the seat sensor cannot be activated.
♦ Only on later loaders, and early loaders which have had BICS Controller and switch replaced.

NOTE: If the Seat Bar is lowered before the seat sensor is activated, a 10 second delay will occur before the valve
and traction lights come on.
* Normal BICS operating voltage is less than the electrical system voltage. If voltage is more, the circuit is shorted
to system voltage.

863, 863H Bobcat Loader

Revised Mar. 99 –8–4– Service Manual
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
(Cont’d)
Troubleshooting Guide
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system
problems. It is recommended that these procedures be Check for correct function after adjustments,
done by authorized Bobcat Service Personnel only. repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W–2004–1285

BICS SYSTEM CONTROLLER

PROBLEM SOLUTION #

Power indicator light does not come ON. 1, 2, 3, 6

All indicator lights flashing. 4

One of the indicator lights flashing. 5

Intermittent indicator lights. 6, 7, 8, 9

SOLUTION SUGGESTIONS

1. Check that ignition switch is ON.

2. Check BICS 10 amp. fuse.

3. Check wiring and connections. Make sure the connector is securely connected
to the controller. Remove controller and pull on connector to check.

4. Look at indicator light windows, if they are milky white in appearance, it is most
likely caused by moisture in the controller. Allow to dry or replace the controller.

5. Refer to BICS controller troubleshooting chart. (See Page 8–4.)

6. Check wire connections to make sure connectors are locked into place.
7. Check pins in connectors for pins pushed back or bent.

8. Move the system wiring back & forth to try to find area that may be causing the
intermittent connection.
9. Use sensor tester MEL1428 to isolate problem between sensor and controller
and wiring.

863, 863H Bobcat Loader

–8–5– Service Manual
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
(Cont’d)
Troubleshooting Guide (Cont’d)
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system
problems. It is recommended that these procedures be Check for correct function after adjustments,
done by authorized Bobcat Service Personnel only. repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W–2004–1285

TRACTION LOCK

PROBLEM SOLUTION #

Traction lock stays engaged. 1, 2, 3, 4, 5, 6, 7, 8

Intermittent activation of traction lock. 9, 10, 11

SOLUTION SUGGESTIONS

1. Check that controller power indicator light is ON.

2. Make sure brake pedal is not engaged.

3. Maneuver loader to allow brake discs to move and remove pressure on the brake
wedge so it can retract.

4. If all lights indicate the brake should be released, but it doesn’t, check the brake
25 amp. fuse.

5. When checking fuse, also check other fuses. Check the fuse block for correct
orientation and location of fuses. (See Electrical System, Page 6–1.)
6. To test the solenoid, the pull coil should be .4 to .5 ohms and the hold coil 10.5 to
11.0 ohms.

7. Check brake solenoid and cover mounting hardware for the correct torque.
8. Remove brake cover and check wedges for binding in the wedge guides.

9. Check wire connections for loose connector body.

10. Check for loose or bent pins in connectors.

11. Check for loose spade connectors in fuse holder.

863, 863H Bobcat Loader

–8–6– Service Manual
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
(Cont’d)
Troubleshooting Guide (Cont’d)
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system
problems It is recommended that these procedures be Check for correct function after adjustments,
done by authorized Bobcat Service Personnel only. repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W–2004–1285

SEAT SENSOR

PROBLEM SOLUTION #

Seat indicator light does not come ON with operator in seat. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11
Seat indicator light stays ON when operator is out of seat. 2, 3, 6, 10, 11, 12, 13, 14

Intermittent indicator light during operation. 11, 15, 16, 17, 18

SOLUTION SUGGESTIONS

1. Check to make sure power indicator light is ON.

2. Check for debris under and around seat.
3. Look for any obstruction around seat.
4. Check to make sure seat rail lowers when weight is in seat.
5. Raise cab and check for magnet collar movement when weight is added to seat.
(Magnet collar should extend approximately 3/8 inch beyond the sensor
assembly with weight in the seat.)
6. Use sensor tester to check operation of sensor and controller. Follow instructions
on tester.
7. Check to make sure the magnet guide pin is in place.
8. Check for contamination on magnets such as metal particles or for shipping plate
over magnets.
9. Check to make sure both magnets are in collar.
10. Check for binding of magnet collar or bushing with hex head on other side for
binding.
11. Check for correct mounting. One spring for standard seat. Two springs for
suspension seats. Thick washers should be under front seat mounting rails on
both sides.
12. Check for loose hardware mounting magnet collar. Check to make sure the
magnet collar bushing is threaded on all the way so it is contacting seat rail.
13. Check to make sure seat rail raises when weight is removed from the seat.
14. Raise cab and check for magnet collar movement when weight is removed from
seat. (Magnet collar should extend approximately 1/8 inch beyond the sensor
assembly without weight in seat.)
15. With smaller operators that operate with the seat forward some mounting
alterations may be required. (See solution suggestions 16, 17 and 18.)
16. Adjust suspension seat to lightest weight setting.
17. Check to make sure the seat rails move up and down freely when weight is added.
18. Add washer between the bushing and the magnet collar assembly which slides on
and the seat rail. This will reduce the amount of seat travel required to activate
the system. Must check, with seat moved all the way back, that indicator light
does not stay on with operator out of seat. If light does not go out with operator
out of the seat, the washer must be removed.

863, 863H Bobcat Loader

–8–7– Service Manual
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
(Cont’d)
Troubleshooting Guide (Cont’d)
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system
problems. It is recommended that these procedures be Check for correct function after adjustments,
done by authorized Bobcat Service Personnel only. repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W–2004–1285

SEAT BAR SENSOR

PROBLEM SOLUTION #

Indicator light does not come ON when seat bar is lowered. 1, 2, 3, 4, 5, 6

SOLUTION SUGGESTIONS

1. Check controller power indicator light. It must be ON.

2. Check sensor wire connection.

3. Use the BICS sensor tester MEL1428 to check sensor and controller.

4. Check for loose hardware.

5. Check keyed bushing to make sure magnet collar rotates with seat bar.

6. Check magnet collar magnets for contamination such as metal particles.

863, 863H Bobcat Loader

–8–8– Service Manual
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
(Cont’d)
Troubleshooting Guide (Cont’d)
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system
problems. It is recommended that these procedures be Check for correct function after adjustments,
done by authorized Bobcat Service Personnel only. repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W–2004–1285

LIFT ARM BY–PASS VALVE

PROBLEM SOLUTION #

By–pass valve stuck. 1

By–pass valve stem bent or broke. 1

SOLUTION SUGGESTIONS

1. Replace manual spool cartridge.

863, 863H Bobcat Loader

–8–9– Service Manual
BICS™ SYSTEM CONTROLLER
A
Removal and Installation
2
Raise the operator cab. (See Page 1–1.)
The controller mounting bolts are located on the back of
the operator cab [A].
Remove the top mounting bolt (Item 1) [A] from the 1
controller.
Loosen the two lower mounting bolts (Item 2) [A].
Lower the operator cab.
NOTE: The operator seat is removed in photo [B] for P–3997
clarity purpose only. The seat does not need
to be removed to remove the controller.
B
Slide the controller (Item 1) [B] up and remove it from the
back of the operator cab.
1
Disconnect the electrical harness from the controller and
remove the controller from the loader.

P–3994

NOTE: Install the harness connector (Item 1) [C] into

the controller (Item 2) [C] before installing the
controller.
C

Be sure the connector to the BICS system

controller are correctly engaged in the
controller when installing the controller. An 1
audible snap can be heard when the
connector is correctly installed. Try to pull the
connector out of the controller, if it cannot be P–4707
removed it has been correctly installed [C].
I–2087–1095

Installation: Tighten the controller mounting bolts to

80–90 in.–lbs. (9–10 Nm) torque.
Reverse the removal procedure to install the controller.

863, 863H Bobcat Loader

–8–10– Service Manual
BICS™ SYSTEM CONTROLLER (Cont’d)
Controller Test
A
MEL1428 Sensor Tester is necessary for the following
procedure:
Turn the key to the ON position. DO NOT START THE
ENGINE. 1
After completing the procedure for the Seat sensor test
or the Seat Bar sensor test, do the Controller test. Refer
to Page 8–3 for correct procedures to do the Seat Bar
sensor test or the Seat sensor test. 2

Move the toggle switch (Item 1) [A] on the sensor tester

(Item 2) [A] to the Present position. P–4703

If the controller is working correctly, the Seat light (Item

1) [B] on the controller will illuminate when the tester is
B
connected to the Seat sensor.

P–4706

When the tester is connected to Seat Bar sensor, the Seat

Bar light (Item 1) [C] will illuminate if the controller is C
working correctly.

P–4704

Move the toggle switch (Item 1) [D] on the sensor tester D

(Item 2) [D] to the Absent position.
The Seat light (Item 1) [B] or the Seat Bar light (Item 1)
[C] should go off.
If the tests above fail, there is a problem with the BICS
system controller or the wiring harness. 1
Refer to Page 8–3 for the correct procedure to inspect the
BICS System Controller.
2

P–4699

863, 863H Bobcat Loader

–8–11– Service Manual
SEAT BAR SENSOR
Removal and Installation
A
Disconnect the seat bar sensor connector (Item 1) [A].
1

P–4702

Remove the mounting bolt (Item 1) [B] from the pivot

bushing. B
Installation: Tighten the mounting bolt to 25–28 ft.–lbs.
(34–38 Nm) torque.
Remove the sensor mounting bolt (Item 2) [B] and nut. 1

2
Be careful to not overtighten the sensor
mounting bolt and nut to prevent breakage of
P–3246
the sensor.
I–2088–1095

Installation: Be sure the tabs on the pivot bushing are

C
positioned in the slotted hole (Item 1) [C] of the operator
cab as shown.
Pull the seat bar back and remove the assembly as
follows:
NOTE: The sensor assembly [D] is shown removed 1
from the operator cab for clarity purpose
only. The sensor assembly can be removed
without removing the seat bar from the
operator cab.
Remove the pivot bushing mounting bolt (Item 1) [D] and
washer (Item 2) [D] from the pivot bushing (Item 3) [D]. P–3247

Installation: Tighten the pivot bushing mounting bolt to

180–200 in.–lbs. (21–23 Nm) torque.
D
Remove the pivot bushing (Item 3) [D], sensor (Item 4)
[D], magnet (Item 5) [D] and plastic bushing (Item 6) [D] 3 6 2
from the seat bar. 1

Inspect all parts for damage and wear and replace if

necessary.
Reverse the removal procedure to install the seat bar
sensor.
Refer to Page 5–1 for seat bar removal and installation Left Side
procedure. 4 5 of Seat Bar

P–3284

863, 863H Bobcat Loader

–8–12– Service Manual
SEAT BAR SENSOR (Cont’d)
Seat Bar Sensor Test
A
Use MEL1428 Sensor Tester for the following procedure:
1
Turn the key to the ON position. DO NOT START THE
ENGINE.
Disconnect the seat bar sensor connector (Item 1) [A].

P–4702

Connect MEL1428 Sensor Tester (Item 1) [B] in–line as

shown to the seat bar sensor connectors. Also see inset
B
[B].

P–4701

P–4700

The power light (Item 1) [C] on the sensor tester will

illuminate. C

P–4698

Lower the seat bar. The sensor test light (Item 1) [D]
should illuminate. D
Raise the seat bar. The sensor test light (Item 1) [D]
should go off.
1
If the above tests fails, there is a problem with the seat bar
sensor.
Refer to Page 8–3 for the correct procedure to inspect the
Seat Bar Sensor.
Refer to Page 5–1 for seat bar removal and installation
procedure.

P–4699

863, 863H Bobcat Loader

–8–13– Service Manual
SEAT SENSOR
A
Removal and Installation
Raise the operator cab. (See Page 1–1.)
Locate the seat sensor (Item 1) [A] beneath the operator
cab.

P–3987

Remove the sensor connector (Item 1) [B] from the

holder. B
Disconnect the sensor connector (Item 1) [B].
Remove the magnet collar mounting bolt (Item 2) [B], 2
washer (Item 1) [C] and magnet (Item 2) [C] from the 1
sensor (Item 3) [B].
3

4
DO NOT overtighten the magnet mounting
bolt to prevent damage to the magnet. P–3988
I–2089–1095

Remove the sensor mounting bolt (Item 4) [B] and nut. C

5

3
2
1
Be careful to not overtighten the sensor
mounting bolt and nut to prevent breakage of 4
the sensor.
I–2088–1095

Remove the sensor (Item 3) [C].

P–4041
NOTE: Be sure not to lose the magnet collar
alignment pin (Item 4) [C] which is located in
the sensor (Item 3) [C] when removing the
sensor. D
Remove the threaded bushing (Item 5) [C] from the seat
track mounting bolt (Item 1) [D].
Inspect all parts for damage and wear and replace if 1
necessary.
Reverse the removal procedure to install the seat sensor.
Refer to Page 5–1 for seat removal and installation
procedure.

P–4044

863, 863H Bobcat Loader

–8–14– Service Manual
SEAT SENSOR (Cont’d)
A
Seat Sensor Test
Use MEL1428 Sensor Tester for the following procedure: 2
Turn the key to the ON position. DO NOT START THE
ENGINE.
Disconnect the seat sensor connector (Item 1 – Inset)
[A].
Connect MEL1428 Sensor Tester (Item 2) [A] in–line as
shown to the seat sensor.

P–3988 P–4705

The power light (Item 1) [B] on the sensor tester will

illuminate.
B

P–4698

Sit on the operator seat. The sensor test light (Item 1) [C]
should illuminate. C
Get off the operator seat. The sensor test light (Item 1) [C]
should go off.
1
If the above tests fail, there is a problem with the seat
sensor.
Refer to Page 8–14 for the correct procedure to inspect
the Seat Sensor.
Refer to Page 5–1 for seat removal and installation
procedure.

P–4699

863, 863H Bobcat Loader

–8–15– Service Manual
TRACTION LOCK
Removal and Installation
A
1

AVOID INJURY OR DEATH

Do not modify the electrical wiring connected
to the traction lock solenoid or any part of the
traction lock system. The traction lock
provides the locking function of the parking
brake. Service work on the traction lock system
should only be performed by a qualified P–5379
technician. Use only genuine Bobcat parts if
repair is necessary.
W–2165–0195
B
Raise the operator cab. (See Page 1–1.)
If the solenoid is being replaced, remove the Do Not
2
Modify sta–strap from the electric solenoid connector
(Item 1) [A].
Installation: Install a new Do Not Modify sta–strap (P/N
6665527) on the electric solenoid connector.
Remove the two mounting bolts (Item 2) [A] from the
electric solenoid mounting bracket.
Installation: Tighten the mounting bolts to 25–28 ft.–lbs. 1
(34–38 Nm) torque. Be sure the solenoid mounting
bracket is installed in the same position. The solenoid
mounting surface has a slight angle which tips the top of
the solenoid toward the rear of the loader when installed P–5387
correctly. Replace the gasket (Item 2) [B] if damaged.
Remove the electric solenoid and bracket assembly from
the chaincase cover [B]. C
Remove and inspect the compression spring (Item 1) [B]
and spring cap washer (Item 2) [C] for wear or damage. 2
Replace if necessary. The spring may also stay with the
shaft when the electric solenoid and bracket are removed
from the chaincase.
1
Installation: Install the compression spring (Item 1) [B]
on the collar located on the electric solenoid.
Remove the traction lock assembly (Item 1) [C] from the
chaincase.
Remove the shaft mounting bolt (Item 1) [D], spring from
the assembly shaft (Item 2) [D]. Remove the wedge (Item
3) [D] and inspect all parts for damage or wear. Replace P–7926
if necessary.
Installation: Thoroughly clean and dry the shaft
mounting bolt (Item 1) [D], the shaft (Item 2) [D] and D
wedge (Item 3) [D]. Use LOCTITE #242 when 2
assembling these parts to the traction lock assembly. 3

Failure to use LOCTITE may allow the traction

lock assembly to loosen up which can cause
damage to the traction lock system.
I–2090–1095
P–7964

863, 863H Bobcat Loader

–8–16– Service Manual
BOSS® DIAGNOSTIC TOOL
Procedure
A
The tool listed will be needed to do the following 1
procedure:
MEL1400 – Diagnostic Tool
Stop the engine.
Lift and block the loader. (See Page 1–1.)
Remove the dust cap from the diagnostic connector plug.
Connect the diagnostic tool plug (Item 1) [A] into the
loader connector.
Use the instructions from the BOSS Operation & P–3871
Maintenance Manual to make service checks of BOSS
system operating unit and other components [A].
SENDER AND SENSOR B
Service Checks
Use the following information when checking the senders
and sensor with a volt/ohmmeter:
Components Value 1
TEMPERATURE SENDER
70 degree F. (21 degree C.) . . . . . . . . . . . . . 970 ohms
80 degree F. (27 degree C.) . . . . . . . . . . . . 1013 ohms
ENGINE OIL PRESSURE SENDER
0 PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ohms Max.
6 PSI (41 kPa) . . . . . . . . . . . . . . . . . . . . . . . 7 ohms Min.
50 PSI (345 kPa) . . . . . . . . . . . . . . . . . . . . . . . . 49 ohms P–5677
70 PSI (483 kPa) . . . . . . . . . . . . . . . . . . . . . . . . 59 ohms
TRANSMISSION CHARGE PRESSURE SENDER
0 PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0–5 ohms C
100 PSI (690 kPa) . . . . . . . . . . . . . . . . . . . . . . . 58 ohms
130 PSI (896 kPa) . . . . . . . . . . . . . . . . . . . . . . . 75 ohms
150 PSI (1034 kPa) . . . . . . . . . . . . . . . . . . . . . 87 ohms 1
FUEL SENDER
Full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ohms
Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 ohms
RPM SENSOR
Adjustment
Continuity Resistance of 3000–3500 ohms.
Disconnect the connector (Item 1) [B] from the engine
harness. P–5675

Loosen the jam nut on the RPM sensor [B].

Turn the RPM sensor (Item 1) [C] in until it makes contact
with the engine flywheel.
Turn the jam nut until it contacts the flywheel housing. The
jam nut should not be tightened, it needs to turn with the
RPM sensor when the sensor is turned back out for
adjustment.
Turn the RPM sensor and the jam nut out from the
flywheel. Set a clearance of 0.050’’ (1,27 mm) between
the jam nut and the housing with a feeler gauge [C].
Retighten the jam nut.
NOTE: The plastic tip is used as a gauge to set a new
RPM SENSOR. The plastic tip is designed to
come off after the engine is started.
863, 863H Bobcat Loader
Revised June 98 –8–17– Service Manual
SERVICE CODES
The following list references the defect codes that are
transmitted to the instrument panel display which can
occur. Some service procedures for correcting the
problems can be found in this manual and other
procedures must be performed ONLY BY QUALIFIED
BOBCAT SERVICE PERSONNEL. 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–2003–0797

SUBJECT DISPLAY READS CONDITION

Engine Coolant Temp. EC–1.1 SHUTDOWN, Engine Temperature
EC–2.1 WARNING, Engine Temperature
EC 3 Wiring Not Connected
EC 4 Wiring Shorted
EC 5 High Sensor Voltage
EC 7 Sensor Out Of Range
Engine Oil Pressure EP 1 SHUTDOWN, Pressure
EP 2 WARNING, Pressure
EP 3 Wiring Not Connected
EP 4 Wiring Shorted
EP 5 High Sensor Voltage
EP 7 Sensor Out Of Range
Engine Speed ES 1 SHUTDOWN, Engine Speed Too High
ES–2.1 WARNING, Engine Speed Slightly High
ES–6 Sensor No Signal
ES–7 Sensor Out Of Range
Air Filter AF 2 WARNING, Restriction Too High
AF 6 Sensor No Signal
Battery b–2.1 WARNING, Bad Battery
b–2.2 WARNING, Battery Voltage
Fuel Level FUEL2 WARNING, Low Level
FUEL3 Wiring Not Connected
FUEL4 Wiring Shorted
FUEL5 High Sensor Voltage
FUEL7 Sensor Out Of Range

863, 863H Bobcat Loader

Revised June 98 –8–19– Service Manual
SUBJECT DISPLAY READS CONDITION
Hydrostatic Charge HF1–2 WARNING, High Restriction (1st FIlter)
Filter Conditions HF1–6 Sensor No Signal
HF2–2 WARNING, High Restriction (2nd FIlter)
HF2–6 Sensor No Signal
Hydrostatic Fluid HP 1 SHUTDOWN, Pressure
HP 2 WARNING, Pressure
HP 3 Wiring Not Connected
HP 4 Wiring Shorted
HP 5 High Sensor Voltage
HP 7 Sensor Out Of Range
Hydrostatic Fluid HC 1 SHUTDOWN, Temperature
Temperature HC 2 WARNING, Temperature
HC 3 Wiring Not Connected
HC 4 Wiring Shorted
HC 5 High Sensor Voltage
HC 7 Sensor Out Of Range

863, 863H Bobcat Loader

Revised June 98 –8–20– Service Manual
TROUBLESHOOTING THE BOSS® & LCD DISPLAY

SUBJECT SYMPTOM INDICATES TO CORRECT SYMPTOM

BOSS Temperature related 12 volt supply and 1. Check stored defects with the BOSS tool.
shutdown codes BOSS failure. *2. If defect list has EC1, HC1, EC2.1, HC2. EP3,
when no heating EP7, HP7, B2.2, low fuel, Fuel 7 and last
occurs. occurrence hr. readings are within a hundredth,
the BOSS is defective and must be replaced.
* NOTE: You may have some or all of the 3. Using a voltmeter, check the alternator output.
codes listed. You will have high
temps, high press, low voltage
and low fuel.
LCD Display Intermittent code of Sensor No Signal or 1. ES6 will occur if the loader is stalled or shutdown
ES6 while engine No RPM’s. during run cycle. The code is generated due to the
running. lack of RPM and the existence of residual
pressure in the system.
Display is dead – No Lack of 5.0 volts 1. Check pin A for 5.0 volts. If 5.0 volts is present
Icons, Bar Graphs, regulated power. replace the display.
Hourmeter. 2. If no power exists at pin A, install BOSS backup
to confirm the BOSS system.
LCD DISPLAY 3. If the problem still exists, check the harness for
continuity.
CONNECTOR
A B C D E
Orange
Purple/White

Black
Purple/Red

12 Volt – Back Light

Orange

Ground
Negative Com. .5 to 1.5 Volts
Positive Com. 3.5 to 4 Volts
5.0 Volts Regulated Power

Power Display Operation

During an active Low voltage (5.0) 1. Turn the ignition switch OFF. Re–starting will
WARNING display, triggered reset. return hourmeter reading.
reset occurs and the 2. If re–starting will not return hourmeter reading,
hourmeter becomes check pins B & C as stated in Step 5 below.
all zero’s.
After glow sequence 1. Turn the key OFF and re–start.
or after a WARNING
goes away, the Icon
remains ON.
No Bar Graphs, no Bad display or BOSS 1. Plug in the BOSS tool and start the engine.
Hours. is not communicating. 2. If data is being received by the BOSS tool, the
BOSS unit is not the cause of the problem.
3. If no data is received at the BOSS tool.
disconnect the LCD display.
*4. If messages are now received at the tool, the
* NOTE: The display has caused the display is the problem. If problem still exists go to
problem by locking the Step 5.
communication lines and 5. Check pins B & C for signal.
stopping communications from 6. If there is no signal, install BOSS backup unit.
the BOSS. 7. If the problem still exists, check the harness for
continuity.

863, 863H Bobcat Loader

Revised June 98 –8–21– Service Manual
OPERATION SENSING SYSTEM UNIT
A
Removal and Installation
Raise the operator cab. (See Page 1–1.) 1
1
Loosen the nuts (Item 1) [A] from the sensing system unit
(Item 2) [A].
Slide the unit forward in the mounting slots and remove 2
it from the operator cab.

P–4043

Use a screwdriver and remove the two connectors (Item

1) [B] from the sensing system unit (Item 2) [B]. B
Installation: Put the heads of the mounting bolts into the
slots of the operator cab and slide the unit back into place.
Tighten the three mounting nuts to 80–90 in.–lbs. (9–10 2
Nm) torque.

1
1
P–4042

863, 863H Bobcat Loader

Revised June 98 –8–22– Service Manual
BOSS® INSTRUMENT PANEL
A
Removal and Installation
Pry the rubber light mount free from the operator cab
(both sides) [A].

P–3995

Lower the light from the operator cab to locate the three
instrument panel mounting bolts (Item 1) [B] (both sides). B
1

P–3955
Remove the three mounting bolts and pull the left panel
(Item 1) [C] down from the operator cab.
Installation: Be careful to not overtighten the panel
C
mounting bolts to prevent stripping the threaded holes of
the panels.
Disconnect the wire harness connectors from the panel
and remove the panel.

P–3958
Remove the three mounting bolts and pull the right panel
(Item 1) [D] down from the operator cab.
Installation: Be careful to not overtighten the panel D
mounting bolts to prevent stripping the threaded holes of
the panels.
Disconnect the wire harness connectors from the panel
and remove the panel.

P–3959

863, 863H Bobcat Loader

Revised June 98 –8–23– Service Manual
PWM MODULE
Description
A
• Take voltage measurements by probing into wires near
the PWM module shown in figure [A]. All connectors
must remain plugged into their respectful harness.

• Turn the key to the ON position with the engine OFF.

• Turn the switches ON to get their appropriate readings.
(Example: Input from Proportional flow switch – Push
switch full left then full right to get the voltage readings
listed below.)

• Press the auxiliary hydraulic switch (Item 2) [B] twice.

Both Green lights will be ON. Check Wire# 9, 17, 18,
or 19.

NOTE: Item descriptions are listed below as Input to

or Output from the Module. Voltage readings
are approximate. They are affected by battery
condition (system voltage). Voltage readings
for Items 10, 18, and 19 are variable and
correspond to Proportional Flow Switch
travel.

Fig. [A]:
Item Description Volts
1 Input for Attachment I.D. 11.5
2 Ground 0
3 Input from Key Switch 12.0 MC–2265
4 Input from *Auxiliary Hydraulic Switch 9.5
5 Output to Momentary Light 7.5
6
7
Output to Auxiliary Hydraulic Switch
Output to Detent Light
11.0
6.5 B
8 Input from Key Switch (Bleed position) 12.5
9 Output to **High Flow Solenoid 11.5
Non High Flow Loaders 0
10 Input from Proportional Flow Switch .5–1.5
11 Ground to Proportional Flow Switch 0
12 Output to Proportional Flow Switch 2.0
13 Input for Loader Model I.D. 12.0 2
14 Input from Detent Switch 12.0 5
15 Input from Rear Aux. Base Switch 11.0
16 Input from Rear Aux. Rod Switch 11.0 3
17 Output to Rear Aux. Diverter Solenoid 10.0 1
18 Output to Aux. Rod Solenoid 0–6.0 4
19 Output to Aux. Base Solenoid 0–6.0
N–00562 P–03272
*Input signal is present only as Auxiliary Hydraulic Switch
is pushed.
**Output signal goes to High Flow dash panel switch, then C DELUXE HANDLES
to solenoid. Used only on H models. Zero voltage on Non
High Flow loaders.

Key Switch Item 1 [B] 1

Auxiliary Hydraulic Switch Item 2 [B] 3
Momentary Light Item 3 [B] 2
Detent Light Item 4 [B]
High Flow Switch Item 5 [B]
Right
Left Steering
Proportional Flow Switch Item 1 [C] Steering Lever
Detent Switch Item 2 [C] Lever Control
Rear Aux. Switch (Base & Rod) Item 3 [C] Control
P–02130 P–02129

863, 863H Bobcat Loader

Revised Oct. 98 –8–24– Service Manual
PWM MODULE (Cont’d)
863,863HServiceManual#6724799–SystemAnalysisPart1of2

Description (Cont’d)
A
Later S/N loaders have additional wires in the PWM
module as shown in Fig. [A]. Loaders with the module
mounted on the inside left fender are equipped with the
auxiliary hydraulic deactivation feature and are listed
below:
Loader S/N’s 514411603 & Above
514511003 & Above
514611002 & Above

• Take voltage measurements by probing into wires near

the PWM module. All connectors must remain plugged
into their respectful harness
• Sit in the operator’s seat. Turn key to ON position.
Lower the seat bar. Check that the BICS™ controller
lights are on. Check input voltage (Item 1) [A]. Press
the auxiliary hydraulics switch. The mode switch light
will come ON. Raise the seat bar. The light should be
OFF. Input voltage will drop to less than 1.0 volts.

NOTE: Item descriptions are listed below as Input to

or Output from the Module. Voltage readings
are approximate. They are affected by battery
condition (system voltage).

Fig. [A]:
Item Description Volts
1 Input from BICS™ Auxiliary Deactivation 12.0 TS–01433
2 For future use
3 For future use
4 For future use

PWM TROUBLESHOOTING
Conditions

• Auxiliary Hydraulic Switch lights will not come ON.

Check the following:

PWM fuse
Wires disconnected, shorted, or cut.
Auxiliary hydraulic switch failure.
Module failure.

Use the voltage tests in the wire identification

section to determine the cause.

• Auxiliary Hydraulic Switch lights are flashing. See the

troubleshooting chart. (See Page 8–30.)

863, 863H Bobcat Loader

Revised Mar. 99 –8–25– Service Manual
PWM TROUBLESHOOTING (Cont’d)
Chart
A
The PWM module sends a diagnostic code to the Mode
Switch lights when the conditions listed in the chart below
occur.
• When the lights are flashing, the key needs to be
turned OFF and then ON. If the problem still exists they
will continue to flash.
• Proportional flow cannot be engaged if the lights are 1
blinking.
• Continuous flow (detent) can be engaged if alternate
blinking lights are off after the key switch is turned OFF 2
and then ON (during a proportional flow switch failure). P–03272

Momentary LED Detent LED

(Item 1) [A] (Item 2) [A] PROBLEM AREA PROBLEM CAUSE

Light Blinking Light OFF Base End Solenoid or Wiring • Wires Disconnected
• Wires Shorted
• Wires Cut
• Solenoid failed. Perform solenoid
coil test.
• PWM module failed.

Light Off Light Blinking Rod End Solenoid or Wiring • Wires Disconnected
• Wires Shorted
• Wires Cut
• Solenoid failed. Perform solenoid
coil test.
• PWM module failed.

Light Blinking Light Blinking Diverter Solenoid or Wiring • Wires Disconnected

• Wires Shorted
• Wires Cut
• Solenoid failed. Perform solenoid
coil test.
• PWM module failed.

*Blinking/OFF *OFF/Blinking Proportional Flow Switch • Wires Disconnected

(Right Handle) • Wires Shorted
• Wires Cut
• Proportional flow switch failed.
Check voltage to switch.
Perform handle test.
• PWM module failed.

*Alternate Blinking Lights

863, 863H Bobcat Loader

Revised June 98 –8–26– Service Manual
PWM CONTROL HANDLE
Handle Testing
A
The right side steering lever handle switch (Item 1) [A]
controls the proportional flow to front auxiliary. Test the
switch with a Ohm test meter.
1
Disconnect the handle switch harness from the controls
harness. Use the chart below to test the handle switch.

Handle Switch Position

Test between
handle wires Full Left Center Full Right P–02129
White/Black No 4.8–5.2 No
& White Test Ohms Test
White/Red 1.3–1.5 2.6–2.8 3.8–4.0
B
& White Ohms Ohms Ohms
White/Red & 3.8–4.0 2.6–2.8 1.3–1.5
White/Black Ohms Ohms Ohms

NOTE: Push the switch gradually from center to

either left or right. The Ohm reading must
change gradually. Replace the handle switch
assembly if required.

PWM ELECTRIC SOLENOID 1

N–00076
Solenoid Coil Testing
The front auxiliary solenoid valves (Item 1) [B] are located
in the hydraulic control valve. Test the solenoid coils with
a Ohm test meter.
Disconnect the coil from the controls harness. The correct
reading is 1–5 Ohms.

863, 863H Bobcat Loader

Revised June 98 –8–27– Service Manual
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
Controls Identification Chart
863,863HServiceManual#6724799–SystemAnalysisPart2of2

Attachment
Solenoid Harness Attachment
Switch Number Terminal Harness
Number Activated Activated Connector
Left Side Right Side
Control Handle RH HFH Control Handle
Switches Switches
1 1 1 1,8 K

2 2 2 2 K

* 3 1 1 1,8 K

4 2 2,3 6,7 K, A, D

5 1 1,3 5,7 K, A, C

6 1 1,3 5,7 K, E

7 1 1,3 5,7 K, F

8 1 1,3 5,7 K, G Viewed from front

(pin side of connector)
9 1 1,3 5,7 K, H of loader.
10, 11, 12, – –– –– K
13, 14

RH – Loaders with Rear Hydraulics Option.

HFH – Loaders with High Flow Hydraulics Option.
* If harness terminals K & L are jumped together, switches 4 thru 9 will function the same as switch 3.

Solenoid Hydraulic Wiring

Number Coupler Color

4 1 Front Dk. Green/

1 8 Female Red
3 6
2 Front Dk. Green/
3 Male Lt. Green
2
3 (Top) Diverter Yellow
4 (Bottom) Bleed – Rear Dk. Green/
Male & Female Yellow
9 8 5 Rear Yellow/
Female Lt. Green

7 6 Rear Yellow/
8 Male Brown
1
6 6 7 (Bottom) Diverter Yellow
5 3
H 8 (Middle) High Lt. Blue/
2 Flow Red
9 (Top) Bleed – Rear Dk. Green/
Male & Female Yellow

MC–02314

NOTE: The Key Switch fully left position activates solenoids number 1, 4 and 9. The high flow rocker switch in
the left side instrument panel must be ON to activate solenoid number 8.

863, 863H Bobcat Loader

Revised June 98 –8–28– Service Manual
SPECIFICATIONS
Page
Number
DECIMAL & MILLIMETER EQUIVALENTS
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–21
ENGINE SPECIFICATIONS
Camshaft and Bearings (BF4M1011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–8
(BF4M1011F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–11
Connecting Rod (BF4M1011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–7
(BF4M1011F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–10
Crankshaft and Main Bearings (BF4M1011) . . . . . . . . . . . . . . . . . . . . . . 9–8
(BF4M1011F) . . . . . . . . . . . . . . . . . . . . . . . 9–11
Cylinder Head and Block (BF4M1011) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–7
(BF4M1011F) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–10
Fuel System (BF4M1011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
(BF4M1011F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–9
General (BF4M1011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
(BF4M1011F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–9
Oil Pump (BF4M1011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–8
(BF4M1011F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–11
Pistons and Rings (BF4M1011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–7
(BF4M1011F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–10
Torque for General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–13
Valve and Valve Guide & Seat Insert (BF4M1011) . . . . . . . . . . . . . . . . . 9–6
(BF4M1011F) . . . . . . . . . . . . . . . . 9–9
HYDRAULIC CONNECTION SPECIFICAITONS
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–15
O–ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–16
O–ring Face Seal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–15
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–18
Straight Thread O–ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–15
Tubelines and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–15
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–19
LOADER SPECIFICATIONS
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
Engine (BF4M1011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
(BF4M1011F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Loader Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3 SPECIFICATIONS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
U.S. TO METRIC CONVERSION
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–21
STANDARD TORQUE SPECIFICATIONS FOR BOLTS
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–20
TORQUE SPECIFICATIONS FOR LOADER
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–14
ENGINE TORQUE
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–12

863, 863H Bobcat Loader

Revised June 98 –9–1– Service Manual
863, 863H Bobcat Loader
Revised June 98 –9–2– Service Manual
LOADER SPECIFICATIONS • Dimensions are given for loader equipped with standard tires and dirt bucket and
may vary with other bucket types. All dimensions are shown in inches. Respective
metric dimensions are given in millimeters enclosed by parentheses.
LOADER DIMENSIONS • Where applicable, specification conform to SAE or ISO standards and are subject
to change without notice.
83.7 ‘‘C”
(2129) 93°

156.2
45° (3973)

21.3
(542)
121.0
(3078)

81.2 91.5
(2066) (2328)

29° 25°
43.7
‘‘B” 8.5 (1112)
(216) 106.9 9.5
(2719) (242)
‘‘A” 135.4
(3444) MC–1113
‘‘A” 12–16.5 TIRES – 67.2 (1710) ‘‘C” 72” C/I BUCKET – 74.0 (1883)
12–16.5 TIRES – 72.0 (1832) 72” L/P BUCKET – 74.0 (1883)
31–15.5 x 15 TIRES – 73.0 (1857) 66” C/I BUCKET – 68.1 (1732)
‘‘B” 12–16.5 TIRES – 54.4 (1384)
12–16.5 TIRES –59.2 (1506)
31–15.5 x 15 TIRES – 57.5 (1463)
Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the
loader parts.

863 863H
PERFORMANCE
Rated Operating Capacity (SAE) . . . . . . . 1900 lbs. (863 kg)
Tipping Load (SAE Rating) . . . . . . . . . . . . 3800 lbs. (1725 kg)
Operating Weight . . . . . . . . . . . . . . . . . . . . . 7135 lbs. (3239 kg) 7180 lbs. (3260 kg)
SAE Breakout Force –Lift . . . . . . . . . . . . . 3700 lbs. (16465 N)
–Tilt . . . . . . . . . . . . . 3800 lbs. (16910 N)
Axle Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 6100 ft.–lbs. (8271 Nm)
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . 0–7.2 MPH (11,6 km/hr.)
CONTROLS
Vehicle Steering . . . . . . . . . . . . . . . . . . . . . . Direction and Speed controlled by two hand levers.
Loader Hydraulics
Lift and Tilt . . . . . . . . . . . . . . . . . . . . . . . . . Controlled by separate foot pedals or optional hand controls.
Front Auxiliary (Option) . . . . . . . . . . . . . . Proportional Controls Controlled by electrical
switch on RH steering lever.
Rear Auxiliary (Option) . . . . . . . . . . . . . . . . Controlled by electrical switch on LH steering lever.
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand lever throttle: Key–type starter switch and shutdown.
Starting Aid . . . . . . . . . . . . . . . . . . . . . . . . . . Glow plug– Rocker Switch operated.
BOSS activated glow plug (If so equipped).
Service Brake . . . . . . . . . . . . . . . . . . . . . . . Two independent hydrostatic systems controlled by two hand
operated steering levers.
Secondary Brake . . . . . . . . . . . . . . . . . . . . One of the hydrostatic transmissions
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Disc, foot operated pedal.
ENGINE
Make/Model . . . . . . . . . . . . . . . . . . . . . . . . . Deutz/BF4M1011F Turbo–Charged
Fuel/Cooling . . . . . . . . . . . . . . . . . . . . . . . . . Diesel/Oil
Horsepower (SAE Net) . . . . . . . . . . . . . . . . 73.0 HP (54 kW)
Maximum Governed RPM . . . . . . . . . . . . . 2350 RPM
Torque @ 1800 RPM (SAE Net) . . . . . . . . 176 ft.–lbs. (238 Nm)
Number of Cylinders . . . . . . . . . . . . . . . . . . Four
Displacement . . . . . . . . . . . . . . . . . . . . . . . . 177.7 cu. in. (2912 cu.cm.)
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . . 3.58/4.41 (91/112)
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure System W/Filter
Crankcase Ventilation . . . . . . . . . . . . . . . . . Closed
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . Dry replaceable cartridge w/safety element
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel–Compression
Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1125 – 1175 RPM
High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2425–2475 RPM

863, 863H Bobcat Loader

Revised June 98 –9–3– Service Manual
LOADER SPECIFICATIONS (Cont’d)
863 863H
ENGINE
Make/Model . . . . . . . . . . . . . . . . . . . . . . . . . Deutz/BF4M1011 Turbo–Charged
Fuel/Cooling . . . . . . . . . . . . . . . . . . . . . . . . . Diesel/Oil
Horsepower (SAE Net) . . . . . . . . . . . . . . . . 73.5 HP (55 kW)
Maximum Governed RPM . . . . . . . . . . . . . 2600 RPM
Torque @ 1800 RPM (SAE Net) . . . . . . . . 164 ft.–lbs. (222 Nm)
Toruqe @ 1900 RPM (Max.) . . . . . . . . . . 166 ft.–lbs. (225 Nm)
Number of Cylinders . . . . . . . . . . . . . . . . . . Four
Displacement . . . . . . . . . . . . . . . . . . . . . . . . 167 cu. in. (2,73 L)
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . . 3.58/4.13 (91/105)
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure System W/Filter
Crankcase Ventilation . . . . . . . . . . . . . . . . . Closed
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . Dry replaceable cartridge w/safety element
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel–Compression
Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1125 – 1175 RPM
High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2770 RPM
HYDRAULIC SYSTEM
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Driven, Gear Type
Pump Capacity @ 2750 RPM . . . . . . . . . . 18.0 GPM (68,1 L/min.) 28.0 GPM (106,0 L/min.)
System Relief at Quick Couplers . . . . . . . 3000 PSI (20685 kPa)
Filters (Charge & Implement) . . . . . . . . . . Full flow replaceable, 3 micron synthetic media element
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . Doubleacting;
Tilt cylinder has custioning feature on dump & rollback
Bore Diameter:
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . 2.50 (63,5)
Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . . 3.50 (88,9)
Rod Diameter:
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . 1.75 (44,5)
Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . . 1.625 (41,3)
Stroke:
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . 32.50 (825,5)
Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . . 18.17 (461,5)
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . 3–spool, open center type w/float detent on lift
and electrically controlled auxiliary spool.
Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . SAE standard tubelines, hoses & fittings
Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . . Bobcat Fluid (P/N 6563328) if fluid is not available, use
10W–30/10W–40 Class SE motor oil for temp. above 0°F (–18°C)
5W–30 Motor Oil for temperatures below 0°F (–18° C).
Hydraulic Function Time
Raise Lift Arms . . . . . . . . . . . . . . . . . . . . . 5.1 Seconds
Lower Lift Arms . . . . . . . . . . . . . . . . . . . . . 3.3 Seconds
Bucket Dump . . . . . . . . . . . . . . . . . . . . . . . 2.8 Seconds
Bucket Rollback . . . . . . . . . . . . . . . . . . . . . 2.4 Seconds
ELECTRICAL
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt driven, 50 amp, open
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt, 1000 cold cranking amps. @ 0°F. (–18°C);
180 minute reserve capacity
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt, Direct Drive; 4.0 HP (3.0 kW)
Instrumentation . . . . . . . . . . . . . . . . . . . . . . Gauges:Hourmeter, Fuel, Voltmeter, Engine Temperature.
Warning Lights: Engine Temperature, Engine Oil Pressure, Hydraulic Oil
Temperature & Pressure, Hydraulic Filter.
Optional BOSS System Monitors; Engine Oil Temperature, Engine
Oil Pressure, Hydraulic System Temperature & Pressure, Hydraulic
& Air Filters, RPM, Battery Condition, Fuel Level & Machine Hours.
Displays visual warnings & sounds audible alarm. Also controls
automatic shutdown function and has diagnostic capability.
DRIVE SYSTEM
Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic 4 wheel drive
Transmission . . . . . . . . . . . . . . . . . . . . . . . . Infinitely variable tandem hydrostatic piston pumps, driving 2 fully
reversing hydrostatic motors
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . #100 HS endless roller chain & sprockets in sealed chaincase with
oil lubrication
Total Engine to Wheel
Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . 39:1
Axle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.76 (70,0)
Wheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . (8) 9/16”

863, 863H Bobcat Loader

Revised June 98 –9–4– Service Manual
LOADER SPECIFICATIONS (Cont’d)
863 863H
CAPACITIES
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 gals. (95 L)
Engine/Cooling Oil W/Filter . . . . . . . . . . . . 16 qts. (15,1 L)
Hydraulic/Hydro. Reservoir . . . . . . . . . . . . 4 gals. (15,1 L)
Hydraulic/Hydro. System . . . . . . . . . . . . . . 10 gals. (38 L)
Chaincase Reservoir . . . . . . . . . . . . . . . . . . 11 gals. (42 L)
TIRES
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–16.5, 10 ply rating
Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–15.5 x 15,8 Ply Rating
Recommended Pressure . . . . . . . . . . . . Inflate tires to MAXIMUM pressure shown on the side wall of
the tire. DO NOT mix brands of tires used on the same loader.

863, 863H Bobcat Loader

Revised June 98 –9–5– Service Manual
ENGINE SPECIFICATIONS (BF4M1011)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

General

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166.7 cu. in. (2732 cu. cm.)

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58 (91)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13 (105)
Crankshaft Rotation (Facing Flywheel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counterclockwise
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Stroke Diesel – Compression
Combustion System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Injection
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17–1
Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363–435 PSI (2503–3000 kPa) (25–30 bar)
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3–4–2
Fuel System

Fuel Injection Pump Pressure (Five Revolutions) . . . . . . . . . . . . . . . . . . . . . . . . . . . Min. 4350 PSI (29993 kPa) (300 bar)
Injection Pump Testing Tightness . . . . . . . . . . . . . . 2175–2030 PSI. (15000–13996 kPa) (150–140 bar) drop in a minute
Injection Nozzle Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3045 PSI (20995 kPa) (210 bar)

Valve and Valve Guide and Seat Insert

Valve Clearance (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 (0,3)

Valve Clearance (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,5)
Valve Guide I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.315 ± 0.0009 (8,0 ± 0,025)
Valve Seat Insert O.D. (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.68° ± 0.0002 (42,67 ± 0,005)
Valve Seat Insert O.D. (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.46° ± 0.0002 (37,075 ± 0,005)
Valve Seat Insert Bore (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.677 + 0.001 (42,6 + 0,03)
Valve Seat Insert Bore (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.457+ 0.001 (37,0 + 0,03)
Valve Stem Diameter (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.314 – 0.0006 (7,98 – 0,015)
Valve Stem Diameter (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.313 – 0.0006 (7,96 – 0,015)
Valve Stem Clearance (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008 — 0.0023 (0,02 — 0,06)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005 (0,12)
Valve Stem Clearance (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0016 — 0.003 (0,04 — 0,08)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Valve Head O.D. (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.579 ± 0.004 (40,1 ± 0,1)
Valve Head O.D. (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.374 ± 0.004 (34,9 ± 0,1)
Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.067 ± 0.016 (1,7 ± 0,4)
Seat Angle (Intake & Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees
Marg Thickness (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.049 (1,25)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.032 (0,8)
Marg Thickness (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.073 (1,85)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.531 (38,9)
Valve Recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.039 ± 0.005 (1,0 ± 0,13)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 (1,53)
Valve Spring Free Length 0.132 (3,35) diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.74 (44,3)
0.134 (3,40) diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.547 (39,3)
Valve Spring Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.126 (3,2)

863, 863H Bobcat Loader

Revised June 98 –9–6– Service Manual
ENGINE SPECIFICATIONS (BF4M1011) (Cont’d)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Piston and Rings

Piston Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.578 (90,93)

I.D. for Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0236 + 0.0004 — 0.00016 (26,0 + 0,01 — 0,004)
Piston Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0236 – 0.0002 (26,0 – 0,005)
Piston Ring Groove – 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0787 + 0.04 — 0.0032 (2,0 + 0,10 — 0,08)
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0787 + 0.04 — 0.0032 (2,0 + 0,10 — 0,08)
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.118 + 0.002 — 0.0008 (3,0 + 0,04 — 0,02)
Piston Ring Clearance – 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 — 0.005 (0,09 — 0,12)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0078 (0,2)
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003 — 0.004 (0,07 — 0,10)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,16)
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0015 — 0.003 (0,04 — 0,07)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005 (0,12)
Piston Ring Gap 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0118 — 0.019 (0,3 — 0,5)
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0315 — 0.041 (0,8 — 1,05)
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.018 — 0.028 (0,45 — 0,7)

Bore for Piston Pin Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 + 0.0008 (29,0 + 0,02)

Piston Pin Bushing O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.299 + 0.004–0.002 (33,0+–0.006)

Piston Pin Bushing I.D. (pressed in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.81 + 0.0014–0.00098 (30,0+0,035–0,025)
Piston Pin Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0009 — 0.0016 (0,025 — 0,04)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0031 (0,08)
Connecting Rod

Small End Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.181+0.00013 — +0.000010 (30,0+0,0035 — +0,0025)

Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003 (0,08)
Bore for Small End Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.299 +0.0008 (33,0 + 0,02)
O.D. for Small Eng Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.299 +0.0043 — +0.0028 (33,0 + 0,110 — +0.070)
Parallel Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tolerance over a distance of 3.937 (100) is 0.0039 (0,10)
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05)
Connecting Rod Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.063 – 0.0023 (27,0 – 0,06)
Connecting Rod End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0078 – 0.022 (0,2 – 0,56)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0315 (0,8)
Center Distance From Small to Large Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.811 ± 0.0012 (173,0 ± 0,03)
Bore for Large End Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.303 + 0.0008 (58,5 + 0,02)
Large End Bearing Shells I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.166 — 2.167 (55,004 — 55,04)
Limit for Undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.146 — 2.147 (54,504 — 54,54)
Large End Bearing Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0009 — 0.003 (0,024 — 0,078)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005 (0,12)
Large End Bearing Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.008 – 0.012 (25,6 – 0,3)

Cylinder Head and Block

Cylinder Head Studs – Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23 ± 0.031 (185,0 ± 0,8)

Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.583 + 0.0008 (91,0 + 0,02)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 (0,1)

863, 863H Bobcat Loader

Revised June 98 –9–7– Service Manual
ENGINE SPECIFICATIONS (BF4M1011) (Cont’d)

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Crankshaft and Main Bearings

Crankshaft Pin Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.220 (31,0)

Crankshaft Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.165 – 0.0004 – 0.0012 (55,0 – 0,01 – 0,03)
Oval Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0004 (0,01)
Crankshaft Journal Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38 (35,0)
Crankshaft Journal Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.756 – 0.0004 – 0.0012 (70,0 – 0,01 – 0,03)
Oval Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0003 (0,008)
Eccentricity Max. Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05)
Thrust Bearing Journal Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.378 + 0.002 (35,0 + 0,04)
Main Bearing Shell I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.757 — 2.758 (70,02 — 70,055)
Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0011 — 0.0033 (0,03 — 0,084)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0047 (0,12)
Bearing Bore in Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.953 + 0.0007 (75,0 + 0,019)
Thrust Bearing Stop Rings O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.374 – 0.005 (34,9 – 0,133)
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0157 (0,4)
Limit for Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.406 – 0.0052 (35,7 – 0,133)
Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0039 – 0.0106 (0,1 – 0,3)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.016 (0,4)

Camshaft and Bearings

Camshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0118 — 0.0236 (0,3 — 0,6)

Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0315 (0,8)
Camshaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.008 + 0.002 (51,0 + 0,054)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0019 — 0.0048 (0,05 — 0,124)
Cam Lift (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.260 (6,6)
Cam Lift (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.268 (6,8)

Oil Pump

Oil Pump Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 PSI (600 kPa) (6 bar)

Thermostat Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200° F (93° C)

863, 863H Bobcat Loader

Revised June 98 –9–8– Service Manual
ENGINE SPECIFICATIONS (BF4M1011F)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

General

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177.7 cu. in. (2912 cu. cm.)

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58 (91)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.41 (112)
Crankshaft Rotation (Facing Flywheel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counterclockwise
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Stroke Diesel – Compression
Combustion System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Injection
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17–1
Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320–392 PSI (2206–2703 kPa) (22–27 bar)
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3–4–2
Fuel System

Fuel Injection Pump Pressure (Five Revolutions) . . . . . . . . . . . . . . . . . . . . . . . . . . . Min. 4350 PSI (29993 kPa) (300 bar)
Injection Pump Testing Tightness . 2175 PSI – 145 PSI permissible drop/min. (14997 kPa–1000kPa) (150 bar–10 bar)
Injection Nozzle Opening Pressure . . . . . . . . . . . . . . . . . . . . . . 3625 PSI + 116 (24994 kPa + 800 kPa) (250 bar + 8 bar)

Valve and Valve Guide and Seat Insert

Valve Clearance (Intake) Oil Temp. Below 176° F (80° C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 (0,3)
Valve Clearance (Exhaust) Oil Temp. Below 176° F (80° C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,5)
Valve Guide I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.315 ± 0.0010 (8,0 ± 0,025)
Valve Seat Insert O.D. (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.680 ± 0.0002 (42,67 ± 0,005)
Valve Seat Insert O.D. (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.460 ± 0.0002 (37,075 ± 0,006)
Valve Seat Insert Bore (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.677 ± 0.001 (42,6 ± 0,03)
Valve Seat Insert Bore (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.457 ± 0.001 (37,0 ± 0,03)
Valve Stem Diameter (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.314 – 0.0006 (7,98 – 0,015)
Valve Stem Diameter (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.313 – 0.0006 (7,96 – 0,015)
Valve Stem Clearance (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008 — 0.0023 (0,02 — 0,06)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005 (0,12)
Valve Stem Clearance (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0016 — 0.003 (0,04 — 0,08)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Valve Head O.D. (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.594 ± 0.004 (40,5 ± 0,1)
Valve Head O.D. (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.374 ± 0.004 (34,9 ± 0,1)
Valve Seat Width . . (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.062 ± 0.016 (1,58 ± 0,4)
(Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.067 ± 0.016 (1,7 ± 0,4)
Seat Angle . . . . . . . (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
(Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Marg Thickness (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0551 (1,4)
Marg Thickness (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.047 (1.2)
Valve Recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0512 ± 0.0051 (1,3 ± 0,13)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0512 (1,3)
Valve Spring Free Length 0.132 (3,35) diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.531 (38,9)
0.134 (3,40) diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.547 (39,3)
Valve Spring Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.126 (3,2 )

863, 863H Bobcat Loader

Revised June 98 –9–9– Service Manual
ENGINE SPECIFICATIONS (BF4M1011F) (Cont’d)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Piston and Rings

Piston Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.578 (90,9)

I.D. for Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0236 + 0.0004 — 0.0016 (26,0 + 0,01 — 0,04)
Piston Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.118 – 0.0002 (30,0 – 0,005)
Piston Ring Groove – 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0787 + 0.004 (2,0 + 0,10–0,08)
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0787 + 0.004 – 0.003 (2,0 + 0,10 – 0,08)
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.118 + 0.002–0.0008 (3,0 + 0,04–0,02)
Piston Ring Clearance – 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004–0.005 (0,09–0,12)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0078 (0,2)
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,003–0.004 (0,07–0,10)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,16)
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015–0.003 (0,04–0,07)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005 (0,12)

Piston Ring Gap . . – 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0118 — 0.019 (0,3 — 0,5)

2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0315 — 0.039 (0,8 — 1,0)
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.018 — 0.028 (0,45 — 0,7)

Wear Limit – 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0315 — (0,8)

2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.071 (1,8)
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035 (0,9)

Bore for Piston Pin Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A

Piston Pin Bushing O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Piston Pin Bushing I.D. (pressed in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Piston Pin Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0009 — 0.0016 (0,025 — 0,04)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0031 (0,08)

Connecting Rod

Small End Bushing I.D. (Pressed In) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.181+0.0014 +0.00010 (30,0+0,035 +0,025)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003 (0,08)
Bore for Small End Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.299+0.0008 (33,0 + 0,02)
O.D. for Small Eng Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.299+0.0043 — +0.0028 (33,0 + 0,11 — +0.07)
Parallel Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Permissible 0.0039 over a distance of 3.937 (0,10 Over 100,0)
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05)
Connecting Rod Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.063 – 0.0023 (27,0 – 0,06)
Connecting Rod End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0078 – 0.022 (0,2 – 0,56)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0315 (0,8)
Center Distance From Small to Large Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.811 ± 0.0012 (173,0 ± 0,03)
Bore for Large End Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.303 + 0.0008 (58,5 + 0,02)
Large End Bearing Shells I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.166 — 2.167 (55,004 — 55,04)
Limit for Undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.146 — 2.147 (54,504 — 54,54)
Large End Bearing Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0009 — 0.003 (0,024 — 0,078)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005 (0,12 mm)
Large End Bearing Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.008 – 0.012 (25,6 – 0,3)

Cylinder Head and Block

Cylinder Head Studs – Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.906 ± 0.031 (150,0 ± 0,8)
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.583+ 0.0008 (91,0 + 0,02)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.587 (91,1)

863, 863H Bobcat Loader

Revised June 98 –9–10– Service Manual
ENGINE SPECIFICATIONS (BF4M1011F) (Cont’d)

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Crankshaft and Main Bearings

Crankshaft Pin Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.220 (31,0)

Crankshaft Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.165 – 0.0004 – 0.0012 (55,0 – 0,01 – 0,03)
Oval Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0004 (0,01)
Crankshaft Journal Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.378 + 0,0016 (35,0, + 0,04)
Crankshaft Journal Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.756 – 0.0004 – 0.0012 (70,0 – 0,01 – 0,03)
Oval Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0003 (0,008)
Eccentricity Max. Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05)
Thrust Bearing Journal Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.378 + 0.002 (35,0 + 0,04)
Main Bearing Shell I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.757 — 2.758 (70,02 — 70,055)
Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0011 — 0.0033 (0,03 — 0,084)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0047 (0,12)
Bearing Bore in Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.953+ 0.0007 (75,0 + 0,019)
Thrust Bearing Stop Rings O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.374 – 0.005 (34,9 – 0,133)
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0157 (0,4)
Limit for Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.406 – 0.0052 (35,7 – 0,133)
Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0039 – 0.0106 (0,1 – 0,27)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.016 (0,4)

Camshaft and Bearings

Camshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0118 — 0.0236 (0,3 — 0,6)

Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0315 (0,8)
Camshaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.126+ 0.0021 (54,0+ 0,054)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.129 (54,08)
Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0019 — 0.0048 (0,05 — 0,124)
Cam Lift (Intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.260 (6,6)
Cam Lift (Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.268 (6,8)

Oil Pump

Oil Pump Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.5 PSI (700 kPa) (7 bar)

Min. Eng. OIl Pressure, Oil Temp. 230° F (110 ° C) at 900 RPM . . . . . . . . . . . . . . . . . . . . . 20.3 PSI (140 kPa) (1.4 bar)
1800 RPM . . . . . . . . . . . . . . . . . . . . 31.9 PSI (220 kPa) (2.2 bar)
2800 RPM . . . . . . . . . . . . . . . . . . . . 43.5 PSI (300 kPa) (3.0 bar)
Thermostat Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203° F (95° C)

863, 863H Bobcat Loader

Revised June 98 –9–11– Service Manual
ENGINE TORQUE
Specifications
Description Ft.–Lbs. Nm
Air Intake Manifold Bolts (M8 Torx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 20
Adapter Housing Bolts (M12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21–24 28–33
Camshaft Bolt (M14 x 1,5 x 110) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 30
Plus 210 degrees
Camshaft Thrust Washer Bolt (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 20
Connecting Rod Cap Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 30
Plus 60 degrees, 60 degrees = 120 degrees
Crankcase Screw Plugs (M18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 50
(M24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 111
(M30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15 16–20
Crankshaft Gear Mount Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243–295 330–400
Cylinder Head Bolts Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 30
Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 80
Step 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 160
Plus 90 degrees
Exhaust Manifold Bolts (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 40
Exhaust Turbocharger Nuts (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 30
Flywheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 30
Plus 60 degrees, 30 degrees = 90 degrees
Front Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 20
Front Mount Foot Bolts M14 x 55) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 52
Fuel Lift Pump Bolts (M8 Torx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 20
Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–18 20–24
Injector Cap Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 47
Injector Pump Mounting Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 21
Main Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 50
Plus 60 degrees, 45 degrees = 105 degrees
Oil Pan Bolts (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 20
Oil Pan Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 54
Oil Pump Bolts (M8 Torx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 22
Oil Press. Control Valve Screw Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 111
Oil Return Line Cap Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–14 18–19
Oil Suction Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 22
Oil Temp. Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 28
Rocker Arm Bracket Bolts (M8 Torx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 20
Rear Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 20
Rear Mounting Foot Bolts (M12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 31
Starter Carrier Bolts (M12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–18 20–24
Starter Fastening Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–28 34–38
Thermostat Housing Screw Plug (M38) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 111
Timing Belt Tensioner Pulley Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 45
V–Belt Pulley Bolts (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30–36 41–49

863, 863H Bobcat Loader

Revised June 98 –9–12– Service Manual
ENGINE TORQUE (Cont’d)
Specifications (Cont’d)

Description In.–Lbs. Nm
Air Intake 3–Hole Flange Bolts (M8 Torx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54–65 6,1–7,3
Breather Vent Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 8,5
Crankcase Screw Plugs (M20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85–104 9,6–11,7
(M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28–36 3,1–4,0
(M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–16 1,4–1,8
(M16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62–78 7,0–8,8
Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 8,5
Fuel Filter Bracket Bolt (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 6,1
Full Load Stop Screw Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 4,5
Governor Lever Shaft Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 9,2
Injector Fastening Bolt (M8 Torx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–59 5,5–6,6
Minimum Speed Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 4,5
Oil Filter Bracket Bolts (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24–30 2,7–3,4
Oil Intake Housing Bolts (M8 Torx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54–65 6,1–7,3
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 13
Piston Cooling Oil Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1,2
Rocker Arm Set Screw Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–59 5,5–6,6
Shut Down Stop Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 4,5
Shut Down Solenoid Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 9
Thermostat Housing Bolts (M6 Torx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–24 2,2–2,7
Thermostat Housing Bolts (M8 Torx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24–32 2,7–3,6
Turbocharger Backing Plate Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 10
Turbocharger Compressor Housing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 7
Turbocharger Compressor Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 5
Valve Plunger Housing Bolts (M8 Torx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24–32 2,7–3,6

Torque For General Metric Bolts

Material
Thread Size
(Dia. x Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M 5 x 0.8 3–4 ft.–lbs.
(4–5 Nm)
M 6 x 1.0 6–7 ft.–lbs. 6–9 ft.–lbs.
(8–9 Nm) (8–12 Nm)
M 8 x 1.25 6–9 ft.–lbs. 11–16 ft.–lbs. 18–25 ft.–lbs.
(8–12 Nm) (15–22 Nm) (24–34 Nm)
M 10 x 1.25 13–18 ft.–lbs. 22–30 ft.–lbs. 36–50 ft.–lbs.
(18–24 Nm) (30–41 Nm) (49–68 Nm)
M 12 x 1.25 22–30 ft.–lbs. 40–54 ft.–lbs. 69–87 ft.–lbs.
(30–41 Nm) (54–73 Nm) (94–118 Nm)
M 14 x 1.25 36–50 ft.–lbs. 58–80 ft.–lbs. 116–137 ft.–lbs.
(49–68 Nm) (79–108 Nm) (157–186 Nm)

863, 863H Bobcat Loader

Added June 98 –9–13– Service Manual
TORQUE SPECIFICATIONS FOR LOADER
Specifications
Item Ft.–Lbs. Nm
Air Cleaner Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–28 34–38
Alternator Pulley Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 68
Axle Hub Mounting Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175–190 240–260
Axle Sprocket Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475–525 645–710
BICS™ Control Valve Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–16 20–22
Bob–Tach Lever Pivot Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–28 34–38
Control Pedal Linkage Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21–25 28–34
Control Valve Mounting Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–16 20–22
Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65–70 88–95
Exhaust Pipe to Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–35 27–47
Filter Housing Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 34
Front Panel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16–20 22–27
Hydraulic Pump Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45–50 61–68
Hydraulic Pump Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–27 34–37
Hydraulic Reservoir Strap Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16–20 22–27
Hydrostatic Motor Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210–230 285–310
Hydrostatic Pump Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65–70 88–95
Hydrostatic Pump Pulley Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175–200 237–271
Lift Arm By–Pass Control Valve Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–16 20–22
Main Frame to Chaincase Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300–330 410–450
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–40 47–54
Motor Carrier Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 447
Operator Cab Fastening Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–50 54–68
Operator Cab Pivot Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–35 34–47
Pedal Lock Linkage to Main Frame Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8 9,5–10,8
Pedal Lock Linkage Tab Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 34
Pivot Pins Lock Bolt & Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18–20 24–27
Seat Belt Fastening Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–45 54–61
Seat Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–11 12,2–15
Seat Bar Pivot Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–28 34–38
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105–115 142–156

863, 863H Bobcat Loader

Added June 98 –9–14– Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS
A

When repairing hydrostatic and hydraulic

systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888
B–07575

O–ring Face Seal Connection

When the fitting is tightened, you can feel when the fitting B
is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
O–ring in position until the fittings are assembled [A]. Nut
Nut
Straight Thread O–ring Fitting
Washer Washer
Lubricate the O–ring before installing the fitting. Loosen
the jam nut and install the fitting. Tighten the jam nut until O–ring
the washer is tight against the surface [B]. O–ring
Tubelines And Hoses
Replace any tubelines that are bent or flattened. They will
restrict flow, which will slow hydraulic action and cause
heat. A–01852

Replace hoses which show signs of wear, damage or

weather cracked rubber. C
Always use two wrenches when loosening and tightening
hose or tubeline fittings. 1
Flare Fitting
Use the following procedure to tighten the flare fitting:
Tighten the nut until it makes contact with the seat. Make 2
a mark across the flats of both the male and female parts
of the connection (Item 1) [C].
Use the chart below to find the correct tightness needed
(Item 2) [C]. If the fitting leaks after tightening, disconnect
it and inspect the seat area for damage. TS–01619

Flare Fitting Tightening Torque

Tubeline TORQUE NEW RE–ASSEMBLY
Outside Ft.–lbs. Rotate No. Rotate No.
Wrench Size Diameter Thread Size (Nm) of Hex Flats of Hex Flats
5/8’’ 5/16’’ 1/2’’ – 20 17 (23) 2–1/2 1
11/16’’ 3/8’’ 9/16’’ – 18 22 (30) 2 1
7/8’’ 1/2’’ 3/4’’ – 16 40 (54) 2 1
1’’ 5/8’’ 7/8’’ – 14 60 (81) 1–1/2 1
1–1/4’’ 3/4’’ 1–1/16’’ – 12 84 (114) 1 3/4
1–3/8’’ 1’’ 1–5/16’’ – 12 118 (160) 3/4 3/4

Added June 98 863, 863H Bobcat Loader

–9–15– Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS
(Cont’d) A O–ring Flare
Primary
O–ring Flare Fitting Seal
The flare is the primary seal, the O–ring is the secondary
seal and helps absorb vibration and pressure pulses at
the connection [A].
If necessary, the O–ring–flare fitting can be used without
an O–ring.
Use the following procedure to tighten the O–ring flare
fitting. Secondary
Seal
Tighten the nut until it contacts with the seat. Make a mark
P–13009
across the flats of both the male and female parts of the
connection (Item 1) [B].
Use the chart below to find the correct tightness needed
(Item 2) [B]. If the fitting leaks after tightening, disconnect
B Hex Flat Tightening Method

it and inspect the seat area for damage.

1

TS–01619

O–ring Flare Fitting Tightening Torque

* ** ***
Tubeline TORQUE NEW RE–ASSEMBLY
Outside Ft.–lbs. Rotate No. Rotate No.
Wrench Size Diameter Thread Size (Nm) of Hex Flats of Hex Flats
5/8’’ 5/16’’ 1/2’’ – 20 17 (23) 2–1/2 1
11/16’’ 3/8’’ 9/16’’ – 18 22 (30) 2 1
7/8’’ 1/2’’ 3/4’’ – 16 40 (54) 2 1
1’’ 5/8’’ 7/8’’ – 14 60 (81) 1–1/2 1
1–1/4’’ 3/4’’ 1–1/16’’ – 12 84 (114) 1 3/4
1–3/8’’ 1’’ 1–5/16’’ – 12 118 (160) 3/4 3/4

* If a torque wrench is used to tighten a new fitting to a ** If using the hex flat tightening method to tighten a new
used hose/tubeline. fitting to a new hose/tubeline.
* If a torque wrench is used to tighten a used fitting to a ** If using the hex flat tightening method to tighten a new
new hose/tubeline. fitting to a used hose/tubeline.
* If a torque wrench is used to tighten a new fitting to a *** If using the hex flat tightening method to tighten a used
new hose/tubeline. fitting to a new hose/tubeline.

863, 863H Bobcat Loader

Added June 98 –9–16– Service Manual
HYDRAULIC
(Cont’d)
CONNECTION SPECIFICATIONS
A Copper Bonnet Orifice

O–ring Flare Fitting (Cont’d)

NOTE: O–ring flare fittings are not recommended in

all applications. Use the standard flare
fittings in these applications.
1
Do not use a O–ring flare fitting when a copper bonnet
orifice is used. When tightened the connection at the
bonnet may distort the flare face and prevent it from
sealing. P–13572
Use a standard flare fitting (Item 1) [A] as shown.
When a O–ring flare fitting is used as a straight thread port B
adapter the O–ring flare face is not used to seal. The
O–ring may come off the fitting and enter the system.
2
Always remove the O–ring (Item 1) [B] from the flare
face as shown.
An O–ring (Item 2) [B] is added to the flat boss of the
fitting to seal the connection in this application.

1
P–13573

863, 863H Bobcat Loader

Added June 98 –9–17– Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS A
(Cont’d)
Port Seal Fitting
The nut is the primary seal, the O–ring is the secondary
seal and helps absorb vibration and pressure pulses at
the connection [A].
The hex portion of the nut does not contact the surface of
the component when the nut is tight.

Use the following procedure to tighten the port seal fitting:

Port seal and nut, washer and O–ring (O–ring Boss)
fittings use the same tightening torque valve chart. Nut Seals
to Fitting
If a torque wrench cannot be used, use the following
method.
Nut Seals
Tighten the nut until it just makes metal to metal contact, to Port
you can feel the resistance.
Tighten the nut with a wrench no more than one hex flat
maximum.
Do not over tighten the port seal fitting.
Secondary O–ring Seal

NOTE: If a torque wrench cannot be used, use the P–13008

hex flat tightening method as an approximate
guideline.

NOTE: Port seal fittings are not recommended in all

Port Seal and O–ring Boss
applications. Use O–ring boss fittings in Tightening Torque
these applications.
Fitting TORQUE
Nut Ft.–lbs.
Wrench Size Thread Size (Nm)
11/16’’ 9/16’’ – 18 22 (30)
15/16’’ 3/4’’ – 16 40 (54)
1–1/8’’ 7/8’’ – 14 60 (81)
1–1/4’’ 1–1/16’’ – 12 84 (114)
1–1/2’’ 1–5/16’’ – 12 118 (160)

Do not use port seal fittings when a thread in orifice (Item

1) [B] is used in the port. The orifice may interfere with the B
fitting and prevent it from sealing.
Use an O–ring boss fitting (Item 1) [B] as shown. 2

P–13571

863, 863H Bobcat Loader

Added June 98 –9–18– Service Manual
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
Specifications
Use Bobcat hydraulic/hydrostatic transmission fluid (P/N 6563328). If this fluid is not
available, use 10W–30 or 10W–40 SAE Motor Oil (5W–30 for 0°F [–18°C] and
Below).

DO NOT use automatic transmission fluids in the loader or permanent damage to the
transmission will result.

Diesel fuel or hydraulic fluid under

pressure can penetrate skin or eyes,
causing serious injury or death.
Fluid leaks under pressure may not
be visible. Use a piece or 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
from a physician familiar with this
injury.
W–2072–0496

When temperatures below zero degree F (–18°C) are common, the loader must be
kept in a warm building. Extra warm–up time must be used each time the loader is
started during cold temperature conditions. Cold fluid will not flow easily and it makes
action of the hydraulic function slower. Loss of fluid flow to the hydrostatic
transmission pump (indicated by TRANS light ON) can cause transmission damage
in less than 60 seconds.

During cold weather 32°F (0°C) and

below, do not operate machine until
the engine has run for at least five (5)
minutes at less than half throttle.
This warm–up period is necessary
for foot pedal operation and safe
stopping. Do not operate controls
during warm–up period. When
temperatures are below –20°F
(30°C), the hydrostatic oil must be
heated or kept warm. The
hydrostatic system will not get
enough oil at low temperatures. Park
the machine in an area where the
temperature will be above 0°F
(–18°C), if possible.
W–2027–1285

863, 863H Bobcat Loader

Added June 98 –9–19– Service Manual
STANDARD TORQUE SPECIFICATIONS FOR BOLTS
The following table shows standard torque specifications for bolts with zinc
phosphate coating. Bolts purchased from Bobcat that have zinc phosphate coating
are specified by the letter H following the part number.

THREAD
SIZE SAE GRADE 5 SAE GRADE 8

INCH. .250 80–90 110–120

LBS. (9,0–10,2) (12,4–13,6)
(Nm)
.3125 180–200 215–240
(20,3–22,6) (24,2–27,1)
.375 25–28 35–40
(34–38) (47–54)
.4375 40–45 60–65
(54–61) (81–88)
.500 65–70 90–100
(88–95) (122–136)
.5625 90–100 125–140
(122–136) (170–190)
.625 125–140 175–190
(170–190) (240–260)
FOOT .750 220–245 300–330
LBS. (300–330) (410–450)
(Nm)
.875 330–360 475–525
(450–490) (645–710)
1.000 475–525 725–800
(645–710) (985–1085)
1.125 650–720 1050–1175
(880–975) (1425–1600)
1.250 900–1000 1475–1625
(1200–1360) (2000–2200)
1.375 1200–1350 2000–2200
(1630–1830) (2720–2980)
1.500 1500–1650 2600–2850
(2040–2240) (3530–3870)
1.625 2000–2800 3450–3800
(2720–2980) (4680–5150)
1.750 2500–2750 4300–4800
(3390–3730) (5830–6500)
1.875 3150–3500 5500–6100
(4270–4750) (7450–8300)
2.000 3800–4200 6500–7200
(5150–5700) (8800–9800)

863, 863H Bobcat Loader

Added June 98 –9–20– Service Manual
DECIMAL AND MILLIMETER EQUIVALENTS

FRACTIONS DECIMALS MM FRACTIONS DECIMALS MM

1/64 0.015625 — 0.397 33/64 0.515625 — 13.097
1/32 0.03125 — 0.794 17/32 0.53125 — 13.494
3/64 0.046875 — 1.191 35/64 0.546875 — 13.891
1/16 0.0625 — 1.588 9/16 0.5625 — 14.288
5/64 0.078125 — 1.984 37/64 0.578125 — 14.684
3/32 0.09375 — 2.381 19/32 0.59375 — 15.081
7/64 0.109375 — 2.778 39/64 0.609375 — 15.478
1/8 0.1250 — 3.175 5/8 0.6250 — 15.875
9/64 0.140625 — 3.572 41/64 0.640625 — 16.272
5/32 0.15625 — 3.969 21/32 0.65625 — 16.669
11/64 0.171875 — 4.366 43/64 0.671875 — 17.066
3/16 0.1876 — 4.762 11/16 0.6875 — 17.462
13/64 0.203125 — 5.159 45/64 0.703125 — 17.859
7/32 0.21875 — 5.556 23/32 0.71875 — 18.256
15/64 0.234375 — 5.953 47/64 0.734375 — 18.653
1/4 0.2500 — 6.350 3/4 0.7500 — 19.050
17/64 0.265625 — 6.747 49/64 0.765625 — 19.447
9/32 0.28125 — 7.144 25/32 0.78125 — 19.844
19/64 0.296875 — 7.541 51/64 0.796875 — 20.241
5/16 0.3125 — 7.938 13/16 0.8125 — 20.638
21/64 0.328125 — 8.334 53/64 0.828125 — 21.034
11/32 0.34375 — 8.731 27/32 0.84375 — 21.431
23/64 0.359375 — 9.128 55/64 0.859375 — 21.828
3/8 0.3750 — 9.525 7/8 0.8750 — 22.225
25/64 0.390625 — 9.922 57/64 0.890625 — 22.622
13/32 0.40625 — 10.319 29/32 0.90625 — 23.019
27/64 0.421875 — 10.716 59/64 0.921875 — 23.416
7/16 0.4375 — 11.112 15/16 0.9375 — 23.812
29/64 0.453125 — 11.509 61/64 0.953125 — 24.209
15/32 0.46875 — 11.906 31/32 0.96875 — 24.606
31/64 0.484375 — 12.303 63/64 0.984375 — 25.003
1/2 0.5000 — 12.700 1 1.000 — 25.400

1 mm = 0.03937’’ 0.001’’ = 0.0254 mm

U.S. TO METRIC CONVERSION

TO CONVERT INTO MULTIPLY BY
LINEAR Miles Kilometers 1.609
MEASUREMENT Yards Meters 0.9144
Feet Meters 0.3048
Feet Centimeters 30.48
Inches Meters 0.0254
Inches Centimeters 2.54
Inches Millimeters 25.4
AREA Square Miles Square Kilometers 2.59
Square Feet Square Meters 0.0929
Square Inches Square Centimeters 6.452
Acre Hectare 0.4047
VOLUME Cubic Yards Cubic Meters 0.7646
Cubic Feet Cubic Meters 0.02832
Cubic Inches Cubic Centimeters 16.39
WEIGHT Tons (Short) Metric Tons 0.9078
Pounds Kilograms 0.4536
Ounces (Avdp.) Grams 28.3495
PRESSURE Pounds/Sq. In. Kilopascal 6.895
WORK Foot–Pounds Newton–Metre 1.356
LIQUID VOLUME Quarts Liters 0.9463
Gallons Liters 3.785
LIQUID FLOW Gallons/Minute Liters/Minute 3.785
TEMPERATURE Fahrenheit Celsius 1.Subtract 32°
2. Multiply by 5/9
863, 863H Bobcat Loader
Added June 98 –9–21– Service Manual
863,863HServiceManual#6724799–Specifications

863, 863H Bobcat Loader

Added June 98 –9–22– Service Manual
863–001
Revision Number

23 August 1996
SERVICE MANUAL Date

REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER X
Product BOBCAT LOADER
SERVICE MANAGER X
Model 863 SALES MANAGER
Manual No. 6724799 (4–96)

NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.

The following pages are a revision to the 863 Service Manual P/N 6724799 (4–96).
Take out the pages shown and put in the revised pages as follows:
TAKE OUT PUT IN
4–15, 4–16 4–15 (Revised August 96), 4–16

Printed in U.S.A.
863–002
Revision Number

13 Sept. 96
SERVICE MANUAL Date

REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER
SERVICE MANAGER X
Model 863, 863H SALES MANAGER
Manual No. 6724799 (4–96)

NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.

Service Manual P/N 6724799 (4–96) is now revised to include Model 863H. All revision pages to this manual note this
change in the lower right margin.
Put in the added pages as follows:
TAKE OUT PUT IN
863 COVER 863, 863H COVER
ALPHABETICAL INDEX ALPHABETICAL INDEX (Revised Sept. 96)
V, VI V (Revised Sept. 96) VI
1–3, 1–4 1–3 (Revised Sept. 96), 1–4
1–9, 1–10 1–9, 1–10 (Revised Sept. 96)
1–11, 1–12 1–11 (Revised Sept.96), 1–12
Hyraulic/Hydrostatic Schematic (P/N 6724573) Hyraulic/Hydrostatic Schematic (P/N 6724573)
863 BICS (Printed April 96) 863 BICS (Printed Sept. 96)
Hyraulic/Hydrostatic Schematic (P/N 6724728)
863H BICS (Printed Sept. 96)
Complete Section 2 Complete Section 2 (Revised Sept. 96)
3–19 through 3–26 3–19 through 3–25 (Revised Sept. 96), 3–26
3–53 through 3–56 3–53 (Revised Sept. 96), 3–54 (Revised Sept. 96),
3–55, 3–56 (Revised Sept. 96)
All Wiring Diagrams 7 sheets (Printed April 96) Wiring Diagrams 17 sheets (Printed Sept. 96)
7–1 through 7–4 7–1, 7–2 (Revised Sept. 96)
7–3 (Revised Sept. 96), 7–4
7–7, 7–8 7–7 (Revised Sept. 96), 7–8
7–29, 7–30, 7–29 (Revised Sept. 96), 7–30
7–37, 7–38 7–37 (Revised Sept. 96), 7–38
7–41, 7–42 7–41, 7–42 (Revised Sept. 96)
7–45, 7–46 7–45 (Revised Sept. 96), 7–46
7–113, 7–114 7–113 (Revised Sept. 96), 7–114
7–115 (Added Sept. 96), 7–116 (Added Sept. 96)
8–1, 8–2, 8–1, 8–2 (Revised Sept. 96)
8–3, 8–4 8–3 (Revised Sept. 96), 8–4
8–27, 8–28 8–27, 8–28 (Revised Sept. 96)
8–29 (Added Sept. 96), 8–30 (Added Sept. 96)
Complete Section 9 Complete Section 9 (Revised Sept. 96)
863–003
Revision Number

11 December 1996
SERVICE MANUAL Date

REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER
SERVICE MANAGER X
Model 863, 863H SALES MANAGER
Manual No. 6724799 (4–96)

NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.

Five new Electrical Wiring Diagram Index pages are added. Install the appropriate index page before wiring
diagram sheet 1 of each group.
Currently section 8 of this Bobcat Loader Service Manual is named BICS/BOSS SYSTEM. This section name is now
changed to SYSTEMS ANALYSIS. Diagnostic information on other Bobcat systems is now added or will be added in the
future. BICS/BOSS system information will remain in section 8. This name more accurately describes the contents of this
section.
Put in the added pages as follows:
TAKE OUT PUT IN
Alphabetical Index Alphabetical Index (Revised Dec. 96)
i, ii i (Revised Dec. 96), ii
1–1,1–2 1–1 (Revised Dec. 96),1–2 (Revised Dec. 96)
1–3, 1–4 1–3 (Revised Dec. 96),1–4
1–15, 1–16 1–15, 1–16 (Revised Dec. 96)
1–17, 1–18 1–17 (Revised Dec. 96), 1–18 (Revised Dec. 96)
1–19, 1–20 1–19 (Revised Dec. 96), 1–20 (Revised Dec. 96)
1–21, 1–22 1–21 (Revised Dec. 96), 1–22 (Revised Dec. 96
1–23, 1–24 1–23 (Revised Dec. 96), 1–24 (Revised Dec. 96)
2–27 (Revised Sept. 96), 2–28 (Revised Sept. 96) 2–27(Revised Dec. 96), 2–28(Revised Sept. 96)
6–1, 6–2 6–1 (Revised Dec. 96), 6–2
Cab Wiring Index (Added Dec. 96)
Engine Wiring Index (Added Dec. 96)
Controls Wiring Index (Added Dec. 96)
BICS Wiring Index (Added Dec. 96)
Optional Wiring Index (Added Dec. 96)
6–3, 6–4 6–3, 6–4 (Revised Dec. 96)
6–5, 6–6 6–5 (Revised Dec. 96), 6–6 (Revised Dec. 96)
6–7, 6–8 6–7 (Revised Dec. 96), 6–8 (Revised Dec. 96)
6–9, 6–10 6–9 (Revised Dec. 96), 6–10 (Revised Dec. 96)
6–11, 6–12 6–11 (Revised Dec. 96), 6–12 (Revised Dec. 96)
6–13, 6–14 6–13 (Revised Dec. 96), 6–14
7–7 (Revised Sept. 96), 7–8 7–7 (Revised Sept. 96), 7–8 (Revised Dec. 96)
7–33, 7–34 7–33, 7–34 (Revised Dec. 96)
7–45, 7–46 7–45 (Revised Dec. 96), 7–46
8–1, 8–2 8–1 (Revised Dec. 96), 8–2 (Revised Dec. 96)
8–27, 8–28 (Revised Sept. 96) 8–27, 8–28 (Revised Dec. 96)
8–29 (Added Sept. 96), 8–30 8–29 (Revised Dec. 96), 8–30 (Revised Dec. 96)
8–31 (Added Dec. 96), 8–32 (Added Dec.96)
863–004
Revision Number

1 February 1997
SERVICE MANUAL Date

REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER X
Product BOBCAT LOADER
SERVICE MANAGER X
Model 863, 863H SALES MANAGER
Manual No. 6724799 (4–96)

NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.

The following pages are a revision to the 863 Service Manual P/N 6724799 (4–96).
Take out the pages shown and put in the revised pages as follows:
TAKE OUT PUT IN
HYDRAULIC/HYDROSTATIC SCHEMATIC HYDRAULIC/HYDROSTATIC SCHEMATIC
863 BICS 863 BICS
(Printed September 1996) (Printed February 1997)
HYDRAUILC/HYDROSTATIC SCHEMATIC HYDRAULIC/HYDROSTATIC SCHEMATIC
863H BICS 863H BICS
(Printed September 1996) (Printed February 1997)
3–5, 3–6 3–5 (Revised Feb. 97), 3–6 (Revised Feb. 97)
3–65, 3–66 3–65, 3–66 (Revised Feb. 97)
5–1 thru 5–26 5–1 thru 5–30 (Revised or Added Feb. 97)
7–1, 7–2 (Revised Sept. 96) 7–1 (Revised Feb. 97), 7–2 (Revised Feb. 97)
7–37 (Revised Sept. 96), 7–38 7–37 (Revised Sept. 96), 7–38 (Revised Feb. 97)
7–45 (Revised Dec. 96), 7–46 7–45 (Revised Dec. 96), 7–46 (Revised Feb. 97)
7–47, 7–48 7–47 (Revised Feb. 97), 7–48
7–49 thru 7–116 (Revised or Added) 7–49 thru 7–122 (Revised or Added Feb. 97)
863–005
® Revision Number

15 April 1997
SERVICE MANUAL Date

REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER X
Product BOBCAT LOADER
SERVICE MANAGER X
Model 863, 863H SALES MANAGER
Manual No. 6724799 (4–96)

NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.

The following pages are a revision to the 863, 863H Service Manual P/N 6724799 (4–96).
Take out the pages shown and put in the revised pages as follows:
TAKE OUT PUT IN
1–3 (Revised Dec. 96), 1–4 1–3 (Revised Apr. 97), 1–4 (Revised Apr. 97)
2–9, 2–10 2–9 (Revised Apr. 97), 2–10 (Revised Apr. 97)
3–53 (Revised Sept. 96), 3–54 (Revised Sept. 96) 3–53 (Revised Sept. 96), 3–54 (Revised Apr. 97)
3–65, 3–66 (Revised Feb. 97) 3–65, 3–66 (Revised Apr. 97)
7–1 (Revised Feb. 97), 7–2 (Revised Feb. 97) 7–1 (Revised Feb. 97), 7–2 (Revised Apr. 97)
7–39, 7–40 7–39 (Revised Apr. 97), 7–40
7–123 (Added Apr. 97), 7–124 (Added Apr. 97)

8–19, 8–20 8–19, 8–20 (Revised Apr. 97)

8–27, 8–28 (Revised Dec. 96) 8–27, 8–28 (Revised Apr. 97)
8–29, 8–30 (Revised Dec. 96) 8–29 (Revised Apr. 97), 8–30 (Revised Dec. 96)
9–7 (Revised Sept. 96), 9–8 (Revised Dec. 96) 9–7 (Revised Apr. 97), 9–8 (Revised Apr. 97)
9–9, 9–10 (Revised Sept. 96) 9–9 (Revised Apr. 97), 9–10 (Revised Sept. 96)
863–006
Revision Number

19 January 1998
SERVICE MANUAL Date

REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER X
Product BOBCAT LOADER
SERVICE MANAGER X
Model 863, 863H SALES MANAGER
Manual No. 6724799 (4–96)

NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.

The following pages are a revision to the 863, 863H Service Manual P/N 6724799 (4–96).
Take out the pages shown and put in the revised pages as follows:
TAKE OUT PUT IN
vii, viii vii, viii (Revised Jan. 98)
ix, x ix (Revised Jan. 98), x
1–3 (Revised Apr. 97), 1–4 (Revised Apr. 97) 1–3 (Revised Jan. 98), 1–4 (Revised Apr. 97)
1–5, 1–6 1–5 (Revised Jan. 98), 1–6 (Revised Jan. 98)
1–7, 1–8 1–7 (Revised Jan. 98), 1–8 (Revised Jan. 98)
1–9, 1–10 (Revised Sept. 96) 1–9, 1–10 (Revised Jan. 98)
1–11 (Revised Sept. 96), 1–12 1–11 (Revised Jan. 98), 1–12 (Revised Jan. 98)
1–13, 1–14 1–13 (Revised Jan. 98), 1–14
1–15, 1–16 (Revised Dec. 96) 1–15 (Revised Jan. 98), 1–16 (Revised Dec. 96)
1–19 (Revised Dec. 96), 1–20 (Revised Dec. 96) 1–19 (Revised Dec. 96), 1–20 (Revised Jan. 98)
1–21 (Revised Dec. 96), 1–22 (Revised Dec. 96) 1–21 (Revised Dec. 96), 1–22 (Revised Jan. 98)
Glossary Of Hydraulic/Hydrostatic Symbols For Loaders Glossary Of Hydraulic/Hydrostatic Symbols For Loaders
863 Hydraulic/Hydrostatic Schematic 863 Hydraulic/Hydrostatic Schematic
(Printed February 1997) (Printed January 1998)
863H Hydraulic/Hydrostatic Schematic 863H Hydraulic/Hydrostatic Schematic
(Printed February 1997) (Printed January 1998)
2–9 (Revised Apr. 97), 2–10 (Revised Apr. 97) 2–9 (Revised Jan. 98), 2–10 (Revised Jan. 98)
2–13, 2–14 2–13, 2–14 (Revised Jan. 98)
2–15, 2–16 (Revised Sept. 96) 2–15 (Revised Jan. 98), 2–16 (Revised Sept. 96)
2–17, 2–18 2–17 (Revised Jan. 98), 2–18
2–21 (Revised Sept. 96), 2–22 (Revised Sept. 96) 2–21 (Revised Jan. 98), 2–22 (Revised Sept. 96)
2–23 (Revised Sept. 96), 2–24 (Revised Sept. 96) 2–23 (Revised Jan. 98), 2–24 (Revised Sept. 96)
2–31 (Revised Sept. 96), 2–32 (Revised Sept. 96) 2–31 (Revised Sept. 96), 2–32 (Revised Jan. 98)
2–35 (Revised Sept. 96), 2–36 (Revised Sept. 96) 2–35 (Revised Jan. 98), 2–36 (Revised Sept. 96)
4–9, 4–10 4–9, 4–10 (Revised Jan. 98)
4–15 (Revised Aug. 96), 4–16 4–15 (Revised Aug. 96), 4–16 (Revised Jan. 98)

5–1 (Revised Feb. 97), 5–2 5–1 (Revised Jan. 98), 5–2
5–15 (Revised Feb. 97), 5–16 5–15 (Revised Feb. 97), 5–16 (Revised Jan. 98)
5–25 (Revised Feb. 97), 5–26 (Revised Feb. 97) 5–25 (Revised Feb. 97), 5–26 (Revised Jan. 98)
5–27 (Added Feb. 97), 5–28 (Added Feb. 97) 5–27 (Revised Jan. 98), 5–28 (Revised Jan. 98)
5–29 (Added Feb. 97), 5–30 (Added Feb. 97) 5–29 (Revised Jan. 98), 5–30 (Revised Jan. 98)
5–31 (Added Jan. 98), 5–32 (Added Jan. 98)
TAKE OUT PUT IN
6–5 (Revised Dec. 96), 6–6 (Revised Dec. 96) 6–5 (Revised Jan. 98), 6–6 (Revised Jan. 98)
6–7 (Revised Dec. 96), 6–8 (Revised Dec. 96) 6–7 (Revised Jan. 98), 6–8 (Revised Dec. 96)
6–9 (Revised Dec. 96), 6–10 (Revised Dec. 96) 6–9 (Revised Dec. 96), 6–10 (Revised Jan. 98)
7–1 (Revised Feb. 97), 7–2 (Revised Feb. 97) 7–1 (Revised Jan. 98), 7–2 (Revised Jan. 98)
7–9, 7–10 7–9, 7–10 (Revised Jan. 98)
7–31, 7–32 7–31, 7–32 (Revised Jan. 98)
7–37 (Revised Sept. 96), 7–38 (Revised Feb. 97) 7–37 (Revised Jan. 98), 7–38 (Revised Feb. 97)
7–121 (Added Feb. 97), 7–122 (Added Feb. 97) 7–121 (Revised Jan. 98), 7–122 (Revised Jan. 98)
7–123 (Added Apr. 97), 7–124 7–123 (Added Apr. 97), 7–124 (Revised Jan. 98)
8–3 (Revised Sept. 96), 8–4 8–3 (Revised Sept. 96), 8–4 (Revised Jan. 98)
9–1 (Revised Sept. 96), 9–14 9–1 (Revised Jan. 98), 9–12 (Revised Jan. 98)
863–007
Revision Number

15 April 1998
SERVICE MANUAL Date

REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER X
Product BOBCAT LOADER
SERVICE MANAGER X
Model 863, 863H SALES MANAGER
Manual No. 6724799 (4–96)

NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.

Take out the pages shown and put in the revised and/or added pages as follows:

TAKE OUT PUT IN

2–27 (Revised Dec. 96), 2–28 (Revised Sept. 96) 2–27 (Revised Dec. 96), 2–28 (Revised Apr. 98)
Section 3 Section 3 (Revised & Added Apr. 98)
4–7, 4–8 4–7 (Revised Apr. 98), 4–8 (Revised Apr. 98)
863–008
Revision Number

June 1998
SERVICE MANUAL Date

REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER X
Product BOBCAT LOADER
SERVICE MANAGER X
Model 863, 863H SALES MANAGER
Manual No. 6724799 (4–96)

NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.

Take out the pages shown and put in the revised and/or added pages as follows:

TAKE OUT PUT IN

Section 1 Section 1
Section 2 Section 2
7–7 thru 7–8 7–7 thru 7–8
7–31 thru 7–54 7–31 thru 7–54
7–65 thru 7–72 7–65 thru 7–72
7–85 thru 7–92 7–85 thru 7–92
7–99 thru 7–100 7–99 thru 7–100
7–123 thru 7–124 7–123 thru 7–124
Section 8 Section 8
Section 9 Section 9
863–009
Revision Number

4 March 1999
SERVICE MANUAL Date

REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER
SERVICE MANAGER X
Model 863, 863H SALES MANAGER
Manual No. 6724799 (4–96)

NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.

The following pages are a revision to the above Service Manual.

Take out existing pages and put in the new pages as listed below:

TAKE OUT PUT IN

Cover Cover
MAINTENANCE SAFETY Page MAINTENANCE SAFETY Page
(Behind Front Cover)
Forward Section (i thru x) Forward Section (i thru x)
1–5 thru 1–6 1–5 thru 1–6
In Section 2 Glossary of In Section 2 Glossary of
Hydraulic/Hydrostatic symbols for Loaders Hydraulic/Hydrostatic symbols for Loaders
ALL Hydraulic/Hydrostatic Hydraulic/Hydrostatic
Schematics and Legends Schematics and Legends
2–23 thru 2–26 2–23 thru 2–26
2–31 thru 2–32 2–31 thru 2–32
2–51 thru 2–52 2–51 thru 2–52
2–59 thru 2–60 2–59 thru 2–60
2–71 thru 2–76 2–71 thru 2–76
3–5 thru 3–14 3–5 thru 3–14
3–23 thru 3–24 3–23 thru 3–24
4–5 thru 4–12 4–5 thru 4–12
4–25 thru 4–26 4–25 thru 4–26
5–11 thru 5–14 5–11 thru 5–14
In Section 6 All Wiring Diagram Indexes, In Section 6 New Wiring Schematics
Legends and Schematics
7–3 thru 7–8 7–3 thru 7–8
7–25 thru 7–26 7–25 thru 7–26
7–37 thru 7–38 7–37 thru 7–38
7–45 thru 7–46 7–45 thru 7–46
8–3 thru 8–4 8–3 thru 8–4
8–23 thru 8–26 8–23 thru 8–26
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: 863-10

Date: 26 July 2010
Product: Bobcat Loader
Model: 863
Manual No: 6724799 (7-10)

The following Pages are a revision to the above Service Manual.

COVER
MAINTENANCE SAFETY

7-31

Printed in U.S.A.