2 of 570

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

3 of 570
4 of 570
 ALPHABETICAL INDEX
ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1
ACTUATOR VOLTAGE TEST . . . . . . . . . . . . . . . . . . 10–1
A.H.C./PWM CONTROLLER . . . . . . . . . . . . . . . . . . 10–1
A.H.C. HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1
A.H.C. STEERING LEVER . . . . . . . . . . . . . . . . . . . . 10–1
AIR CLEANER HOUSING . . . . . . . . . . . . . . . . . . . . . . 7–1
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . 1–1
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
AXLE SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
AXLE, SPROCKET AND BEARINGS . . . . . . . . . . . . 4–1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
BICS™ CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . 2–1
BICS™ SYSTEM CONTROLLER . . . . . . . . . . . . . . . . 8–1
BICS™ VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1
BICS™ VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 2–1
BLOWER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
BLOWER HOUSING/FAN GEARBOX . . . . . . . . . . . 7–1
BOBCAT INTERLOCK CONTROL SYSTEM
(BICS™) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1, 10–1
BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 5–1
BOSS® DIAGNOSTIC TOOL . . . . . . . . . . . . . . . . . . . 8–1
BOSS® INSTRUMENT PANEL . . . . . . . . . . . . . . . . . 8–1
CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . . . . .
CHAINCASE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL ROD GUIDE BUSHING . . . . . . . . . . . . . .
CONTROL TOWER (M46 Pump & AHC) . . . . . . . . .
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRABKSHAFT GEAR MOUNTING BOLT . . . . . . . .
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER LINERS . . . . . . . . . . . . . . . . . . . . . . . . . . .
DECIMAL & MILLIMETER EQUIVALENTS . . . . . . .
DEUTZ ENGINE TOOLS . . . . . . . . . . . . . . . . . . . . . . .
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE BELT SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE BELT TENSIONER PULLEY . . . . . . . . . . . . .
DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELEC./HYD. CONTROLS REFERENCE . . . . . . . . .
ELECTRICAL SYSTEM INFORMATION . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . .
ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .
ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . .
ENGINE TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Continued On Next Page
5 of 570
Revised Feb. 99
FAN DRIVE TENSION PULLEY . . . . . . . . . . . . . . . . . . 7–1
FAN GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 & 7–1
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . 1–1
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
FRONT CHAINCASE COVER . . . . . . . . . . . . . . . . . . . 4–1
FRONT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
FRONT LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
FRONT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . 7–1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
HANDLE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . 10–1
HANDLE CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . 10–1
HANDLE CONTROL UNIT TEST . . . . . . . . . . . . . . . . 10–1
HYDRAULIC CONNECTION SPECIFICATIONS . . . 9–1
HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . 2–1
HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . 2–1
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . 2–1
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
HYDRAULIC PUMP (Double Gear) 863H . . . . . . . . . . 2–1
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . 2–1
HYDRAULIC/HYDROSTATIC OIL COOLER . . . . . . . 3–1
HYDRAULIC/HYDROSTATIC FLUID SPECS . . . . . . 9–1
7–1 HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . 1–1
HYDROSTATIC FILTER HOUSING . . . . . . . . . . . . . . . 2–1
4–1 HYDROSTATIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3–1 HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
7–1 HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . 3–1
2–1
7–1 LIFT ARM BY–PASS CONTROL VALVE . . . . . . . . . . 2–1
3–1 LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
1–1 LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . 1–1
LIFT CYLINDER(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
7–1 LIFTING AND BLOCKING THE LOADER . . . . . . . . . 1–1
7–1 LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 9–1
7–1 LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . 1–1
7–1
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
9–1 MONITOR SERVICE CODE . . . . . . . . . . . . . . . . . . . . . 8–1
7–1 MOTOR CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3–1 OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3–1 OPERATION SENSING SYSTEM UNIT . . . . . . . . . . . 8–1
3–1 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . 1–1 & 5–1
4–1 OPERATOR CAB GAS CYLINDER . . . . . . . . . . . . . . . 5–1
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
8–1
6–1 PARKING BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . 4–1
7–1 PARKING BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . 4–1
PEDAL INTERLOCK LINKAGE . . . . . . . . . . . . . . . . . . 2–1
1–1 PISTON AND PISTON PIN . . . . . . . . . . . . . . . . . . . . . . 7–1
7–1 PWM CONTROL HANDLE . . . . . . . . . . . . . . . . . . . . . . 8–1
7–1 PWM ELECTRIC SOLENOID . . . . . . . . . . . . . . . . . . . . 8–1
7–1 PWM MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
9–1 PWM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 8–1
7–1
9–1 REAR AUXILIARY DEVERTER . . . . . . . . . . . . . . . . . . 2–1
REAR CHAINCASE COVER . . . . . . . . . . . . . . . . . . . . . 4–1
REAR COVER SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
RECONDITIONING THE ENGINE . . . . . . . . . . . . . . . . 7–1
RELAY SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
REMOTE START SWITCH . . . . . . . . . . . . . . . . . . . . . . 1–1
ROCKER ARM AND BRACKET . . . . . . . . . . . . . . . . . . 7–1
RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
 ALPHABETICAL INDEX (Cont’d)

SEAT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . 1–1
SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
SEAT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
SELECT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
SENDER AND SENSOR . . . . . . . . . . . . . . . . . . . . . . . 8–1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
SOLID STEERING LINKAGE NEUTRAL
ADJUSTMENT (M46 Pump) . . . . . . . . . . . . . . . . . . . 3–1
STANDARD INSTRUMENT PANEL . . . . . . . . . . . . . . 6–1
STANDARD TORQUE SPECS. FOR BOLTS . . . . . 9–1
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
STEERING LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
STEERING LINKAGE (M44 Pump) . . . . . . . . . . . . . . 3–1
SWITCH HANDEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1

TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
TRACTION LOCK CONTROL SYSTEM . . . . . . . . . . 8–1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . 1–1
TORQUE SPECIFICATIONS FOR LOADER . . . . . . 9–1
TRANSPORTING THE LOADER . . . . . . . . . . . . . . . . 1–1
TROUBLESHOOTING . . . . . 2–1, 3–1, 6–1, 7–1 & 10–1
TROUBLESHOOTING THE BOSS® &
L.C.D. DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

U.S. TO METRIC CONVERSION . . . . . . . . . . . . . . . . 9–1

VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

WIRING SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 6–1

WIRING SCHEMATICS–WITH ADVANCED
HAND CONTROL OPTIONS . . . . . . . . . . . . . . . . . 10–1

6 of 570
Revised Feb. 99
 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 Feb. 99
8 of 570 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

9 of 570
Revised Feb. 99 iii Service Manual
 863, 863H Bobcat Loader
10 of 570 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

Dealer Copy -- Not for Resale

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

11 of 570
Revised Feb. 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].

SI06–0398 P–3705

863, 863H Bobcat Loader

Revised Feb. 99
12 of 570 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)
Module 1. – Model/Engine
B
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

Dealer Copy -- Not for Resale

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

13 of 570 vii Service Manual
 BOBCAT LOADER IDENTIFICATION
863,863H(S/N514425001&Abv.,514525001&Above,514625001&Abv.)ServiceManual#6900648–ContentsSection

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
REAR GRILL LIFT ARM

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 Feb. 99
14 of 570 viii Service Manual
 PREVENTIVE MAINTENANCE PREVENTIVE
MAINTENANCE

AIR CLEANER SERVICE

Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14
ALTERNATOR BELT
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19

BOB–TACH
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–27
COOLING SYSTEM
Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18

ENGINE LUBRICATION SYSTEM

Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17
Replacing Of Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17

FAN GEARBOX
Checking And Maintaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–26
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23
Removing Oil From The Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23

FUEL SYSTEM
Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 1–16

HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20
Replacing Hydraulic/Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . . . . . 1–20
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–24

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–28

Continued On Next Page

863, 863H Bobcat Loader

Revised Feb. 99
15 of 570 –1–1– Service Manual
 PREVENTIVE MAINTENANCE (Cont’d)

SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONROLS)

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13

SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS)
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
SERVICE SCHEDULE
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

TIRE MAINTENANCE
Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–22
Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–22
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–22

TOWING THE LOADER

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
TRANSPORTING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5

863, 863H Bobcat Loader

Revised Feb. 99570
16 of –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 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

ITEM
Engine Oil
Engine Air Cleaner
Engine Cooling System
Lift Arms, Cyl., Bob–Tach
Pivot Pins and Wedges
Engine Air System
Tires
Seat Belt, Seat Bar & Pedal
Interlocks
◊
SERVICE REQUIRED 8–10 50 250 500 1000 3000
Check the oil level and add oil as needed.
Check condition indicator or display panel. Service only
when required.
Clean debris from oil cooler radiator and grill.
Lubricate with multi–purpose lithium based grease
(12 places).
Check for leaks and damaged components.
Check for damaged tires and correct air pressure.
Check the condition of seat belt. Check the seat bar and foot
pedal interlocks for correct operation. Clean dirt and debris from
moving parts.

Dealer Copy -- Not for Resale

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
17 of 570Feb. 99 –1–3– Service Manual
 A

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

Read the Removal & Installation, Disassembly &

Assembly, etc. completely to become familiar with the
procedure before beginning [A].
B–07023
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
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
B
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

Put the floor jack under the front of the loader [C].
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 Feb. 99570
18 of –1–4– Service Manual
TRANSPORTING THE BOBCAT LOADER
Procedure
A

Adequately designed ramps of sufficient

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

A loader with an empty bucket or no attachment must be

loaded backward onto the transport vehicle [A].
B
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

Dealer Copy -- Not for Resale

size and capacity (See SPECIFICATIONS Section Page
9–1, for weight of loader.) P–10462 P–10464

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

19 of 570 –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:
P–10830
Put jackstands under the rear corners of the loader.
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 Feb. 99570
20 of –1–6– Service Manual
LIFT ARM SUPPORT DEVICE (Cont’d)
To Install The Lift Arm Support Device (Cont’d)
A
Raise the lift arms, until the lift arm support device drops
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.
(Foot Pedal Controls) Move both pedals until both lock. 1
(Mechanical Hand Controls) Move the hand control until
both lock.
(Advanced Hand Controls) Move the hand controls to the P–07659
NEYTRAL POSITION to make sure that both lift and tilt
functions are deactivated.
Install pin (Item 1) [A] into the rear of the lift arm support B
device below the cylinder rod.
To Remove The Lift Arm Support Device
Remove the pin from the lift arm support device (Item 1)
[A]. 1

Connect the spring (Item 1) [B] from the lift arm support

Dealer Copy -- Not for Resale

device to the bracket below the lift arms.
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 P–07656
support device off the lift cylinder rod. Lower the lift arms.
Stop the engine.
Raise the seat bar. C
(Foot Pedal Controls) Move both pedals until both lock.
(Mechanical Hand Controls) Move the hand control until
both lock.
(Advanced Hand Controls) Move the hand controls to the
NEYTRAL POSITION to make sure that both lift and tilt
functions are deactivated.
Disconnect the spring from the bracket.
Raise the support device into storage position and insert 1
pin through lift arm support device and bracket [C]. P–10829
Connect spring to the retaining pin (Item 1) [C].

863, 863H Bobcat Loader

Revised Feb. 99
21 of 570 –1–7– Service Manual
OPERATOR CAB
The Bobcat loader has an operator cab (ROPS and FOPS)
A
as standard equipment to protect the operator from rollover
and falling objects. Check with your dealer if the operator
cab has been damaged.
ROPS/FOPS – Roll Over Protective Structure per SAE
J1040 and ISO 3471, and Falling Object Protective
Structure per SAE J1043 and ISO 3449, Level l. Level ll is
available.
Level l – Protection from falling bricks, small concrete
blocks and hand tools encountered in operations such as
highway maintenance, landscaping, and other
construction site services.
Level ll – Protection from falling trees, rocks; for machines P–10887 P–10888
involved in site clearing, overhead demolition or forestry.

Never modify operator cab by welding,

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 falling objects,
and result in injury or death.
W–2069–1285

Raising The Operator Cab

Stop the loader on a level surface. Lower the lift arms. Stop P–03470
the engine. If the lift arms must be up while raising the
operator cab, install the lift arm support device. (See Page
1–6.) C
Install jackstands under the rear of the loader frame (Inset)
[C].
Loosen the nut (both sides) at the front corner of the
operator cab [A].
Remove the nut and plate (both sides) [A].
Mechanical Hand controls Only: Disconnect the control
linkage joint from the bottom hole (work position) and move
to the TOP hole on the control handle (both sides) [B].Both
control handles must be in the vertical position so there will
be no cab interference with the steering levers when the
operator cab is raised or lowered.
P–10449 P–10826
Advanced Hand Controls Only: Hold the steering levers
forward so that the cab does not hit the levers when raising
the cab.
Lift on the grab handle and bottom of the operator cab
slowly until the cab latching mechanism engages and the
cab is all the way up [C].

Before the cab or the lift arms are raised for

service, jackstands must be put under the rear
corners of the frame. Failure to use jackstands
Use care when raising or lowering the operator can allow the machine to tip backward causing
cab to prevent damaging the shaft of the lift injury or death.
lock by–pass valve. W–2014–0895
I–2070–0495

863, 863H Bobcat Loader

Revised Feb. 99570
22 of –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. Always use
the grab handles to lower the cab.
Advanced Hand Controls Only: Hold the steering levers
forward so that the cab does not hit the levers 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.

Dealer Copy -- Not for Resale

Use care when raising or lowering the operator
cab to prevent damaging the shaft of the lift
lock by–pass valve.
I–2070–0495

P–10888 P–10887

Mechanical Hand Controls Only

Move the control linkage from the top hole to the BOTTOM C
hole (work position) on the control handle (both sides) [C].

P–03561

863, 863H Bobcat Loader

Revised Feb. 99
23 of 570 –1–9– Service Manual
OPERATOR CAB (Cont’d)
Emergency Exit
A
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 [A].

P–10168

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

P–10810

NOTE: When an Operator Cab Enclosure Kit is

installed, the window of the front door can be C
used as an emergency exit [C].
Pull the plastic loop at the top of the window in the front door
to remove the rubber cord [C].

P–09216

Push the window out with your foot [D].

D
Exit through the front door.

P–09217

863, 863H Bobcat Loader

24 of 570 –1–10– Service Manual
SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)
Description
A
Clean
The seat bar restraint system has a pivoting, spring assist (Both Sides)
seat bar with arm rests and has spring loaded interlocks for
the lift and tilt control functions.
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 hand controls.
When the seat bar is up, the lift and tilt control functions are
locked when returned to the NEUTRAL POSITION.

P–10361

AVOID INJURY OR DEATH

The Seat Bar System must lock the lift and tilt
foot pedals or hand controls in neutral when the
Seat Bar is up. Service the system if controls do
not lock correctly.
W–2263–0597
AVOID INJURY OR DEATH
Never operate loader without interlock shield
6705474 on both interlocks. Shields prevent

Dealer Copy -- Not for Resale

foot from unlocking interlocks when leaving
loader seat. W–2158–0594
Seat Bar Inspection
Sit in the seat and fasten the seat belt. Engage the parking
brake. Pull the seat bar all the way down. Start the engine.
Loaders without seat sensors press the green PRESS TO
OPERATE Button. 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. B
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. Loaders without seat sensors press
the green PRESS TO OPERATE Button. Lower the lift
arms. Operate the lift pedals. While the lift arms are going
up, raise the seat bar and the lift arms must stop.
Lower the seat bar. Loaders without seat sensors press the
green PRESS TO OPERATE Button. Lower the lift arms
and put the bucket flat on the ground. Stop the engine. Interlock
Interlock
Raise the seat bar and operate the foot pedals to be sure Shield
Shield
that the pedals are firmly locked in the neutral position.
Unbuckle the seat belt.
Clean
Seat Bar Maintenance1.See the SERVICE SCHEDULE (Both Sides)
Page 1–3 and on the loader for correct service interval.
Clean any debris or dirt from the moving parts [A] & [B].
Inspect the linkage bolts and nuts for tightness. The correct
torque is 25–28 ft.–lbs. (34–38 Nm).
If the seat bar system does not function correctly, check 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.

P–10821

863, 863H Bobcat Loader

Revised Feb. 99
25 of 570 –1–11– Service Manual
SEAT BAR RESTRAINT SYSTEM (MECHANICAL
HAND CONTROLS) A
Description Clean
(Both Sides)
The seat bar restraint system has a pivoting, spring assist
seat bar with arm rests and has spring loaded interlocks for
the lift and tilt control functions.
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 hand controls.
When the seat bar is up, the lift and tilt control functions are
locked when returned to the NEUTRAL POSITION.
P–10361

AVOID INJURY OR DEATH

The Seat Bar System must lock the lift and tilt
foot pedals or hand controls in neutral when the AVOID INJURY OR DEATH
Seat Bar is up. Service the system if controls do Never operate loader without interlock shield
not lock correctly. 6705474 on both interlocks. Shields prevent
W–2263–0597 foot from unlocking interlocks when leaving
loader seat. W–2158–0594
Seat Bar Inspection
Sit in the seat and fasten the seat belt. Engage the parking
brake. Pull the seat bar all the way down. Loaders without
seat sensors press the green PRESS TO OPERATE
Button. Start the engine. Operate each hand control to
check both the lift and tilt functions. Raise the lift arms until
the bucket is about 2 feet (600 mm) off the ground. B
Raise the seat bar. Try to move each hand control. The
controls must be firmly locked in NEUTRAL POSITION.
There must be no motion of the lift arms or tilt (bucket) when
the controls are moved.
Interlock
Interlock
Pull the seat bar down. Loaders without seat sensors press Shield
Shield
the green PRESS TO OPERATE Button. Lower the lift
arms. Operate the lift control. While the lift arms are going Clean
up, raise the seat bar and the lift arms must stop. (Both Sides)

Lower the seat bar. Loaders without seat sensors press the
green PRESS TO OPERATE Button. Lower the lift arms
and put the bucket flat on the ground. Stop the engine.
Raise the seat bar and operate the hand controls to be sure
that the controls 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.
Clean any debris or dirt from the moving parts [A] & [B].
Inspect the linkage bolts and nuts for tightness. The correct
torque is 25–28 ft.–lbs. (34–38 Nm).
If the seat bar system does not function correctly, check for
free movement of each linkage part. Check for excessive
wear. Adjust hand control linkage. Replace parts that are
worn or damaged. Use only genuine Bobcat replacement
parts.
P–09671

863, 863H Bobcat Loader

Revised Feb. 99570
26 of –1–12– Service Manual
SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND
CONTROLS) A
Description
The seat bar restraint system has a pivoting seat bar (Item
1) [A] with arm rests. 1
The operator controls the use of the seat bar. The seat bar
in the down position helps to keep the operator in the seat.
When the seat bar is down and the green PRESS TO
OPERATE Button is activated, the lift, tilt, and traction drive
functions can be operated.
When the seat bar is up, the lift, tilt, and traction drive
functions are deactivated. P–13721

Seat Bar Inspection

Sit in the operator’s seat. Turn the key ON, lower the seat B
bar and press the green PRESS TO OPERATE Button.
Clean
Both lights on the left handle should be ON.
(Both Sides)
Move each hand control back and forth. You should hear
the zip,zip sound of the lift and tilt actuators moving the
control valve spools (under the seat).
Raise the seat bar fully. Both lights on the left handle should

Dealer Copy -- Not for Resale

be OFF.
Move each hand control back and forth. There must be no
zip–zip sound of the lift or tilt actuators. If either actuator
makes a sound while the seat bar is raised, contact your
dealer for service. P–10361

Seat Bar Maintenance

See the SERVICE SCHEDULE Page 1–3 for correct
service interval.
Clean any debris or dirt from the moving parts [B].
If the seat bar system does not function correctly replace
parts that are worn or damaged. Use only genuine Bobcat
replacement parts.
Before you leave the operator’s seat:
• Lower the lift arms, put the attachment flat on
the ground.
• Stop the engine.
• Engage the parking brake.
• Raise seat bar.
• (Advanced Hand Controls) Move the hand
controls to the NEUTRAL POSITION to make
sure that both lift and tilt functions are
deactivated.
The seat bar system must deactivate the lift
and tilt control functions when the seat bar is
up. Service the system if hand controls do
not deactivate.
W–2321–0698

863, 863H Bobcat Loader

27 of 570 –1–13– 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].
NOTE: Before replacing the filter element, push the 1
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.
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. P–10799

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].
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

28 of 570 –1–14– 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.
Only replace the inner filter element under the following
conditions [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 P–10798
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
B
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.
Push dust cover into place and secure with wire fasteners.
1

Dealer Copy -- Not for Resale

Check the air intake hose for damage. Check the air
cleaner housing for damage. Check to make sure all
connections are tight.

P–10802

P–10800

863, 863H Bobcat Loader

Revised Feb. 99
29 of 570 –1–15– 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 free B–13456
movement of air and no open flames or sparks. NO
SMOKING! [B].
Install and tighten the fuel fill cap [A]. C
Fuel Filter
See the SERVICE SCHEDULE, Page 1–3 for the 2
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].
Clean the area around the filter housing. Put oil on the seal 1
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
system prior to starting the engine. 3
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.
Tighten the air vent plug.
P–10803

863, 863H Bobcat Loader

Revised Feb. 99570
30 of –1–16– 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.
1
RECOMMENDED SAE VISCOSITY NUMBER
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

Dealer Copy -- Not for Resale

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 B
CLASSIFICATION CD, CF4, CG4 )
* 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 1
interval for replacing the engine oil and filter.
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,
flames, sparks or lighted tobacco away from
Put 10 qts. (9,5 L) of oil in the engine. fuel and oil. Failure to use care around
combustibles can cause explosion or fire
Start the engine and let it run for several minutes. Stop the which can result in injury or death.
engine. Check for leaks and check the oil level. Add oil as W–2103–1285
needed if it is not at the top mark on the dipstick.

863, 863H Bobcat Loader

Revised Feb. 99
31 of 570 –1–17– 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.

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].
1
Remove the hair pin (Item 1) [B] (both sides) so the oil
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 Feb. 99570
32 of –1–18– Service Manual
ALTERNATOR BELT
Adjusting The Alternator Belt
A
Stop the engine.
Loosen the alternator mounting bolt (Item 1) [A]. 1

P–10357

Loosen the adjustment bolt (Item 1) [B].

B
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].
Tighten the adjustment and mounting bolts.

Dealer Copy -- Not for Resale

1

P–10358

863, 863H Bobcat Loader

Revised Feb. 99
33 of 570 –1–19– 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:
Put the Bobcat loader on a level surface. Lower the lift arms
2
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
If fluid is needed, remove the fill cap (Item 2) [A].

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.
Raise the operator cab. (See Page 1–8.)
Use a filter wrench to remove the filter element (Items 1)
[C].
Clean the surface of the filter housing where the element
seal contacts the housing. Put clean oil on the rubber seal 1
of the filter elements.
Install and hand tighten the filter elements.
N–17395

863, 863H Bobcat Loader

Revised Feb. 99570
34 of –1–20– 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.
Raise the operator cab. (See Page 1–8.) P–07672

Disconnect the hose (Item 1) [B] from the hydraulic fluid

reservoir and drain the fluid into a container.
B LEFT CASE DRAIN
FILTER
Replace the filter element. (See Page 1–17.)
Remove the case drain filters (Item 2) [B] & (Item 1) [C] and
clean thoroughly with clean solvent.
Install the case drain filters and tighten all the hoses.

Dealer Copy -- Not for Resale

Add the correct fluid to the reservoir until the fluid level is
to the top mark on the dipstick. (See Page 1–17.)

Diesel fuel or hydraulic fluid under pressure 2

can penetrate skin or eyes, causing serious
injury or death. 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 from a physician
familiar with this injury.
W–2072–0496
Always clean up spilled fuel or oil. Keep heat,
flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around N–17398
combustibles can cause explosion or fire
which can result in injury or death.
W–2103–1285
RIGHT CASE DRAIN
C FILTER
Lower the operator cab. Start the engine and operate the
loader hydraulic controls. Stop the engine. Check for leaks.
Check the fluid level in the reservoir and add as needed.
1

N–17397

863, 863H Bobcat Loader

35 of 570 –1–21– 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–07649

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–09976
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 Feb. 99570
36 of –1–22– 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.

Dealer Copy -- Not for Resale

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 Feb. 99
37 of 570 –1–23– 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 Feb. 99570
38 of –1–24– Service Manual
LUBRICATION OF THE BOBCAT LOADER (Cont’d)
Procedure (Cont’d)
A
5. Rod End Tilt Cylinder [A].
5
6. Bob–Tach Pivot Pin (Both Sides) [A].
7. Bob–Tach Wedge (Both Sides) [A].

6
7
P–07653

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

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

Dealer Copy -- Not for Resale

9

N–17497

P–13767

10. 250 Hours: Steering Linkage Pivot [D] (If Equipped).

D
863,863H(S/N514425001&Abv.,514525001&Above,514625001&Abv.)ServiceManual#6900648–PreventiveMaintenanceSectionPart1of2

10

N–17398

863, 863H Bobcat Loader

Revised Feb. 99
39 of 570 –1–25– Service Manual
FAN GEARBOX
Checking And Maintaining
A
See the SERVICE SCHEDULE Page 1–3 for the correct
service interval.
Raise the operator cab. (See Page 1–8.)
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 Feb. 99570
40 of –1–26– Service Manual
BOB–TACH
Inspection And Maintenance
A
Move the Bob–Tach levers to engage the wedges [A]. The
levers and wedges must move freely. 1
The wedges must extend through the holes in the N–17048
attachment mounting frame (Item 1) [A].

N–17050
Bob–Tach wedges must extend through the
holes in attachment. Levers must be fully
down and locked. Failure to secure wedges
can allow attachment to come off and cause B
injury or death.
W–2102–0588

The spring loaded wedge (Item 1) [A] must contact the

lower edge of the hole in the attachment (Item 1) [B] and
[C].

Dealer Copy -- Not for Resale

If the wedge does not contact the lower edge of the hole [B]
and [C], the attachment will be loose and can come off the 1
Bob–Tach.

Inspect the mounting frame on the attachment and the N–17046

Bob–Tach, linkages and wedges for excessive wear or
damage. Replace any parts that are damaged, bent, or
missing. Keep all fasteners tight.
C Bob–Tach
Wedge
Look for cracked welds.
Lubricate the wedges

Wedge Must Contact

Lower Edge Of Hole
In The Attachment

863, 863H Bobcat Loader

Revised Feb. 99
41 of 570 –1–27 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.)
Raise the lift arms and install an approved lift arm support
device. (See Page 1–6.) 1
P–07101
Raise the operator cab. (See Page 1–8.)
NOTE: On current model loaders, the connector on
the BICS harness is round (7–pin) connector, B
not a rectangular (8–pin) connector. Use the
adapter harness (Item 1) [A] to connect the 1
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

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

Never work on a machine with the lift arms up 1

unless the lift arms are secured by an approved 1
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

Added Feb.4299of 570 –1–28– Service Manual
REMOTE START SWITCH (Cont’d)
Procedure (Cont’d)
A
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.

Dealer Copy -- Not for Resale

2
P–04714

863, 863H Bobcat Loader

Added
43 ofFeb.
570 99 –1–29 Service Manual
863,863H(S/N514425001&Abv.,514525001&Above,514625001&Abv.)ServiceManual#6900648–PreventiveMaintenanceSectionPart2of2

863, 863H Bobcat Loader

Added Feb. 99570
44 of –1–30– Service Manual
 HYDRAULIC SYSTEM

Page
Number

BICS™ CONTROL VALVE HYDRAULIC

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–26 SYSTEM

BICS™ VALVE ASSEMBLY

BICS™ Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–32
Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–30
Lift Arm By–Pass Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–29
Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–31
CONTROL PEDALS
Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–73
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–73
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–33
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 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

Continued On Next Page

863, 863H Bobcat Loader

45 of 570 –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 ARM BY–PASS CONTROL VALVE
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–25
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–24
LIFT CYLINDER(S)
Checking The Lift Cylinder(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
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
MAIN RELIEF VALVE (Advanced Hand Control)
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–19
PEDAL INTERLOCK LINKAGE
Pedal Interlock Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–75
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–74
REAR AUXILIARY DIVERTER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–76
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–76
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–76
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–76
SELECT VALVE 863H
Checking The High Flow Pump Relief Valve . . . . . . . . . . . . . . . . . . . . 2–20
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–21
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–23
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
46 of 570 –2–2– Service Manual
47 of 570

1 RESERVOIR:
 Capacity . . . 16.0 Qts (15.1 L)
 Screen Filter  . . . . . 60 Mesh
2 FILTER - CASE DRAIN (90 M icron)
3 FILTER - HYDRAULIC (CANISTER)
4 SPRING LOADED FILTER BYPASS
 VALVE: 45-55 PSI (311-379
5 ANTI-DRAIN BACK VALVE
6 DIFFERENTIAL PRESSURE SWITCH:
       36-44 PSI (248-303 kPa)
              Without B.O.S.S.
        (Normally Open - Shown)
                 With B.O.S.S.
   (Normally Closed - NOT Shown)
7 FLOW DIVIDER ADJUSTMENT VALVE
8 CHECK VALVE - BUCKET POSITION
 VALVE
9 FIXED CAPACITY DISPLACEMENT
  BIDIRECTIONAL HYDROSTATIC
  MOTOR
10 PILOT ACTIVATED DIRECTIONAL
  CONTROL VALVE - FLOW CONTROL
  SPOOL
11 PILOT ACTIVATED DIRECTIONAL
  CONTROL VALVE - UNLOADING
  SPOOL
Printed in U.S.A.
48 of 570
HYDRAULIC/HYDROSTATIC SCHEMATIC (M44 PUMPS)
863 (S/N 514425001-39999)
    (S/N 514525001-39999)
(Printed Octobrt 1998)
MC2406LE
LEGEND
12 PILOT ACTIVATED DIRECTIONAL 24 SOLENOID ACTIVATED DIRECTIONAL 37 PILOT ACTIVATED DIRECTIONAL
  CONTROL VALVE - TILT CONTROL   CONTROL VALVE - AUXILIARY   CONTROL VALVE - FOR REAR
13 PILOT ACTIVATED DIRECTIONAL 25 RELIEF VALVE - PORT: . (Optional)   AUXILIARY - NORMALLY OPEN
  CONTROL VALVE - LIFT CONTROL   ("D1")
           3500 PSI (24132 kPa)
14 SOLENOID ACTIVATED DIRECTIONAL 26 RELIEF/REPLENISHING VALVE - HIGH 38 FILTER - DIVERTER VALVE
  CONTROL VALVE - BICS CONTROL PRESSURE:   4712 PSI (32489 kPa)   (SCREEN) INTEGRATED IN SOLENOID
27 PRESSURE SWITCH 39 SOLENOID ACTIVATED DIRECTIONAL
kPa) 15 PULL BUTTON ACTIVATED
  DIRECTIONAL CONTROL VALVE -   CONTROL VALVE - TO ACTIVATE
28 RELIEF VALVE - CHARGE:
  LIFT ARM BY PASS   REAR AUXILIARY ("SV1")
140∞F. (62∞C.) Fluid at Full RPM
16 FILTER - BICS CONTROL VALVE Neutral . . . . 420 PSI 40 PILOT ACTIVATED DIRECTIONAL
  (SCREEN)                     (2894 kPa)   CONTROL VALVE - FOR REAR
  AUXILIARY - NORMALLY CLOSED
17 ONE WAY RESTRICTOR VALVE 29 CHARGE PUMP . . . .  11.0 GPM
  ("P2" and "F2")
    (41,6 L./M in .) at 2750 RPM
18 LOAD CHECK VALVE
41 CHECK VALVE - BICS CONTROL
30 HYDRAULIC PUMP   . . . .Gear Type
19 RELIEF VALVE - MAIN:   VALVE
        18.0 GPM (68,1 L/min.)
2950-3050 PSI (20340-21030 kPa) Dealer Copy -- Not for Resale 42 RESTRICTION
at 2750 RPM
at Front Quick Couplers 31 DRIVE MOTOR SHUTTLE VALVE
20 RELIEF VALVE - PORT: 43 CHECK VALVE - AUXILIARY
21
           3500 PSI (24132 kPa)
ANTICAVITATION VALVE
32 SHUTTLE RELIEF VALVE:
             225 PSI (1551 kPa) + 44 MUFFLER (I f Equipped )
33 SOLENOID ACTIVATED DIRECTIONAL 45 VARIABLE CAPACITY DISPLACEMENT
22 RELIEF/ANTICAVITATION VALVE -   BIDIRECTIONAL HYDROSTATIC
  CONTROL VALVE - BLEED OFF REAR
PORT (TILT BASE END)
  AUXILIARY ("SV2")   PUMP
           3500 PSI (24132 kPa)
34 LOAD SHUTTLE VALVE - BLEED OFF
23 ONE WAY RESTRICTOR VALVE
35 PILOT ACTIVATED DIRECTIONAL
  CONTROL VALVE - FOR REAR
  AUXILIARY - NORMALLY CLOSED
  ("P1" and  "F1")
36 PILOT ACTIVATED DIRECTIONAL
  CONTROL VALVE - FOR REAR NOTE: U nless otherwise specified
  AUXILIARY - NORMALLY OPEN springs have NO significant
  ("D2") pressure value .
MC 2406LE (10-14-98)
 HYDRAULIC/HYDROSTATIC SCHEMATIC (M44 PUMPS) DIVERTER VALVE (OPTIONAL) FRONT
WITH Bleed Off
863 (S/N 514425001-39999) AUXILIARY

    (S/N 514525001-39999) D1
37 FEMALE
(Printed October, 1998)

MC2406
D2
MALE
36
HYDRAULIC FILTER P1

P2
3
5
35
39
4 34
REAR
OIL AUXILIARY
COOLER

40
F1
FEMALE

F2

+
MALE
6
(I f Equipped ) 38 33

PILOT PRESSURE CASE
DRIVE MOTOR INPUT DRAIN

32
31
2 BUCKET POSITION VALVE (OPTIONAL)
D
7
8
9

43 A

HYDROSTATIC PUMPS HYDRAULIC CONTROL VALVE
10 C
8
Dealer Copy -- Not for Resale
25
11
26
27
B
1

24 AUXILIARY SPOOL TILT CYLINDER
B A 24

30
OUTLET
INLET
23 BICS CONTROL VALVE
OUTLET

22
29

28

B A TILT CYLINDER SPOOL
12
45
18
21

LIFT CYLINDERS

45 17
20
13

26
B A

+ 44

LIFT CYLINDER SPOOL

18

DRIVE MOTOR

19 14 42
41
16 16
9

LIFT ARM BY-PASS VALVE

32 2 15
31

WORKING CIRCUITS
PILOT PRESSURE
DRAIN CIRCUITS
COMPONENTS

Printed in U.S.A.
49 of 570 MC 2406 (10-14-98)
50 of 570
51 of 570

1 RESERVOIR:
 Capacity . . . 16.0 Qts (15.1 L)
 Screen Filter  . . . . . 60 Mesh
2 FILTER - CASE DRAIN (90 M icron)
3 FILTER - HYDRAULIC (CANISTER)
4 SPRING LOADED FILTER BYPASS
 VALVE:   45-55 PSI (311-379 kPa)
5 ANTI-DRAIN BACK VALVE
6 DIFFERENTIAL PRESSURE SWITCH:
       36-44 PSI (248-303 kPa)
              Without B.O.S.S.
        (Normally Open - Shown)
                 With B.O.S.S.
   (Normally Closed - NOT Shown)
7 FLOW DIVIDER ADJUSTMENT VALVE
8 CHECK VALVE - BUCKET POSITION
 VALVE
9 FIXED CAPACITY DISPLACEMENT
  BIDIRECTIONAL HYDROSTATIC
  MOTOR
10 PILOT ACTIVATED DIRECTIONAL
  CONTROL VALVE - FLOW CONTROL
  SPOOL
11 PILOT ACTIVATED DIRECTIONAL
  CONTROL VALVE - UNLOADING
  SPOOL
52inof
Printed US 570
A MC 2407LE (10 14 98)
HYDRAULIC/HYDROSTATIC SCHEMATIC (M44 PUMPS)
863 (S/N 514425001-39999) WITH HIGH FLOW OPTION
(S/N 514625001-39999)
(Printed October 1998)
MC2407LE
LEGEND
12 PILOT ACTIVATED DIRECTIONAL 24 SOLENOID ACTIVATED DIRECTIONAL 36 SOLENOID ACTIVATED DIRECTIONAL
  CONTROL VALVE - TILT CONTROL   CONTROL VALVE - AUXILIARY   CONTROL VALVE - DIVERTER
13 PILOT ACTIVATED DIRECTIONAL 25 RELIEF VALVE - PORT: . (Optional) 37 RELIEF VALVE - MAIN (HIGH FLOW)
  CONTROL VALVE - LIFT CONTROL            3500 PSI (24132 kPa)            3000 PSI (20685 kPa)
14 SOLENOID ACTIVATED DIRECTIONAL 26 RELIEF/REPLENISHING VALVE - HIGH 38 SOLENOID ACTIVATED DIRECTIONAL
  CONTROL VALVE - BICS CONTROL PRESSURE:   4712 PSI (32489 kPa)   CONTROL VALVE (TWO COIL)
27 PRESSURE SWITCH
15 PULL BUTTON ACTIVATED 39 PILOT TO OPEN CHECK VALVE
  DIRECTIONAL CONTROL VALVE - 28 RELIEF VALVE - CHARGE:
40 SOLENOID ACTIVATED DIRECTIONAL
  LIFT ARM BY PASS 140∞F. (62∞C.) Fluid at Full RPM
16 FILTER - BICS CONTROL VALVE Neutral . . . . 420 PSI   CONTROL VALVE - BLEED OFF
  (SCREEN)                     (2894 kPa) 41 LOAD SHUTTLE VALVE
17 ONE WAY RESTRICTOR VALVE 29 CHARGE PUMP . . . .  11.0 GPM
42 RESTRICTION
    (41,6 L./Min.) at 2750 RPM
18 LOAD CHECK VALVE 43 CHECK VALVE - AUXILIARY
30 HYDRAULIC PUMP               . . . .Gear Type
19 RELIEF VALVE - MAIN:
2950-3050 PSI (20340-21030 kPa)
PUMP CAPACITY:
        18.0 GPM (68,1 L/min.)
+ 44 MUFFLER (If Equipped)
at Front Quick Couplers 45 VARIABLE CAPACITY DISPLACEMENT
HI FLOW CAPACITY: (Includes      ) 31
20 RELIEF VALVE - PORT:   BIDIRECTIONAL HYDROSTATIC
       28.0 GPM (106,0 L/min.)   PUMP
           3500 PSI (24132 kPa)
21 ANTICAVITATION VALVE at 2750 RPM
31 AUXILIARY HYDRAULIC PUMP:
22 RELIEF/ANTICAVITATION VALVE -
PORT (TILT BASE END) PUMP CAPACITY:
       3500 PSI (24132kPa)        10.0 GPM (37,8 L/min.)
23 ONE WAY RESTRICTOR VALVE at 2750 RPM
32 DRIVE MOTOR SHUTTLE VALVE
33 SHUTTLE RELIEF VALVE:
             225 PSI (1551 kPa)
34 CHECK VALVE
35 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
  CONTROL VALVE - HIGH FLOW       springs have NO significant
      pressure value.
 HYDRAULIC/HYDROSTATIC SCHEMATIC (M44 PUMPS)
863 (S/N 514425001-39999) WITH HIGH FLOW OPTION FEMALE

(S/N 514625001-39999) SELECT VALVE C1 C2
MALE

(Printed  October, 1998) RIGHT SIDE
MC2407 LIFT ARM

MALE

FEMALE

MALE

FEMALE
41
40
39 39
HYDRAULIC FILTER
REAR QUICK
3 COUPLERS
5
(Optional)

+ (I f Equipped )
4
PP

OIL 42 42 34
COOLER

Press. 38 PB
FEMALE

FRONT AUXILIARY
36 (LEFT SIDE LIFT ARM)
6

37 35 MALE

DRIVE MOTOR
DRAIN
(MALE)

33
+ 44 32
BUCKET POSITION VALVE (OPTIONAL)

2 D
7
8
9

43 A

Dealer Copy -- Not for Resale

HYDRAULIC CONTROL VALVE
10 C
HYDROSTATIC PUMPS
8

25
11
27
26
B

1 24 AUXILIARY SPOOL TILT CYLINDER
B A 24
31
OUTLET

30
OUTLET INLET
23 BICS CONTROL VALVE
OUTLET 22

29

28
B A TILT CYLINDER SPOOL
12

45 18
21

LIFT CYLINDERS

17
20
45 13

B A

+
26
44
LIFT CYLINDER SPOOL

18 42

DRIVE MOTOR
19 14
34
16 16
9

LIFT ARM BY-PASS VALVE

2 15
33
32 WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
53 of 570 MC 2407 (10-14-98)
Printed in U.S.A.
54 of 570
55 of 570

1 RESERVOIR:
 Capacity . . . 16.0 Qts (15.1 L)
 Screen Filter  . . . . . 60 Mesh
2 FILTER - CASE DRAIN (90 Micron)
3 FILTER - HYDRAULIC (CANISTER)
4 SPRING LOADED FILTER BYPASS
 VALVE: 45-55 PSI (311-379kPa)
5 ANTI-DRAIN BACK VALVE
6 DIFFERENTIAL PRESSURE SWITCH:
       36-44 PSI (248-303 kPa)
              Without B.O.S.S.
        (Normally Open - Shown)
                 With B.O.S.S.
   (Normally Closed - NOT Shown)
7 FLOW DIVIDER ADJUSTMENT VALVE
8 CHECK VALVE - BUCKET POSITION
 VALVE
9 FIXED CAPACITY DISPLACEMENT
  BIDIRECTIONAL HYDROSTATIC
  MOTOR
10 PILOT ACTIVATED DIRECTIONAL
  CONTROL VALVE - FLOW CONTROL
  SPOOL
11 PILOT ACTIVATED DIRECTIONAL
  CONTROL VALVE - UNLOADING
  SPOOL
Printed in U.S.A.
56 of 570
HYDRAULIC/HYDROSTATIC SCHEMATIC (M46 PUMPS)
863 (S/N 514425001-39999)
    (S/N 514525001-39999)
(Printed October 1998)
MC2459LE
LEGEND
12 PILOT ACTIVATED DIRECTIONAL 24 SOLENOID ACTIVATED DIRECTIONAL 37 PILOT ACTIVATED DIRECTIONAL
  CONTROL VALVE - TILT CONTROL   CONTROL VALVE - AUXILIARY   CONTROL VALVE - FOR REAR
13 PILOT ACTIVATED DIRECTIONAL 25 RELIEF VALVE - PORT: . (Optional)   AUXILIARY - NORMALLY OPEN
  CONTROL VALVE - LIFT CONTROL   ("D1")
           3500 PSI (24132 kPa)
14 SOLENOID ACTIVATED DIRECTIONAL 26 RELIEF/REPLENISHING VALVE - HIGH 38 FILTER - DIVERTER VALVE
  CONTROL VALVE - BICS CONTROL PRESSURE:   4712 PSI (32489 kPa)   (SCREEN) INTEGRATED IN SOLENOID
27 PRESSURE SWITCH 39 SOLENOID ACTIVATED DIRECTIONAL
15 PULL BUTTON ACTIVATED
  DIRECTIONAL CONTROL VALVE -   CONTROL VALVE - TO ACTIVATE
28 RELIEF VALVE - CHARGE:
  LIFT ARM BY PASS   REAR AUXILIARY ("SV1")
140∞F. (62∞C.) Fluid at Full RPM
16 FILTER - BICS CONTROL VALVE Neutral . . . . 460 PSI 40 PILOT ACTIVATED DIRECTIONAL
  (SCREEN)                     (3169 kPa)   CONTROL VALVE - FOR REAR
  AUXILIARY - NORMALLY CLOSED
17 ONE WAY RESTRICTOR VALVE 29 CHARGE PUMP . . . .  11.0 GPM
  ("P2" and "F2")
    (41,6 L./M in .) at 2750 RPM
18 LOAD CHECK VALVE
30 HYDRAULIC PUMP  . . . .Gear Type 41 CHECK VALVE - BICS CONTROL
19 RELIEF VALVE - MAIN:   VALVE
        18.0 GPM (68,1 L/min.)
2950-3050 PSI (20340-21030 kPa) 42 RESTRICTION
at 2750 RPM
at Front Quick Couplers 31 DRIVE MOTOR SHUTTLE VALVE
20 RELIEF VALVE - PORT: 43 CHECK VALVE - AUXILIARY
           3500 PSI (24132 kPa)
21 ANTICAVITATION VALVE
32 SHUTTLE RELIEF VALVE:
             225 PSI (1551 kPa) + 44 MUFFLER (I f Equipped )
33 SOLENOID ACTIVATED DIRECTIONAL 45 VARIABLE CAPACITY DISPLACEMENT
22 RELIEF/ANTICAVITATION VALVE -   BIDIRECTIONAL HYDROSTATIC
  CONTROL VALVE - BLEED OFF REAR
PORT (TILT BASE END)   PUMP
  AUXILIARY ("SV2")
           3500 PSI (24132 kPa)
34 LOAD SHUTTLE VALVE - BLEED OFF 46 DISPLACEMENT CONTROL VALVES
23 ONE WAY RESTRICTOR VALVE
35 PILOT ACTIVATED DIRECTIONAL
  CONTROL VALVE - FOR REAR
  AUXILIARY - NORMALLY CLOSED
  ("P1" and  "F1")
36 PILOT ACTIVATED DIRECTIONAL
  CONTROL VALVE - FOR REAR NOTE: U nless otherwise specified
  AUXILIARY - NORMALLY OPEN springs have NO significant
  ("D2") pressure value .
MC 2459LE (10-14--98)
 HYDRAULIC/HYDROSTATIC SCHEMATIC (M46 PUMPS) DIVERTER VALVE (OPTIONAL) FRONT
WITH Bleed Off
863 (S/N 514425001-39999) AUXILIARY

    (S/N 514525001-39999) D1
37 FEMALE
(Printed October 1998)
MC2459
D2
MALE
36
HYDRAULIC FILTER P1

P2
3
5
35
39
4 34
REAR
OIL AUXILIARY
COOLER

40
F1
FEMALE

F2

+ 6 MALE
(I f Equipped ) 38 33

PILOT PRESSURE CASE
DRIVE MOTOR INPUT DRAIN

32
31
2 BUCKET POSITION VALVE (OPTIONAL)
D
7
8
9

43 A

HYDROSTATIC PUMPS HYDRAULIC CONTROL VALVE
10 C
8
Dealer Copy -- Not for Resale
25
11
26
27
B
1
46
24 AUXILIARY SPOOL TILT CYLINDER
B A 24

30
OUTLET INLET

23 BICS CONTROL VALVE
OUTLET

22
29

45

28 B A TILT CYLINDER SPOOL
12

18
45 21

LIFT CYLINDERS

46 17
20
13

26 B A

+ 44

LIFT CYLINDER SPOOL

18

DRIVE MOTOR

19 14 42
41
16 16
9

LIFT ARM BY-PASS VALVE

32 2 15
31

WORKING CIRCUITS
PILOT PRESSURE
DRAIN CIRCUITS
COMPONENTS

MC 2459 (10-14-98)
Printed in U.S.A. 57 of 570
58 of 570
59 of 570

1 RESERVOIR:
 Capacity . . . 16.0 Qts (15.1 L)
 Screen Filter  . . . . . 60 Mesh
2 FILTER - CASE DRAIN (90 M icron)
3 FILTER - HYDRAULIC (CANISTER)
4 SPRING LOADED FILTER BYPASS
 VALVE: 45-55 PSI (311-379 kPa)
5 ANTI-DRAIN BACK VALVE
6 DIFFERENTIAL PRESSURE SWITCH:
       36-44 PSI (248-303 kPa)
              Without B.O.S.S.
        (Normally Open - Shown)
                 With B.O.S.S.
   (Normally Closed - NOT Shown)
7 FLOW DIVIDER ADJUSTMENT VALVE
8 CHECK VALVE - BUCKET POSITION
 VALVE
9 FIXED CAPACITY DISPLACEMENT
  BIDIRECTIONAL HYDROSTATIC
  MOTOR
10 PILOT ACTIVATED DIRECTIONAL
  CONTROL VALVE - FLOW CONTROL
  SPOOL
11 PILOT ACTIVATED DIRECTIONAL
  CONTROL VALVE - UNLOADING
  SPOOL
Printed in U.S.A.
60 of 570
HYDRAULIC/HYDROSTATIC SCHEMATIC (M46 PUMPS)
863 (S/N 514425001-39999) WITH HIGH FLOW OPTION
(S/N 514625001-39999)
(Printed October 1998)
MC2460LE
LEGEND
12 PILOT ACTIVATED DIRECTIONAL 24 SOLENOID ACTIVATED DIRECTIONAL 36 SOLENOID ACTIVATED DIRECTIONAL
  CONTROL VALVE - TILT CONTROL   CONTROL VALVE - AUXILIARY   CONTROL VALVE - DIVERTER
13 PILOT ACTIVATED DIRECTIONAL 25 RELIEF VALVE - PORT: . (Optional) 37 RELIEF VALVE - MAIN (HIGH FLOW)
  CONTROL VALVE - LIFT CONTROL            3500 PSI (24132 kPa)            3000 PSI (20685 kPa)
14 SOLENOID ACTIVATED DIRECTIONAL 26 RELIEF/REPLENISHING VALVE - HIGH 38 SOLENOID ACTIVATED DIRECTIONAL
  CONTROL VALVE - BICS CONTROL PRESSURE:   4712 PSI (32489 kPa)   CONTROL VALVE (TWO COIL)
27 PRESSURE SWITCH
15 PULL BUTTON ACTIVATED 39 PILOT TO OPEN CHECK VALVE
  DIRECTIONAL CONTROL VALVE - 28 RELIEF VALVE - CHARGE:
40 SOLENOID ACTIVATED DIRECTIONAL
  LIFT ARM BY PASS 140∞F. (62∞C.) Fluid at Full  RPM
16 FILTER - BICS CONTROL VALVE Neutral. . . . 460 PSI   CONTROL VALVE - BLEED OFF
  (SCREEN)                     (3169 kPa) 41 LOAD SHUTTLE VALVE
17 ONE WAY RESTRICTOR VALVE 29 CHARGE PUMP . . . .  11.0 GPM
42 RESTRICTION
    (41,6 L./Min.) at 2750 RPM
18 LOAD CHECK VALVE 43 CHECK VALVE - AUXILIARY
30 HYDRAULIC PUMP               . . . .Gear Type
19 RELIEF VALVE - MAIN:
2950-3050 PSI (20340-21030 kPa)
PUMP CAPACITY:
        18.0 GPM (68,1 L/min.)
+ 44 MUFFLER (If Equipped)
at Front Quick Couplers 45 VARIABLE CAPACITY DISPLACEMENT
HI FLOW CAPACITY: (Includes     ) 31
20 RELIEF VALVE - PORT:   BIDIRECTIONAL HYDROSTATIC
       28.0 GPM (106,0 L/min.)   PUMP
           3500 PSI (24132 kPa)
21 ANTICAVITATION VALVE at 2750 RPM 46 DISPLACEMENT CONTROL VALVE
31 AUXILIARY HYDRAULIC PUMP:
22 RELIEF/ANTICAVITATION VALVE -
PORT (TILT BASE END) PUMP CAPACITY:
       3500 PSI (24132 kPa)        10.0 GPM (37,8 L/min.)
23 ONE WAY RESTRICTOR VALVE at 2750 RPM
32 DRIVE MOTOR SHUTTLE VALVE
33 SHUTTLE RELIEF VALVE:
             225 PSI (1551 kPa)
34 CHECK VALVE
35 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
  CONTROL VALVE - HIGH FLOW       springs have NO significant
      pressure value.
MC 2460LE (10-14-98)
 HYDRAULIC/HYDROSTATIC SCHEMATIC (M46 PUMPS)
863 (S/N 514425001-39999) WITH HIGH FLOW OPTION FEMALE

(S/N 514625001-39999) SELECT VALVE C1 C2
MALE

(Printed October 1998) RIGHT SIDE
MC2460 LIFT ARM

FEMALE

FEMALE
MALE

MALE
41
40
39 39
HYDRAULIC FILTER
REAR QUICK
3 COUPLERS
5
(Optional)

+ (I f Equipped )
4
PP

OIL 42 42 34
COOLER

Press. 38 PB
FEMALE

FRONT AUXILIARY
36 (LEFT SIDE LIFT ARM)
6

37 35 MALE

DRIVE MOTOR
DRAIN
(MALE)

33
+ 44 32
BUCKET POSITION VALVE (OPTIONAL)

2 D
7
8
9

43 A

HYDRAULIC CONTROL VALVE
10 C
HYDROSTATIC PUMPS
8

25
11
26 27
B

46
1 24 AUXILIARY SPOOL TILT CYLINDER
B A 24

31
OUTLET

30 23 BICS CONTROL VALVE
OUTLET INLET
22
OUTLET

29

45
B A TILT CYLINDER SPOOL
12
28

18
21
45
LIFT CYLINDERS

17
20
13
46

B A

+ 44 26
LIFT CYLINDER SPOOL

18 42

DRIVE MOTOR
19 14
34
16 16
9

LIFT ARM BY-PASS VALVE

2 15
33
32 WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS

MC 2460 (10-14-98)
Printed in U.S.A.

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62 of 570
TROUBLESHOOTING
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.
Check for correct function after adjustments,
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, 6, 7, 8, 9

Dealer Copy -- Not for Resale

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
By–pass valve stuck. 12
By–pass valve stem bent or broke. 13

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.
12. Rotate shaft.
13. Replace manual spool cartridge.
863, 863H Bobcat Loader
63 of 570 –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

64 of 570 –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
wood to find leaks. Do not use your bare hand. CD–15067
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.

Dealer Copy -- Not for Resale

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

Raise the lift arms so the rod end retaining pin will clear the C
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–07960

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

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65 of 570 –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.

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

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. CD–15073
W–2103–1285

863, 863H Bobcat Loader

66 of 570 –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

Diesel fuel or hydraulic fluid under pressure

can penetrate skin or eyes, causing serious
P–01187
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
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.

Dealer Copy -- Not for Resale

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 P–07694
repair.
Removal And Installation C
Remove the attachment. Roll the Bob–Tach fully forward
1
[B].
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–07693

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.
1

P–07695

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67 of 570 –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–07678
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–07679

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–03911

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–03910

863, 863H Bobcat Loader

68 of 570 –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–01060

863, 863H Bobcat Loader

69 of 570 –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–01688
3
2

5 1
6

15
9

10 16

11 17

12

18
13

19
MC–01688 20
19
14

TS–01233

863, 863H Bobcat Loader

70 of 570 –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–07429
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].

Dealer Copy -- Not for Resale

P–07435

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

P–07428

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

P–07434

863, 863H Bobcat Loader

71 of 570 –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–07430

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–07439

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–07422

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–07426

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72 of 570 –2–12– Service Manual
HYDRAULIC CYLINDERS (Cont’d)
Assembly
A
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 it
on the piston.
1

Standard Piston: Install the seal (Item 1) [B] and O–ring

Dealer Copy -- Not for Resale

(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.

P–07438

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

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

P–07427

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73 of 570 –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.
NOTE: Clean and dry the threads before install the 1
nut. Install the new nut from the kit.
2
3

P–07422

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

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74 of 570 –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

Dealer Copy -- Not for Resale

P–07429

P–07435

863, 863H Bobcat Loader

75 of 570 –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 B
couplers.
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. C
I–2024–0284

Left Right
Steering 1 Steering
Lever Lever
Control Control
Put jackstands under the front axles and rear (Optional) (Optional)
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. P–02154 P–02152
W–2017–0286

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
76 of 570 –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

Dealer Copy -- Not for Resale

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

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

77 of 570 –2–17– Service Manual
MAIN RELIEF VALVE (Cont’d)
Removal And Installation
A
Raise the operator cab. (See Page 1–1.)

When repairing hydrostatic and hydraulic

systems, clean the work area before 1
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage N–00077
the system.
I–2003–0888

The main relief valve (Item 1) [A] is located at the lower

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

P–07745
Remove the O–rings and back–up washers from the main
relief valve [C].
Clean the main relief valve in clean solvent. Use air
C
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.
Remove the end cap (Item 2) [B]. D
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,
replace the main relief valve. Check the
pressure setting of the new relief valve.
1

P–07746

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78 of 570 –2–18– Service Manual
MAIN RELIEF VALVE (Advanced Hand Control)
Adjustment
A
Raise the operator cab. (See Page 1–1.)
1 2

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 N–17399
the system.
I–2003–0888

The main relief valve (Item 1) [A] is located at the lower

B
front of the control valve.
Remove the right side motor cover. (See Page 3–1.)
Clean the area around the control valve.
Loosen and remove the main relief valve (Item 1) [B].

Dealer Copy -- Not for Resale

Installation: Tighten the main relief valve to 35–40 ft.–lbs.
(47–54 Nm) torque.
Remove the O–rings and back–up washers from the main 1
relief valve [B].
CD–15092
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 C
relief valve and tighten [A]. Check the pressure again. (See
Page 2–16 or 2–17.)
If the pressure is not correct, adjust the main relief valve. 1
Remove the end cap (Item 2) [A].
Turn the adjusting screw (Item 1) [C] in or out until the
pressure is correct. Turning screw in will increase pressure.
NOTE: If the correct pressure can not be reached,
replace the main relief valve. Check the
pressure setting of the new relief valve.

P–17400

863, 863H Bobcat Loader

79 of 570 –2–19– Service Manual
SELECT VALVE 863H
Checking The High Flow Pump Relief Valve
A
The tools listed will be needed to do the following
procedure: 2

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–09153

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–02130 P–00998

Put jackstands under the front axles and rear

corners of the frame before running the engine
for service. Failure to use jackstands can allow
C
the machine to fall or move and cause injury or
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 3
engage the front auxiliary hydraulics momentary, the light 1
(Item 2) [B] will come ON.
Push the rocker switch (Item 3) [B] for fluid pressure to the
secondary quick couplers.
Watch the flow meter on the hydraulic tester to make sure 2 2
P–09174 P–13407
the flow is correct. Increase the engine speed to full RPM.
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).
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) [C]. Inspect
the O–rings (Item 2) [C] and back–up ring (Item 3) [C] for
damage.
Replace the relief valve if required. This relief valve is not
adjustable.

863, 863H Bobcat Loader

80 of 570 –2–20– Service Manual
SELECT VALVE (863H) (Cont’d)
Removal And Installation
A
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].
Remove the rear bolt on the left side pedal link (Item 3) [A] 2
and lower the link.
NOTE: Steering panel brace is removed for photo 2
clarity. 1
P–13046
Drain the hydraulic reservoir. (See Page 1–1.)
Loosen the clamp (Item 1) [B] and disconnect the hose. B 1
Disconnect the tubeline (Item 2) [B].
Disconnect the hose (Item 3) [B].
Install caps and plugs on open connections.

Dealer Copy -- Not for Resale

2

P–13047

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–09166

Disconnect the tubelines (Item 1) [D].

D
Remove the select valve.
Installation: Connect controls harness to select valve 1
solenoids. See Page 2–22 for solenoid identification and
correct controls harness wire color.

P–13048

863, 863H Bobcat Loader

81 of 570 –2–21– Service Manual
SELECT VALVE 863H (Cont’d)
Disassembly And Assembly
A
Clean the select valve to remove dirt before disassembly. 2
1
3

When repairing hydrostatic and hydraulic

systems, clean the work area before 4
disassembly and keep all parts clean. Always 5
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage P–09168
the system.
I–2003–0888

Remove the solenoid valve coils in Fig. [A].

B
NOTE: The controls wiring harness colors are listed
below for identification during select valve
assembly installation. 1
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
Second aux. diverter (Item 5) [A] Yellow 2

Assembly: The coils largest opening (Item 1) [B] must P–09177

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)
torque. C

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
them. Install new O–rings and back–up washers. 1
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
(Item 2) [D] to 20 ft.–lbs. (27,1 Nm) torque.
2
3
P–09170

863, 863H Bobcat Loader

82 of 570 –2–22– 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.

Dealer Copy -- Not for Resale

5 4
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

83 of 570 –2–23– Service Manual
LIFT ARM BY–PASS CONTROL VALVE
Removal And Installation
A
Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)

1
When repairing hydrostatic and hydraulic
systems, clean the work area before 1
disassembly and keep all parts clean. Always P–07760
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888
B

P–07937

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 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 Feb. 99570
84 of –2–24– 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.

Always clean up spilled fuel or oil. Keep heat, P–07938

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. B
W–2103–1285

Disassembly And Assembly 1

Remove the by–pass valve (Item 1) [B] from the valve
block. Inspect the by–pass valve for damage and replace
if necessary.

Dealer Copy -- Not for Resale

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–07939
863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.) – Hydraulic System Section Part 1 of 4

863, 863H Bobcat Loader

85 of 570 –2–25– Service Manual
BICS™ CONTROL VALVE
Removal And Installation
A
Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)

When repairing hydrostatic and hydraulic

1
systems, clean the work area before 1
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and N–17628
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888
B

N–17397

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
lift arms or attachment to fall and cause injury
or death. W–2059–0598

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

Drain the fluid from the hydraulic reservoir. (See Page 1–1.)
Mark all tubelines for correct installation.
Disconnect the three hoses (Item 1) [A] at the lift arm N–17405
by–pass control valve.
Remove the bolt and nut (Item 1) [B] and remove the
tubeline clamp.
D
At the engine compartment remove the tubeline bolt and
nut (Item 1) [C] and remove the tubeline clamp.

1
2
Disconnect the hydraulic hose (Item 1) [D] from hydraulic
control valve to hydrostatic cooler.
Disconnect the charge pressure hose (Item 2) [D] from the
control valve.

N–17629

863, 863H Bobcat Loader

Revised Feb. 99570
86 of –2–26– Service Manual
BICS™ CONTROL VALVE (Cont’d)
Removal And Installation (Cont’d)
A
Disconnect the auxiliary hydraulic tubelines (Item 1) [A] 1
and lift tubelines (Item 2) [A] at hydraulic control valve.

N–17630

Disconnect the lift tubelines (Item 1) [B] at the control

valve. B
1

Dealer Copy -- Not for Resale

N–17631

Disconnect the lift tubeline (Item 1) [C] at the control valve.

C
NOTE: BICS™ control valve can be removed without
removing hydraulic control valve. Valve
removed for photo clarity.

N–17632

863, 863H Bobcat Loader

87 of 570 –2–27– Service Manual
BICS™ CONTROL VALVE (Cont’d)
Removal And Installation (Cont’d)
A
1
Loosen the six mounting bolts (Item 1) [A] at the BICS
valve. 1

N–00076

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

B

N–00093

Remove the BICS valve assembly from the top of the

control valve [C].
C
Installation: Always replace the four large O–rings (Item 1
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.
(21,5–23,7 Nm) 1, 2, 3, 4, 5 & 6 1 2

3* 190–210 in.–lbs. 5 4
(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

88 of 570 –2–28– Service Manual
BICS™ VALVE ASSEMBLY
Lift Arm By–Pass Orifice
A
Remove the control valve from the loader. (See Page
2–33.)
1
To remove, replace or check the orifice for the lift arm
by–pass function, use the following procedure.

N–00079
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
B
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888

1
Remove the fitting (Item 1) [A] from the BICS valve.

Dealer Copy -- Not for Resale

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

89 of 570 –2–29– Service Manual
BICS™ VALVE ASSEMBLY (Cont’d)
Check Valve
A
Loosen and remove the check valve (Item 1) [A].
Installation: Tighten the check valve to 20 ft.–lbs. (27 Nm) 1
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

90 of 570 –2–30– 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

Dealer Copy -- Not for Resale

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

91 of 570 –2–31– Service Manual
BICS™ VALVE ASSEMBLY (Cont’d)
BICS™ Valve Solenoid
A
Loosen the mounting nut (Item 1) [A] at the solenoid.
1

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

92 of 570 –2–32– Service Manual
HYDRAULIC CONTROL VALVE
Removal And Installation
A
Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)

1
2

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 N–17626
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888
B
2

Dealer Copy -- Not for Resale

1
N–17627

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
lift arms or attachment to fall and cause injury
or death. W–2059–0598

Stop the engine. Raise the seat bar.

Raise the operator cab. (See Page 1–1.) 1
Clean the area around the control valve.
Disconnect the wire harness connectors (Item 1) [A] from N–17625
the auxiliary solenoids connectors.
Disconnect the wire harness connector (Item 2) [A] from
the BICS valve solenoid connector.
D
Disconnect the linkage (Item 1 & 2) [B] from the lift and tilt
spools at the control valve.
Remove the bolt and nut (Item 1) [C] and remove the
tubeline clamp.
1
At the engine compartment remove the bolt and nut (Item
1) [D] and remove the tubeline clamp.

N–17405

863, 863H Bobcat Loader

Revised Feb. 99
93 of 570 –2–33– Service Manual
HYDRAULIC CONTROL VALVE
Removal And Installation (Cont’d)
A
Disconnect the three hoses (Item 1) [A] at the lift arm
by–pass control valve.

N–17628

Disconnect the hydraulic hose (Item 1) [B] from the

hydraulic control valve to the hydrostatic cooler. B
Disconnect the charge pressure hose (Item 2) [B] from the
control valve.
1

N–17629

Disconnect the auxiliary hydraulic tubelines (Item 1) [C]

and lift tubelines (Item 2) [C] at hydraulic control valve. C
1

N–17630

Disconnect the lift tubelines (Item 1) [C] at the control

valve. D

N–17631

863, 863H Bobcat Loader

94 of 570 –2–34– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Removal and Installation (Cont’d)
A
Disconnect the lift tubeline (Item 1) [A] at the control valve.

N–17632

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

control valve.
B
Remove the control valve from the loader.

Dealer Copy -- Not for Resale

N–17633

863, 863H Bobcat Loader

95 of 570 –2–35– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Identification Chart
A H3 H1
H2
Item 863 Loader

A1 Lift Cylinder Base End/Restrictor

C4
A2 Tilt Cylinder Base End
G3 B3 A3 D3
A3 Auxiliary Hydraulics
C3
B1 Lift Cylinder Rod End B2 A2 D2
G2 E2
B2 Tilt Cylinder Rod End F2 C2
G1 B1 A1 E1 D1
B3 Auxiliary Hydraulics F1 C1

C1 Load Check Valve/Lift Function MR

C2 Load Check Valve/Tilt Function

MC–02229
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

96 of 570 –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 2–26.)
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 2–36.)
2
N–00095

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.

Dealer Copy -- Not for Resale

I–2003–0888 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. C 4
Load Check Valve
Loosen the load check valve plug (Item 1) [B]. 1
Installation: Always use new O–ring. tighten the plug to
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

97 of 570 –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–06764

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

CD–15092

863, 863H Bobcat Loader

98 of 570 –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).
Installation: Always use new O–rings and back–up 1
washers. Tighten to 35–40 ft.–lbs. (47–54 Nm) torque.

P–09134

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

B

Dealer Copy -- Not for Resale

1

P–09135

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

relief valve [C]. C 1 2
3 4

E–01509

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

99 of 570 –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–01509

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

CD–15102

863, 863H Bobcat Loader

100 of 570 –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

Dealer Copy -- Not for Resale

N–00105

Remove the retainer (Item 1) [C] and large O–ring (Item 2)

[C]. C

1
2
N–00106

863, 863H Bobcat Loader

101 of 570 –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].
Remove the washer (Item 2) [A]. 1

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 the detent
sleeve is removed.
C

N–00113

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

D

N–00114

863, 863H Bobcat Loader

102 of 570 –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

Dealer Copy -- Not for Resale

1

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

103 of 570 –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

104 of 570 –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

Dealer Copy -- Not for Resale

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

105 of 570 –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

106 of 570 –2–46– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Auxiliary Spool
A
Remove the end cap screws (Item 1) [A] & [B].
2
Installation: Tighten the screws to 90–100 in.–lbs. 5
(10,2–11,3 Nm) torque. 3

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

Dealer Copy -- Not for Resale

4 1
N–00121

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

C

N–00064

863, 863H Bobcat Loader

107 of 570 –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

108 of 570 –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.

Dealer Copy -- Not for Resale

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

109 of 570 –2–49– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
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.
863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.) – Hydraulic System Section Part 2 of 4

N–00118

863, 863H Bobcat Loader

110 of 570 –2–50– Service Manual
HYDRAULIC PUMP
Checking the Output of the Pump
A
NOTE: This procedure is the same for 863 and 863H in 1
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–07754
*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.)

Dealer Copy -- Not for Resale

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–07753

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

111 of 570 –2–51– Service Manual
HYDRAULIC PUMP (Cont’d)
Removal and Installation
A

1
2

N–17599

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.) 2

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

N–17600
Loosen the hose clamps and disconnect the inlet hose
(Item 1) [A] from the pump inlet fitting.
Disconnect the inlet hoses (Item 2) [A] from the pump inlet
fitting.
Disconnect the hose (Item 1) [B] from the pump outlet to
the control valve

Remove the pump mounting bolts (Item 2) [B] (both sides).

Installation: Tighten the mounting bolts to 25–27 ft.–lbs.
(34–37 Nm) torque.
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 Feb.
11299
of 570 –2–52– Service Manual
HYDRAULIC PUMP (Cont’d)
Parts Identification

1
2 3
4
5
6 7
8

10
8 6

Dealer Copy -- Not for Resale

5

13 14
11 12

TS–01022

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

113 of 570 –2–53– Service Manual
HYDRAULIC PUMP (Cont’d)
Disassembly
A
Marks

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 CD–15160

Mark the pump sections for correct assembly [A].

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

1
1

CD–15141
Remove the end housing (Item 1) [C].

CD–15142
Remove the mounting flange end housing (Item 1) [D].

1
CD–15143

863, 863H Bobcat Loader

114 of 570 –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

Dealer Copy -- Not for Resale

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

115 of 570 –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 worn, CD–15148
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

116 of 570 –2–56– Service Manual
HYDRAULIC PUMP (Cont’d
Assembly
A
Always use new O–rings and seals when assembling the
hydraulic pump.

When repairing 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 CD–15150
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888
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.

Dealer Copy -- Not for Resale

Install the bearing housing/gears assembly into the pump
housing [B].

CD–15151
Install the back–up seals/O–ring seals (Item 1) [C].
Install the large O–ring (Item 2) [C]. C

1
2

CD–15152
Install the mounting flange housing on the pump housing
[D].
D

CD–15153

863, 863H Bobcat Loader

117 of 570 –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

118 of 570 –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.
N–17595
Lift and block the loader. (See Page 1–1.)
Remove the right side rear wheel.
Remove the four bolts and cover (Item 1) [A].
B
Disconnect the OUTLET hose from the pump fitting (Item1) 1
[B]. Remove the fitting (Item 1) [B] and install a 90° elbow
fitting.
Connect the INLET hose from the tester to the OUTLET of
the pump. Connect the OUTLET hose from the tester to the

Dealer Copy -- Not for Resale

hose which was disconnected from the pump [C].

N–17596

Put jackstands under the front axles and rear

corners of the frame before running the engine
for service. Failure to use jackstands can allow
C
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. P–09155

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

119 of 570 –2–59– Service Manual
HYDRAULIC PUMP (Double Gear) 863H (Cont’d)
Removal and Installation
A
Lift and block the loader. (See Page 1–1.)
Remove the right side rear wheel.
Remove the four bolts and cover (Item 1) [A].
1
Raise the operator cab. (See Page 1–1.)
Drain the hydraulic reservoir. (See Page 1–1.)
Disconnect the outlet hose from the small pump fitting
(Item 1) [B]. N–17595

Remove the fitting (Item 1) [B].

B
1

N–17596

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved C
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
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]. N–17597

Remove the inlet fitting (Item 2) [D].

D
1

2
1

N–17599

863, 863H Bobcat Loader

Revised Feb.
12099
of 570 –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]. (Both sides.)
Installation: Install a new gasket. Tighten the mounting 1
bolts (Item 1) [A] to 25–27 ft.–lbs. (34–37 Nm) torque.

N–17600

863, 863H Bobcat Loader

121 of 570 –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–01078

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

Added Sept.
12296of 570 –2–62– Service Manual
HYDRAULIC PUMP (Double Gear) 863H (Cont’d)
Disassembly
A Mark

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 Mark
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888 CD–15159

Mark the pump sections for correct assembly [A].

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

Dealer Copy -- Not for Resale

3

2
CD–15017
Remove the O–ring (Item 1) [C] from the end housing.
Remove the back–up seal/O–ring seal (Item 2) [C] from the
pump housing.
C

1
2

CD–15018
Remove the O–ring (Item 1) [D] from the center housing.
Remove the back–up seal/O–ring seal (Item 2) [D]. D

1 CD–15019

863, 863H Bobcat Loader

123 of 570 –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

124 of 570 –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

Dealer Copy -- Not for Resale

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

863, 863H Bobcat Loader

125 of 570 –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) [B] 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

126 of 570 –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 them CD–15028
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).

Dealer Copy -- Not for Resale

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

127 of 570 –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 repairing 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 CD–15032
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888
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.
1
Install the large drive and idler gears into the bearing
housing (Item 1) [B].

CD–15026
Install the bearing housing/gears assembly into the large
pump housing [C].
Install the back–up seal/O–ring seal (Item 1) [C].
C
Install the large O–ring (Item 2) [C].

1
2

CD–15033
Turn the large pump housing around; install the back–up
seal/O–ring seal (Item 1) [D].
Install the large O–ring (Item 2) [D]. D

2
1

CD–15034

863, 863H Bobcat Loader

128 of 570 –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

Dealer Copy -- Not for Resale

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

129 of 570 –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

130 of 570 –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 or B] at the case drain filter
and drain the fluid into a container.
1

N–17398

Dealer Copy -- Not for Resale

1

N–17597
Loosen the hose clamp and disconnect the reservoir outlet
hose (Item 1) [C].
Disconnect the case drain hose (Item 2) [C] at the C
reservoir. 1 2

N–17597
Remove the bolt and plate from the mounting strap (Item
1) [D] (both sides)
D
Installation: Tighten the bolt to 16–20 ft.–lbs. (21–27 Nm)
torque.
Remove the mounting strap.
Remove the hydraulic reservoir from the loader.
1

N–17598

863, 863H Bobcat Loader

Revised
131 of Feb.
570 99 –2–71– Service Manual
HYDROSTATIC FILTER HOUSING
Removal and Installation
A 4
4

2 3

N–17395

B
Never work on a machine with the lift arms up 2
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.)
1
Raise the operator cab. (See Page 1–1.)
Disconnect the wires (Item 1) [A] from the hydraulic filter N–17396
sender and switch.
Disconnect the hose clamp and hose (Item 2) [A] from the
filter housing.
Disconnect the hydraulic tubeline (Item 3) [A]
Remove the four mounting bolts (Item 4) [A].
Installation: Tighten the mounting bolts to 25 ft.–lbs. (34
Nm) torque.
Remove the filter housing/filter assembly.

Hydrostatic Charge Pressure Sender

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

863, 863H Bobcat Loader

Revised Feb.
13299
of 570 –2–72– 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–05380
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.

Dealer Copy -- Not for Resale

AVOID INJURY OR DEATH P–05383
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 2–75 for correct procedure to adjust

the pedal interlock linkage.

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133 of 570 –2–73– Service Manual
PEDAL INTERLOCK LINKAGE
Removal and Installation
A

1
2

P–01216

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
device. (See Page 1–1.) 1

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

Remove the interlock shield mounting nuts (Item 1) [A]. P–01210

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: 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–01219

P–01213

863, 863H Bobcat Loader

Revised Feb.
13499
of 570 –2–74– Service Manual
PEDAL INTERLOCK LINKAGE (Cont’d)
Removal And Installation (Cont’d)
A
Remove the panel from the loader frame [A].

P–01215

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

the panel as shown.
B

Dealer Copy -- Not for Resale

P–01212

Pedal Interlock Linkage Adjustment

Check the pedal interlock linkage so it is free and locks both C
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–01214

AVOID INJURY OR DEATH D

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.
863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.) – Hydraulic System Section Part 3 of 4

P–04051

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135 of 570 –2–75– Service Manual
REAR AUXILIARY DIVERTER
Disassembly
A
Clean the diverter block to remove dirt before disassembly.
Block ports are labeled for correct assembly.

When repairing hydrostatic and hydraulic 1

systems, clean the work area before
disassembly and keep all parts clean. Always 1
use caps and plugs on hoses, tubelines and N–00527
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].
Remove the nuts (Item 1) [C], seal washers (Item 2) [C], 1
and solenoid valve coils (Item 3) [C].
2
Remove the diverter control solenoid valve (Item 4) [C]
from port SV1. Remove the pressure relieving solenoid N–00529
valve (Item 5) [C] from block port SV2.
Inspection C 4
Inspect cartridges, check valves, solenoid valves and
sealing washers for contamination or damage. Wash all
parts in clean solvent. Use air pressure for drying them. 2
Install new O–rings and back–up washers. 3

Inspect diverter block cavities for contamination. Wash 5 2

block in clean solvent. Use air pressure to dry.
2
Solenoid Testing
Use a test meter to measure coil resistance [D]. Coil wires
do not have polarity. Correct resistance is 6–9 ohms. 3
2 1
Replace the test meter with 12 volt power. You can see and N–00528
hear the spool shift.
Assembly
D
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–09137
863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.) – Hydraulic System Section Part 4 of 4

863, 863H Bobcat Loader

136 of 570 –2–76– Service Manual
 HYDROSTATIC SYSTEM

Page
Number

CHARGE PUMP (M44)

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–104
CONTROL TOWER (M46 Pump & AHC)
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–14
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–13 HYDROSTATIC
SYSTEM
DRIVE BELT
Adjusting the Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–108
Replacing the Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–108

DRIVE BELT SHIELD

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–97
DRIVE BELT TENSIONER PULLEY
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–109
Tension Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–111
FRONT PANEL (M44 Hydraulic Pump)
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7

FRONT PANEL (M46 Pump & AHC)

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
HYDRAULIC/HYDROSTATIC OIL COOLER
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–112

HYDROSTATIC MOTOR (S/N 514427762 & Above; 514525304 & Above;

514625302 & Above)
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–32
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–31
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–28
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–27
HYDROSTATIC MOTOR (S/N 514427761 & Below; 514525303 & Below;
514625301 & Below)
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–41
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–39
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–40
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–38
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–36

Continued On Next Page

863, 863H Bobcat Loader

Revised
137 of Feb.
570 99 –3–1– Service Manual
 HYDROSTATIC SYSTEM (Cont’d)

Page
Number

HYDROSTATIC PUMP (M46)

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–70
Charge Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–51
Charge Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–79
Charge Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–57
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–58
Displacement Control Servo (Solid Linkage) . . . . . . . . . . . . . . . . . . . . 3–82
Hydraulic Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–80
Hydraulic Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–56
Hydrostatic Pump Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–80
Hydrostatic Pump Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–56
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–67
Parts Identification (Left Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–54
Parts Identification (RIght Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–52
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–49
Replenishing/High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . 3–51
Swashplate Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–81
HYDROSTATIC PUMP (M44)
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–99
Charge Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–89
Charge Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–91
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–93
Hydraulic Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–90
Hydrostatic Pump Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–91
Parts Identification (Left Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–86
Parts Identification (RIght Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–84
Replenishing/High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . 3–88
HYDROSTATIC SYSTEM INFORMATION
Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
MOTOR CARRIER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–47
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–45
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–44
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–43
SOLID STEERING LINKAGE NEUTRAL ADJUSTMENT (M46 Pump)
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16
STEERING LEVERS (M44 Pump)
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11
STEERING LEVERS (M46 Pumps & AHC)
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9
STEERING LINKAGE (M44 Pump)
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–19
Steering Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–22
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

863, 863H Bobcat Loader

Revised Feb.
13899
of 570 –3–2– Service Manual
TROUBLESHOOTING
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.
Check for correct function after adjustments,
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 warn- 8, 11, 12, 13, 14

Dealer Copy -- Not for Resale

ing light comes ON.

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. External leak from the lift cylinder(s).
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

139 of 570 –3–3– Service Manual
HYDROSTATIC SYSTEM INFORMATION
A CHARGE OIL

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. Valve Moves for Charge
I–2003–0888 FUNCTION 1 Oil Replacement

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].
See Page 3–51 (M46 Pump) or 3–88 (M44 Pump) for valve
location and repair information.
Valve Stays on Seat to
Hold High Pressure for Drive
FUNCTION 2
B–02804

863, 863H Bobcat Loader

140 of 570 –3–4– Service Manual
FRONT PANEL (M46 Pump & AHC)
Removal and Installation
A 1

3
2

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
N–17501

Dealer Copy -- Not for Resale

1

Never work on a machine with the lift arms up N–17388

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.) 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.
N–17391
Remove the mounting bolt (Item 3) [A].
Disconnect the wire harness connectors (Item 1) [B] from
the steering lever wire harness.
NOTE: The 863 without front auxiliary hydraulics or
Advanced Hand Controls does not have
electric control handles.
Remove the steering panel brace bolts (Item 1) [C].

863, 863H Bobcat Loader

Revised
141 of Feb.
570 99 –3–5– Service Manual
FRONT PANEL (M46 Pump & AHC) (Cont’d)
Removal and Installation (Cont’d)
A 2

Disconnect the steering linkage ball joints (Item 1) [A] from

the steering cross shaft.
Remove the top mounting bolt (Item 2) [A]. 1

P–13480

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

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

P–07970

863, 863H Bobcat Loader

142 of 570 –3–6– Service Manual
FRONT PANEL (M44 Hydraulic Pump)
Removal And Installation
A 1

Put jackstands under the front axles and rear

corners of the frame before running the engine 3
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.
W–2017–0286
Never work on a machine with the lift arms up N–17634
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
B
or death.
W–2059–0598

Dealer Copy -- Not for Resale

1
1

N–17622
Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
C
Remove the engine speed control (Item 1) [A]. (See Page
7–1.) 1
Loosen the jam nut from the by–pass control knob (Item 2) 1
[A].
Remove the control knob, jam nut and rubber washer.
Disconnect the control harness wiring connector (Item 3)
[A] from the right side steering lever.
NOTE: If the loader is equipped with rear auxiliary
hydraulics, also disconnect the electrical N–17635
connectors from the left side steering lever.
Scribe a mark across the top of the steering linkage bars
(Item 1) [B] which are connected to the steering shaft on D
the control panel.
Remove the four steering linkage mounting bolts (Item 2)
[B]. 1
Installation: Tighten the steering linkage mounting bolts to
25–28 ft.–lbs. (34–38 Nm) torque.
Remove the control panel mounting bolts (Item 1) [C] & [D]
from right side of the control panel.
1
Installation: Tighten the control panel mounting bolts to
25–28 ft.–lbs. (34–38 Nm) torque. 1
N–17637

863, 863H Bobcat Loader

Revised
143 of Feb.
570 99 –3–7– Service Manual
FRONT PANEL (M44 Hydraulic Pump) (Cont’d)
Removal And Installation (Cont’d)
A
Remove the control panel mounting bolts (Item 1) [A] from
the left side of the control panel.
1
1
Installation: Tighten the control panel mounting bolts to
25–28 ft.–lbs. (34–38 Nm) torque.
Remove the control panel from the loader.

1
1

N–17638

863, 863H Bobcat Loader

144 of 570 –3–8– Service Manual
STEERING LEVERS (M46 Pumps & AHC)
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] and spring.

1
N–17497

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

Remove the left steering lever. B

Dealer Copy -- Not for Resale

N–17499

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

Remove the right steering lever. C 1

Remove the steering shaft assembly bolts (Item 2) [C]

(both sides).
Remove the steering shaft.

N–17500

863, 863H Bobcat Loader

145 of 570 –3–9– Service Manual
STEERING LEVERS (M46 Pumps & AHC) (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 (Item 4) [B].

P–05040

Remove the foam backing from the control panel.

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

1
N–17648

1
2
N–17647

863, 863H Bobcat Loader

146 of 570 –3–10– Service Manual
STEERING LEVERS (M44 Pumps)
Removal And Installation
A 1
Loosen both U–bolts (Item 1) [A] at the steering lever (both
sides).
Remove the steering cross shaft mounting bolts (Item 2)
[A] (both sides).
Installation: Tighten the mounting bolts to 180–200
in.–lbs. (21–23 Nm) torque.
Remove the steering cross shaft from the control panel. 2

N–17643

Disassembly And Assembly

B
Disassemble the right and left steering shafts from the
cross shaft assembly.
1
NOTE: Some loaders may have a sleeve (Item 1) [B] 3
between the bearing (Item 2) [B] and the bell 3
crank (Item3) [B].

Dealer Copy -- Not for Resale

2
N–17639

Check the bearings (Item 1) [C] for wear and replace as

needed. C
Check the fiber washers (Item 2) [C] for wear and replace 1
as needed.
Replace the wave washer (Item 3) [C] if worn. 2

N–17640

Check the end bearing (Item 1) [D] and fiber washer (Item
2) [D] and replace as needed. D
1

2
P–13773

863, 863H Bobcat Loader

147 of 570 –3–11– Service Manual
STEERING LEVERS (M44 Pumps) (Cont’d)
Disassembly And Assembly (Cont’d)
A
1
NOTE: Some loaders may have a spacer (Item 1) [A]
between the bearing (Item 2) [A] and the bell 2
crank (Item 3) [A].
Check the fiber wsher (Item 4) [A] and replace all worn
parts.

3
4
P–13774

863, 863H Bobcat Loader

148 of 570 –3–12– Service Manual
CONTROL TOWER (M46 Pump & AHC)
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

Dealer Copy -- Not for Resale

Never work on a machine with the lift arms up P–13483
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 C
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) [B]
& [C] from the control tower.
P–13474

Remove the four mounting bolts (Item 1) [D] from the

control tower mounting bracket. D
Installation: Tighten the four mounting bolts to 25 ft.–lbs.
(34 Nm) torque.
Remove the control tower assembly from the loader.
1
Installation: See Page 3–16 to adjust neutral at the
steering linkage.
1

P–13482

863, 863H Bobcat Loader

149 of 570 –3–13– Service Manual
CONTROL TOWER (M46 Pump & AHC) (Cont’d)
Disassembly and Assembly
A 1

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 needed. C
1

P–13490

863, 863H Bobcat Loader

150 of 570 –3–14– Service Manual
CONTROL TOWER (M46 Pump & AHC) (Cont’d)
Disassembly and Assembly (Cont’d)
A
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

Dealer Copy -- Not for Resale

P–13486

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

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

P–13492

863, 863H Bobcat Loader

151 of 570 –3–15– Service Manual
SOLID STEERING LINKAGE NEUTRAL ADJUSTMENT
(M46 Pump) 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
Lift and block the loader. (See Page 1–1.)
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 3–81 for hydrostatic pump neutral
adjustment before beginning the linkage
adjustment.
1
The short steering linkage (Item 1) [A] & [B] at the 1
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
turning each equal amounts to reach a distance of 1.000 (25,4 mm)
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 Feb.
15299
of 570 –3–16– Service Manual
SOLID STEERING LINKAGE NEUTRAL ADJUSTMENT
(M46 Pump) (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 1
cam.

N–17388

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

Dealer Copy -- Not for Resale

N–17498

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
2
Push the left steering lever forward and move the right
steering lever cam (Item 1) [B], to the rear of the slot to get
free play in the left steering lever. Tighten the nut (Item 1)
[C].
1

N–17497

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.

N–17646

863, 863H Bobcat Loader

153 of 570 –3–17– Service Manual
SOLID STEERING LINKAGE NEUTRAL ADJUSTMENT
(M46 Pump) (Cont’d) A
Procedure (Cont’d) Pocket Cam
The cam must be centered in the pocket in the detent Detent
bracket [A]. Bracket

Connect the long steering linkage ball joints (Item 1) [B] at

the steering cross shaft.
Loosen the lock nuts (Item 2) [B] (both ends).
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
Increase the engine speed to full RPM. Move the steering
lever forward and let it return to neutral and the wheels
should stop. Move the steering lever backward and let it
return to neutral and the should stop. If not re–adjust the
steering linkage rod again. 2

Repeat the above procedure for the other side of the loader. 1
NOTE: The following procedure is for MINOR
adjustment in full forward travel only. Steering
neutral setting must be correctly adjusted 2
before doing this procedure.
1 N–17388

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 minor
D
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

154 of 570 –3–18– Service Manual
STEERING LINKAGE (M44 Pump)
Removal And Installation
A
Remove the nut (Item 1) [A] from the end of the centering
spring shoulder bolt (Item 2) [A].
Remove the shoulder bolt/spring assembly.
Installation: Tighten the centering spring shoulder bolt
and a NEW lock nut to 25–28 ft.–lbs. (34–38 Nm) torque.
2

N–17601

Drain the hydraulic reservoir. (See Page 2–1.)

Remove the hydraulic hoses (Item 1) [B]. B
Remove the hydraulic fitting (Item 2) [B] from the pump.

2
1

Dealer Copy -- Not for Resale

N–17602

Slide the plate (Item 1) [C] to the right and remove it from
the two guide pins (Item 2) [C]. C
NOTE: The two guide bushings (Item 3) [C] will be 2
loose and can fall out of the plate as soon as 3
it is removed from the guide pins. 1

3 2

N–17603

The centering plate/centering spring assembly consists of

the following parts: D
Item Description 4 2
1 Centering Spring Assembly
2 Guide Bushings
3 Lock Nut 1
4 Centering Plate

2 3
N–17608

863, 863H Bobcat Loader

Revised
155 of Feb.
570 99 –3–19– Service Manual
STEERING LINKAGE (M44 Pump) (Cont’d)
Removal and Installation (Cont’d)
A 2 5
1
The centering plate/centering spring assembly consists of
the following parts:
Item Description
1 Bolt
2 Washer
3 Sleeve
4 Bushing
5 Spring 4

3
N–17609
Check the wear on the centering blocks (Item 1) [B].

B 1

N–17607
If the centering blocks need replacement, remove the bolts
(Item 1) [C]. Remove the centering blocks.
Installation: Tighten the centering block bolts to 25–28 C
ft.–lbs. (34–38 Nm) torque.

N–17606
Check the surface of the four pintle cams (Item 1) [D].
If worn replace the cam.
D 1 1
Installation: Tighten the bolts to 45–50 ft.–lbs. (62–68
Nm) torque.

1 1

N–17604

863, 863H Bobcat Loader

156 of 570 –3–20– Service Manual
STEERING LINKAGE (M44 Pump) (Cont’d)
Removal and Installation (Cont’d)
A 1
Remove the linkage bar nut (Item 1) [A] from the torsion
bushing.
The bolt is threaded into the linkage bar, remove the bolt
from underneath the pintle arm.
Installation:Tighten the bolt to 11–13 ft.–lbs. (21–25 Nm)
torque, then tighten the nut (Item 2) [C] to 21–25 ft.–lbs.
(28–33 Nm) torque.

N–17611

Remove the linkage bar (Item 1) [B] from the pintle arm.
remove the torsion bushing (Item 2) [B].
B
1

Dealer Copy -- Not for Resale

N–17612

Remove the nuts (Item 1) [A] from both shock absorber ball
joint ends.
C
Installation: Tighten the nuts to 25–28 ft.–lbs. (34–38 Nm)
torque.
Disconnect the shock absorbers from the linkage bars.
2
Remove the nuts (Item 1) [C] from the linkage bar mounting
bolt. The bolts are threaded into the linkage bars, remove
the bolts. 1
Installation: Tighten the bolts to 11–13 ft.–lbs. (21–25 Nm)
torque, then tighten the nuts to 21–25 ft.–lbs. (28–33 Nm)
torque.
The torsion bushings can now be removed from the N–17624
steering bell cranks.
The linkage and the centering plate must be readjusted for
neutral after the components have been reassembled. See
Page 3–22 for the neutral adjustment procedure.

863, 863H Bobcat Loader

157 of 570 –3–21– Service Manual
STEERING LINKAGE (M44 Pump) (Cont’d)
Steering Linkage Adjustment
A
2

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
N–17624

B
1

2
Never work on a machine with the lift arms up N–17613
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.)
Lift and block the loader. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
Connect the remote start switch. (See Page 1–1.)
Pre–load tension in the torsion bushings must be removed
before adjusting the steering linkage.
Loosen the nut (Items 1) [A] (three to four turns), then
loosen the bolt. The bolt is threaded into the linkage bar
(Item 2) [A]. The bolt must be loosened enough to allow the
torsion bushing to turn freely between the steering
bellcrank and the linkage bar.
Loosen the nut (three to four turns), then loosen the bolt at
the linkage bar (Items 1) [B]. The bolt is threaded into the
linkage bar (Items 2) [B]. The bolt must be loosened
enough to allow the torsion bushing to turn freely between
the pintle arm and the linkage bar.

863, 863H Bobcat Loader

Revised Feb.
15899
of 570 –3–22– Service Manual
STEERING LINKAGE (M44 Pump) (Cont’d)
Steering Linkage Adjustment (Cont’d)
A
Move the right side steering lever to the rear and install a
3/8 inch (10 mm) thick spacer (Item 1) [A] between the
pintle arm cam (Item 2) [A] and the centering block (Item
3) [A].

3 2
1

N–17619

Move the right side steering lever forward and install a

15/16 inch (24 mm) thick spacer (Item 1) [B] between the
centering plate (Item 2) [B] and the mounting plate (Item B
3) [B].
This will allow the pintle arms to move freely while adjusting
the steering linkage for full forward travel speed.
Remove the 3/8 inch (10 mm) thick spacer (Item 1) [A].

Dealer Copy -- Not for Resale

3

2 1

N–17620

863, 863H Bobcat Loader

Revised
159 of Feb.
570 99 –3–23– Service Manual
STEERING LINKAGE (M44 Pump) (Cont’d)
Steering Linkage Adjustment (Cont’d)
A
2
Check that the pintle arm mounting bolt (Item 1) [A] is tight,
25–28 ft.–lbs. (34–38 Nm) torque and that there is no play
between the pintle arm and the square pump shaft. Also
check that the cam mounting bolts (Item 2) [A] are tight,
45–50 ft.–lbs. (62–68 Nm) torque. 1

N–17616

Loosen the two bolts and nuts (Item 1) [B] on each steering
linkage bar. B

1
1

N–17622

Move the left side steering lever to the full forward position
(until the steering lever hits the stop), then pull forward on
the left side rear linkage bar until the pintle arm is rotated C
to the front as far as possible. Use a clamping plier and
clamp the two linkage bars together [C].
Tighten the nuts and bolts to 25–28 ft.–lbs. (34–38 Nm)
torque.
Check the lever movement to make sure that the pintle arm
and the steering lever are both at full stroke at the same
time. This will allow for maximum forward speed.
Repeat the procedure for the right side steering linkage bar.
After both sides of the linkage bars have been adjusted, the
feel of both levers at full stroke should be the same. N–17623
Readjust the linkage if necessary.

Remove the spacer (Item 1) [D]. D

N–17620

863, 863H Bobcat Loader

Revised Feb.
16099
of 570 –3–24– Service Manual
STEERING LINKAGE (M44 Pump) (Cont’d)
Steering Linkage Adjustment (Cont’d)
A
The following tool listed will be needed to do the following
procedure:
MEL1429A – Remote Start Switch 1
1
Connect the remote start switch to the engine harness.
(See Page 1–1.)
Loosen the four bolts (Item 1) [A] holding the two centering
blocks. Move the right side centering block to the right as
far as possible.
NOTE: Bolt holes are slotted for pintle arm centering N–17602
adjustment.
Adjust the left side centering block first [B].
Start the engine and run at high RPM.
B

Dealer Copy -- Not for Resale

N–17621
Move the traction lock override switch (Item 1) [C] to the
OFF position so the traction function is unlocked. The
wheels are now able to turn. C
Move the left hand steering lever until the tires do not turn 1
(neutral position).
Move the left side centering block to the left until it contacts
both pintle cams and the steering lever is still in the neutral
position [B].
Tighten the bolts to 25–28 ft.–lbs. (34–38 Nm) torque.
863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.) – Hydostatic System Section Part 1 of 5

P–04714

863, 863H Bobcat Loader

Revised
161 of Feb.
570 99 –3–25– Service Manual
STEERING LINKAGE (M44 Pump) (Cont’d
Steering Linkage Adjustment (Cont’d)
A
Adjust the right side centering block [A].
Move the right side steering lever until the tires do not turn
(neutral position).
Move the right side centering block to the left until it
contacts both pintle cams and the steering lever is still in the
neutral position [A].
Tighten the bolts to 25–28 ft.–lbs. (34–38 Nm) torque.
Test both levers by moving them backward and forward
and letting them return to neutral by the return spring force. N–17618

If the levers do not return to neutral and the tires do not

come to a complete stop, repeat the adjustment procedure
again. B
Stop the engine.

Tighten the two linkage bar bolts to 11–13 ft.–lbs. (15–17 1

Nm) torque, then tighten the two nuts to 21–25 ft.–lbs.
(28–33 Nm) torque at the pintle levers (Items 1) [B].

N–17602
Tighten the two linkage bar bolts to 11–13 ft.–lbs. (15–17
Nm) torque, then tighten the two nuts to 21–25 ft.–lbs.
(28–33 Nm) torque at the steering cross shaft (Items 1 &
2) [C]. C
1

N–17624

863, 863H Bobcat Loader

Revised Feb.
16299
of 570 –3–26– Service Manual
HYDROSTATIC MOTOR (S/N 514427762 & Above;
514525304 & Above; 514625302 & Above) A
Removal And Installation
Lift and block the loader. (See Page 1–1.)
1

N–17874

Never work on a machine with the lift arms up 1

unless the lift arms are secured by an approved 1
lift arm support device. Failure to use an
approved lift arm support device can allow the 1 2 1
lift arms or attachment to fall and cause injury

Dealer Copy -- Not for Resale

or death. W–2059–0598 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.) N–17786

Remove the motor cover.

Mark the hoses for correct installation. C
Disconnect the case drain hose (Item 1) [A].
Disconnect the high pressure hoses (Item 2) [A].
Remove the ten mounting bolts (Item 1) [B]. 1

NOTE: The two bolts (Item 2) [B] mount the cam ring
to the motor, and do not have to be removed,
to remove the motor from the loader.
Remove the motor/cam ring section from the loader.
Remove the piston/roller section (Item 1) [C] from the
loader, if it was not removed with the motor/cam ring. P–05405

To remove the motor carrier. (See Page 3–45.)

863, 863H Bobcat Loader

Revised
163 of Feb.
570 99 –3–27– Service Manual
HYDROSTATIC MOTOR (S/N 514427762 & Above; 514525304 & Above; 514625302 & Above) (Cont’d)
Parts Identification

1 2 3

4 6 5
8 7
9
10
12
11

13

26 23 15
14
27 25

28

29

30 16
22
24 21
20
19
18
17

C–03374

Ref. Description Ref. Description

1. DISTRIBUTOR 17. PLUG
2. SPRING 18. O–RING
3. SEAL 19. SPRING
4. O–RING 20. SHIM
5. PLUG 21. POPPET
6. 0–RING 22. O–RING
7. SPRING 23. SEAL
8. WASHER 24. O–RING
9. SPOOL 25. SEAL
10. SPRING 26. O–RING
11. REAR HOUSING 27. CAM
12. PLUG 28. ROLLER
13. O–RING 29. PISTON
14. O–RING 30 BLOCK
15. STOP PIN
16. BOLT

863, 863H Bobcat Loader

Revised Feb.
16499
of 570 –3–28– Service Manual
HYDROSTATIC MOTOR (S/N 514427762 & Above;
514525304 & Above; 514625302 & Above) (Cont’d) A
1
Disassembly
Remove the piston/roller section (Item 1) [A] from the
motor.

N–17861

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

1

Dealer Copy -- Not for Resale

1

N–17860

Remove the cam ring (Item 1) [C] from the motor housing. C
1

N–17863

Remove the stop pin (Item 1) [D] from the rear motor D 1
housing.

N–17864

863, 863H Bobcat Loader

Revised
165 of Feb.
570 99 –3–29– Service Manual
HYDROSTATIC MOTOR (S/N 514427762 & Above;
514525304 & Above; 514625302 & Above) (Cont’d) A
Disassembly (Cont’d) 2
1

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. N–17865
I–2003–0888

Use a brass drift punch, thru the stop pin hole (Item 1) [A]
to remove the distributor (Item 2) [A].
B
Remove the two seals (Item 1) [B] from the housing.
Remove the two O–rings, that are located under the seals.

N–17866

Remove the nine springs (Item 1) [C] from the distributor. C 1

N–17869

Remove the two seals (Item 1) [D] from the distributor.

D
Remove the two O–rings, that are located under the seals.

1
N–17870

863, 863H Bobcat Loader

Revised Feb.
16699
of 570 –3–30– Service Manual
HYDROSTATIC MOTOR (S/N 514427762 & Above;
514525304 & Above; 514625302 & Above) (Cont’d) A
Disassembly (Cont’d)
Remove the plug (Item 1) [A] spring (Item 2) [A] shim (Item
3) [A] and poppet (Item 4) [A].
Inspect all parts and replace as needed.

1 2 3 4

N–17872

Remove the plug (Item 1) [B] springs (Item 2) [B] spool

(Item 3) [B] and washer (Item 4) [B]. B
Inspect all parts and replace as needed.

Dealer Copy -- Not for Resale

2 3 4 2 1

N–17871

Apply low air pressure to each port in the cylinder block to

remove the roller (Item 1) [C] and piston/ring assembly
(Item 2) [C]. C
NOTE: Put all the roller/piston assembly back in their
original position. 2
1

B–05765

Inspection
Clean all parts in clean solvent and use air pressure to dry
D
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 distributor surface for scratches [D].

N–17870

863, 863H Bobcat Loader

Revised
167 of Feb.
570 99 –3–31– Service Manual
HYDROSTATIC MOTOR (S/N 514427762 & Above;
5714525304 & Above; 514625302 & Above) (Cont’d A
Inspection (Cont’d)
Check the cam ring inside surface for wear and scratches
[A].

P–05753

Check the cylinder block surface for scratches [B]. B

Check all the roller/piston assembly for scratches and wear
[B].
Replace the parts as needed.

Assembly

P–05759

C
When repairing hydrostatic and hydraulic
systems, clean the work area before
disassembly and keep all parts clean. Always 2
use caps and plugs on hoses, tubelines and 1
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888

NOTE: Always use new O–rings and seals when

assembling the hydrostatic motor.
Install the roller (Item 1) [C] in the piston (Item 2) [C].
Dip the roller/piston assembly into oil and install into the P–05765
bore in the cylinder.
Repeat for each roller/piston assembly.
D
Install new O–rings and seals (Item 1) [D] on the distributor.

N–17870

863, 863H Bobcat Loader

Revised Feb.
16899
of 570 –3–32– Service Manual
HYDROSTATIC MOTOR (S/N 514427762 & Above;
514525304 & Above; 514625302 & Above) (Cont’d) A
Assembly (Cont’d) 1
Put grease on the springs (Item 1) [D] to hold them in place.
Install the springs into the distributor.

N–17869

Install the spring (Item 1) [B] spool (Item 2) [B] washer

(Item 3) [B] and spring into the rear housing. B
Replace the O–ring (Item 4) [B] on the plug.
Install the plug into the rear housing and tighten to 18–22
ft–lbs. (25–30 Nm) torque.

Dealer Copy -- Not for Resale

4
1 2 3 1

N–17871

Install the poppet (Item 1) [C] the shim (Item 2) [C] spring
(Item 3) [C] into the rear housing.
C
Replace the O–ring (Item 4) [C] on the plug.
Install the plug into the rear housing and tighten to 9–11
ft–lbs. (12–15 Nm) torque.

4 3 2 1

N–17872

Install the two O–rings into the housing.

D
Install the two seals (Item 1) [D] into the housing, over the
top of the O–rings, with minimum distortion.
Lightly smear grease over the seals.

N–17866

863, 863H Bobcat Loader

Revised
169 of Feb.
570 99 –3–33– Service Manual
HYDROSTATIC MOTOR (S/N 514427762 & Above;
514525304 & Above; 514625302 & Above) (Cont’d) A
2 3
Assembly (Cont’d)
Install the stop pin (Item 1) [A] and tighten to 7–9 ft.–lbs.
(10–12 Nm) torque.
Install the distributor (Item 2) [A] into the housing.
Align the distributor hole (Item 3) [A] with the stop pin.
When aligned correctly, the distributor can be depressed
slightly.
1

N–17868

Lightly smear grease on the O–ring. B

Install he O–ring (Item 1) [C] on the rear housing.

N–17862

Install the cam ring (Item 1) [C] on the rear housing and C
align the mounting bolt holes.

N–17863

Install the two cam ring mounting bolts (Item 1I [D] and D
tighten to 50 ft.–lbs. (67,8 Nm) torque. 2

N–17860

863, 863H Bobcat Loader

Revised Feb.
17099
of 570 –3–34– Service Manual
HYDROSTATIC MOTOR (S/N 514427762 & Above;
514525304 & Above; 514625302 & Above) (Cont’d) A
Assembly (Cont’d)
Install the piston/roller section (Item 1) [D] in the motor.
Install the motor on the loader and tighten the mount bolts
to 110 ft.–lbs. (149,2 Nm) torque.
NOTE: Before operating the hydrostatic motor, make
sure it is full of oil. There are several methods
to fill the motor with oil; (1) with the case drain
hose disconnected, fill the motor with oil
through the case drain port; (2) with the case
drain hose disconnected, BICS™ brake
locked, engine running, stroke the steering N–17861
lever until oil comes out of the case drain port.

863, 863H Bobcat Loader

Revised
171 of Feb.
570 99 –3–35– Service Manual
HYDROSTATIC MOTOR (S/N 514427761 & Below;
514525303 & Below; 514625301 & Below) A
Removal And Installation
2

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. N–17373
I–2003–0888

B 1 1

1 1

1
1
1 1
P–05407

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved C
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

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

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 tire/wheel assembly.
P–05408
Remove the motor cover.

Mark the hoses for correct installation.

D
Disconnect the case drain hose (Item 1) [A].
Disconnect the high pressure hoses (Item 2) [A].

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

Remove the first motor section (Item 1) [C].

Remove the outer ring section (Item 1) [D].

P–05403

863, 863H Bobcat Loader

Revised Feb.
17299
of 570 –3–36– Service Manual
HYDROSTATIC MOTOR (S/N 514427761 & Below;
514525303 & Below; 514625301 & Below) (Cont’d) A
Removal And Installation (Cont’d)
Remove the piston/roller section (Item 1) [A].
To remove the motor carrier. (See Page 3–43.)
1

P–05405

Installation: .
B
NOTE: In early model loaders install two slotted studs 1
for easier Removal And Installation of the
motor sections.
On later model loaders the cam ring (Item 1) [B] is bolted
to the rear cover using two shorter length bolts (Item 1) [C]

Dealer Copy -- Not for Resale

Tighten to 85–96 ft.–lbs. (115–130 Nm) torque.

N–17148

C
Install the piston/roller section (Item 1) [D] in the motor.
Install the motor on the loader and tighten the mount bolts
to 85–96 ft.–lbs. (115–130Nm) torque.
NOTE: Before operating the hydrostatic motor, make 1
sure it is full of oil. There are several methods
to fill the motor with oil; (1) with the case drain
hose disconnected, fill the motor with oil
through the case drain port; (2) with the case
drain hose disconnected, BICS™ brake 1
locked, engine running, stroke the steering
lever until oil comes out of the case drain port.
N–17091

D
1

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

N–17147

863, 863H Bobcat Loader

Revised
173 of Feb.
570 99 –3–37– Service Manual
HYDROSTATIC MOTOR (S/N 514427761 & Below; 514525303 & Below; 514625301 & Below) (Cont’d)
Parts Identification

12
11
10
9

7 1
6 3 2

4 5
1 2 3 8

13
14
15 19
16
17 18
21
20

32

23
31 22
30

26
27
24
25
28
29
C–03374

Ref. Description Ref. Description

1. PLUG 17. SNAP RING
2. O–RING 18. ORIFICE
3. SPRING 19. BOLT
4. WASHER 20. O–RING
5. PISTON 21. PLUG
6. DISTRIBUTOR 22. O–RING
7. SPRING 23. PLUG
8. WASHER 24. PLUG
9. O–RING 25. O–RING
10. SEAL 26. REAR HOUSING
11. SEAL 27. O–RING
12. SEAL 28. CAM
13. PLUG 29. BLOCK
14. O–RING 30. PISTON
15. SPRING 31. RING
16. POPPET 32. ROLLER

863, 863H Bobcat Loader

Revised Feb.
17499
of 570 –3–38– Service Manual
HYDROSTATIC MOTOR (S/N 514427761 & Below;
514525303 & Below; 514625301 & Below) (Cont’d) A
Disassembly

1 2 3

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. P–05751
I–2003–0888

Remove the plug (Item 1) [A], spring (Item 2) [A] and

poppet (Item 3) [A].
B
Remove the O–ring from the plug.
Remove the end plug (Item 1) [B] from the housing.
Remove the O–ring from the plug.

Dealer Copy -- Not for Resale

1
P–05755
Use a brass drift and remove the distributor (Item 1) [C]
from the housing.
Remove the three seals (Item 2) [C] and O–ring (Item 3) [C]
C
from the housing.
1
2

N–17475
Remove the plug (Item 1) [D], spring (Item 2) [D], washer
(Item 3) [D] and piston (Item 4) [D] from the distributor.
Remove the O–ring from the plug.
D

1 2 3

4
P–05750

863, 863H Bobcat Loader

Revised
175 of Feb.
570 99 –3–39– Service Manual
HYDROSTATIC MOTOR (S/N 514427761 & Below;
514525303 & Below; 514625301 & Below) (Cont’d) A
Disassembly (Cont’d)
Remove the plug (Item 1) [A], spring (Item 2) [A] and
shuttle washer (Item 3) [A] from the other end of the
distributor.
Remove the nine springs (Item 4) [A]
2
1
Remove the O–ring from the plug.
4

3
N–17370

B
Apply low air pressure to each port in the cylinder block to
remove the roller (Item 1) [B] and piston/ring assembly
(Item 2) [B]. 2
NOTE: Put all the roller/piston assembly back in their 1
original position.

P–05755

Inspection
Clean all parts in clean solvent and use air pressure to dry
C
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 distributor surface for scratches [C].

P–05754

Check the cam ring inside surface for wear and scratches
[D]. D

P–05753

863, 863H Bobcat Loader

Revised Feb.
17699
of 570 –3–40– Service Manual
HYDROSTATIC MOTOR (S/N 514427761 & Below;
514525303 & Below; 514625301 & Below) (Cont’d) A
Inspection (Cont’d)
Check the cylinder block surface for scratches [A].
Check all the roller/piston assembly for scratches and wear
[A].
Replace the parts as needed.
Assembly

P–05759

When repairing hydrostatic and hydraulic

B
systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and 2
ports to keep dirt out. Dirt can quickly damage 1
the system.
I–2003–0888

Dealer Copy -- Not for Resale

NOTE: Always use new O–rings and seals when
assembling the hydrostatic motor.
Install the roller (Item 1) [B] in the piston (Item 2) [B].
Dip the roller/piston assembly into oil and install into the
bore in the cylinder. P–05765

Repeat for each roller/piston assembly.

Put grease on the springs (Item 1) [C] to hold them in place. C
Install the springs (Item 1) [C] into the distributor (Item 2)
[C].
Install the washer (Item 3) [C] spring (Item 4) [C] and plug
(Item 5) [C]. 2
4
Tighten the plug to 60–65 ft.–lbs. (80–90 Nm) torque. 5

3
N–17370

Install the piston (Item 1) [D], washer (Item 2) [D], spring

(Item 3) [D] and plug (Item 4) [D].
D
Tighten the plug to 60–65 ft.–lbs. (80–90 Nm) torque.

4 3 2

1
P–05750

863, 863H Bobcat Loader

Revised
177 of Feb.
570 99 –3–41– Service Manual
HYDROSTATIC MOTOR (S/N 514427761 & Below;
514525303 & Below; 514625301 & Below) (Cont’d) A
Assembly (Cont’d) 2
Install the O–ring (Item 1) [A] into the housing.
1
Install the three seals (Item 2) [A] into the housing with
minimum distortion.
Lightly smear grease over the seals and O–ring.

P–05757

Install the stop pin (Item 1) [B] (if it was removed) and
tighten to 7–9 ft.–lbs. (10–12 Nm) torque. B
Install the distributor (Item 2) [B] into the housing.
Align the distributor hole (Item 3) [B] with the stop pin (Item 2 3
1) [B]. When aligned correctly, the distributor can be
depressed slightly.

N–17475

Install the plug (Item 1) [C] and tighten to 60–65 ft.–lbs. C

(80–90 Nm) torque.

1
P–05755

Install the poppet (Item 1) [D] and spring (Item 2) [D]. D

Install the plug (Item 3) [D] and tighten to 37–44 ft.–lbs.
(50–60 Nm) torque.
See Page 3–26 to install the hydrostatic motor into the 3 1
motor carrier. 2

P–05751

863, 863H Bobcat Loader

Revised Feb.
17899
of 570 –3–42– Service Manual
MOTOR CARRIER
Removal And Installation
A
Lift and block the loader. (See Page 1–1.)
Raise the lift arm and install an approved lift arm support 1
device. (See Page 1–1.) 1
Raise the operator cab. (See Page 1–1.)
Remove the fluid from the chaincase. (See Page 4–1.)
Remove the front axle. (See Page 4–1.)
If the motor carrier is removed from the right side, remove
the lift arm by–pass control valve, (See Page 2–1.) and P–05467
remove the hydraulic control valve. (See Page 2–1.)
Remove the six mounting bolts (Item 1) [A] from the carrier.
B
Installation: Tighten the mounting bolts to 330 ft.–lbs.
(447 Nm) torque.
1
Slide the motor carrier toward the rear and remove the rear
drive chain.
NOTE: For easier access for the motor carrier coming
out and going into the chaincase, tie the front

Dealer Copy -- Not for Resale

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–05489

863, 863H Bobcat Loader

Revised
179 of Feb.
570 99 –3–43– Service Manual
MOTOR CARRIER (Cont’d)
Parts Identification

1
2
3

5
5
6
7

TS–01227

Ref. Description
1. SHAFT
2. BEARING
3. RACE
4. HOUSING
5. SEAL (2)
6. RACE
7. BEARING
8. SNAP RING

863, 863H Bobcat Loader

Revised Feb.
18099
of 570 –3–44– Service Manual
MOTOR CARRIER (Cont’d)
Disassembly
A
Remove the large O–ring from the groove (Item 1) [A] in the
housing.

P–05760

Put the motor carrier in a hydraulic press [B].

Put a small amount of pressure on the shaft to release the B
pre–load on the snap ring.

Dealer Copy -- Not for Resale

P–05768

Remove the snap ring (Item 1) [C] and washer from the
shaft. C

P–05756

863, 863H Bobcat Loader

Revised
181 of Feb.
570 99 –3–45– Service Manual
MOTOR CARRIER (Cont’d)
Disassembly (Cont’d)
A
Use a hydraulic press, remove the shaft from the housing
[A].

P–05766

Install the bearing puller tool under the bearing flange, use
the hydraulic press to remove the bearing from the shaft B
[B].

P–05761

Remove the two seals (Item 1) [C] from the housing.

C
Check the bearing cup (Item 2) [C] (both sides) and replace
as needed.
1 2

P–05763

863, 863H Bobcat Loader

Revised Feb.
18299
of 570 –3–46– Service Manual
MOTOR CARRIER (Cont’d)
Assembly
A
2
The tool listed will be needed to the following procedure:
MEL1431 – Seal Driver Tool
1
Install the first seal (Item 1) [A] into the housing with the
seal lip facing away from you.
Use the tool (Item 2) [A] as shown in the figure.

P–05764

Install the second seal (Item 1) [B] into the housing with the
seal lip facing toward you. B 2
Use the tool (Item 2) [B] as shown in the figure.

Dealer Copy -- Not for Resale

P–05762

Install the bearing on the shaft [C].

C
Use a pipe (Item 1) [C] with O.D. that seats on the I.D. of
the bearing.

P–05767

863, 863H Bobcat Loader

Revised
183 of Feb.
570 99 –3–47– Service Manual
MOTOR CARRIER (Cont’d)
Assembly (Cont’d)
A
Install the shaft/bearing assembly into the housing.
Install the bearing (Item 1) [A] using the tool (Item 2) [A]
(MEL1431).
After the bearing is seated. Install the washer and snap ring
on the shaft.
It may be necessary to use the tool to push the washer and
2
snap ring down into position because of the pre–load on the
bearings.

P–05769

863, 863H Bobcat Loader

Revised Feb.
18499
of 570 –3–48– Service Manual
HYDROSTATIC PUMP (M46)
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

Dealer Copy -- Not for Resale

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
185 of Feb.
570 99 –3–49– Service Manual
HYDROSTATIC PUMP (M46) (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 Feb.
18699
of 570 –3–50– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Replenishing/High Pressure Relief Valve
A 1

M46 Pump
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
N–17149

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

Dealer Copy -- Not for Resale

1
2

N–17162

Charge Pressure Relief Valve

C 1
Loosen the charge pressure relief valve plug (Item 1) [C].

N–17160

Remove the plug, spring, and poppet.

D 1
There are several different thicknesses of shims (Item 1)
[D] and they are used to adjust the charge pressure.

N–17161

863, 863H Bobcat Loader

Revised
187 of Feb.
570 99 –3–51– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Parts Identification (Right Half)

1 2

3 37
8 36
9
10 35
2 5
34
33
7 32
9 31
11
12 30
13 29
28 41
27 40
15 26 39
25

17 24 38
14
23
18 22 42
21
16 20
19
71
72 43
73
70 58
60
44
63 62
57
66 59 54
61
67 53
64 56 55 45
69 65
52
68
51 46

47
50 48
49

B–15138

863, 863H Bobcat Loader

Revised Feb.
18899
of 570 –3–52– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Parts Identification (Right Half) (Cont’d)

Ref. Description Ref. Description

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

863, 863H Bobcat Loader

Revised
189 of Feb.
570 99 –3–53– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Parts Identification (Left Half) (Cont’d)

89

88
87
86
85
84
58 72 83

60 59
71 82
70 73 81
74 80
61 69 75
55 76 79
62 68
53 63 67 77
51 66 64
65 78
57
56
21
54
52 20
50 19

49 18 16
46
15
45
48 22
47
17
23
44
29
24
43 30 28
31 25
27 26
36 34
38 37
32 13
33
41
35 9
39 8 7
14 6 5

42 12
40
3 4
10 8 3 1
11 7

5
2
1

B–15137

863, 863H Bobcat Loader

Revised Feb.
19099
of 570 –3–54– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Parts Identification (Left Half) (Cont’d)
Ref. Description Ref. Description
1. SNAP RING 45 ADAPTER
2. SEAL 46 SEAL
3 SNAP RING 47 PLUG
4 BEARING 48 ORIFICE
5 BOLT 49 PLUG
6 COVER 50 COUPLER
7 JOURNAL BEARINGS 51 PIN
8 PIN 52 GEROTOR
9 SWASH PLATE 53 PIN
10 PIN 54 COVER
11 SLEEVE 55 O–RING
12 PIN 56 O–RING
13 KEY 57 O–RING
14 SHAFT 58 VALVE
15 ROTATING PIECE 59 RING
16 VALVE PLATE 60 O–RING
17 PIN 61 PLUG
18 BEARING 62 O–RING
19 GASKET 63 RELIEF VALVE
20 PIN 64 PLUG
21 HOUSING 65 NUT
22 PLUG 66 NUT
23 GASKET 67 SNAP RING
24 SERVO COVER 68 GUIDE
25 NUT 69 STOP
26 PLUG 70 SPRING
27 PLUG 71 GUIDE
28 O–RING 72 SCREW
29 RELIEF VALVE 73 PLUG
30 SLEEVE 74 O–RING
31 O–RING 75 SHIM
32 BACK–UP RING 76 SPRING
33 SPOOL 77 VALVE
34 O–RING 78 BOLT
35 BACK–UP RING 79 SEAL
36 SPRING GUIDE 80 O–RING
37 SPRING 81 RING
38 BRACKET 82 PISTON
39 BOLT 83 RING
40 HANDLE 84 O–RING
41 WASHER 85 SEAL
42 NUT 86 GASKET
43 BOLT 87 COVER
44 PLUG 88 BOLT
89 PLUG

863, 863H Bobcat Loader

Revised
191 of Feb.
570 99 –3–55– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Hydraulic Pump Removal
A
1

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. 1
I–2003–0888 N–17151

Remove the two hydraulic pump mounting bolts (Item 1)

[A&B] from both sides of the Hi–Flow hydraulic pump, or
from the standard hydraulic pump.
B 1

1
N–17152

Remove the hydraulic pump and gasket (Item 1) [C] from

the hydrostatic pump. C
1

Hydrostatic Pump Separation N–17153

Remove the mounting bolt (Item 1) [D] from both sides of

the pump assembly. D 1

2
Remove the nut and lift bracket (Item 2) [D] from the pump
assembly.

N–17154

863, 863H Bobcat Loader

Revised Feb.
19299
of 570 –3–56– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Hydrostatic Pump Separation (Cont’d)
A
Separate the two pumps [A].

N–17155

Charge Pump Disassembly

Remove the large O–ring (Item 1) [B] from the pump. B
Remove the two O–rings (Items 2&3) [B] from the gerotor 2
cover.

Dealer Copy -- Not for Resale

1

N–17156

Remove the gerotor pump assembly and splined coupler

from the pump [C]. C
NOTE: The location of the pin (Item 1) [C] must be
installed in the bottom hole in the pump
housing to allow for proper pump rotation

N–17157

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

D

N–17158

863, 863H Bobcat Loader

Revised
193 of Feb.
570 99 –3–57– Service Manual
HYDROSTATIC PUMP (M46) (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.

N–17159

Disassembly
B
1

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 2
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888
N–17160
Use the following procedure to disassemble the hydrostatic
pumps.
NOTE: Keep individual pump parts separate during C 1
disassembly and assembly.
Remove the charge pressure relief valve (Item 1) [B] from
the pump. 4

NOTE: The charge pressure relief valve is only

located in the shaft end hydrostatic pump.
2
Remove the plug (Item 1) [C], shims (Item 3) [C] (if 3
equipped), spring (Item 4) [C] and charge pressure relief
valve (Item 5) [C], check for wear and replace if necessary.
5
Remove the O–ring (Item 2) [C] from the plug, check for
wear and replace if necessary.
N–17161
NOTE: The by–pass valve (Item 2) [B] is a
non–functional valve. It is located in the shaft
end hydrostatic pump only. If the valve is
removed, it must be tightened securely during D
assembly to prevent a hydraulic leak. 1
Remove the three mounting bolts (Item 1) [D] from the
adapter housing of the shaft end pump only.

N–17163

863, 863H Bobcat Loader

Revised Feb.
19499
of 570 –3–58– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Disassembly (Cont’d)
A
Remove the adapter housing (Item 1) [A] and O–ring plate
1
(Item 2) [A].

N–17164

Mark the position of the neutral bracket (Item 1) [B] for

reference during assembly.
B
NOTE: Removal of any part of the mechanical control 2
will result in the loss of the neutral setting and 3
will require neutral adjustment. Refer to Page
3–81 for the correct neutral adjustment 1
procedure. The neutral adjustment procedure
must be performed with the pump installed
and engine running. 2

Dealer Copy -- Not for Resale

Remove the two mounting bolts (Item 2) [B].
Remove the control lever spool assembly (Item 3) [B].
1
N–17165

Remove the plug (Item 1) [C] at the control inlet orifice port.
C

N–17166

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

contamination, clean and replace. D

P–13689

863, 863H Bobcat Loader

Revised
195 of Feb.
570 99 –3–59– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Disassembly (Cont’d)
A
1
Remove the nut (Item 1) [A] lock washer (Item 2) [A] from
the control spool.

N–17167

Remove the control lever (Item 1) [B] neutral bracket (Item

2) [B] centering spring (Item 3) [B]. B 2 3

N–17168

Remove the spring guide (Item 1) [C].from the control

spool (Item 2) [C]. C
2
1

N–17169

Remove the control sleeve (Item 1) [D] from the pump

housing. D

N–17166

863, 863H Bobcat Loader

Revised Feb.
19699
of 570 –3–60– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Disassembly (Cont’d)
A 1

Remove the seven mounting bolts (Item 1) [A] from the

pump end housing.
1 1

N–17171

Remove the pump end housing with the shaft assembly

[B]. B
Remove the swashplate journal bearings (Item 1) [B] from
the end housing.
1

Dealer Copy -- Not for Resale

N–17173

Remove the snap ring (Item 1) [C] at the seal.

C

N–17174

Drill two small holes in the seal (Item 1) [D] and install a seal
puller and remove the seal. D
NOTE: Be careful not to damage the bearing behind
the seal. 1

N–17175

863, 863H Bobcat Loader

Revised
197 of Feb.
570 99 –3–61– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Disassembly (Cont’d)
A 1
Remove the snap ring (Item 1) [A] from the end pump
housing.

N–17176

Remove the shaft and bearing assembly from the end

housing. B
Remove the snap ring (Item 1) [B] from the shaft and
remove the bearing.
1
Check the bearing and replace as needed.

N–17177

Remove the gasket (Item 1) [C] from the pump.

C 1
Remove the swashplate (Item 2) [C] from the pump
housing. 2

N–17179

Remove the piston assembly (Item 1) [D] from the pump

housing. D
1

N–17180

863, 863H Bobcat Loader

Revised Feb.
19899
of 570 –3–62– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Disassembly (Cont’d)
A
1
Remove the piston block assembly (Item 1) [A] from the
pump housing.

N–17181

Remove the valve plate (Item 1) [B] from the pump

housing. B
1

Dealer Copy -- Not for Resale

N–17182

Remove the five mount bolts (Item 1) [C] from the servo
cover end cap, and remove the end cap. C
1
1

1
1

1
N–17208

Remove the end cap gasket (Item 1) [D]

D

N–17209

863, 863H Bobcat Loader

Revised
199 of Feb.
570 99 –3–63– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Disassembly (Cont’d)
A
Measure and record the distance between the servo piston
and the housing [A].

N–17210

While holding the centering screw (Item 1) [B] stationary,

remove the neutral adjustment lock nut (Item 2) [B]. B
Remove the five mounting bolts (Item 3) [B] from the end
3
cap.
3 2
1
3

3
N–17211

Turn the end cap off the centering screw. Remove the end
cap and gasket [C]. C

N–17212

Push the end of the servo piston past the edge of the pump
housing [D].
D
1
Remove the fiber seal (Item 1) [D] from the piston.

N–17214

863, 863H Bobcat Loader

Revised Feb.
20099
of 570 –3–64– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Disassembly (Cont’d)
A
Remove the servo piston from the pump housing [A].

N–17213

Remove the O–ring (Item 1) [B] from the servo piston.

B 1
Remove the bearing ring (Item 2) [B] from the servo piston.

Dealer Copy -- Not for Resale

2

N–17565

Remove the seal and O–ring and bearing ring from the
centering screw end of the servo piston [C]. C

N–17216
If it is necessary to disassemble the piston, use the
following procedure:
While holding the centering screw, loosen the jam nut (Item
D
1) [D]. Tighten the nut at the piston (Item 2) [D] to release
the spring tension on the snap ring.
2

N–17215

863, 863H Bobcat Loader

Revised
201 of Feb.
570 99 –3–65– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Disassembly (Cont’d)
A
Remove the snap ring and centering spring assembly from
the servo piston [A].

CD–00106

Disassemble the centering spring assembly as shown in

[B]. B
Remove the lock nut (Item1), nut (Item 2), short spring
guide (Item 3), spring (Item 4), stop (Item 5) and long spring 1 3 4 5 6
guide (Item 6) from the centering screw (Item 7).

7
2

CD–00105

863, 863H Bobcat Loader

Revised Feb.
20299
of 570 –3–66– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Inspection
A 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. 1

Check the two bearing locater pins (Item 1) [A] in the end
housing. The pins must measure 0.0625–0.080 inch
(1,65–2,03 mm) from the end housing surface to the end
of the pins.

CD–00098

Check the shafts for wear or damage in the splined and

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

Dealer Copy -- Not for Resale

CC–00110

Check the needle bearing (Item 1) [C] in the pump housing

for proper operation. C 2
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 1
housing. When installed correctly, the end of the bearing
must measure 0.08–0.10 inch (2,0–2,5mm) above the
machined housing surface.
Check the locating spring pin (Item 2) [C].
The pin must measure 0.165–0.185 inch (4,19–4,70 mm)
from the housing to the end of the pin.

N–17183

Check the swashplate (Item 1) [D] and the pistons (Item 2)

[D]. D 2
1
The surface finish must be smooth and free of scratches.
If scratches can be felt with a fingernail, replace the parts.

N–17203

863, 863H Bobcat Loader

Revised
203 of Feb.
570 99 –3–67– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Inspection (Cont’d)
A 1
Check the end of the piston block (Item 1) [A] and the
surface of the valve plate (Item 2) [A]. The surfaces must
be smooth and free of scratches.
2

N–17207

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

B 1
Remove the slipper guide and piston assembly (Item 1) [B]
from the cylinder block.

Check each piston and the slipper guide for wear or

scratches.
Check the slipper guide. The slipper guide must be flat with
no sign of cracks or wear.

N–17204

Check the ball guide retainer (Item 1) [C] for wear or

damage. C 1

N–17205

Check the three slipper pins (Item 1) [D].

D 1
Check the seven cylinder bores in the piston block for wear 1
or scratches.

N–17206

863, 863H Bobcat Loader

Revised Feb.
20499
of 570 –3–68– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Inspection (Cont’d)
A
Check the control lever parts for wear and replace as
needed [A].

N–17168

Check the spring guide (Item 1) [B] for wear and replace
as needed. B
Check the control spool O–ring (Item 2) [B] and back–up 3
1
washer (Item 3) [B] for wear and replace as needed.

Dealer Copy -- Not for Resale

N–17169

Check the control sleeve O–ring (Item 1) [C] and back–up

washer (Item 2) [C] for wear and replace as needed. C
Check the notch (Item 3) [C] on the end of the control 3
sleeve for wear and replace if worn. 1
2

N–17221

Check and replace the spring pin (Item 1) [D] if worn.

D
Check the guide pin (Item 2) [D] and guide (Item 3) [D] for 3
wear and replace as needed.

1
N–17184

863, 863H Bobcat Loader

Revised
205 of Feb.
570 99 –3–69– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Inspection (Cont’d)
A
Check the fit between the control sleeve (Item 1) [A] and
the swashplate spring pin (Item 2) [A]. This must be an
interference fit and if it is to loose, replace the spring pin and 1
control sleeve.
2

P–13690

Assembly
If the guide pin has to be replaced, be sure to install the pin B
with the split toward the center of the swashplate [B]. The
spring pin must measure 0.33–0.50 inch (8,4–8,9 mm)
from the swashplate to the end of the pin (Item 1) [B].

P–13692

Apply oil and install the guide on the swashplate with the
guide offset (Item 1) [C] positioned toward the swashplate. C
1

P–13691
Be sure there is clearance between the guide and the
spring pin (Item 1) [D].
D

N–17202

863, 863H Bobcat Loader

Revised Feb.
20699
of 570 –3–70– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Assembly (Cont’d)
A
2
Install the spring guide (Item 1) [A] on the control spool 1
(Item 2) [A].

N–17169

Install the centering spring (Item 1) [B], neutral bracket

(Item 2) [B], and control lever (Item 3) [B] onto the control B 2 1
spool.
3

Dealer Copy -- Not for Resale

N–17168

NOTE: When assembling the control spool and

centering assembly be sure the notch (Item 1) C
[C], at the thread end of the control spool, is 1
located toward the outer end of the hydrostatic
pump.

P–13688

Install the lockwasher (Item 1) [D] and nut (Item 2) [D] and
tighten to 10–12 ft.–lbs. (13,6–16,3 Nm) torque. D
2

N–17167

863, 863H Bobcat Loader

Revised
207 of Feb.
570 99 –3–71– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Assembly (Cont’d)
A 2
1 2
Install the slipper guide retainer (Item 1) [A] and the three
slipper holddown pins (Item 2) [A].

N–17206

Install the ball guide retainer (Item 1) [B].

B
1

N–17205

Apply a light coating of oil and install the slipper guide and
piston assembly (Item 1) [C] into the cylinder block.
C 1

N–17204

If disassembled, assemble the centering spring assembly

as shown in [D]. D
Apply oil to and install the long spring guide (Item 1) [D],
stop (Item 2) [D], spring (Item 3) [D], short spring guide 4 3 1
(Item 4) [D], nut (Item 5) [D], and lock nut (Item 6) [D] onto 6 2
the center screw (Item 7) [D].

7
5

CD–00105

863, 863H Bobcat Loader

Revised Feb.
20899
of 570 –3–72– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Assembly (Cont’d)
A
Hold the centering screw (Item 1) [A] from turning and
tighten the nut (Item 2) [A] to compress the spring.
2
Install the centering spring and snap ring into the piston [A]. 1

CD–00106

To seat the snap ring, loosen the nut until the centering
screw is loose [B]. B
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 [B]. 1
NOTE: It will be impossible to set the pump neutral
position if there is any free play between the

Dealer Copy -- Not for Resale

piston and spring assembly or between the
spring assembly and centering screw.
While holding the nut, tighten the jam nut (Item 1) [B] to
18–27 ft.–lbs. (24–37 Nm) torque.
N–17215

Apply oil and install the bearing rings (Item 1) [C], O–rings
(Item 2) [C]. C
2
1

1
2

N–17216

Apply oil and install the fiber seal (Item 1) [D] over the
O–ring, only to the adjustment end of the servo piston at
D
this time.
1
Apply a light coat of oil to the servo piston seats.

N–17217

863, 863H Bobcat Loader

Revised
209 of Feb.
570 99 –3–73– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Assembly (Cont’d)
A
Install the servo piston into the pump housing as shown in
[A].
NOTE: Install the servo piston in the pump so the
centering screw is toward the front of the
pump for ease of neutral adjustment.

N–17213

Push the end of the servo piston past the opposite edge of
the pump housing as shown in [B]. B 1
Install the fiber seal (Item 1) [B] over the O–ring, on the
servo piston.

Apply a light coat of oil to the fiber seal and center the servo
piston in the pump housing.

N–17214

Install the gasket and end cap, and turn the end cap on the
centering screw [C]. C

N–17212

Center the piston using the measurement recorded during

disassembly [D].
D
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.
(See Page 3–81 for proper neutral adjustment.)

N–17210

863, 863H Bobcat Loader

Revised Feb.
21099
of 570 –3–74– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Assembly (Cont’d)
A
1
Install the five mounting bolts (Item 1) [A] into the end cap
and tighten to 10–13 ft.–lbs. (14–18 Nm) torque.
1 2
Hold the centering screw stationary tighten the neutral
adjustment lock nut (Item 2) [A].
1

1 N–17211

Install a new gasket and end cap [B] to the opposite end
of the servo. Install the five end cap mounting bolts (Item
1) [B] and tighten to 10–13 ft.–lbs. (14–18 Nm) torque. B 1
1

1 1

Dealer Copy -- Not for Resale

1
N–17208

Apply oil to the valve plate. Install the valve plate, bronze
side up, into the housing [C].
C 1

N–17182
The notch (Item 1) [D] in the valve plate must engage the
locating spring pin (Item 1) [C] in the housing.
863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.) – Hydostatic System Section Part 3 of 5
D 1

P–13687

863, 863H Bobcat Loader

Revised
211 of Feb.
570 99 –3–75– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Assembly (Cont’d)
A
Apply oil to all parts and surfaces in the rotating group.
Using a snap ring pliers, lower the rotating group into the
housing [A].

N–17180

Install the swashplate into the housing [B].

Adjust the swashplate so that the guide (Item 1) [B] B
engages the piston.
Center the rotating group and swashplate over the needle
bearing.
Check that the ball guide retainer is on top of the three
slipper pins.

N–17179

Install the bearing on the pump shaft and install the snap
ring (Item 1) [C].
C

N–17177

Install the bearing, shaft assembly into the end housing [D].
D 1
Install the snap ring (Item 1) [D].

N–17176

863, 863H Bobcat Loader

Revised Feb.
21299
of 570
–3–76– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Assembly (Cont’d)
A
Install a new seal into the face plate. Install the snap ring
(Item 1) [A].
1

N–17174

Apply oil to both journal bearings. Install the journal

bearings (Item 1) [B] on the end housing.
B
Check that the journal bearings are seated on the bearing
locater pins.
NOTE: Petroleum jelly can be applied between the 1
journal bearings and end housing to retain the
journal bearings during installation on the
pump.

Dealer Copy -- Not for Resale

N–17173

Install a new gasket. Carefully install the end housing and

shaft assembly [C]. C
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 [C].

N–17219

Install the seven end housing bolts (Item 1) [D].

Evenly tighten the seven mounting bolts to 60–74 ft.–lbs.
D 1
(81–100 Nm) torque.
Rotate the shaft periodically while tightening the bolts to
assure the correct pump assembly. When fully assembled 1 1
a torque of 4–8 ft.–lbs. (5,4–10,8 Nm) will be required to
turn the shaft.

N–17171

213 of 570
863, 863H Bobcat Loader
Revised Feb. 99 –3–77– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Assembly (Cont’d)
A 2

Apply petroleum jelly to a new O–ring and back–up washer. 1

Install the O–ring (Item 1) [D] and back–up washer (Item
2) [A] on the control sleeve.
Apply oil to the control sleeve. Install the sleeve into the 3
housing [A].
The notch (Item 3) [A] in the control sleeve must be
installed toward the end housing and engage the spring pin
on the swashplate.

N–17220

Install the screened orifice and plug (Item 1) [B] at the inlet
orifice and tighten to 8–12 ft.–lbs. (10,8–16,3 Nm) torque.
B

N–17166

Apply oil to the spool. Install the control lever and spool
assembly into the housing [C]. C
NOTE: Be sure the notch (Item 3) [A] in the servo 2
1
spool faces toward the servo piston during
assembly.
Align the neutral bracket with the reference marks (Item 1) 2
[B] made during disassembly. Install the flange head
screws (Item 2) [B] and tighten to 15–20 ft.–lbs. (20–27
Nm) torque.
NOTE: Removal of any part of the mechanical control
will result in the loss of the neutral setting and 1
will require neutral adjustment. Refer to Page
3–81 for the correct neutral adjustment
procedure. The neutral adjustment procedure N–17165
must be performed with the pump installed
and engine running.
Apply oil to the molded O–ring plate (Item 1) [D] and install D
the adapter housing (Item 2) [D].
2
Evenly tighten the three mounting bolts to 16–21 ft.–lbs.
(22–28 Nm) torque.

N–17164

863, 863H Bobcat Loader

Revised Feb.
21499
of 570
–3–78– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Charge Pump Assembly
A
Apply oil to the gerotor assembly and gerotor cover. Install
the gerotor assembly into the gerotor cover [A].

N–17159

Apply oil to the splined coupler (Item 1) [B] and drive pin
(Item 2) [B].
B
Install the splined coupler and drive pin into the gerotor
assembly.

The drive pin must be engaged in the gerotor slot (Item 3)

[B].
1
3

Dealer Copy -- Not for Resale

2

N–17158

Install the gerotor assembly into the pump [C].

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

N–17157

Apply petroleum jelly to the three new O–rings and install

the O–rings (Item 1) [D] on the gerotor cover. D
Apply petroleum jelly to the two small O–rings on the pump
face (Item 2) [D]. 2

2
1
N–17156

215 of 570
863, 863H Bobcat Loader
Revised Feb. 99 –3–79– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Hydrostatic Pump Connection
A
Connect the two hydrostatic pumps [A].

N–17155

Install the lift bracket and nut (Item 1) [B].

Install a bolt on each side of the pump (Item 2) [B]. B 1
Evenly tighten the two bolts and the nut to 67–82 ft.–lbs.
(91–111 Nm) torque.
Rotate the tandem pump input shaft to check for proper
assembly.

N–17154

Hydraulic Pump Installation

Install a new gasket (Item 1) [C] and install the hydraulic C
pump assembly.
Install the two mount bolts and tighten to 25–27 ft.–lbs. 1
(34–37 Nm) torque.

N–17153

863, 863H Bobcat Loader

Revised Feb.
21699
of 570
–3–80– Service Manual
HYDROSTATIC PUMP (M46) (Cont’d)
Swashplate Neutral Adjustment
A
After the hydrostatic pump has been rebuilt, the neutral for 1
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
Disconnect the linkage (Item 1) [A] from the displacement
control servo. 1
Remove the plug (Item 2) [A] from both sides of the
swashplate servo end cap.

Dealer Copy -- Not for Resale

Connect a hose (Item 1) [B] between the two ports.
Loosen the servo lock nut (Item 3) [A] while holding the
servo adjustment screw in position.
Start the engine. WHEN THE ENGINE IS RUNNING THE P–13495
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.
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 servo. (See Page 3–82.)

217 of 570
863, 863H Bobcat Loader
Revised Feb. 99 –3–81– Service Manual
HYDROSTATIC PUMP (M46) (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

The following tool will be needed to do the following

P–13474
procedure:
MEL1429A – Remote Start Switch
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.) 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. Mark 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 neutral adjustment bracket between the two
marks and tighten the holddown 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
3–16.)

863, 863H Bobcat Loader

Revised Feb.
21899
of 570
–3–82– Service Manual
 219 of 570
863, 863H Bobcat Loader
Revised Feb. 99 –3–83– Service Manual
HYDROSTATIC PUMP (M44)
Parts Identification (Right Half)

5
8 4
7 3
6

2
9 1

13 14
10
15

11 12
17

19
21
16
18
23
20
25
27
22
29 24
26

28

38
30 33
36
34 32
31
37
35
46
47 48
40 45
42
39 44

49
41

43

D–02427

863, 863H Bobcat Loader

Revised Feb.
22099
of 570
–3–84– Service Manual
HYDROSTATIC PUMP (M44) (Cont’d)
Parts Identification (Right Half) (Cont’d)

Ref. Description Ref. Description

1. BOLT 26 RETAINER
2 END CAP 27 RETAINER
3 PLUG 28 PISTON ASSEMBLY
4 O–RING 29 PLATE
5 PLUG 30 SWASHPLATE
6 O–RING 31 PIN
7 O–RING 32 HOUSING
8 RELIEF VALVE 33 PLUG
9 BOLT 34 BEARING
10 GASKET 35 SEAL
11 BEARING 36 O–RING
12 PLUG 37 COVER
13 O–RING 38 BOLT
14 O–RING 39 SHAFT
15 RELIEF VALVE 40 SNAP RING
16 PIN 41 BEARING
17 VALVE PLATE 42 SNAP RING
18 RETAINER 43 SNAP RING
19 WASHER 44 PLUG
20 SPRING 45 O–RING
21 WASHER 46 BEARING
22 BLOCK 47 O–RING
23 RETAINER 48 PLATE
24 PIN 49 BOLT
25 WASHER

221 of 570
863, 863H Bobcat Loader
Revised Feb. 99 –3–85– Service Manual
HYDROSTATIC PUMP (M44) (Cont’d)
Parts Identification (Left Half)

4
17 6
16
8 1
11 2
14 3
13 10
5
12 7

15 9
22
23

18
19
21

20 24
26

28

30 25
32
27
34
29
36 31
38

33
35
37 47
46
39
45
44
52 43
51 48
49 42 40

50
53
54 65
41
55
58 56
60 64
61 55 54 66

57
63
59
62 D–02428

863, 863H Bobcat Loader

Revised Feb.
22299
of 570
–3–86– Service Manual
HYDROSTATIC PUMP (M44) (Cont’d)
Parts Identification (Left Half) (Cont’d)

Ref. Description Ref. Description

1. SNAP RING 34 WASHER
2 WASHER 35 SPRING
3 SEAL 36 WASHER
4 SNAP RING 37 WASHER
5 SNAP RING 38 VALVE PLATE
6 BEARING 39 PIN
7 SNAP RING 40 GASKET
8 KEY 41 BEARING
9 SHAFT 42 PLUG
10 HOUSING 43 POPPET
11 PLUG 44 SPRING
12 O–RING 45 SHIM
13 BEARING 46 O–RING
14 SEAL 47 PLUG
15 O–RING 48 PLUG
16 COVER 49 O–RING
17 BOLT 50 O–RING
18 PIN 51 O–RING
19 O–RING 52 RELIEF VALVE
20 PLUG 53 PLUG
21 BEARING 54 PIN
22 O–RING 55 O–RINGS
23 PLATE 56 PIN
24 BOLT 57 GEROTOR
25 SWASH PLATE 58 SPACER
26 WEAR PLATE 59 O–RING
27 PISTON ASSEMBLY 60 O–RING
28 PISTON RETAINER 61 PIN
29 RETAINER 62 COUPLER
30 WASHER 63 BOLT
31 PIN 64 O–RING
32 RETAINER 65 O–RING
33 BLOCK 66 RELIEF VALVE

223 of 570
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Revised Feb. 99 –3–87– Service Manual
HYDROSTATIC PUMP (M44) (Cont’d)
Replenishing/High Pressure Relief Valve
A
M44 Pump
1
There are four replenishing/high pressure relief valves
(Item 1) [A] in the hydrostatic pump. Two are located at the
top of the pump and two at the bottom of the pump.
See Page 3–4 for valve function.

N–17227

Remove the high pressure relief valve from the pump [B].
B
Check the O–rings (Items 1 & 2) [B] for damage and
replace as needed. 1
If the high pressure relief valve must be replaced, it must
be replaced as a complete unit.
The pressure setting for a new high presure relief valve is
4712 PSI (32489 kPa).

N–17228

863, 863H Bobcat Loader

Revised Feb.
22499
of 570
–3–88– Service Manual
HYDROSTATIC PUMP (M44) (Cont’d)
Charge Pressure Relief Valve
A 1

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. N–17230
I–2003–0888

Loosen the charge relief valve plug (Item 1) [A].

B

Remove the plug, spring and poppet [B].

Dealer Copy -- Not for Resale

N–17231

There are several different thickness of the shims (Item 1)

[C] and they are used to adjust the charge pressure. C
The charge pressure should be set at 420 PSI (2896 kPa).

N–17232

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Revised Feb. 99 –3–89– Service Manual
HYDROSTATIC PUMP (M44) (Cont’d)
Hydraulic Pump Removal
A 2
Remove the standard flow hydraulic pump (Item 1) [A]
from the hydrostatic pumps, by removing the two mounting
bolts (Item 2) [A].
2

1
N–17226

Remove the O–ring (Item 1) [B] and coupler (Item 2) [B]

with the hydraulic pump. B

1 2

N–17229

Remove the Hi–flow hydraulic pump (Item 1) [C] (if loader

is so equipped) from the hydrostatic pumps, by removing C 2
the two mounting bolts (Item 2) [C].

N–17223

Remove the gasket (Item 1) [D] and coupler (Item 2) [D]

with the hydraulic pump. D

N–17 356

863, 863H Bobcat Loader

Revised Feb.
22699
of 570
–3–90– Service Manual
HYDROSTATIC PUMP (M44) (Cont’d)
Hydraulic Pump Separation
A 1

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

N–17230

B 1

Dealer Copy -- Not for Resale

1

N–17233

Separate the two hydrostatic pumps [C].

C

N–17234

Charge Pump Disassembly

D 1
Remove the two O–rings (Item 1) [D] from the groves in the
gerotor spacer on the charge pump.
Remove the O–rings (Item 2) [D] from the charge pump
housing end cap. 2 2

N–17235

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Revised Feb. 99 –3–91– Service Manual
HYDROSTATIC PUMP (M44) (Cont’d)
Charge Pump Disassembly (Cont’d)
A
1
Remove the gerotor assembly (Item 1) [A] & [B] from the
charge pump.

N–17236

N–17237

Inspect the gerotor spacer (Item 1) [C] the gerotor

assembly (Item 2) [C], drive coupling (Item 3) [C] and drive
pin (Item 4) [C] for wear and replace as needed. C 1

4
N–17185

Remove the locating pin (Item 1) [D] from the pump end
cap. D 1
2
NOTE: The charge pump rotation is determined by the
position of the gerotor spacer and locating pin 2
(Item 1) [D] in the pump end cap, and must be
noted for proper installation.
Remove the four mounting bolts (Item 2) [D] from the
charge pump.

2
2

N–17186

863, 863H Bobcat Loader

Revised Feb.
22899
of 570
–3–92– Service Manual
HYDROSTATIC PUMP (M44) (Cont’d)
Disassembly
A
Mark the charge pump (Item 1) [A] case and the pump case
(Item 2) [A] for proper installation. 1
Mark the trunnion cover (Item 3) [A] and pump case for
proper installation.
2

3
N–17191

Remove the charge pump (Item 1) [B] from the hydrostatic

shaft end pump.
B

Dealer Copy -- Not for Resale

N–17192

Check the valve plate (Item 1) [C] for wear and remove
from charge pump.
C 1

N–17193
Check the valve plate locating pin (Item 1) [D] for wear and
replace if needed.
D 2
Check the needle bearing (Item 2) [D] for wear and replace 1
if needed.

N–17194

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Revised Feb. 99 –3–93– Service Manual
HYDROSTATIC PUMP (M44) (Cont’d)
Disassembly (Cont’d)
A
Remove the rotating group (Item 1) [A] from the pump. 1

N–17197

Remove the slipper guide and pistons (Item 1) [B] from the
cylinder block.
B 1
Check the pistons (Item 2) [B] for wear and replace as
needed.

N–17198

Remove the ball guide retainer (Item 1) [C] from the

cylinder block.
C 1

N–17199
Check the ball guide retainer (Item 1) [D] and washer (Item
2) [D] for wear and replace as needed.
D 3 3
Remove the four slipper holddown pins (Item 3) [B] from
the cylinder block.
Check the cylinder block for wear and replace as needed.

3 2 1
3

N–17200

863, 863H Bobcat Loader

Revised Feb.
23099
of 570
–3–94– Service Manual
HYDROSTATIC PUMP (M44) (Cont’d)
Disassembly (Cont’d)
A
Remove the thrust plate (Item 1) [A] from the pump
housing.

N–17201

Remove the driveshaft key (Item 1) [B] the snap ring (Item
2) [B] and the support washer (Item 3) [B] from the drive B
shaft end of the pump.
1

Dealer Copy -- Not for Resale

3

N–17481

Use a seal puller and remove the seal (Item 1) [C] from the
pump housing.
C
1

N–17239
Remove the snap ring (Item 1) [D] from the pump housing
and remove the driveshaft and bearing from the housing.
D

N–17240

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Revised Feb. 99 –3–95– Service Manual
HYDROSTATIC PUMP (M44) (Cont’d)
Disassembly (Cont’d)
A
Remove the snap ring (Item 1) [A] from the driveshaft and
remove the bearing.

N–17241

Check the bearing for wear and replace if worn.

B
Check the pump shaft (Item 1) [B] for wear and replace if 1
needed.

N–17242

Remove the four mount bolts (Item 1) [C] from the lower
trunnion cover. Remove the cover. C

1 1

N–17243
Remove the O–ring (Item 1) [D] and bearing race (Item 2)
[D] from the pump housing.
D
2

N–17244

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Revised Feb.
23299
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–3–96– Service Manual
HYDROSTATIC PUMP (M44) (Cont’d)
Disassembly (Cont’d)
A
Check the bearing race (Item 1) [A] and O–ring (Item 2) [A]
for wear and replace as needed.
1

N–17245

Remove the four mount bolts (Item 1) [B] from the pump
housing and remove the steering bracket (Item 2) [B]. B

Dealer Copy -- Not for Resale

1 1

N–17246

Remove the upper trunnion cover (Item 1) [C].

C

N–17247
Inspect the seal (Item 1) [D] in the upper trunnion cover and
replace if needed.
D

N–17250

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Revised Feb. 99 –3–97– Service Manual
HYDROSTATIC PUMP (M44) (Cont’d)
Disassembly (Cont’d)
A
Remove the O–ring (Item 1) [A] and bearing race (Item 2)
[C] from the pump housing.

2
N–17248

Inspect the bearing race (Item 1) [B] and O–ring (Item 2)

[D] and replace as needed. B

N–17249

Slide the swashplate from side to side and remove the

tapered roller bearing (Item 1) [C] from the swashplate
shaft. C

N–17251
Tilt the swashplate (Item 1) [D] and remove the swashplate
and lower bearing from the pump housing.
D 1

N–17252

863, 863H Bobcat Loader

Revised Feb.
23499
of 570
–3–98– Service Manual
HYDROSTATIC PUMP (M44) (Cont’d)
Assembly
A 1
Install the lower bearing (Item 1) [A] on the swashplate.

N–17253

Install the swashplate and bearing into the pump housing

[B].
B

Dealer Copy -- Not for Resale

N–17252

Install the tapered bearing (Item 1) [C] on the swashplate

shaft. C

N–17249

Install the bearing race (Item 2) [C] and O–ring (Item 3) [C]
as shown in [D]. D

N–17248

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Revised Feb. 99 –3–99– Service Manual
HYDROSTATIC PUMP (M44) (Cont’d)
Assembly (Cont’d)
A
Install the upper trunnion seal (Item 1) [A] and cover.

N–17247

Install the steering bracket (Item 1) [B] and the four

mounting bolts and tighten to 18–22 ft.–lbs. (24–30 Nm)
torque. B

N–17246

Install the bearing race (Item 1) [C] and O–ring (Item 2) [C]
at the lower trunnion as shown in [D].
C
863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.) – Hydostatic System Section Part 4 of 5

N–17245

N–17244

863, 863H Bobcat Loader

Revised Feb.
23699
of 570
–3–100– Service Manual
HYDROSTATIC PUMP (M44) (Cont’d)
Assembly (Cont’d)
A
Align the marks on the lower trunnion cover and pump
housing as shown in [A].
Install the four mounting bolts and tighten to 18–22 ft.–lbs.
(24–30 Nm) torque.

N–17243

Install the snap ring (Item 1) [B] on the pump shaft.

B
1

Dealer Copy -- Not for Resale

N–17242

Install the bearing and snap ring (Item 1) [C] on the pump
shaft.
C

N–17241
Install the pump shaft into the pump housing [D].
Install the snap ring (Item 1) [D]. D

N–17240

863, 863H Bobcat Loader

Revised
237 of Feb.
570 99
–3–101– Service Manual
HYDROSTATIC PUMP (M44) (Cont’d)
Assembly (Cont’d)
A 1 1
Install the four slipper pins (Item 1) [A] into the cylinder
block.
Apply a small amount of grease to the washer (Item 2) [A] 1 3
and install into the ball guide retainer (Item 3) [A]. 2
1

N–17200

Install the ball guide retainer and washer (Item 1) [B] onto
the slipper holddown pins. B 1

N–17199

Assemble the piston assemblies into the slipper guide [C].

Lubricate the pistons and cylinder block bores and insert C
the piston assemblies into the cylinder bores [C].

N–17198

Lay the pump housing on its side and install the cylinder
block, piston assembly into the housing. D
Place the pump on a work surface with the end cap opening
up [D].

N–17197

863, 863H Bobcat Loader

Revised Feb.
23899
of 570
–3–102– Service Manual
HYDROSTATIC PUMP (M44) (Cont’d)
Assembly (Cont’d)
A 1
2
Replace the needle bearing (Item 1) [A] and valve plate
locating pin (Item 2) [A] in the charge pump.

N–17194

The bearing cage (Item 1) [B] will protrude from 0.08–0.10

inch (2,0–2,5 mm) from the surface of the charge pump. B
The valve plate locating spring pin (Item 2) [B] will protrude
from 1.65–0.185 inch (4,19–4,70 mm) from the surface of
the charge pump. 2 1

Dealer Copy -- Not for Resale

N–17196

Coat the backside of the valve plate with petroleum jelly to

hold it in position and install the valve plate onto the charge C
pump, bronze face up [C].
1
The notch (Item 1) [C] on the valve plate must engage the
locating pin.

N–17193

Coat a new end cap gasket (Item 1) [D] with petroleum jelly D
and install onto the charge pump.

N–17192

863, 863H Bobcat Loader

Added Feb.
239 of 570 99
–3–103– Service Manual
HYDROSTATIC PUMP (M44) (Cont’d)
Assembly (Cont’d)
A
Align the marks on the charge pump with the pump housing
and install the charge pump [A].
When the charge pump is properly installed, the cylinder
block spring will hold the charge pump end cap away from
the housing approximately .125 inch (3 mm).

N–17191

Install the four mounting bolts (Item 1) [B] and tighten

evenly to 35–45 ft.–lbs. (47–61 Nm) torque.
B
1
1

1 1

N–17186

CHARGE PUMP (M44)

Assembly C 1
Install the locating pin (Item 1) [C] in the pump end cap.

NOTE: The charge pump rotation is determined by the

position of the gerotor space and locating pin
(Item 1) [C] in the pump end cap.
Prior to assembly, lubricate the gerotor assembly with
clean hydraulic oil.

N–17186

Install the gerotor assembly (Item 1) [D] into the pump D

housing.
1

N–17187

863, 863H Bobcat Loader

Added Feb.240
99of 570 –3–104– Service Manual
CHARGE PUMP (M44) (Cont’d)
Assembly (Cont’d)
A
2
Apply petroleum jelly to the gerotor drive pin (Item 1) [A]
and install the gerotor pin into the drive coupler (Item 2) [A].
NOTE: The gerotor drive coupler (Item 2) [A] must be
installed with the longer portion down toward
the rear of the pump.

N–17188

Install the coupler and drive pin into the gerotor, be sure the
pin engages the gerotor slot (Item 1) [B]. B
Install the gerotor spacer (Item 2) [B] into the pump end
cap. 2

Dealer Copy -- Not for Resale

11
1
N–17189

A spanner wrench may be used in the two holes (Item 1)

[C] to slightly rotate the gerotor spacer to align with the
C
locating pin.
When the spacer is properly installed the surface of the 1
gerotor spacer and pump face are flush [C].
1

N–17190

Install the two large O–rings (Item 1) [D] into the gerotor
cap.
D 3
1

Install the two smaller O–rings (Item 2) [D] in the pump

housing end cap.
2 2
Install the two aligning pins into the alignment holes (Item
3) [D] in the pump.

N–17235

863, 863H Bobcat Loader

Added Feb.
241 of 570 99
–3–105– Service Manual
CHARGE PUMP (M44) (Cont’d)
Assembly (Cont’d)
A
Slide the two sections of the pumps together [A].

N–17234

Install the four mounting bolts (Item 1) [B] & [C] and tighten
to 35–45 ft.–lbs. (47–61 Nm) torque.
B 1
Check for proper internal assembly by slowly rotating the
pump shaft while tightening the mount bolts.

N–17233

C 1

N–17230

863, 863H Bobcat Loader

Added Feb.242
99of 570 –3–106– 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

Dealer Copy -- Not for Resale

1

P–07889

863, 863H Bobcat Loader

Added Feb.
243 of 570 99
–3–107– 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 3–107.)
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 Feb.244
99of 570 –3–108– 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].

Dealer Copy -- Not for Resale

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 Feb.
245 of 570 99
–3–109– 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 Feb.246
99of 570 –3–110– Service Manual
DRIVE BELT TENSIONER PULLEY (Cont’d)
Tension Spring
A
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.

Dealer Copy -- Not for Resale

P–05563

863, 863H Bobcat Loader

Added Feb.
247 of 570 99
–3–111– Service Manual
HYDRAULIC/HYDROSTATIC OIL COOLER
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].

863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.) – Hydostatic System Section Part 5 of 5

P–07887

863, 863H Bobcat Loader

Added Feb.248
99of 570 –3–112– Service Manual
 DRIVE SYSTEM

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 . . . . . . . . . . . . . . . . . . . . . . 4–17
DRIVE CHAIN
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–16 DRIVE
SYSTEM
FRONT CHAINCASE COVER
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8

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
Continued On Next Page

863, 863H Bobcat Loader

249 of 570 –4–1– Service Manual
 863, 863H Bobcat Loader
250 of 570 –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).

P–07737

Remove the five lower mounting bolts from the lower panel
(Item 1) [B]. B 1

Dealer Copy -- Not for Resale

P–07741

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–04769

Remove the mounting bolts (Item 1) [D] for the parking

brake pedal. D
Remove the parking brake pedal assembly.

1
P–04768

863, 863H Bobcat Loader

251 of 570 –4–3– Service Manual
PARKING BRAKE PEDAL (Cont’d)
Disassembly And Assembly
A 5
Loosen and remove the mounting bolt (Item 1) [A] and nut 6
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–04189

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–04156

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252 of 570 –4–4– Service Manual
PARKING BRAKE DISC
Removal And Installation
A
2

P–07743

B
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved 1
lift arm support device. Failure to use an
approved lift arm support device can allow the 4
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

Dealer Copy -- Not for Resale

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–07797
Remove the traction lock solenoid (Item 1) [B], spring, and
spring cup (Item 2) [B].
Remove the wedge assembly (Item 3) [B] from the guides C
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.
1
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–13772

Remove the hairpin clip and cross–pin from the control

valve lift spool (Item 1) [D].
D
Disconnect the crossmember from the control valve.

N–17627

863, 863H Bobcat Loader

Revised
253 of Feb.
570 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–07740

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–07798

Remove the two nuts (Item 1) [C] from the disc bolts.
C

1 1

P–07799
Remove the two disc bolts (Item 1) [D] from the disc.
D

1
1

P–07801

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254 of 570 –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.
Remove the snap ring (Item 1) [A] from the end of the
1
carrier shaft.

P–07800

Remove the disc (Item 1) [B] from the shaft.

B
1

Dealer Copy -- Not for Resale

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

255 of 570 –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.

1
REAR CHAINCASE COVER
Removal And Installation
P–04800

1
2

Never work on a machine with the lift arms up P–07934

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 C
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.)

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].
P–07935
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 Feb.
25699
of 570 –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 each P–04850
other.
Install puller (Item 1) [B] on the wheel hub.
B

NEVER STAND IN–LINE OF THE HUB WHEN

Dealer Copy -- Not for Resale

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

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257 of 570 –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
If the axle is damaged or worn, an axle repair sleeve kit is 1
available from Bobcat Parts Sales in Chicago.
NOTE: If a new wear ring is being installed with new P–04817
seal, put LOCTITE sealant on the inside
diameter of the wear ring.
Place the taper on the wear ring so it faces the outside [B]. 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 D
the correct surface for the axle seal (Item 2) [D].
These loaders MAY or MAY NOT have a wear 2
ring installed. When ordering the axle seal,
check to see if the axle uses a wear ring.

P–10553

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258 of 570 –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–04810

B
2

Dealer Copy -- Not for Resale

1
Never work on a machine with the lift arms up 2
unless the lift arms are secured by an approved
lift arm support device. Failure to use an P–04850
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.)
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.)
Remove the front cover. (See Page 4–8.)
Remove the fluid from the chaincase. (See Page 4–16.)
Remove the axle sprocket bolt (Item 1) [A] and backing
washer (Item 2) [A].
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.

863, 863H Bobcat Loader

Revised
259 of Feb.
570 99 –4–11– Service Manual
AXLE, SPROCKET AND BEARINGS (Cont’d)
Removal And Installation (Cont’d)
A
Install a puller (Item 1) [A] on the wheel hub.

NEVER STAND IN–LINE OF THE HUB WHEN

REMOVING A HUB FROM AN AXLE. The hub 1
has a tapered fit on the axle end and can come
off the axle with great force and cause serious P–04849
injury.
W–2186–0395

Remove the hub from the axle.

B
Install a Port–a–Power ram between the two sprockets [B].

P–04809

863, 863H Bobcat Loader

Revised Feb.
26099
of 570 –4–12– Service Manual
AXLE, SPROCKET AND BEARINGS (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–04808

A bearing puller (Item 1) [B] is needed to do the following

procedure: B
Be sure the bearing puller makes good contact with the
inner race and press the bearing off the mounting surface 1
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.

Dealer Copy -- Not for Resale

P–04171

Press the splined end of the axle free from the bearing [C].
C

P–04171
Installation: Put the spline end of the axle shaft into the
bearing and press the bearing onto the axle.
NOTE: Hold onto the axle during installation as it will D
slide freely after the bearing is pressed over
the splined end of the shaft.
Put a piece of tubing (Item 1) [D] that contacts inner race
of the bearing only. 1
Press the bearing onto the mounting surface until the
bearing is fully seated [D].

P–04175

863, 863H Bobcat Loader

Revised
261 of Feb.
570 99 –4–13– Service Manual
AXLE, SPROCKET AND BEARINGS (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–04812

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–04818

Use the slide hammer and remove the bearing cup from the
axle tube [C]. C

P–04816

863, 863H Bobcat Loader

Revised Feb.
26299
of 570 –4–14– Service Manual
AXLE, SPROCKET AND BEARINGS (Cont’d)
Removal And Installation (Cont’d)
A 1

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 threaded 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–04807

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.

Dealer Copy -- Not for Resale

1

P–04811

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–04813

863, 863H Bobcat Loader

Revised
263 of Feb.
570 99 –4–15– Service Manual
DRIVE CHAIN
Removal And Installation
A Rear Chain

Front Chain
Raise the loader lift arms and install an approved lift arm
support device. (See Page 1–1.)
P–07866
Lift and block the loader. (See Page 1–1.)
Raise the loader operator cab. (See Page 1–1.) B
Drain the fluid from the chaincase. (See Page 4–16.)
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.

B–13504

DO NOT exceed the recommended torque of

130 ft.–lbs. (176 Nm). The tool may fail under too
much torque. Put cloth around the tool to
protect yourself from flying debris.
W–2233–0296

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

The tool listed is needed for the following procedure:

MEL1037 – Chain Link Tool
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 Feb.
26499
of 570 –4–16– Service Manual
CHAINCASE FLUID
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–01616

Remove the drain plug (Item 1) [B] and drain the oil into a
container. B
Check the drain plug and replace if necessary.

Dealer Copy -- Not for Resale

1

P–01619

863, 863H Bobcat Loader

Added Feb.
265 of 570 99 –4–17– Service Manual
863,863H(S/N514425001&Abv.,514525001&Above,514625001&Abv.)ServiceManual#6900648–DriveSystemSection

863, 863H Bobcat Loader

Added Feb. 99of Feb.
Added
266 570 99 –4–18– Service Manual
 MAIN FRAME

Page
Number

BOB–TACH
Bob–Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12
Bob–Tach Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13
Pivot Pin Bushing And Seal Replacement . . . . . . . . . . . . . . . . . . . . . . 5–26
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14

FUEL TANK
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–24
Fuel Pick–Up Screen/Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–24
Inlet Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–35
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–23

LIFT ARMS
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–17

OPERATOR CAB
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9 MAIN
FRAME
OPERATOR CAB GAS CYLINDER
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7

OPERATOR SEAT
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11
REAR DOOR
Door Latch And Catch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–22
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–21
REAR GRILL
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–20

SEAT BAR
Assembling Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6
Compression Spring Disassembly And Assembly . . . . . . . . . . . . . . . . 5–6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3

863, 863H Bobcat Loader

267 of 570 –5–1– Service Manual
 863, 863H Bobcat Loader
268 of 570 –5–2– Service Manual
SEAT BAR
Removal And Installation
A
Lower the seat bar (Item 1) [A] so the compression
springs (Item 2) [A] will be in a down position.

2 2
P–09543

Loosen the adjustment lock nut (Item 1) [B] (both sides).

B

Dealer Copy -- Not for Resale

2

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 D

(both sides).

P–09541

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269 of 570 –5–3– Service Manual
SEAT BAR (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

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270 of 570 –5–4– Service Manual
SEAT BAR (Cont’d)
Removal And Installation (Cont’d)
A 3 2
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 the B
grab handle (Item 1) [B]. 1

Dealer Copy -- Not for Resale

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 cab D
[D].
Reverse the above procedure to install the seat bar into the
operator cab.

P–09950

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271 of 570 –5–5– Service Manual
SEAT BAR (Cont’d)
Assembling Components
A 6
3
1
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)
Sensor Mounting Nut (Item 5) 2
Sensor Bracket (Item 6)
Sensor Mounting Bolt (Item 7) 8
Pivot Bushing (Item 8) 9 5
Mounting Bolt (Item 9) 7
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)
Pivot Bushing (Item 2) 1
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)
Bushing (Item 7) 4
Bolt (Item 8) 5
8
6

7
P–09586

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272 of 570 –5–6– Service Manual
OPERATOR CAB GAS CYLINDER
Removal And Installation
A
2

Cylinder contains high pressure gas. Do not

open. Opening cylinder can release rod and
cause injury or death.
W–2113–0288 1

Remove the operator cab stop (Item 1) [A] (both sides).

P–07711
NOTE: If the operator cab is equipped with a rear
window, the rear grill and rear grill mounts
(Item 2) [A] must be removed to prevent
window damage. B
Raise the operator cab. (See Page 1–1.)
Remove the bolts and nuts (Item 1) [B] from the gas
cylinder mounting bracket.

Dealer Copy -- Not for Resale

1

P–07705

Use a pliers to unlock cotter pin (Item 1) [C].

C

P–07710

NOTE: Cotter pin (Item 1) [D] is shown in locked

position. D
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

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273 of 570 –5–7– Service Manual
OPERATOR CAB GAS CYLINDER (Cont’d)
Disassembly And Assembly
A
Remove the clevis (Item 1) [A] and washer (Item 2) [A]
from the end of the gas cylinder.
2
Remove the gas cylinder from the outer housing. 1

P–01008

Assembly: Install a replacement cylinder inside the

cylinder housing. B
Apply a small amount of LOCTITE on the threads of the
cylinder rod [B].
Reinstall the washer and clevis on the cylinder rod.

P–01006

863, 863H Bobcat Loader

274 of 570 –5–8– 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].

Dealer Copy -- Not for Resale

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

275 of 570 –5–9– 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

276 of 570 –5–10– Service Manual
OPERATOR SEAT
Removal And Installation
A
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 seat
sensor assembly. (See Page 8–1.) 2

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
covers (Item 3) [B] (if equipped) and the two spaces (Item 3
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

Dealer Copy -- Not for Resale

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.
NOTE: The bushing (Item 1) [B] has precoated 1
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
shown.
D Operator
Seat

Inspect the seat adjustment track.

Remove the mounting bolt from each end of the track and
replace the adjustment track if necessary. Seat Seat
1 Spring
Sensor
Reverse the removal procedure to install the operator seat.
Check for correct seat sensor operation. (See BICS™ Seat Rail
inspection procedure in your Operation & Maintenance Cover
Manual.

MC–02043

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277 of 570 –5–11– Service Manual
BOB–TACH
Bob–Tach Lever And Wedge
A
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

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278 of 570 –5–12– 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].

Dealer Copy -- Not for Resale

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] (both
sides) if worn or damaged. 1

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

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279 of 570 –5–13– 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

280 of 570 –5–14– Service Manual
BOB–TACH (Cont’d)
Removal And Installation (Cont’d)
A
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.
NOTE: Removal procedure is shown for the right side.
Left side procedure is the same.

P–03910

Remove the retainer bolt and nut (Item 1) [B] from the
Bob–Tach pivot pin. B 1
Installation: Tighten the bolt and retainer nut to 25 ft.–lbs.
(34 Nm) torque.

Dealer Copy -- Not for Resale

P–07697

Install an adapter (Item 1) [C] into the Bob–Tach pivot pin.

Install the slide hammer into the adapter and pull the pivot
C
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

281 of 570 –5–15– 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

282 of 570 –5–16– 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 5–19.)
1
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

Dealer Copy -- Not for Resale

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

283 of 570 –5–17– 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.
Raise the lift arms enough to remove the auxiliary tubelines 2
(if so equipped) from the lift arms [B].
Remove the nut and retainer bolt (Item 1) [A] from the pivot
pin for the base of the tilt cylinder. 1

Remove the pivot pin from the base end of the tilt cylinder
(Item 2) [A].
P–07726

Remove the tilt cylinder (Item 1) [B] from the lift arms.
B
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.
Remove the nut and retainer bolt (Item 2) [C] from the pivot 2 1
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.
Remove the lift arm support device (Item 3) [C]. P–07728

Lower the lift arms with the chain hoist.

Install the lift strap on the lift arm as shown in Figure [D]
D
(both sides).
Install the pivot pin (Item 1) [D] retainer bolt and nut (both
sides).
Connect the loops of the lifting straps to the chain hoist
1
(both lift straps).

P–07731

863, 863H Bobcat Loader

284 of 570 –5–18– 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.

Dealer Copy -- Not for Resale

P–07733

863, 863H Bobcat Loader

285 of 570 –5–19– Service Manual
REAR GRILL
Removal And Installation
A
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
sides). 1

P–07946

Remove the rear grill from the loader [C].

C

P–07947

863, 863H Bobcat Loader

286 of 570 –5–20– Service Manual
REAR DOOR
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.

Dealer Copy -- Not for Resale

1

N–15410

863, 863H Bobcat Loader

287 of 570 –5–21– Service Manual
REAR DOOR (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 for B
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

288 of 570 –5–22– 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.)

Dealer Copy -- Not for Resale

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

289 of 570 –5–23– Service Manual
FUEL TANK (Cont’d)
Removal And Installation (Cont’d)
A
Remove the mounting plate (Item 1) [A] for the battery
holddown plate.
Lift the fuel tank and remove it from the loader frame.
1

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 located 2
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

290 of 570 –5–24– Service Manual
FUEL TANK (Cont’d)
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.
863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.) – Main Frame Part 1 of 2

P–05509

863, 863H Bobcat Loader

291 of 570 –5–25– Service Manual
863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.) – Main Frame Part 2 of 2

863, 863H Bobcat Loader

292 of 570 –5–26– Service Manual
 ELECTRICAL SYSTEM

Page
Number

ALTERNATOR
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14
Rectifier (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13
BATTERY
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
Servicing The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
Using A Booster Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
ELECTRICAL SYSTEM INFORMATION
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
ELECTRICAL
FRONT LIGHTS SYSTEM
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–27
RELAY SWITCHES
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–28

STANDARD INSTRUMENT PANEL

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–26

STARTER
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–17
External Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–21
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–22
Magnetic Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–25
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–25
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–16
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–15
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5

WIRING SCHEMATICS
863 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

863, 863H Bobcat Loader

293 of 570 –6–1– Service Manual
 863, 863H Bobcat Loader
294 of 570 –6–2– Service Manual
 863, 863H Bobcat Loader
295 of 570 –6–3– Service Manual
 863, 863H Bobcat Loader
296 of 570 –6–4– Service Manual
 863 WITHOUT BOSS - WIRING SCHEMATIC
BICS CONTROLLER HARNESS - 6713932

C417
WITH HIGH FLOW OPTION C457
TO           THIS SHEET OR
BLK B B
REAR AUXILIARY HIGH FLOW CONTROLS HARNESS - 6712524
S/N 514425001-39999 C406
YEL/LGN A A BASE SOLENOID

(Printed October 1998)
TO ATTACHMENT
C302

C414 C411 C410

FRONT AUXILIARY

C406
B YEL/LGN
BLK 2 2 ROD SOLENOID
MC2411 C
A
YEL/BRN
RNG/WHT
DGN/LGN 1 1 BICS CONTROLLER

C416
FRONT AUXILIARY
2 2

14

19

10
20

22
16
13
23
21

15

17

18
11
12
BLK B B BLK BASE SOLENOID

2
7

6
4

3
5
8
1
TO REAR AUXILIARY
RIGHT HANDLE (IF EQUIPPED) DGN/RED 1 1
ATTACHMENT YEL/BRN A A ROD SOLENOID
WATER KIT
1 DBL

PUR/WHT

PNK/WHT
A

DBL/WHT
PUR/RED
WHT/BLK 1

YEL/DGN
RNG

YEL/RED

LBL/DGN
LBL/RED
YEL/DBL

YEL/BLK

LBL/BLK

YEL/LBL
DIVERTER
FRONT DBL/YEL BLK 2 2
E 2

C405
WHT/RED 2 SOLENOID

WHT

RNG
DGN
GRY

RED
C440
AUX.

DBL
BLK

BLK
B DGN/WHT WHT 3 3 DBL/WHT YEL 1 1
F RNG/WHT 5 4 DGN

C303
RNG
YEL/BLU A A YEL/DBL
C DGN 6 5
OPEN B B PUR/WHT
D YEL DGN 4 6
OPEN C C PUR/RED
SKI CONTROL DETENT

TO ATTACHMENT

C404

C304
RED A A
A DGN/YEL
REAR AUXILIARY BLK B B
B RELIEF SOLENOID SEAT
SENSOR DGN C C

C415
(IF EQUIPPED)

A
B
RNG BLK BUCKET LEVEL BLK B B

C401
SOLENOID
A DGN/YEL A A
B OPEN
DGN/YEL
C307

A
B
C305
LEFT HANDLE (IF EQUIPPED) RED A A

RNG/DGN
TO OPTIONS

DGN/RED
DBL/WHT

DGN/LGN

YEL/DBL
YEL/BRN
YEL/LGN
DBL/YEL
RNG/WHT
TO (RELIEF ADAPTER HARNESS) SEAT BAR BLK B B

DGN/YEL
SKI CONTROL SENSOR

C403
ATTACHMENT
C441

DBL

DBL

YEL
DGN C C
A RNG

BLK
B DBL RNG/WHT A
WHT RNG/DBL B B RNG/DBL
A

TO LH HANDLE TO ENGINE

C111
G
C

H
D

C
B
A

B
A
E
B
A
K
F
TRACTION

J
HORN
A LOCK

C402
REAR AUX. B DGN
DGN B
C407 C408 C409 B OVERRIDE
C457

C YEL/DGN
BRN A C YEL SWITCH

C413
HYDRAULIC
B YEL/RED A A CHARGE
A BRN

G
C
D
B

E
A
C

F
G
YEL

B
A

B
A
H
D

C
F

E
B
A
J
A RNG B B PRESSURE HERE OR HERE OR
TURN
SIGNAL OPENS AT 25 PSI TO OPTIONS TO OPTIONS
C C
C406
TO           THIS SHEET OR CLOSED AT 29 PSI (RELIEF ADAPTER HARNESS) (RELIEF ADAPTER HARNESS)
C301
TO ATTACHMENT C457 A
B
A
B
DGN/RED
DGN/YEL B F G C D E A

C412
C418
YEL C C LGN/PNK
CONTROLS MODULE
A A LBL/RED HYDRAULIC OIL
HIGH FLOW TEMPERATURE D D RNG
B B

PNK/WHT
BLK
SOLENOID 568-1804 OHMS
E E LGN/DBL

WHT

RNG
DGN
RED
BLK
DBL
F F LGN/RED

YEL/BLK
TO ATTACHMENT
MAINFRAME CONTROLLER HARNESS -
C442

A DGN 6712523 HYDRAULIC

MANUAL
BRAKE
B LOCK SWITCH
BRAKE SOLENOID SOLENOID

C306
HYDRAULIC OIL
FILTER WHT RED
A A

RNG/DBL

YEL/BRN
B B BLK

YEL/DBL
LBL/RED
DIFFERENTIAL
PRESSURE

RNG
RNG
DGN
BRN

BLK
BLK

YEL

BLK
FILTER HARNESS (WITHOUT BOSS) - 6716642

C308
RED A A
BLK C C BLK

C
A
B
G
D

C
H

D
C
E

B
K

E
B
A

A
F
F

J
WHT B B

C106 C107 C108 C109 C110 C203

TO TO CAB HARNESS (WITHOUT BOSS) - 6711767

G
B

C
A

B
A

A
K
F
TO

J
ATTACH. ATTACH. D F E C B A DGN/RED
CONTROLS
(USED W/ HIGH FLOW SWITCH (IF EQUIPPED)

LGN/RED

LGN/PNK
ADVANCED

LGN/DBL

DGN/YEL
RNG/DBL

DGN/YEL
DGN/RED WIRE JUMPER FROM 2 TO 3

LBL/RED
HAND WHEN NOT EQUIPPED WITH HIGH FLOW SWITCH
RNG

BLK
RNG
BLK

BLK

RNG
YEL/DBL
YEL/BRN
RNG

RNG
DGN
RNG

BRN
ACC
BLK

BLK

YEL

YEL
CONTROLS LBL/RED 1
OFF 2
ONLY) ENGINE COOLANT 3 DGN/RED
TO BICS 1075-2231 OHMS
RUN BLK

C111
START
BLK

C119
YEL/LBL A C A D B E 4 WHT/BLK
ENGINE RPM 5
(MAGNETIC B B BLK 6
PICKUP) BLK B D A C B E
A A PUR/WHT

SO
MODE RNG/DBL BLK
LIGHT DETENT B
ENGINE OIL RED/WHT
PRESSURE SWITCH LIGHT ST HORN (IF EQUIPPED)
HERE OR HERE OR RED/WHT
AUXILIARY HYDRAULIC SWITCH
RNG

TO OPTIONS TO OPTIONS
YEL/DGN (IF EQUIPPED)
(K TO P DIVERTER (K TO P DIVERTER BUCKET LEVEL
HARNESS) HARNESS) SWITCH (IF EQUIPPED)

C113 C112
FUSE 6
RNG

I 1
BLK B B
Dealer Copy -- Not for Resale
25A
C105

TO OPTIONS REAR AUXILIARY FUEL LEVEL WHT/BLK

RNG 2
DGN/YEL A A RELIEF (IF 33-246 OHMS YEL/DBL A U IGNITION SWITCH 3

C117
SV2

C202
RNG EQUIPPED) 4 WHT/BLK
B B BLK YEL/BRN K T
RED

LBL/DGN 5
PUR/WHT P M WHT 6
BLK B B A A PUR
TO OPTIONS YEL/DGN F L WHT/BLK
YEL A A  DIVERTER
J BLK SV1 (IF EQUIPPED) PUR N G RED/WHT
FUSE 8 FUSE 2
G RNG RNG RED RED RNG RNG C W LBL/RED
25A 10A TO OPTIONS
F BRN RNG/DBL X X RNG/DBL
(FRONT WIPER)
E V V
C104

BRN/DGN RNG RNG

C204
D BRN/YEL LBL/RED W B RED/WHT RED/WHT 1

C114
C DBL DBL H D BLK BLK 2
B PNK PNK R F YEL/DGN
A RED/WHT RED/WHT E J LBL/BLK LBL/BLK 1
RED/WHT
H DBL/WHT S C RNG 2
3
K DBL/BLK WHT/BLK L A YEL/DBL 4

TO OPTIONS
RED/WHT B E RED/WHT 6 5
(WIPER/WASHER BOTTLE) AUXILIARY WHT M S DBL/WHT GLOW PLUG SWITCH
C102 C103

HOURMETER AND
A DBL/BLK HARNESS (IF EQUIPPED) T H DBL
DIODE
B BLK
BLK h RNG
STARTER RELAY GLOW PLUG RELAY LBL/RNG
U
J
R
P
PNK
PUR/WHT
ENGINE WARNING LIGHT
TO OPTIONS YEL/DGN
(BACK-UP ALARM SWITCHES) RED/WHT G N PUR
RNG

C201
RED/WHT

RED/WHT

RNG BLK D K YEL/BRN

A
B

GLOW RNG
RNG/DGN
C121
85 86 86 85
h RNG

C116
SWITCHED POWER RELAY WHT BLK BLK LBL/RNG PLUGS

HERE OR 87 87 BLK BLK HOURMETER YEL/DBL

BLK
A

WHT/LGN LBL/RNG HR
B

TO OPTIONS) 87A 30 30
FUSE 4
FUSE 3
WHT/BLK

30 87A RED RED 87A

BACKUP RNG C F RNG/DGN
25A
25A

TRANSMISSION WARNING LIGHT
RNG

RED BLK HR
ALARM
BLK

87 BLK
RNG/DGN F C RNG RED
BLK HR FUEL GAUGE BLK
G G 85 86
C101

RNG BLK PUR

E B GND

C205
BLK BLK HR
S GRY
PNK A D BRN/DGN
LGHT GRY
LGN/WHT

D E BRN/YEL DBL/WHT
I RNG DBL
DBL/WHT H A PNK GRY
RED

RNG
BLK B H DBL/WHT
FUSE 5 ENGINE RNG
FUSE 1

LEFT RIGHT
FUEL SHUTOFF SOLENOID RED/WHT TEMPERATURE HEAD
HEAD
10A

15A GAUGE LIGHT LIGHT

S PUR/WHT

C206
LGN/WHT BLK (IF EQUIPPED) (IF EQUIPPED)
RED/DBL BLK
BRAKE RELAY GND
DBL/WHT

DBL/WHT

BLK BLK BLK

RNG

LGN I RNG
87A
BLK

BLK

FUSE 7 LGHT GRY

PNK
BLK

A
B

1
PNK
BLK

30 RED/WHT
RED/WHT
87
C118 RED
RED
RED 25A WHT VOLTMETER RNG
RNG
BLK
BLK
3
2

86 85

C207
S RED BLK PNK/WHT I
A
B

M V
RED BLK

G
RED GND
RIGHT RED RED BLK DBL/WHT DBL/WHT
LEFT WHT/LGN RED 4
TAILLIGHT TAILLIGHT LEFT RIGHT LGHT PNK
PUR RED S B GRY
WORK WORK B 5
EXC DBL
LIGHT LIGHT BATTERY GRY 6

REAR LIGHT HARNESS - 6714350 BLK B B BLK

LIGHT SWITCH (IF EQUIPPED)

C115
STARTER
ALTERNATOR
WHT C C WHT
PNK/WHT D D PNK/WHT
RNG A A RNG

ENGINE HARNESS (WITHOUT BOSS) - 6715947 OR 6718070

RED = RED
RNG = ORANGE
BICS
WIRES CONNECT BY SOME CONNECTOR BLK = BLACK
ENGINE

LBL = LIGHT BLUE
FUSE 1 10A
FUSE 5 LETTER ACROSS BODIES NOT SHOWN
15A

DBL = DARK BLUE
CONNECTORS FOR DRAWING CLARITY LGN = LIGHT GREEN
DGN = DARK GREEN
BOSS

A B YEL = YELLOW
10A

FUSE 2 25A FUSE 6

B A PNK = PINK
PWM WHT = WHITE
BRN = BROWN
LIGHT
TAN = TAN
FUSE 3
BRAKE

25A FUSE 7 PUR = PURPLE

25A

GRY = GREY
ACCESSORY

FUSE 8
25A

FUSE 4
MC2411 (10-29-99)
25A
ACCESSORY

FUSE BLOCK

297 of 570
298 of 570
 863 BOSS - WIRING SCHEMATIC
S/N 514425001-39999
BICS CONTROLLER HARNESS - 6713932
(Printed October 1998)
C457
TO           THIS SHEET OR
CONTROLS HARNESS - 6712669
TO ATTACHMENT C406
MC2415 C302

C411 C410
C406
B YEL/LGN BLK 2 2
FRONT AUXILIARY
C
A
YEL/BRN
RNG/WHT
DGN/LGN 1 1 ROD SOLENOID
BICS CONTROLLER

14

19
15
10
20

18

22
16
13
23
21

17

11
12
BLK 2 2

2
7

6
4

3
5
8
1
RIGHT HANDLE (IF EQUIPPED) FRONT AUXILIARY
TO
ATTACHMENT
DGN/RED 1 1 BASE SOLENOID
WATER KIT
A WHT/BLK 1 1 DBL

PUR/WHT

PNK/WHT
RNG

DBL/WHT
PUR/RED

YEL/DGN
YEL/RED

LBL/DGN
LBL/RED
YEL/DBL

YEL/BLK

LBL/BLK

YEL/LBL
FRONT
E WHT/RED 2 2 DBL/YEL

C440

WHT
AUX.

RNG
DGN
GRY

RED
DBL
BLK

BLK
C405
B DGN/WHT WHT 3 3 DBL/WHT
F RNG/WHT 5 4 DGN

C303
C RNG
YEL/DBL A A YEL/DBL
DGN 6 5
D B B PUR/WHT
YEL DGN 4 6
SKI CONTROL C C PUR/RED
DETENT

A
B
TO ATTACHMENT
C307
C404

C304
RED A A
A DGN/YEL

A
B
SEAT
BLK B B
B
SENSOR DGN C C
(IF EQUIPPED)

LEFT HANDLE (IF EQUIPPED)

C305
RNG BLK
RED A A

RNG/DGN

DBL/WHT

DGN/RED
DGN/LGN

YEL/DBL
YEL/BRN
YEL/LGN
DBL/YEL
TO TRACTION

RNG/WHT
SEAT BAR B B

PNK/WHT
BLK

DGN/YEL
ATTACHMENT SKI CONTROL LOCK
C441

SENSOR

C403

DGN

DBL
C C

YEL
DGN OVERRIDE

WHT
A

RNG
DGN
B DBL RNG/WHT A RNG

RED
DBL
BLK
BLK
BUCKET
SWITCH
A WHT RNG/DBL B B RNG/DBL LEVEL
SOLENOID
(IF EQUIPPED))
TO ENGINE

C111
G
C

H
D
B
A

B
A
K

E
B
A
F
HORN

J
REAR AUX. A
BOSS CHARGE HARNESS -

G
C402

C
D
B

E
A
F
DGN B B DGN
C407 C408
C457

C YEL/DGN
BRN A C YEL C409 B
B
6717131
YEL/RED
YEL C A BRN C301

G
B
A

B
A
C

H
D
F

E
B
A
J
A RNG TURN HERE OR HERE OR

C455
SIGNAL C C HYDRAULIC TO OPTIONS TO OPTIONS
C406 CHARGE

G
TO           THIS SHEET OR

C
D
(RELIEF ADAPTER HARNESS) (RELIEF ADAPTER HARNESS)

E
A
F
A A PRESSURE
TO ATTACHMENT C457 B B 5-90 OHMS A A DGN/RED

PNK/WHT
B B DGN/YEL

C412
C C LGN/PNK
CONTROLS MODULE

WHT

RNG
DGN
RED
DBL
BLK
TO OPTIONS
(RELIEF ADAPTER HARNESS) D D RNG

C401

DGN
E E LGN/DBL

BLK
A DGN/YEL
F F LGN/RED
B

MAINFRAME CONTROLLER MANUAL

A
B
HYDRAULIC BRAKE
HYDRAULIC OIL TEMPERATURE LOCK SWITCH
568-1804 OHMS
C413 HARNESS - 6712523
SOLENOID

C306
A A

A
B
BRAKE SOLENOID
HYDRAULIC OIL FILTER B B BLK
DIFFERENTIAL PRESSURE
WHT RED

RNG/DBL
DGN/YEL

YEL/BRN

YEL/DBL
FILTER HARNESS

YEL/LBL
RNG

RNG
DGN
BRN

BLK

BLK
BLK

YEL

YEL
(BOSS) -

BLK

C308
RED A A RED

6716643 BLK C C BLK

C
D
A
B

E
G

D
C
H
C

B
A
K

E
B
A

F
F

J
WHT B B WHT

C106 C107 C108 C109 C110 C117 C119 C203

DGN/RED
TO TO TO
G
*  PIN NUMBER = 30 PIN CONNECTOR BOSS # PIN NUMBER = 18 PIN CONNECTOR D F E C B A
B

C
D
A

B
A

B
A

A
B

E
F

F
J
ATTACH. ATTACH. CONTROLS
(USED W/ FUEL SHUTOFF

* G1
SOLENOID

* C1

# C1

* D1

* H1

* D1
* E1
* B1

# B1

* A1

* G2
* G3

* K1

# E1
# A1
* F1

# F1
* H2
* C3
* C2
* D3
# C3
# C2

# B3
# D1
# D2
# D3
* D2

* H3
* B3
* F3
* B2
# A2
# A3
# B2

* E2
* E3

# E3

*  J1

# F3
# E2

* K2
* A3
* A2
* F2

# F2
* J2
* J3

LGN/RED

LGN/PNK
DGN/YEL
ADVANCED

LGN/DBL
RNG/DBL

DGN/YEL
LBL/RED

YEL/BRN

YEL/DBL
DBL/YEL
YEL/LBL
HAND
RNG

RNG

RNG
BLK

BLK

CONTROLS ACC
RNG

RNG
DGN
RNG

BRN
BLK

BLK

BLK
YEL

YEL

BLK

BLK
OFF
ONLY)

RNG/WHT
RNG/WHT
WHT/RNG

PUR/WHT
RUN

PUR/RED

RNG/DBL
LBL/WHT
YEL/DGN
YEL/BRN
DBL/YEL
YEL/DBL

YEL/LBL

YEL/LBL

PUR/RED
START

YEL/RED
C A D B E

RNG
RNG
PUR

RED
BLK

BLK

BLK

BLK

BLK

BLK
DIODE

BLK
BLK

BLK
D A C B E

DGN/YEL SO
MODE
SHUTDOWN RELAY B
FUEL LEVEL LIGHT DETENT RED/WHT DBL/WHT DBL
DIODE LIGHT
33-246 OHMS ST

86 85 AUXILIARY HYDRAULIC SWITCH LEFT
RNG

ENGINE COOLANT RIGHT
BLK (IF EQUIPPED) HEAD HEAD
HERE OR TO OPTIONS 1075-2231 OHMS
HERE OR TO OPTIONS (K TO P HARNESS) 87 LIGHT LIGHT

C113 C112
(IF EQUIPPED)

Dealer Copy -- Not for Resale

(K TO P HARNESS)
FUSE 6

RED/DBL
RNG

ENGINE OIL 30 I (IF EQUIPPED)
RNG
B B
25A

BLK PRESSURE 87A BLK

C105

TO OPTIONS REAR AUXILIARY
3-90 OHMS
DGN/YEL A A RELIEF (IF
RNG SV2 EQUIPPED) ENGINE RPM IGNITION SWITCH
(MAGNETIC PICKUP) TO BICS BLK

C111
AIR FILTER
RED

YEL/LBL YEL/LBL A RNG C M WHT

BLK B B
TO OPTIONS DIVERTER RNG F L WHT/BLK WHT/BLK
YEL A A (IF EQUIPPED) BLK BLK B
J BLK SV1 PUR/RED N G RED/WHT
FUSE 8 FUSE 2
G RNG RNG RED RED RNG/WHT PUR/WHT P R PNK
25A 10A S DBL/WHT
F BRN RNG/DBL X
H DBL
C104

E BRN/DGN RNG V
E RED/WHT RED/WHT 1
D BRN/YEL LBL/RED W
W LBL/RED BLK 2
C DBL DBL H
3
B PNK PNK R X RNG/DBL BLK

A E B RED/WHT

C114
RED/WHT RED/WHT
H DBL/WHT S V RNG DBL/WHT
4
PNK

K DBL/BLK WHT M C RNG DBL/WHT

5
WHT/BLK L F RNG DBL
6
TO OPTIONS
(WIPER/WASHER BOTTLE) AUXILIARY RED/WHT B P PUR/WHT
LIGHT SWITCH (IF EQUIPPED)
C102 C103

HOURMETER AND N PUR/RED
A DBL/BLK K
HARNESS (IF EQUIPPED) DIODE
B BLK LBL/RNG J D BLK

TO OPTIONS
BLK h RNG U A BLK
J
RED/WHT

RED/WHT

(BACK-UP ALARM SWITCHES) BLK D HIGH FLOW SWITCH (IF EQUIPPED)

DGN/RED WIRE JUMPER FROM 2 TO 3
RNG BLK A U WHEN NOT EQUIPPED WITH HIGH FLOW SWITCH
RNG/DGN RED/WHT G T LBL/RED 1 2
STARTER RELAY GLOW PLUG RELAY K 3 DGN/RED
T BLK
B
A

FUSE 4
FUSE 3

HERE OR
TO OPTIONS BLK

C116
C121
25A
25A

86 4 WHT/BLK
BACKUP RNG C F RNG/DGN 85 86 85 5
WHT BLK BLK LBL/WHT GLOW BLK 6
ALARM PLUGS BLK
RNG/DGN F C RNG
B
A

SWITCHED POWER RELAY 87 87
G G WHT/LGN 30 LBL/RNG BLK HR
30
C101

87A RED RED 87A HORN (IF EQUIPPED)

E B BLK 87A BLK
WHT/BLK

HR
BLK
RNG

PNK A D BRN/DGN 30 DIAGNOSTIC PORT

RED
D E BRN/YEL RED 87 BLK HR 1 RED RNG/DBL BLK
DBL/WHT H A PNK 86 2 PUR/RED
RED

85 BLK HR
RNG BLK
BLK B H DBL/WHT 3 PUR/WHT
FUSE 5 TO OPTIONS
RED/WHT 4 BLK (FRONT WIPER)
FUSE 1

10A

C204
15A
RED/WHT 1
LGN/WHT
BRAKE RELAY BOSS DISPLAY BLK 2
DBL/WHT

DBL/WHT

RNG

LGN B PUR/RED
87A
BLK

BLK

FUSE 7 C PUR/WHT BUCKET LEVEL

PNK
BLK

B
A

SWITCH (IF EQUIPPED)
PNK
BLK

30
RED/WHT A RNG
87
C118 S
RED
RED
RED 25A WHT
E RNG
1 2
WHT/BLK
86 85 RNG
RED BLK PNK/WHT D BLK 3
B
A

WHT/BLK

M
RED 4

G
RED DGN/WHT
RIGHT RED RED 5
LEFT WHT/LGN RED DGN/WHT 6
TAILLIGHT TAILLIGHT LEFT RIGHT PUR RED S B
WORK WORK B
EXC
LIGHT LIGHT BATTERY

REAR LIGHT HARNESS - 6714350 BLK B B BLK

CAB HARNESS (BOSS) - 6711774

C115
STARTER
WHT C C WHT
ALTERNATOR
PNK/WHT D D PNK/WHT
RNG A A RNG

ENGINE HARNESS (BOSS) - 6715948 OR 6718071

RED = RED
RNG = ORANGE
BICS
WIRES CONNECT BY SOME CONNECTOR BLK = BLACK
ENGINE

LBL = LIGHT BLUE
FUSE 1 10A
FUSE 5 LETTER ACROSS BODIES NOT SHOWN
15A

DBL = DARK BLUE
CONNECTORS FOR DRAWING CLARITY LGN = LIGHT GREEN
DGN = DARK GREEN
BOSS

A B YEL = YELLOW
10A

FUSE 2 25A FUSE 6

B A PNK = PINK
PWM WHT = WHITE
BRN = BROWN
LIGHT
TAN = TAN
FUSE 3
BRAKE

25A FUSE 7 PUR = PURPLE

25A

GRY = GREY
ACCESSORY

FUSE 8
25A

FUSE 4 25A
ACCESSORY

FUSE BLOCK MC2415 (10-28-99)
299 of 570
300 of 570
 863 WITHOUT BOSS - WIRING SCHEMATIC
S/N 514425001-39999
BICS CONTROLLER HARNESS - 6713932
(Printed October 1998)
C457
TO           THIS SHEET OR
CONTROLS HARNESS - 6712669
C406
TO ATTACHMENT
C302

C411 C410
MC2414

C406
B YEL/LGN BLK 2 2
FRONT AUXILIARY
C
A
YEL/BRN
RNG/WHT
DGN/LGN 1 1 ROD SOLENOID
BICS CONTROLLER

20

23
21
14

19
15
10

17

18
11
12
22
16
13
BLK 2 2

6
4

3
5
8
2

1
RIGHT HANDLE (IF EQUIPPED) FRONT AUXILIARY
TO
ATTACHMENT
DGN/RED 1 1 BASE SOLENOID
WATER KIT
A WHT/BLK 1 1 DBL

PUR/WHT

PNK/WHT
RNG

DBL/WHT
PUR/RED

YEL/DGN
YEL/RED

LBL/DGN
LBL/RED
YEL/DBL

YEL/BLK

LBL/BLK

YEL/LBL
FRONT
E WHT/RED 2 2 DBL/YEL

C440

WHT
AUX.

GRY

RNG
DGN
RED
DBL
BLK

BLK
C405
B DGN/WHT WHT 3 3 DBL/WHT
F RNG/WHT 5 4 DGN

C303
C RNG
YEL/DBL A A YEL/DBL
DGN 6 5
D B B PUR/WHT
YEL DGN 4 6
SKI CONTROL C C PUR/RED
DETENT

TO ATTACHMENT

C404

C304
RED A A
A DGN/YEL
SEAT
BLK B B
B
SENSOR DGN C C
(IF EQUIPPED)

A
B
C307

A
B
LEFT HANDLE (IF EQUIPPED)

C305
RNG BLK
RED A A

RNG/DGN

DGN/RED
DBL/WHT

DGN/LGN

YEL/DBL
YEL/BRN
YEL/LGN
DBL/YEL
TO

RNG/WHT
SEAT BAR BLK B B

DGN/YEL
ATTACHMENT SKI CONTROL
C441

SENSOR

C403

DGN

DBL
C C

YEL
DGN
B DBL RNG/WHT A A RNG

BLK
BUCKET
WHT RNG/DBL B B RNG/DBL LEVEL
A
SOLENOID
(IF EQUIPPED)) TO ENGINE

C111
C

G
B
A

B
A
C

H
D

B
K

A
F
HORN TRACTION

J
REAR AUX. A LOCK

C402
DGN B B DGN
C407 C408
C457

C YEL/DGN
BRN A C YEL C409 B OVERRIDE
SWITCH

C413
B YEL/RED HYDRAULIC
YEL C A BRN A A CHARGE B F G C D E A

G
B
A

B
A
C

H
D
E
B
A
F

K
J
A RNG TURN B B PRESSURE HERE OR HERE OR
SIGNAL OPENS AT 25 PSI TO OPTIONS TO OPTIONS
C406
TO           THIS SHEET OR C C
CLOSED AT 29 PSI (RELIEF ADAPTER HARNESS) (RELIEF ADAPTER HARNESS)
C301
TO ATTACHMENT C457 A A DGN/RED
B B DGN/YEL B F G C D E A

C412
YEL C C LGN/PNK
CONTROLS MODULE
TO OPTIONS HYDRAULIC OIL
(RELIEF ADAPTER HARNESS) TEMPERATURE D D RNG

PNK/WHT
568-1804 OHMS

C401
E E LGN/DBL

WHT
A DGN/YEL

RNG
DGN
RED
BLK
DBL
F F LGN/RED
B
MAINFRAME CONTROLLER HARNESS -

YEL/BLK
6712523 HYDRAULIC
LOCK MANUAL
SOLENOID BRAKE
SWITCH
BRAKE SOLENOID 8-10 ohms

C306
HYDRAULIC OIL
FILTER WHT RED
A A

RNG/DBL
DGN/YEL

YEL/BRN
B B BLK

YEL/DBL
DIFFERENTIAL
PRESSURE

RNG

RNG
DGN
BRN

BLK
BLK

YEL

YEL
(HOLD COIL IS

BLK
(PULL COIL IS 10-11 ohms -

FILTER HARNESS (WITHOUT BOSS) - 6716642 0.4-0.5 OF
RED TO BLK)

C308
AN ohm - RED A A
WHT TO BLK) BLK C C BLK

C
G

A
B
H
C

D
C
K

E
B
A

B
A
F
F

J
WHT B B

C106 C107 C108 C109 C110 C203

TO TO CAB HARNESS (WITHOUT BOSS) - 6711767

C
B
A

D
B
A

B
A

B
A

A
F
TO

J
ATTACH. ATTACH. D F E C B A DGN/RED
CONTROLS
(USED W/ HIGH FLOW SWITCH (IF EQUIPPED)

LGN/RED

LGN/PNK
ADVANCED

DGN/YEL
LGN/DBL
RNG/DBL
DGN/RED WIRE JUMPER FROM 2 TO 3

DGN/YEL
LBL/RED
HAND WHEN NOT EQUIPPED WITH HIGH FLOW SWITCH
RNG

BLK
RNG
BLK

BLK

RNG
YEL/DBL
YEL/BRN
RNG

RNG

RNG
DGN
BRN ACC
BLK

BLK

YEL

YEL
CONTROLS LBL/RED 1
OFF 2
ONLY) ENGINE COOLANT 3 DGN/RED
TO BICS 1075-2231 OHMS
RUN BLK

C111
START
BLK

C124
YEL/LBL A C A D B E 4 WHT/BLK
ENGINE RPM 5
(MAGNETIC B B BLK 6
PICKUP) BLK B D A C B E
A A PUR/WHT

SO
MODE RNG/DBL BLK
LIGHT DETENT B
ENGINE OIL RED/WHT
PRESSURE SWITCH LIGHT ST HORN (IF EQUIPPED)
HERE OR HERE OR RED/WHT
AUXILIARY HYDRAULIC SWITCH
RNG

TO OPTIONS TO OPTIONS
YEL/DGN (IF EQUIPPED)
(K TO P DIVERTER (K TO P DIVERTER BUCKET LEVEL
HARNESS) HARNESS) SWITCH (IF EQUIPPED)

C113 C112
RNG

FUSE 6

I 1
BLK B B
25A

Dealer Copy -- Not for Resale

C105

TO OPTIONS REAR AUXILIARY FUEL LEVEL WHT/BLK

RNG 2
DGN/YEL A A RELIEF (IF 33-246 OHMS YEL/DBL A U IGNITION SWITCH 3

C117
SV2

C210
RNG EQUIPPED)
4 WHT/BLK
B B BLK YEL/BRN K T
RED

LBL/DGN 5
PUR/WHT P M WHT 6
BLK B B A A PUR
TO OPTIONS YEL/DGN F L WHT/BLK
YEL A A  DIVERTER
J BLK SV1 (IF EQUIPPED) PUR N G RED/WHT
FUSE 8 FUSE 2
G RNG RNG RED RED RNG RNG C W LBL/RED
25A 10A TO OPTIONS
F BRN RNG/DBL X X RNG/DBL
(FRONT WIPER)
E
C104

BRN/DGN RNG V V RNG

C204
D BRN/YEL LBL/RED W B RED/WHT RED/WHT 1

C114
C DBL DBL H D BLK BLK 2
B PNK PNK R F YEL/DGN
A RED/WHT RED/WHT E J LBL/BLK LBL/BLK 1
RED/WHT
H DBL/WHT S C RNG 2
3
K DBL/BLK WHT/BLK L A YEL/DBL 4

TO OPTIONS
RED/WHT B E RED/WHT 6 5
(WIPER/WASHER BOTTLE) AUXILIARY WHT M S DBL/WHT GLOW PLUG SWITCH
C102 C103

HOURMETER AND
A DBL/BLK HARNESS (IF EQUIPPED) T H DBL
DIODE
B BLK
BLK h RNG
STARTER RELAY GLOW PLUG RELAY LBL/RNG
U
J
R
P
PNK
PUR/WHT
ENGINE WARNING LIGHT
TO OPTIONS YEL/DGN
(BACK-UP ALARM SWITCHES) RED/WHT G N PUR
RNG

C201
RED/WHT

RED/WHT

RNG BLK D K YEL/BRN

A
B

RNG
h
86 86 GLOW
RNG/DGN 85 85 RNG

C116
HERE OR
C121 SWITCHED POWER RELAY WHT BLK BLK LBL/RNG PLUGS

YEL/DBL
87 87 BLK BLK HOURMETER
BLK
A

WHT/LGN LBL/RNG HR
B

TO OPTIONS) 87A 30 30
FUSE 4
FUSE 3
WHT/BLK

30 87A RED RED 87A

BACKUP RNG C F RNG/DGN
25A
25A

BLK TRANSMISSION WARNING LIGHT
RNG

RED HR
ALARM
BLK

87 BLK
RNG/DGN F C RNG RED
BLK HR FUEL GAUGE BLK
G G 85 86
C101

RNG BLK PUR

E B GND

C205
BLK BLK HR
S GRY
PNK A D BRN/DGN
LGHT GRY
LGN/WHT

D E BRN/YEL DBL/WHT
I RNG
DBL/WHT H A PNK DBL GRY
RED

RNG
BLK B H DBL/WHT
FUSE 5 ENGINE RNG
FUSE 1

LEFT RIGHT
FUEL SHUTOFF SOLENOID RED/WHT TEMPERATURE HEAD
HEAD
10A

15A GAUGE LIGHT LIGHT

S PUR/WHT

C206
LGN/WHT BLK (IF EQUIPPED) (IF EQUIPPED)
RED/DBL
BRAKE RELAY GND BLK
DBL/WHT

DBL/WHT

BLK BLK BLK

RNG

LGN I RNG
BLK

BLK

87A
FUSE 7 LGHT GRY
PNK
BLK

A
B

1
PNK
BLK

30 RED/WHT
RED/WHT
87
C118 RED
RED
RED 25A WHT VOLTMETER RNG
RNG
BLK
BLK
3
2

86 85

C207
S RED BLK PNK/WHT I
A
B

M V
RED BLK

G
RED GND
RIGHT RED RED BLK DBL/WHT DBL/WHT
LEFT WHT/LGN RED 4
TAILLIGHT TAILLIGHT LEFT RIGHT LGHT PNK
PUR RED S B GRY
WORK WORK B 5
EXC DBL
LIGHT LIGHT BATTERY GRY 6

REAR LIGHT HARNESS - 6714350 BLK B B BLK

LIGHT SWITCH (IF EQUIPPED)

C115
STARTER
ALTERNATOR
WHT C C WHT
PNK/WHT D D PNK/WHT
RNG A A RNG

ENGINE HARNESS (WITHOUT BOSS) - 6715947 OR 6718070

RED = RED
RNG = ORANGE
BICS
WIRES CONNECT BY SOME CONNECTOR BLK = BLACK
ENGINE

LBL = LIGHT BLUE
FUSE 1 10A
FUSE 5 LETTER ACROSS BODIES NOT SHOWN
15A

DBL = DARK BLUE
CONNECTORS FOR DRAWING CLARITY LGN = LIGHT GREEN
DGN = DARK GREEN
BOSS

A B YEL = YELLOW
10A

FUSE 2 25A FUSE 6

B A PNK = PINK
PWM WHT = WHITE
BRN = BROWN
LIGHT
TAN = TAN
FUSE 3
BRAKE

25A FUSE 7 PUR = PURPLE

25A

GRY = GREY
ACCESSORY

FUSE 8
25A

FUSE 4 25A
ACCESSORY

FUSE BLOCK MC2414 (10-28-99)
301 of 570
302 of 570
 863 BOSS - WIRING SCHEMATIC
BICS CONTROLLER HARNESS - 6713932

C417
WITH HIGH FLOW OPTION C457
TO           THIS SHEET OR
BLK B B
REAR AUXILIARY HIGH FLOW CONTROLS HARNESS - 6712524
S/N 514425001-39999 C406
YEL/LGN A A BASE SOLENOID

(Printed October 1998)
TO ATTACHMENT
C302

C414 C411 C410

FRONT AUXILIARY

C406
B YEL/LGN BLK 2 2 ROD SOLENOID
MC2410 C
A
YEL/BRN
RNG/WHT
DGN/LGN 1 1 BICS CONTROLLER

C416
FRONT AUXILIARY
2 2

21
14

19
15
10
20
17

18

12
22
16
13
23
11
BLK B B BLK BASE SOLENOID

6
4

3
2
7

5
8
1
TO REAR AUXILIARY
RIGHT HANDLE (IF EQUIPPED) DGN/RED 1 1
ATTACHMENT YEL/BRN A A ROD SOLENOID
WATER KIT
1 DBL

PUR/WHT

PNK/WHT
A

DBL/WHT
PUR/RED
WHT/BLK 1

YEL/DGN
RNG

YEL/RED

LBL/DGN
LBL/RED
YEL/DBL

YEL/BLK

YEL/LBL
LBL/BLK
DIVERTER
FRONT DBL/YEL BLK 2 2
E 2

C405
WHT/RED 2 SOLENOID

WHT

RNG
DGN
GRY

RED
C440
AUX.

DBL
BLK

BLK
B DGN/WHT WHT 3 3 DBL/WHT YEL 1 1
F RNG/WHT 5 4 DGN

C303
RNG
YEL/BLU A A YEL/DBL
C DGN 6 5
OPEN B B PUR/WHT
D YEL DGN 4 6
OPEN C C PUR/RED
SKI CONTROL
DETENT

TO ATTACHMENT

C404

C304
RED A A
A DGN/YEL
REAR AUXILIARY BLK B B
B RELIEF SOLENOID SEAT
SENSOR DGN C C

C415
(IF EQUIPPED)

B
A
RNG BLK BUCKET LEVEL BLK B B

C401
SOLENOID
A DGN/YEL A A
B OPEN
DGN/YEL
C307

B
A
C305
LEFT HANDLE (IF EQUIPPED) RED A A

RNG/DGN
TO OPTIONS

DGN/RED
DBL/WHT

DGN/LGN

YEL/DBL
YEL/BRN
YEL/LGN
DBL/YEL
RNG/WHT
TO (RELIEF ADAPTER HARNESS) SEAT BAR BLK B B

DGN/YEL
SKI CONTROL SENSOR

C403
ATTACHMENT
C441

DBL

DBL
C C

YEL
DGN
A A RNG

BLK
B DBL RNG/WHT
A WHT RNG/DBL B B RNG/DBL

TO LH HANDLE TO ENGINE

C111
G
C
B

B
H
D

C
A

A
K

E
B
A
F
TRACTION

J
HORN
A
BOSS CHARGE HARNESS -
LOCK

C402
REAR AUX. B DGN
B
DGN
C407 C408 C409 B OVERRIDE
C457

C YEL/DGN
BRN A C YEL SWITCH
B YEL/RED
A BRN
6717131

G
C
D
B

E
A
C

F
G
YEL

B
A

B
A
H
D

C
E
B
F

A
J
A RNG HERE OR HERE OR
TURN

C455
SIGNAL C C HYDRAULIC TO OPTIONS TO OPTIONS

C406
TO           THIS SHEET OR A A
CHARGE
PRESSURE
(RELIEF ADAPTER HARNESS) (RELIEF ADAPTER HARNESS)
C301
TO ATTACHMENT C457 B B 5-90 OHMS A
B
A
B
DGN/RED
DGN/YEL B F G C D E A

C412
C418
C C LGN/PNK
CONTROLS MODULE
A A LBL/RED
HIGH FLOW B B D D RNG

PNK/WHT
BLK
SOLENOID

DGN
E E LGN/DBL

BLK

WHT

RNG
DGN
RED
DBL
BLK
F F LGN/RED

MAINFRAME CONTROLLER HARNESS -

A
B
TO ATTACHMENT HYDRAULIC OIL TEMPERATURE
C442

568-1804 OHMS
A DGN C413 6712523 HYDRAULIC
MANUAL
BRAKE
B LOCK SWITCH

A
B
BRAKE SOLENOID SOLENOID
HYDRAULIC OIL FILTER

C306
DIFFERENTIAL PRESSURE
WHT RED
A A

RNG/DBL

YEL/BRN
B B BLK

YEL/DBL
FILTER HARNESS

LBL/RED

YEL/LBL
RNG
RNG
DGN
BRN

BLK

BLK
BLK

YEL
(BOSS) -

BLK

C308
RED A A

6716643 BLK C C BLK

C
D
A
B

E
G
H

D
C
D

E
B
A

B
A
K

F
J
WHT B B

C106 C107 C108 C109 C110 C117 C119 C203

DGN/RED
TO *  PIN NUMBER = 30 PIN CONNECTOR BOSS # PIN NUMBER = 18 PIN CONNECTOR

G
TO TO
B
A

C
D
B
A

B
A

A
B

E
D F E C B A

F
J
ATTACH. ATTACH. CONTROLS
(USED W/ FUEL SHUTOFF

* G1
SOLENOID

* C1

# C1

* D1

* H1

* G2
* G3

* D1
* E1
* B1

# B1

* A1

* K1

# E1
# A1
* H2
* C3
* C2
* D3
# C3
# C2

# D2
# D3
* D2

* H3

* F1

# F1
* B2
# A2
# A3
# B2
# B3
# D1

* E2
* E3

* B3
# E3

# E2

* K2
* A3
* A2
* F3

* F2

* J1

# F3
# F2
* J2
* J3

LGN/RED

LGN/PNK
DGN/YEL
ADVANCED

LGN/DBL
RNG/DBL

DGN/YEL
LBL/RED

YEL/BRN

YEL/DBL
DBL/YEL
YEL/LBL
HAND
RNG

RNG

RNG
BLK

BLK

ACC
CONTROLS
RNG

RNG

RNG
DGN
BRN
BLK

BLK

YEL

YEL
BLK

BLK

BLK
OFF
ONLY)

RNG/WHT
RNG/WHT
WHT/RNG

PUR/WHT
RUN

PUR/RED

RNG/DBL
LBL/WHT
YEL/DGN
YEL/BRN
DBL/YEL
YEL/DBL

YEL/LBL

YEL/LBL

PUR/RED
START

YEL/RED

RNG
RNG
C A D B E

PUR

RED
BLK

BLK

BLK

BLK

BLK

BLK
DIODE

BLK
BLK

BLK
D A C B E

DGN/YEL SO
MODE
SHUTDOWN RELAY B
FUEL LEVEL LIGHT DETENT RED/WHT DBL/WHT DBL
DIODE
33-246 OHMS LIGHT ST

86 85 AUXILIARY HYDRAULIC SWITCH LEFT
RNG

ENGINE COOLANT RIGHT
BLK (IF EQUIPPED) HEAD
HERE OR TO OPTIONS 1075-2231 OHMS HEAD
HERE OR TO OPTIONS (K TO P HARNESS) 87 LIGHT LIGHT

C113 C112
(K TO P HARNESS) (IF EQUIPPED)
FUSE 6

RED/DBL
RNG

ENGINE OIL 30 I (IF EQUIPPED)
RNG
B B
Dealer Copy -- Not for Resale
25A

BLK PRESSURE 87A BLK

C105

TO OPTIONS REAR AUXILIARY
3-90 OHMS
DGN/YEL A A RELIEF (IF
RNG SV2 EQUIPPED) ENGINE RPM IGNITION SWITCH
(MAGNETIC PICKUP) TO BICS BLK
AIR FILTER

C111
RED

YEL/LBL YEL/LBL A RNG C M WHT

BLK B B
TO OPTIONS DIVERTER RNG F L WHT/BLK WHT/BLK
YEL A A (IF EQUIPPED) BLK BLK B
J BLK SV1 PUR/RED N G RED/WHT
FUSE 8 FUSE 2
G RNG RNG RED RED RNG/WHT PUR/WHT P R PNK
25A 10A S DBL/WHT
F BRN RNG/DBL X
H DBL
C104

E BRN/DGN RNG V
E RED/WHT RED/WHT 1
D BRN/YEL LBL/RED W
W LBL/RED BLK 2
C DBL DBL H
3
B PNK PNK R X RNG/DBL BLK

A E B RED/WHT

C114
RED/WHT RED/WHT
H DBL/WHT S V RNG DBL/WHT
4
PNK

K DBL/BLK WHT M C RNG DBL/WHT

5
WHT/BLK L F RNG DBL
6
TO OPTIONS
(WIPER/WASHER BOTTLE) AUXILIARY RED/WHT B P PUR/WHT
LIGHT SWITCH (IF EQUIPPED)
C102 C103

HOURMETER AND N PUR/RED
A DBL/BLK K
HARNESS (IF EQUIPPED) DIODE
B BLK LBL/RNG J D BLK

TO OPTIONS
BLK h RNG U A BLK
J
RED/WHT

RED/WHT

(BACK-UP ALARM SWITCHES) BLK D HIGH FLOW SWITCH (IF EQUIPPED)

DGN/RED WIRE JUMPER FROM 2 TO 3
RNG BLK A U WHEN NOT EQUIPPED WITH HIGH FLOW SWITCH
RNG/DGN RED/WHT G T LBL/RED 1 2
STARTER RELAY GLOW PLUG RELAY K 3 DGN/RED
T BLK
B
A

FUSE 4
FUSE 3

HERE OR
TO OPTIONS BLK

C116
25A

C121
25A

86 4 WHT/BLK
BACKUP RNG C F RNG/DGN 85 86 85 5
WHT BLK BLK LBL/WHT GLOW BLK 6
ALARM PLUGS BLK
RNG/DGN F C RNG
B
A

SWITCHED POWER RELAY 87 87
G G WHT/LGN 30 LBL/RNG BLK HR
30
C101

87A RED RED 87A HORN (IF EQUIPPED)

E B BLK 87A BLK
WHT/BLK

HR
BLK
RNG

PNK A D BRN/DGN 30 DIAGNOSTIC PORT

RED
D E BRN/YEL RED 87 BLK HR 1 RED RNG/DBL BLK

C202
DBL/WHT H A PNK 86 2 PUR/RED
RED

85 BLK HR
RNG BLK
BLK B H DBL/WHT 3 PUR/WHT
FUSE 5 TO OPTIONS
4 BLK (FRONT WIPER)
FUSE 1

RED/WHT
10A

C204
15A
RED/WHT 1
LGN/WHT BLK 2
BRAKE RELAY BOSS DISPLAY
DBL/WHT

DBL/WHT

RNG

LGN B PUR/RED
87A
BLK

BLK

FUSE 7 PUR/WHT BUCKET LEVEL

PNK

C
BLK

A
B

SWITCH (IF EQUIPPED)
PNK
BLK

30

C201
RED/WHT A RNG
87
C118 RED
RED
RED 25A WHT
E RNG
1 2
WHT/BLK
S 86 85 BLK RNG
RED BLK PNK/WHT D 3
A
B

WHT/BLK

M
RED 4

G
RED DGN/WHT
LEFT RIGHT RED RED 5
WHT/LGN RED DGN/WHT 6
TAILLIGHT TAILLIGHT LEFT RIGHT PUR RED S B
WORK WORK EXC B
LIGHT LIGHT BATTERY

REAR LIGHT HARNESS - 6714350 BLK B B BLK

CAB HARNESS (BOSS) - 6711774

C115
STARTER
ALTERNATOR
WHT C C WHT
PNK/WHT D D PNK/WHT
RNG A A RNG

ENGINE HARNESS (BOSS) - 6715948 OR 6718071

RED = RED
RNG = ORANGE
BICS
WIRES CONNECT BY SOME CONNECTOR BLK = BLACK
ENGINE

LBL = LIGHT BLUE
FUSE 1 10A
FUSE 5 LETTER ACROSS BODIES NOT SHOWN
15A

DBL = DARK BLUE
CONNECTORS FOR DRAWING CLARITY LGN = LIGHT GREEN
DGN = DARK GREEN
BOSS

A B YEL = YELLOW
10A

FUSE 2 25A FUSE 6

B A PNK = PINK
PWM WHT = WHITE
BRN = BROWN
LIGHT
TAN = TAN
FUSE 3
BRAKE

25A FUSE 7 PUR = PURPLE

25A

GRY = GREY
ACCESSORY

FUSE 8
25A

FUSE 4
ACCESSORY
25A
MC2410 (10-28-99)
FUSE BLOCK

303 of 570
304 of 570
 863 - WIRING SCHEMATIC
ATTACHMENT CONTROL OPTION LIFT ARM HARNESS - 6710299
S/N 514425001-39999 ATTACHMENT CONTROLS HARNESS - 6710300 TO OPTIONS
TO OPTIONS
(Printed October 1998) (K TO P DIV ERTER HA RNESS) BLK B B BLK B
MC2416

C508
A LGN LGN J J LGN J
B PNK PNK N N PNK N
C WHT WHT P P WHT P
RED A A RED A
RNG/DBL L L RNG/DBL L
D D D

C506
BRN BRN

C507
DIODE MODUL E
LBL C C LBL C
RNG/WHT E E RNG/WHT E
DBL F F DBL F
K K LBL DG N G G DG N G
E E YEL YEL H H YEL H
D D DG N DG N M M DG N M
C C YEL/WHT RNG K K RNG K

C509
B B DBL R R
A A RNG/WHT
F F BRN
H H
G G WHT
J J BRN/Y EL

TO CONTROLS

C406
YEL/RED B
YEL/LGN C
RNG A

RELAY 1 - TO WA TER KIT

(EXAMPLE -  A NGLE BROOM POWER) TO CONTROLS

C505
(RIGHT HA NDLE)
87A B BLK
30 A LGN/WHT LGN/WHT B
RED/WHT
87 E
RED

C440
86 85
BLK F
BLK WHT
YEL D
DG N C
RNG A

RELAY 2 - TO CONTROLS

C404
(EXAMPLE - FRONT/REA R A UXILIA RY  -  BA SE END) (AUXILIA RY  RELIEF)
DGN/Y EL A
87A
30
YEL/RED B
YEL/WHT
87
LGN
86 85
BLK RNG/DBL

TO CONTROLS
(LEFT HA NDLE)

C441
DBL B
RELAY 3 -
(EXAMPLE - FRONT/REA R A UXILIA RY  -  ROD END) WHT A
RED = RED 87A TO CONTROLS
YEL/LGN
RNG = ORANGE 30 (LEFT HA NDLE)
BRN/Y EL
BLK = BLACK 87

C457
LGN RNG A
LBL = LIGHT BLUE
DBL = DARK BLUE BLK
86 85
RNG/DBL
YEL/RED B
LGN = LIGHT GREEN YEL/LGN C
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE RELAY 3 -
(EXAMPLE -  STUMP GRINDER)
GRY = GREY
87A
DG N
30 TO CONTROLS
LGN (USED WITH HIGH
87
FLOW MA CHINES ONLY )

C421
86 85
WIRES CONNECT BY SOME CONNECTOR BLK DG N DG N A
LETTER ACROSS BODIES NOT SHOWN B
CONNECTORS FOR DRAWING CLARITY
A B
B A
305 of 570

RED/WHT
RNG
BLK
TO TO
ENGINE B A ENGINE B A

C106 C107
MC2416 (11-4-99)
306 of 570
 863 - WIRING SCHEMATIC TO ATTACHMENT TO ATTACHMENT
TO NEWER
MODEL ATTACHMENTS
TO CONTROLS TO CONTROLS K TO P RELAY

OPTIONS

C401

C401
B B B 87A
DGN/YEL A DGN/YEL A 30 YEL
S/N 514425001-39999 J J D
B BLK B
YEL
87
N N N TO CAB
(Printed October 1998) TO ENGINE

C202
86 85
P P P BLK WHT (REAR AUXLIARY
TO ENGINE
MC2417 M
TO OLDER
M
TO OLDER
TO ATTACHMENT M TO CONTROLS TO CONTROLS TO CONTROLS TO CONTROLS
TO CAB RED RELIEF)

C112
MODEL ATTACHMENTS MODEL ATTACHMENTS

C112
A C C WHT A YEL YEL A

C412 or C230

C412 or C230
C412 or C 230

C412 or C 230

A LBL/RED A A LBL/RED A B BLK BLK B
D WHT S D S S DGN A

C211
B B B B

C506

C506

C627
DGN/YEL DGN/YEL DGN/YEL DGN/YEL
C BRN LT A BRN LT LT BRN J PUR
C LGN/PNK C C LGN/PNK C

C623

C626

C628
E BLK TM E BLK TM TM BLK E
D RNG D D RNG D TO
F DBL CENTER F DBL CENTER CENTER DBL F DBL
E LGN/DBL E E LGN/DBL E ATTACHMENT
G RED GD G RED GD GD RED G

C508
F LGN/RED F F LGN/RED F A
H YEL RT H YEL RT RT YEL H YEL
B
L RNG L L
C

BLK
RELIEF ADAPTER HARNESS AUXILIARY BLEED ADAPTER BLK WHT

BLK
K RNG K K
NEW TO OLD OLD TO NEW
6710435 6718111 SHUTDOWN MODULE K TO P DIVERTER HARNESS - 6716798
RIGHT TURN
LAMP/
LEFT TURN
LAMP/ GRADER HARNESS ADAPTER HARNESS ADAPTER HARNESS
FLASHER FLASHER
6707303 6706391 6706392

BRN/DGN
V

BRN/YEL
REAR WIPER
MOTOR M
TO OPTIONS
(4-WAY FLASHER) M M HEATER RELAY M RED

RNG/BLK
BRN/YEL B B

C604
FRONT WIPER FRONT WIPER
A

BLK
BLK
BRN/DGN BOTTLE AND TANK FRONT WIPER BOTTLE AND TANK FRONT WIPER REAR WIPER
SWITCH 85 86
MOTOR MOTOR TO HEATER BLK
BLK C FAN SWITCH
RNG
1
2 1 V 2 1 V 2
RNG/BLK WHT WHT 87
30
STARTER
M M

C618
87A RED/WHT
JV REAR LIGHT HARNESS C622 C625 3
RNG

RED/WHT
YEL

C619
6711160 2 1 2 1
4
RED TO ACCESSORY
DBL/BLK RNG
5

RNG/BLK

RNG/BLK
BLK

BLK
6 RED
TO ENGINE
YEL RNG A C BLK

DBL/BLK

DBL/BLK

C617
TO ENGINE

C105
25A

BLK

BLK
J RNG RED/WHT B B RED/WHT RED RNG
FRONT WIPER FRONT WIPER
BEACON SWITCH SWITCH K BLK BLK C A RNG RNG
OR STROBE DBL/BLK M
1 RNG/BLK
1 RED/WHT G HEATER WIRING HARNESS HEATER WIRING HARNESS
B A RED/WHT RED/WHT HEATER (OPT.)
2 2 E (HEATER SECTION) (ENGINE SECTION)

C609

C104
3 3 D

RED/WHT

RED/WHT
F
B A
4
DBL/BLK
4 A HEATER WIRING HARNESSES - 6660894 AND 6660892
5 5 B
6 6 C
BRN/RED
BLK

TO CAB TO OPTIONS
H TO ENGINE
C601, C602 or C 603 TO ENGINE (DIVERTER VALVE)

C204

C204

C113

C113
TO OPTIONS 1 1
2 2 A YEL A
BLK BLK
BRN/RED E
REAR WIPER HARNESS - 6712260 B BLK B TO ENGINE

C616

C103
D TO CONTROLS TO CONTROLS RED/WHT A
C FRONT WIPER HARNESS FRONT WIPER HARNESS J BLK J TO ENGINE
TO ENGINE
(REAR AUX. BLEED)
DBL/BLK B
M

C112

C112
BLK F BOTTLE/PUMP
B 6712259 6708269 (LH HINGED DOOR) K BLK K A DGN/YEL A
A G BLK G B BLK B
TO OPTIONS BLK
(BRACON/STROBE)
E E

C408

C408
A
TO ENGINE D BLK D DIVERTER RELIEF REAR WIPER/WASHER BOTTLE HARNESS - 6709164
TO TO F BLK F
MAINFRAME MAINFRAME BLK J A BLK A HARNESS - 6710870

C603
C416
C416
TO CAB TO OPTIONS A A K
BEACON/STROBE HARNESS YEL BLK B BLK B

C624
C204
FRONT WIPER
1 RED/WHT B BLK B F BLK G BLK
6 C C
MOTOR 2 TO ENGINE
6708318 BLK B
4 5
E H BLK H TO ENGINE (DIVERTER VALVE) TO ENGINE

C113

C113
C104
TO
V

C105
TO E D
MAINFRAME MAINFRAME A YEL A
M WIPER HARNESS F RNG

C417
C417
A YEL A
BRN/RED
3
RED/WHT A ELECTRIC CONNECTOR B BLK B
B BLK B 1 2
6708225 B
ASSEMBLY HARNESS- 6704114
BEACON DIVERTER TO ENGINE

C102
SWITCH
C
RNG
DIVERTER RELIEF

RNG/BLK
H
BEACON
OR STROBE
FOR REAR AUXILIARY ONLY HARNESS - 6704203 RNG/DGN

A B HARNESS - 6710870 BEACON/STROBE HARNESS -
LEFT RIGHT
C608
BLK

BLK

CLEARANCE
(WORK LIGHT)
CLEARANCE
(WORK LIGHT)
FRONT WIPER
SWITCH 6712258
LAMP LAMP A B TO ENGINE
RIGHT 1 BLK
LEFT RED/WHT BACKUP RNG C BACK-UP ALARM
TURN TURN 2 ALARM SWITCHES
LAMP LAMP RNG/DGN F BLK
3 G
BRN/RED
BLK

C101
FLASHER
E
DGN
PNK

Dealer Copy -- Not for Resale PNK A

PNK
PNK
YEL

5 HAZARD
SWITCH
D BACK-UP ALARM SWITCHES HARNESS - 6704358
6 DBL/WHT H
TO OPTIONS
TO OPTIONS BLK B
BACK-UP ALARM SWITCHES HARNESS - 6704815
C601 or C 602

BRN/RED E
C624

1 RED/WHT BRN BRN/DGN

PNK D 2 1
2 TO OPTIONS BRN

PNK
PNK
BLK
C 3 TO ENGINE

DBL/WHT
BLK

BLK

BLK
BLK F

BLK
BRN/YEL J
5 4 BLK
DGN B FRONT WIPER HARNESS C602 6
BLK K
DOME LIGHT
SWITCH
TO ENGINE
YEL A BACK-UP RNG C
G
6568739 (RH HINGED DOOR) F
B
BLK
BRN/DGN BRN/DGN E
TO CAB
ALARM
RNG/DGN F

C209
A RED G

C104
4-WAY FLASHER HARNESS - 6709530 BRN/YEL D DBL/WHT

C101
BRN/YEL
B BLK E
BRN F
TO OPTIONS LEFT RIGHT LEFT WORK RIGHT WORK A
TO ENGINE TO ENGINE RED/WHT A TAILLIGHT TAILLIGHT
(JV REAR LIGHT) D
B
C113
C113

A A DOME LIGHT BACK-UP ALARM HARNESS
C604

YEL B BRN/YEL H
C
B BLK B A BRN/DGN B
H
C BLK
REAR LIGHT HARNESS - 6707669 6715659
BEACON
DIVERTER HARNESS EUROPEAN USE ONLY
OR STROBE
A B 4-WAY FLASHER HARNESS - 6712288
6704203
C607
BLK

A B
TO ENGINE

V REAR WIPER BACKUP
ALARM
RNG RNG C
BLK

BLK

MOTOR
M RNG/DGN RNG/DGN F
BRN/RED
BLK

DBL/BLK G

C101
BEACON FLASHER
LEFT TURN RIGHT TURN YEL E

RNG/BLK
LAMP/ LAMP/ SWITCH
FLASHER FLASHER PNK A
BLK REAR WIPER DGN D
TO OPTIONS 6 SWITCH

C612
HAZARD DBL/BLK DBL/WHT H
DGN

C601 or C602
YEL

BRN/RED E 4 5 SWITCH 1
RNG RNG/BLK BLK BLK B
D 2 M
RED/WHT BRN BRN/DGN BOTTLE/PUMP
C 3 2 1
BRN/RED RED/WHT BRN 3

RED/WHT
BLK F 1 2 3

DBL/WHT

BLK
BRN/RED
DGN B 4

BRN/RED
TO
BRN/YEL DBL/BLK

BRN/RED
5 4 ENGINE
YEL A 5
RED/WHT

BLK

DGN
PNK
BLK
6

PNK
PNK
YEL
BLK
RNG 6 BLK J
K
JV FLASHER LIGHT HARNESS - 6710905 DBL/BLK
G E F D A B C F E D C B A DBL/WHT
RNG B A BLK
BRN/DGN E
C613 C614 C615

C104
REGISTRATION LEFT WORK RIGHT WORK
BRN/YEL D
FOR LAMP
TO OPTIONS F E F D A
BRN B C FUTURE USE F E D C B A
BRN/RED RED/WHT A
PNK PNK B
C601

BEACON
OR STROBE DBL DBL C
B A
F BLK H
C606 B BRN/DGN LEFT TAILLIGHT RIGHT TAILLIGHT
BRN/YEL
B A
TO OPTIONS
REAR TAILLIGHT HARNESS - 6709048
LEFT TURN RIGHT TURN
RED/WHT
BRN/DGN

(JV REAR LIGHT)
BRN/YEL

LAMP LAMP
C604

B BRN/YEL
RNG
BRN/RED

BLK
BLK

A BRN/DGN
C BLK REAR WIPER
TO OPTIONS SWITCH
C601 or C602

BRN/RED E A B A C B 1 V
DGN

RNG/BLK
M
YEL

D 2
C
C610 C611 REAR WIPER
3

RED/WHT
A B A C B MOTOR
BLK F
DGN B 4
YEL A 5
BLINKER MODULE
6

4-WAY LIGHT HARNESS - 6714213 TO ENGINE
CAB ACCESSORY HARNESS - 6710481

C103
DBL/BLK B
RED/WHT A

RED = RED
RNG = ORANGE REAR WIPER
BLK = BLACK
LBL = LIGHT BLUE HARNESS - 6708285
DBL = DARK BLUE WIRES CONNECT BY SOME CONNECTOR
LGN = LIGHT GREEN LETTER ACROSS
DGN = DARK GREEN BODIES NOT SHOWN
YEL = YELLOW CONNECTORS FOR DRAWING CLARITY
PNK = PINK
A B
WHT = WHITE
BRN = BROWN B A MC2417 (10-29-99)
TAN = TAN
PUR = PURPLE
307 of 570 GRY = GREY
308 of 570
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 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

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

Dealer Copy -- Not for Resale

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

Revised
309 of Feb.
570 99 –6–5– 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–07627

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.

1
2

N–17636

The decal (Item 2 ) [B] inside the rear door specifies the
fuse sizes used in loader circuits [C].
C

P–13771

863, 863H Bobcat Loader

310 of 570 –6–6– Service Manual
BATTERY
Removal And Installation
A 1

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 B
quantities of water or milk! DO NOT induce
vomiting. Get prompt medical attention. 1
W–2065–1296

Open the rear door.

Dealer Copy -- Not for Resale

Disconnect the negative (–) cable (Item 1) [A] from the
battery.
Remove the bolt from the cable clamp (Item 2) [A] and
loader frame.
P–10809
Remove the battery holddown clamp (Item 1) [B].

Disconnect the positive (+) cable (Item 1) [C] from the C 1

battery.
Remove the battery from the loader.

P–10806

863, 863H Bobcat Loader

311 of 570 –6–7– 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
clothing and rubber gloves to keep acid off
body. 1
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 P–10811
vomiting. Get prompt medical attention.
W–2065–1296

The battery cables must be clean and the connections

D
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

312 of 570 –6–8– Service Manual
BATTERY (Cont’d)
Using A Booster Battery
A

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

Dealer Copy -- Not for Resale

Keep arcs, sparks, flames and lighted tobacco
away from batteries. When jumping from 3
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 disconnect the battery
cables. Damage to the alternator can occur if:
• 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
Connect the end of the first cable (Item 1) [A] to the positive fast charger or when welding on the loader
(+) terminal of the booster battery. Connect the other end (Remove both cables from the battery).
of the same cable (Item 2) [A] to the positive terminal on • Extra battery cables (booster cables) are
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

313 of 570 –6–9– 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
the machine to fall or move and cause injury or 1
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
Connect the fuel stop solenoid, start the engine and run at Terminal
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

314 of 570 –6–10– Service Manual
ALTERNATOR (Cont’d)
Alternator Regulator Test
A

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.

Dealer Copy -- Not for Resale

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.
Remove the wires from the back of the alternator. P–07716

Remove the regulator cover from the back of the alternator.

Install the wires on the back of the alternator. B
Connect a jumper wire (Item 1) [B] from the brush terminal
to the ground stud.
Connect the negative (–) battery cable and start the engine. Ground
Run at 1500 RPM. Stud

If the voltmeter reading is 14.5 or above, replace the

regulator.
Brush
If the voltmeter reading is below 14.5, repair or replace the Terminal
alternator.
1
P–01364

863, 863H Bobcat Loader

315 of 570 –6–11– 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.

Disconnect the wiring harness connectors (Item 2) [B].
B

2 1

P–07896

Loosen the adjustment bolt (Item 1) [C].

Remove the alternator belt.
C
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

316 of 570 –6–12– 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

Dealer Copy -- Not for Resale

11 14
10
9

15 C–03312

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–01369

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–01386

863, 863H Bobcat Loader

317 of 570 –6–13– Service Manual
ALTERNATOR (Cont’d)
Rotor Continuity Test
A
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–01365

Rotor Ground Test

Touch one probe to one of the slip rings and the other probe B
to the rotor shaft [B].
There should be no continuity.
Replace the rotor if there is continuity.

P–01378

Rectifier Continuity (Diode) Test

NOTE: In the diode tests there should be continuity in C
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–01373

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–01370

863, 863H Bobcat Loader

318 of 570 –6–14– 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

Dealer Copy -- Not for Resale

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.
Remove the starter. 1

P–07895

863, 863H Bobcat Loader

319 of 570 –6–15– 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–02297

863, 863H Bobcat Loader

320 of 570 –6–16– 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].
Assembly: Tighten the through bolts to 60–104 in.–lbs. B
(6,8–11,8 Nm) torque.

Dealer Copy -- Not for Resale

B–14474

Remove the field windings housing from the magnetic

switch [C].
C

B–14442
Assembly: When installing the field windings housing to
the magnetic switch, engage the tab (Item 1) [D] on the field
windings housing with the notch in the magnetic switch. D 1

B–14468

863, 863H Bobcat Loader

321 of 570 –6–17– 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). Make sure that the positive brush wires are not Insulator
grounded when assembling the brush holder to the field Negative
windings, take care not to damage and get oil on the Brush
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

322 of 570 –6–18– 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 6–21.)

Dealer Copy -- Not for Resale

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

Revised
323 of Feb.
570 99 –6–19– 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

324 of 570 –6–20– 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

Dealer Copy -- Not for Resale

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

325 of 570 –6–21– 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

326 of 570 –6–22– 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.

Dealer Copy -- Not for Resale

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

327 of 570 –6–23– 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 field B
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 the D
starter rotation and locked in the opposite rotation [D].

B–14465

863, 863H Bobcat Loader

328 of 570 –6–24– 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
connecting Terminal C and M.T. are closed, the pinion M.T.
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 should
remain in the engaged position.
B 50
C

Dealer Copy -- Not for Resale

M.T.

B–14470

Return Test: With the same conditions as in the hold–in

test, open the connecting Terminal 50 [C]. The pinion
should return immediately.
C 50

M.T. . . . Main Terminal to which the main cable from the C

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.
No Load Test M.T.
The following test should be done after reassembling the
starter: B–14469

Clamp the starter in a vise. Use a 12 volt battery and

ammeter, connect the positive wire of the battery, and the
ammeter to the 50 Terminal [D]. Connect the negative wire
D Ammeter
to the starter body.
50
The starter should show smooth and steady rotation M.T.
immediately after the pinion is engaged, it should draw less
than the specified current. C

Service Limit – 200 Amp. Maximum Draw

863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.) – Electrical System Part 1 of 2

Starter
B–14440

863, 863H Bobcat Loader

329 of 570 –6–25– Service Manual
STANDARD INSTRUMENT PANEL
Removal And Installation
A
Pry the rubber light mount loose from the operator cab
(both sides) [A].

P–03995

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 sure 1
you have the correct wiring schematic for the
loader.

P–03955

Pull the left instrument panel down and disconnect the wire
harness connectors from the panel. Remove the panel [C]. C

P–03951

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–03953

863, 863H Bobcat Loader

330 of 570 –6–26– Service Manual
FRONT LIGHTS
Removal And Installation
A
The front lights are mounted in the upper corners of the
operator cab [A].

P–03956

Pry the rubber light mount free from the operator cab [B].
B

Dealer Copy -- Not for Resale

P–03995

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–03955

863, 863H Bobcat Loader

331 of 570 –6–27– Service Manual
RELAY SWITCHES
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.
863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.) – Electrical System Part 2 of 2

P–07896

863, 863H Bobcat Loader

332 of 570 –6–28– 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
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–122
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
DEUTZ ENGINE TOOLS
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–55
ENGINE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–26
ENGINE MOUNTS ENGINE
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–32 SERVICE
ENGINE MUFFLER
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6
ENGINE OIL COOLER
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–121
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

Continued On Next Page

863, 863H Bobcat Loader

Revised
333 of Feb.
570 99 –7–1– Service Manual
 ENGINE SERVICE (Cont’d)

Page
Number

FUEL INJECTOR
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–43
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–42
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–40
FUEL INJECTION PUMP
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–36
Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–36
GLOW PLUGS
Checking The Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–34
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 Feb.
33499
of 570 –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
Slow cranking speed.
Engine will not start.
Difficult to start.
No power for engine.
Engine is mis–firing.
Too much fuel consumption.
Black exhaust.
Blue/white exhaust.
Low oil pressure.
Engine knocking.
Engine running rough.
Vibration.
High oil pressure warning.
Overheating.
Too much crankcase pressure.
CAUSE
1, 2, 3, 4
2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29
5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 47, 46
4, 31, 32, 33, 34, 35, 37, 39, 48
13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 49
7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 49
12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
4, 33, 36
10, 12, 13, 15, 16, 20, 21, 32, 40, 44, 47
22, 27, 29, 46

Dealer Copy -- Not for Resale

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. 26. Incorrect high pressure fuel pipes.
2. Bad electrical connections. 27. Worn cylinder bores.
3. Faulty starter motor. 28. Worn valve and seats.
4. Incorrect grade of oil. 29. Broken, worn or sticking piston rings.
5. Low cranking speed. 30. Worn valve stems or guides.
6. Fuel tank empty. 31. Worn or damaged bearings.
7. Faulty stop control operation. 32. Not enough oil in the oil pan.
8. Plugged fuel line. 33. Switch/sensor is defective.
9. Plugged fuel filter. 34. Oil pump worn.
10. Restriction in the air cleaner. 35. Pressure relief valve is sticking open.
11. Air in the fuel system. 36. Pressure relief valve is sticking closed.
12. Faulty fuel injection pump. 37. Broken relief valve spring.
13. Faulty fuel injectors. 38. Faulty suction pipe.
14. Broken injection pump drive. 39. Plugged oil filter.
15. Incorrect injection pump timing. 40. Piston seizure.
16. Incorrect valve timing. 41. Incorrect piston height.
17. Poor compression. 42. Faulty engine mounting.
18. Plugged fuel tank vent. 43. Incorrect alignment of flywheel.
19. Incorrect grade of fuel. 44. Faulty thermostat.
20. Exhaust pipe restriction. 45. Plugged oil cooler
21. Cylinder head gasket leaking. 46. Plugged PCV system.
22. Overheating. 47. Damaged valve stem oil deflectors.
23. Cold running. 48. Plugged oil pump pipe strainer.
24. Incorrect tappet adjustment. 49. Broken valve spring.
25. Sticking valves.
863, 863H Bobcat Loader
335 of 570 –7–3– Service Manual
ENGINE SPEED CONTROL
Removal And Installation
A

1
P–04731

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.)
Remove the two mounting bolts (Item 1) [A].
P–05368
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 C 1 2
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 mounting
bracket (Item 2) [C].

P–05375

Remove the retainer pin (Item 1) [D] and pivot pin (Item 2)
[D] from the speed control arm (Item 3) [D] to disconnect D
the speed control cable clevis.
NOTE: Do not lubricate the speed control parts when
assembling.
3

1 2
P–05378

863, 863H Bobcat Loader

Revised Feb.
33699
of 570 –7–4– Service Manual
ENGINE SPEED CONTROL (Cont’d)
Speed Control Cable
A 1

P–07940

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 2
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 arm and install an approved lift arm support

Dealer Copy -- Not for Resale

device. (See Page 1–1.)
3 1
Raise the operator cab. (See Page 1–1.)
Remove the speed control lever assembly. (See Page 4
7–4.) P–05545

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.
NOTE: The throttle mount bracket bolts (Item 2) [B]
can be removed to assist u–bolt removal. 5
4
Remove the nut (Item 3) [B] to disconnect the cable from
the linkage.
1
P–05544
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
337 of Feb.
570 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–07898

Remove the three bolts and nuts (Item 1) [B] from the
muffler exhaust flange. B

P–07900

Remove the two bolts and nuts (Item 1) [C] from the muffler
mounting bracket. C
Remove the muffler.

P–07899

863, 863H Bobcat Loader

338 of 570 –7–6– Service Manual
AIR CLEANER HOUSING
Removal And Installation
A
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–07901

BOSS® option loader:

Disconnect the sensor wire connector (Item 1) [B]. B

Dealer Copy -- Not for Resale

P–07802

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–07779

863, 863H Bobcat Loader

339 of 570 –7–7– Service Manual
BLOWER HOUSING/FAN GEARBOX
Removal And Installation
A

P–07966

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
Remove the mounting bolts (Item 1) [A] from the gas
cylinder mounting bracket. P–05860

Installation: Tighten the mounting bolts to 80–90 in.–lbs.

(9–10 Nm) torque. C
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–07772
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–07774

863, 863H Bobcat Loader

Revised Feb.
34099
of 570 –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.

Dealer Copy -- Not for Resale

1

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
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
D
(Item 1) [D] from the blower housing.
Install the new grill and replace the screws.
1

P–07776

863, 863H Bobcat Loader

341 of 570 –7–9– Service Manual
FAN DRIVE TENSION PULLEY
Removal And Installation
A
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
bushing. Clean all parts and assemble dry. Do 3
not lubricate. (See Parts Mircofiche for correct
2
part numbers.) 4 1

N–00303

863, 863H Bobcat Loader

342 of 570 –7–10– Service Manual
BLOWER FAN
Removal And Installation
A
Remove the lock nut and spacer [A].
Installation: Tighten the nut to 45–55 ft.–lbs. (61–75 Nm)
torque.

CD–09952

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 .

Dealer Copy -- Not for Resale

1

P–03006

Remove the fan from the tapered shaft [C].

C

CD–09953

To remove the blower housing mounting plate, remove the

six bolts (Item 1) [D]. D
1

1
CD–09954

863, 863H Bobcat Loader

343 of 570 –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–01002

863, 863H Bobcat Loader

344 of 570 –7–12– Service Manual
FAN GEARBOX (Cont’d)
Disassembly
A
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 Below) 1
5. Internal Parts
NOTE: The short housing is only available as an 2
assembly. See the parts identification Page
7–12 for reference. (Order parts from Bobcat
Parts Sales.) P–03005
NOTE: Be sure to count the number and thickness of
shims during disassembly. Install the shims in
the original location during assembly. B
Remove the fan and blower housing mounting plate. (See
Page 7–11.)
Long Housing
Part Number
Loosen the set screws (Item 1) [A] and remove the pulley Tag
(Item 2) [A].

Dealer Copy -- Not for Resale

Remove the long key (Item 3) [A].
Remove the four mounting bolts and the part number tag
[B].
Remove the oil from the gearbox. P–02983

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–02999

Remove the small snap ring [D].

D

P–02964

863, 863H Bobcat Loader

345 of 570 –7–13– Service Manual
FAN GEARBOX (Cont’d)
Disassembly (Cont’d)
A
Remove the small shims [A].

P–02963

Remove the screw and washer from the shaft [B].

B

P–02966

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–03004

Support the bearing and press the shaft from the bearing
[D]. D

P–03298

863, 863H Bobcat Loader

346 of 570 –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–02997
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].

Dealer Copy -- Not for Resale

P–02996

Remove the large snap ring from the flange end of the
housing [C]. C

P–02970

Remove the large shims from the housing [D].

NOTE: Use the same size and thickness of shims
D
during assembly.

P–02969

863, 863H Bobcat Loader

347 of 570 –7–15– Service Manual
FAN GEARBOX (Cont’d)
Disassembly (Cont’d)
A
Remove the screw and washer (Item 1) [A] from the shaft.

P–02978

Remove the snap ring from the cap end of the housing [B].
B

P–02973

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–02998

Press the bearing from the tapered end of the shaft [D].
D

P–03088

863, 863H Bobcat Loader

348 of 570 –7–16– Service Manual
FAN GEARBOX (Cont’d)
Disassembly (Cont’d)
A
Press the bearing, shims and gear from the shaft [A].

P–03001

Remove the key (Item 1) [B] from the shaft.

B

Dealer Copy -- Not for Resale

P–02972

863, 863H Bobcat Loader

349 of 570 –7–17– Service Manual
FAN GEARBOX (Cont’d)
Assembly
A
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.
NOTE: For procedures requiring the use of #242
LOCTITE adhesive, thoroughly clean and dry P–02961
affected parts before the application of #242
LOCTITE.
Long Housing B
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–02960

Install a bearing on the long keyed end of the shaft [C].

C
Support the lower bearing and press the other bearing in
the housing until the bearings seat in the housing [C].

P–02962

Install on the bearing, the same number and size shims that
were removed during disassembly [D]. D

P–02963

863, 863H Bobcat Loader

350 of 570 –7–18– Service Manual
FAN GEARBOX (Cont’d)
Assembly (Cont’d)
A
Install the small snap ring in the groove above the shims
[A].

P–02964

Install the gear key in the flange end of the shaft [B].
B

Dealer Copy -- Not for Resale

P–02965

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–02967
Install the washer [D].
Put liquid adhesive (LOCTITE #242) on the screw threads. D
Install and tighten the screw [D].

P–02966

863, 863H Bobcat Loader

351 of 570 –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–02968

Install the large shims on the bearing (flanged end) [B].

B

P–02969

Install the large snap ring in the groove above the shims
[C]. C

P–02970

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–02971

863, 863H Bobcat Loader

352 of 570 –7–20– Service Manual
FAN GEARBOX (Cont’d)
Assembly (Cont’d)
A
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–02975

Install the shaft in the housing, tapered end in the bearing

at the round flange end of the housing [B]. B

Dealer Copy -- Not for Resale

P–02976

Install on the shaft, the same number and size shims that
were removed during disassembly [C]. C

P–02977

Install a bearing on the gear end of the shaft [D]. D

P–02974

863, 863H Bobcat Loader

353 of 570 –7–21– Service Manual
FAN GEARBOX (Cont’d)
Assembly (Cont’d)
A
Install the snap ring in the groove above the bearing [A].

P–02973

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–02978

863, 863H Bobcat Loader

354 of 570 –7–22– Service Manual
FAN GEARBOX (Cont’d)
Checking Backlash
A
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–02987

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

Dealer Copy -- Not for Resale

shims.

P–02981

Install the four mounting bolts through the flange holes [C].
Install the part number tag [C].
C
Install and tighten the nut to 25–28 ft.–lbs. (34–38 Nm)
torque.

Part Number
Tag

P–02983

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
(to be used with a dial indicator) [D]. 1.000 inch
(25,4 mm)

P–02984

863, 863H Bobcat Loader

355 of 570 –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–02982

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.
If the backlash is LESS than 0.005 inch (0,127 mm) do the P–02979
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

356 of 570 –7–24– Service Manual
FAN GEARBOX (Cont’d)
Checking Backlash (Cont’d)
A
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–03089

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.

Dealer Copy -- Not for Resale

863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.) – Engine Service Part 1 of 5

P–02985

C SHORT HOUSING

P–02986

863, 863H Bobcat Loader

357 of 570 –7–25– Service Manual
ENGINE
Removal And Installation
A
NOTE: The engine and hydrostatic pumps will be
removed as an assembly.

2
1
P–05496

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.)
Raise the operator cab. (See Page 1–1.) P–07774 P–07772

Drain the fluid from the hydraulic reservoir.

Remove the hydraulic reservoir. (See Page 2–1.)
C
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].
Remove the fan drive belt (Item 2) [B]. 2
Disconnect the engine wiring harness (Item 1) [C] from the
operator cab wiring harness. P–04860

Remove the bolt (Item 2) [C] from the harness mounting

clamp.
NOTE: The electrical harness will be removed with the
engine.

863, 863H Bobcat Loader

Revised Feb.
35899
of 570 –7–26– Service Manual
ENGINE (Cont’d)
Removal And Installation (Cont’d)
A

When repairing hydrostatic and hydraulic 1

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–17597
I–2003–0888

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

Dealer Copy -- Not for Resale

hydrostatic and hydraulic filter assembly. (See Page 2–1.)
Disconnect the fuel level sender wiring connector at the fuel
tank.

P–07781

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–05507

Disconnect the four high pressure hoses (Item 1) [D] from

the hydrostatic pumps. D 1

1
P–07787

863, 863H Bobcat Loader

359 of 570 –7–27– Service Manual
ENGINE (Cont’d)
Removal And Installation (Cont’d)
A
Disconnect pump case drain hose (Item 1) [A].

P–07782

Remove the bolt and nut (Item 1) [B] at the right front
engine mount. B

P–07786

Remove the bolt (Item 1) [C] at the left front engine mount.
NOTE: The nut is held in the housing and will not turn. C
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.)
Remove the air cleaner housing. (See Page 7–7.)

P–07785

863, 863H Bobcat Loader

360 of 570 –7–28– Service Manual
ENGINE (Cont’d)
Removal And Installation (Cont’d)
A
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 and/or 1
engine. Add the same amount of oil to the
engine crankcase when adding engine oil.

P–07911

Disconnect the fuel hose (Item 1) [B] from the fuel pump.
B
1

Dealer Copy -- Not for Resale

P–07621

Disconnect the fuel return hose (Item 1) [C]. C

Remove the three bolts (Item 2) [C] from the engine muffler 2
bracket. Remove the bracket.

P–07912

863, 863H Bobcat Loader

361 of 570 –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–05545

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–07914

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–07917

863, 863H Bobcat Loader

362 of 570 –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

Dealer Copy -- Not for Resale

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)
Connect a chain hoist to the ring (Item 1) [B] on the lift
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.

863, 863H Bobcat Loader

363 of 570 –7–31– Service Manual
ENGINE MOUNTS
Replacement
A 1
2

Use the following procedure to install new engine mounts: 3

Remove the existing mount from the engine. Refer to 4

engine removal and installation for engine mount locations.
Replace all four engine mounts (two front and two rear).
5
Use the parts shown to install the new engine mounts [A].
6
Item 1 – Square Nut – Used on left side engine mounts
Item 2 – Hex Nut – Used on right side engine mounts 7
MC–01771
Item 3 – Mount Washer
HEAVY DUTY
Item 4 – Engine Mount
B ENGINE
Engine
Mounting
Item 5 – Tube Spacer MOUNT Bracket
Washer
Item 6 – Snubbing Washer
Item 7 – Mounting Bolt
Loader Engine
Frame Mount
Install the new engine mount as shown in the cut away side
view [B].
Tighten the mounting bolts to 61–69 ft.–lbs. (83–94 Nm)
torque.

Snubbing Spacer
Washer TS–01520

863, 863H Bobcat Loader

364 of 570 –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–05558

Remove the flywheel from the engine crankshaft [B].

B
Flywheel Ring Gear
NOTE: The lead chamfer on ring gear tooth must face 1
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.

Dealer Copy -- Not for Resale

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–05564
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
Remove the hydrostatic pump. (See Page 3–1.) 1
Remove the belt tension pulley assembly. (See Page 3–1.)
Remove the starter. (See Page 6–1.)
Remove the flywheel housing mounting bolts (Item 1) [C].
P–05562
Remove the flywheel housing from the engine.

863, 863H Bobcat Loader

365 of 570 –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). (Item 1) [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.

Connect the testmeter lead to the terminal of the glow plug B
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.
Replace the glow plug if needed. Tighten the glow plug to P–05541
15–18 ft.–lbs. (20–24 Nm) torque.

Late S/N Loaders: C

Late S/N loaders use four glow plugs, one for each cylinder.
The glow plugs are located on the rear side of engine in the 1
cylinder head as shown in figure [C].
Unplug the wire from the glow plug (Item 1) [C].

Use a testmeter to measure the resistance of each glow P–09451

plug.
Connect the testmeter lead to the terminal of the glow plug
as shown in figure [D]. 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

366 of 570 –7–34– Service Manual
VALVE CLEARANCE
Adjustment
A
Make the valve clearance adjustment with engine stopped 1
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–05297

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°) and DO NOT ADJUST ADJUST
set the other valves.

Dealer Copy -- Not for Resale

MC–02174

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–05633

863, 863H Bobcat Loader

367 of 570 –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–05282
equipment.
I–2028–0289

B
Removal
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–05280

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–05281

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–05283

863, 863H Bobcat Loader

368 of 570 –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].

Injection Pump Timing B
The fuel injection pump does not need to be timed if the
tappet, shim(s) and the camshaft are not changed.

Dealer Copy -- Not for Resale

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:
Specifications (BF4M1011) P–05284
Installation Depth . . . . . . . . . . . . . . . . 2.28 inch (58 mm)
Measured Depth a . . . . . . . . . . . . 2.25 inch (57,55 mm)
Difference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D
0.030 inch (0,76 mm)
Tappet
Specifications (BF4M1011F)
Installation Depth . . . . . . . . . . . . . . . . 2.32 inch (59 mm)
Measured Depth a . . . . . . . . . . . . 2.25 inch (57,55 mm)
Difference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.030 inch (0,76 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

369 of 570 –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 7–55,
for correct tool.) C 2
1

P–05288
Install the centering pin (Item 1) [D] into the injection pump
and into the control lever (Item 2) [D]. Align the marks (Item
3) [D] on the pump body and the control lever. Make sure D 2 3
the control lever is in the center position. 1

P–05289

863, 863H Bobcat Loader

370 of 570 –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.
Install the two nuts (Item 1) [A].
1

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].

Dealer Copy -- Not for Resale

2

1
P–05291
Install the high pressure fuel line.
Tighten the fuel line nut to 10–12 ft.–lbs. (13,5–16,5 Nm)
torque [C]. C

P–05280
Install new washers (Item 1) [D] on the fuel line fastening
bolt.
Install the fuel line on the injection pumps and tighten to D
20–23 ft.–lbs. (27–31 Nm) torque.

P–05285

863, 863H Bobcat Loader

371 of 570 –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.

P–05280
Do not bend the high pressure fuel injection
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–05293

Remove the fuel injector (Item 1) [C] and washer (Item 2) C

[C] from the cylinder head.

P–05290

863, 863H Bobcat Loader

372 of 570 –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–08971
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)

Dealer Copy -- Not for Resale

Injection Pressure: (BF4M1011F) . 3625 PSI. (250 bar)

MC–02177

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

373 of 570 –7–41– Service Manual
FUEL INJECTOR (Cont’d)
Disassembly
A
Remove the nozzle cap nut [A].

CD–15332

Disassembly the parts as shown in Fig. [B].

B
1. Nozzle Cap Nut
2. Injector Nozzle
3. Adapter 1
4. Thrust Pin 2
5. Spring 3
6. Shim(s)
5 4
Wash all the parts in clean diesel fuel and blow dry using 6
compressed air.

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

374 of 570 –7–42– Service Manual
FUEL INJECTOR (Cont’d)
Assembly
A
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

Dealer Copy -- Not for Resale

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

375 of 570 –7–43– Service Manual
FUEL INJECTOR (Cont’d)
Assembly (Cont’d)
A
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

376 of 570 –7–44– Service Manual
TIMING BELT
Inspection
A
NOTE: The timing belt is maintenance free. Timing
belts that are in operation do not need to be 2
re–tensioned. The timing belt, belt tensioner
and mount bolt must be replaced every 3000 1
operating hours or every 5 years. A repair kit is
available.
NOTE: If the timing belt has to be removed before 200
hours of engine operation, the timing belt can
be re–used and re–tensioned according to the
procedure listed.
3
To do the following procedure on the BF4M1011F engine
P–05292
only, you need the following tool:
MEL1552 – Torx Bit
Remove the bolts (Item 1) [A] from the timing belt
B
inspection cover.
Remove the torx bolt (Item 2) [A]. (BF4M1011F only.)
Remove the cover (Item 3) [A].

Dealer Copy -- Not for Resale

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

1
Removal
Remove the bolts (Item 1) [A] from the timing belt 1
inspection cover. 2

Remove the torx bolt (Item 2) [A]. (BF4M1011F only.)

P–05295
Remove the cover (Item 3) [A].
Remove the bolts (Item 1) [C] from the v–belt pulley (Item
2) [C].
D
Remove the v–belt pulley.
Remove the bolts (Item 3) [C] from the timing belt cover.
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

377 of 570 –7–45– Service Manual
TIMING BELT (Cont’d)
Installation
A
NOTE: Remove the fuel injectors and rocker brackets
from the cylinder head. (See Page 7–40.) This 2
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 be
seen through the plug hole. B–14402

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.

Measure the distance from the edge of the belt to the front
D
cover surface [D].

P–05630

863, 863H Bobcat Loader

378 of 570 –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].

Dealer Copy -- Not for Resale

1

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

379 of 570 –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.
Remove the belt tension tool. 1

NOTE: See Valve Timing, Page 7–54 before installing

the timing belt cover.
P–05296

Install the belt cover (Item 1) [B] and tighten the bolts.
B
Install the v–belt pulley (Item 2) [B] and tighten the bolts to 1
30–36 ft.–lbs. (41–49 Nm) torque.

P–05295

Install the timing belt inspection cover (Item 1) [C] and

tighten the bolts. C

1
P–05292

863, 863H Bobcat Loader

Revised Feb.
38099
of 570 –7–48– Service Manual
TIMING BELT (Cont’d)
Belt Replacement In Loader
A
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
7–94.)
NOTE: The rear door is removed for photo clarity only. 1
Disconnect the negative (–) battery cable. 2
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.

Dealer Copy -- Not for Resale

P–09566
Loosen the alternator adjustment bolt (Item 1) [B] and
remove the alternator belt.
Remove the crankshaft pulley bolts (Item 2) [B]. Remove B
the pulley. 1

P–09563

863, 863H Bobcat Loader

Revised
381 of Feb.
570 99 –7–49– Service Manual
TIMING BELT (Cont’d)
Belt Replacement In Loader (Cont’d)
A 2
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.

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
right side front engine mount. 1

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.
863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.) – Engine Service Part 2 of 5

P–09570

863, 863H Bobcat Loader

382 of 570 –7–50– Service Manual
TIMING BELT (Cont’d)
Belt Replacement In Loader (Cont’d)
A
Install the camshaft timing tool (Item 1) [A] and tighten.
(See Page 7–55 for correct tool.) 1

♦ For Broken Belt Replacement Only

♦ Remove the number four cylinder fuel injector. (See
Page 7–40)
P–09573
♦ 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.).
B
NOTE: The crankshaft must be turned in correct
rotation. Turn clockwise as viewed from the
timing belt end of engine. 1
♦ Install the crankshaft timing tool (Item 1) [C] and
tighten. (See Page 7–55 for correct tool.)
♦ Rotate crankshaft against timing tool.

Dealer Copy -- Not for Resale

Install the crankshaft timing tool (Item 1) [C] and tighten.
(See Page 55 for the correct tool.)

P–09605

C
1

Remove the tensioner bolt (Item 1) [D] and the tensioner.

Remove the timing belt.
NOTE: The timing belt, belt tensioner and mount bolt
must be replaced as a set. A repair kit is
available. P–09578

Install the new timing belt, belt tensioner and mount bolt. Do
not tighten the mount bolt.
D
NOTE: Align the timing belt on gears to obtain equal
distance between the belt and front cover to
insure belt runs straight on gears.

P–09565

863, 863H Bobcat Loader

383 of 570 –7–51– Service Manual
TIMING BELT (Cont’d)
Belt Replacement In Loader (Cont’d)
A
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
a scale reading of 3.0–3.5. Tighten the idler tension pulley C
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

384 of 570 –7–52– Service Manual
TIMING BELT (Cont’d)
Belt Replacement In Loader (Cont’d)
A
Remove the camshaft and crankshaft timing tools (Item 1)
[A] & [C]; Page 7–51). 1
Mark the crankshaft pulley hub (Item 1) [A].

P–09565

Make four complete crankshaft revolutions in the direction

of engine rotation. Bring the mark on the crankshaft pulley B
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.

Dealer Copy -- Not for Resale

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

385 of 570 –7–53– Service Manual
VALVE TIMING
Checking
A
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 C
Nm) torque [C].
Remove the torque wrench, DO NOT change the
crankshaft position.

P–09563
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
D
above the right side front engine mount. 1
2
Turn the crankshaft timing tool (Item 2) [D] into the
crankcase until it makes slight contact with the crankshaft.
Mark the position of the timing tool.
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

386 of 570 –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

387 of 570 –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

388 of 570 –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.

Dealer Copy -- Not for Resale

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

389 of 570 –7–57– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
Disassembly (Cont’d)
A
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

390 of 570 –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.

CD–15525

Remove the camshaft [B].

B

Dealer Copy -- Not for Resale

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

391 of 570 –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

392 of 570 –7–60– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
Assembly (Cont’d)
A
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

Dealer Copy -- Not for Resale

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

393 of 570 –7–61– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
Assembly (Cont’d)
A
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

394 of 570 –7–62– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
Assembly (Cont’d)
A
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].

Dealer Copy -- Not for Resale

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

395 of 570 –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].

NOTE: The main bearing cap No. 1, at the flywheel C
end, the chamfer must be towards the flywheel
end.

CD–15552

Install the main bearing caps/main bearing assembly [D].

Make sure they are returned to their original location.
D

CD–15553

863, 863H Bobcat Loader

396 of 570 –7–64– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
Assembly (Cont’d)
A
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

Dealer Copy -- Not for Resale

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 cylinder
[D].
D

CD–15557

863, 863H Bobcat Loader

397 of 570 –7–65– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
Assembly (Cont’d)
A
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.

Install the piston/connecting rod assembly into the engine
D
block [D].
NOTE: The flywheel symbol on the piston must be
toward the flywheel.

CD–15561

863, 863H Bobcat Loader

398 of 570 –7–66– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
Assembly (Cont’d)
A
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°

Dealer Copy -- Not for Resale

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

399 of 570 –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.

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

400 of 570 –7–68– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
Assembly (Cont’d)
A
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

Dealer Copy -- Not for Resale

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

401 of 570 –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

402 of 570 –7–70– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
Assembly (Cont’d)
A
Make sure the dowel pins are installed in the engine block
[A].

CD–15476

Install the cylinder head gasket [B]. Gasket is marked TOP.

Make sure the sealing surfaces of the cylinder head gasket B
is free of oil.
Install the cylinder head.

Dealer Copy -- Not for Resale

CD–15477

Measure the cylinder head bolts.

Specifications: (BF4M1011) C
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
Tighten the cylinder head bolts to the correct torque in the 10 3 1 2 7
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

403 of 570 –7–71– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
Assembly (Cont’d)
A
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

404 of 570 –7–72– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
Assembly (Cont’d)
A
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

Dealer Copy -- Not for Resale

CD–15485

Install the fuel lift pump [C].

C

CD–15486
Tighten the lift pump bolts to 15 ft.–lbs. (21 Nm) torque [D].
Install a new oil filter. D
Install the fuel injectors. (See Page 7–40.)
Install the fuel injector pumps. (See Page 7–36.)

CD–15487

863, 863H Bobcat Loader

405 of 570 –7–73– Service Manual
RECONDITIONING THE ENGINE (Cont’d)
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

406 of 570 –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

Dealer Copy -- Not for Resale

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
863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.) – Engine Service Part 3 of 5

3
b

B–14697

863, 863H Bobcat Loader

407 of 570 –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

bushings.
(118,9+0,3 mm)

8.98 +0.012 inch

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

408 of 570 –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

Dealer Copy -- Not for Resale

CD–15404

863, 863H Bobcat Loader

409 of 570 –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].
NOTE: Carefully clean the engine block after drilling.
D

CD–15413

863, 863H Bobcat Loader

410 of 570 –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.

Dealer Copy -- Not for Resale

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

411 of 570 –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

412 of 570 –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

Dealer Copy -- Not for Resale

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

413 of 570 –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

414 of 570 –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

Dealer Copy -- Not for Resale

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

415 of 570 –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
shown in Figure [C].

(20,4+0,2 mm)

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

416 of 570 –7–84– Service Manual
CRANKSHAFT
Checking The Crankshaft
A
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)

– 0.0004 CD–15443
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:

Dealer Copy -- Not for Resale

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

417 of 570 –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

418 of 570 –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

Dealer Copy -- Not for Resale

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

419 of 570 –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 piston B

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

420 of 570 –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

Dealer Copy -- Not for Resale

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 Ring0.008 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

421 of 570 –7–89– Service Manual
PISTON AND PISTON PIN (Cont’d)
Checking Piston Pin (Cont’d)
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

422 of 570 –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)

Dealer Copy -- Not for Resale

B–08205
Measure the valve stem diameter [C].
Std. Intake Valve . . . . . . . . . . . . . . 0.314 –0.0006 inch C
(7,98 –0,015 mm)
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
Diameter
Specifications (BF4M1011F)
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° B–08202

863, 863H Bobcat Loader

423 of 570 –7–91– Service Manual
CYLINDER HEAD (Cont’d)
Checking Valve Seats
A
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

424 of 570 –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

Dealer Copy -- Not for Resale

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

425 of 570 –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

426 of 570 –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

Dealer Copy -- Not for Resale

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

427 of 570 –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

428 of 570 –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

Dealer Copy -- Not for Resale

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

429 of 570 –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

430 of 570 –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

Dealer Copy -- Not for Resale

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

431 of 570 –7–99– Service Manual
FRONT COVER (Cont’d)
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)
torque. 0–0,39 inch
(0–1 mm)
5 4
B–14704

863, 863H Bobcat Loader

432 of 570 –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)

Dealer Copy -- Not for Resale

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

433 of 570 –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

434 of 570 –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

Dealer Copy -- Not for Resale

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

435 of 570 –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].

D
Install the speed control lever into the front cover [D].

CD–15387

863, 863H Bobcat Loader

436 of 570 –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

Dealer Copy -- Not for Resale

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

437 of 570 –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

438 of 570 –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

Dealer Copy -- Not for Resale

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

439 of 570 –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

440 of 570 –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.

Dealer Copy -- Not for Resale

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

441 of 570 –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

442 of 570 –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 housing B
[B].
Remove the turbine housing.
Remove the compressor housing.

Dealer Copy -- Not for Resale

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

443 of 570 –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

444 of 570 –7–112– Service Manual
TURBOCHARGER (Cont’d)
Disassembly (Cont’d)
A
Carefully push out the shaft and turbine wheel assembly
[A].

Dealer Copy -- Not for Resale

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

445 of 570 –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.

Remove the sleeve from the back plate.
B
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

446 of 570 –7–114– Service Manual
TURBOCHARGER (Cont’d)
Inspection
A
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.
Examine the gas inlet and outlet flanges of the turbine CD–15303
housing for distortion.
Examine the turbine and compressor wheels, for bent or
broken, and the shaft for scoring at bearing seats.
B
NOTE: Wear parts which have excessive wear, as well

Dealer Copy -- Not for Resale

as rotating parts with cracks must be replace.
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

447 of 570 –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

448 of 570 –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.

Dealer Copy -- Not for Resale

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

449 of 570 –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

450 of 570 –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 [A].

Dealer Copy -- Not for Resale

CD–15316

Pre–heat the shaft nut. Install and tighten to 44 in–lbs. (5

Nm) torque [B].
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

451 of 570 –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 force. 1
Set to zero. Release the shaft.
Radial Play – Max. . . . . . . . . . . . . 0.018 inch (0,4 6 mm)

B–14710

863, 863H Bobcat Loader

452 of 570 –7–120– Service Manual
ENGINE OIL COOLER
Removal And Installation
A
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 removing or B
installing the oil cooler.

1
1

2
2

Dealer Copy -- Not for Resale

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. Replace the D
seals as needed.

P–07909

863, 863H Bobcat Loader

453 of 570 –7–121– Service Manual
CRANKSHAFT GEAR MOUNTING BOLT
Torque Procedure
A
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

454 of 570 –7–122– Service Manual
 SYSTEMS ANALYSIS
Page
Number
BICS™ (With Press To Operate Button)
Additional Inspection For Loaders With Advance Hand Controls . . . 8–3
Deactivation Of The Auxiliary Hydraulics System
(Engine STOPPED – Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Inspecting the BICS™ System Controller
(Engine STOPPED – Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Inspecting The Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . 8–3
Inspecting The Seat Bar Sensors (Engine RUNNING) . . . . . . . . . . . 8–3
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . 8–3
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
BICS™ (Without Press To Operate Button)
Inspecting Deactivation Of The Auxiliary Hydraulics System
(Engine STOPPED – Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Inspecting the BICS™ System Controller
(Engine STOPPED – Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Inspecting The Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . 8–5
Inspecting The Seat And Seat Bar Sensors (Engine RUNNING) . . . 8–5
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . 8–5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6
BICS™ SYSTEM CONTROLLER
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–7
BOSS® DIAGNOSTIC TOOL
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–19
BOSS® INSTRUMENT PANEL
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–24
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
Controls Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–30
MONITOR SERVICE CODES
Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–20
OPERATION SENSING SYSTEM UNIT
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–23 SYSTEMS
ANALYSIS
PWM CONTROL HANDLE
Handle Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–29
PWM ELECTRIC SOLENOID
Solenoid Coil Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–29
PWM MODULE
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–25
PWM TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–27
Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–26
RPM SENSOR
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–19
Continued On Next Page
BICS™ – BOBCAT INTERLOCK CONTROL SYSTEM
BOSS – BOBCAT OPEARTION SENSING SYSTEM
PWM – PULSE WITH MODULATION

863, 863H Bobcat Loader

455 of 570 –8–1– Service Manual
 SYSTEMS ANALYSIS (Cont’d)

Page
Number

SEAT BAR SENSOR

BICS™ Seat Bar Sensor Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–18
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–17
Seat Bar Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–16
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–15
SEAT SENSOR
BICS™ Controller Seat Sensor Circuit Test . . . . . . . . . . . . . . . . . . . . . 8–14
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–13
Seat Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–12
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–11
SENDER AND SENSOR
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–19
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–19
TRACTION LOCK
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–10
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9
TRACTION LOCK CONTROL SYSTEM
(S/N 514427600 & Above; 514525300 & Above; 514625300 & Above)
Inspecting The Traction Lock Control System . . . . . . . . . . . . . . . . . . . 8–28
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–28
TRACTION LOCK CONTROL SYSTEM
(S/N 514123809 & Below; 514222299 & Below)
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–28
Inpsection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–28
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–28
TROUBLESHOOTING THE BOSS® & L.C.D. DISPLAY . . . . . . . . . . . . 8–22

BICS™ – BOBCAT INTERLOCK CONTROL SYSTEM

BOSS – BOBCAT OPEARTION SENSING SYSTEM

863, 863H Bobcat Loader

456 of 570 –8–2– Service Manual
BICS™ (With Press To Operate Button)
Inspecting The BICS™ Controller (Engine STOPPED
A 1
– Key ON)
2
1. Sit in the operator’s seat. Turn key ON, lower the
seat bar and disengage the parking brake. Press the 3
green PRESS TO OPERATE Button. Four (4) BICS 4
controller lights should be ON (Items 1, 2, 3, & 5) [A].
2. Engage the parking brake and raise the seat bar 5
fully. System Activated (Item 1) [A], seat bar light
(Item 2) [A], valve light (Item 3) [A] and traction light
(Item 4) [A] should be OFF.
NOTE: If lights on BICS Controller are blinking, see
BICS Troubleshooting Chart, Page 8–4.)
3. Exit the loader and press traction lock override P–10157
button. Traction light (Item 4) [A] should be ON.
Press override button again and traction light (Item
4) [A] should be OFF.
Deactivation Of The Auxiliary Hydraulics System
(Engine STOPPED – Key ON)
4. Sit in the operator’s seat. Lower the Seat Bar. Press
the green PRESS TO OPERATE Button. Press the
auxiliary hydraulics switch. The auxiliary switch light
will come ON. Raise the Seat Bar. The light should
be OFF. AVOID INJURY OR DEATH
Inspecting The Seat Bar Sensor (Engine RUNNING) The Bobcat Interlock Control System (BICS™)

Dealer Copy -- Not for Resale

must deactivate the lift, tilt and traction drive
5. Sit in the operator’s seat. Lower the seat bar. Press functions. If it does not, contact your dealer for
the green PRESS TO OPERATE button. Engage service. DO NOT modify the system.
the parking brake. Fasten the seat belt.
W–2151–0394
6. 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.
Inspecting The Traction Lock (Engine RUNNING)
7. 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
should be engaged. Lower the seat bar.
8. Engage the parking brake pedal and move the
steering levers slowly forward and backward. The
traction lock should be engaged.
Inspecting The Lift Arm By–Pass Control
9. Raise the lift arms 6 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
By–Pass Control Knob until the lift arms slowly
lower.
Additional Inspection For Loaders With Advanced
Hand Controls
10. Sit in the operator’s seat and fasten the Seat Belt.
Lower the Seat Bar, start the engine and press the
green PRESS TO OPERATE Button.
11. Start the engine and raise the lift arms about 3 feet
(1 meter) off the ground.
12. Turn the key OFF and wait for the engine to come
to a complete stop.
13. Turn the key ON. Move the left hand control toward
the operator. The lift arms should not lower.
14. With the key on and bucket installed, move the right
hand control away from the operator. The bucket
should not tip forward.

863, 863H Bobcat Loader

457 of 570 –8–3– Service Manual
BICS™ (With Press To Operate Button)
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
System PRESS TO OPERATE PRESS TO OPERATE Lift, tilt and traction 2 System Activated circuit shorted to
Activated button is activated button not activated functions will not battery voltage.*
operate. 3 System Activated 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 Control Valve Lift and tilt functions 2 Valve output circuit shorted to battery
Can Be Used. Cannot Be Used. will not operate. 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 N/A N/A
correctly. correctly. operate.

* Normal BICS operating voltage is less than the electrical system voltage. If voltage is more, the circuit is shorted
to system voltage.
NOTES:
(1) If the System Activated 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 Instructions
in Preventive Maintenance section.
(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.

863, 863H Bobcat Loader

Revised Feb.
45899
of 570 –8–4– Service Manual
BICS™ (Without Press To Operate Button)
Inspecting The BICS™ Controller (Engine STOPPED
A
– Key ON) 1
1. Sit in the operator’s seat. Turn key ON, lower the 2
seat bar and disengage the parking brake. The four
BICS Controller lights should be ON (Items 1, 2, 3, 3
& 5) [A], the traction light (Item 4) [A] should be
OFF.
4
2. Engage the parking brake and raise the seat bar 5
fully. Seat bar light (Item 2) [A], valve light (Item 3)
[A] and traction light (Item 4) [A] should be OFF.
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 8–5. P–03760
4. Exit the loader and press traction lock override
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 1

Dealer Copy -- Not for Resale

switch light will come ON. Raise the seat bar. The
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–03763
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.
Inspecting The Traction Lock (Engine RUNNING)
C Operator
Seat
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
should be engaged. Lower the seat bar. Seat
Seat 1 Spring
9. Engage the parking brake pedal and move the Sensor
steering levers slowly forward and backward. The
traction lock should be engaged.
Inspecting The Lift Arm By–Pass Control Seat Rail
10. Raise the lift arms six feet (2 m) off the ground. Stop Cover
the engine. Turn the Lift Arm By–Pass Control Knob
clockwise 1/4 turn. Then pull up and hold the Lift Arm
By–Pass Control Knob until the lift arms slowly
lower. MC–02043
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.
Clearance is necessary under the seat spring (Item 1) [C] AVOID INJURY OR DEATH
and the seat, to allow the seat to move up and down freely.
With adequate clearance, the seat sensor will be allowed The Bobcat Interlock Control System (BICS™)
to function correctly. must deactivate the lift, tilt and traction drive
functions. If it does not, contact your dealer for
Inspect seat bar pivot area for tightness of linkage bolts. service. DO NOT modify the system.
W–2151–0394
Replace parts that are damaged. Use only genuine Bobcat
replacement parts.

863, 863H Bobcat Loader

Revised
459 of Feb.
570 99 –8–5– Service Manual
BICS™ (Without Press To Operate Button)
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 Feb.
46099
of 570 –8–6– Service Manual
BICS SYSTEM CONTROLLER
Troubleshooting Guide
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system
problems. It is recommended that these procedures be
done by authorized Bobcat Service Personnel only. Check for correct function after adjustments,
repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W–2004–1285

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

Dealer Copy -- Not for Resale

KEY TO CORRECT THE CAUSE

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

Revised
461 of Feb.
570 99 –8–7– Service Manual
BICS™ SYSTEM CONTROLLER (Cont’d)
Removal And Installation
A
2
NOTE: Photo’s may be different but the procedure is
the same for all models.
Raise the operator cab. (See Page 1–1.)
The controller mounting bolts are located on the back of the
operator cab [A]. 1

Remove the top mounting bolt (Item 1) [A] from the

controller.
Loosen the two lower mounting bolts (Item 2) [A].
P–03997
Lower the operator cab.
NOTE: The operator seat is removed in photo [B] for
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.
NOTE: Install the harness connector (Item 1) [C] into
the controller (Item 2) [C] before installing the
controller.

P–03994

C
Be sure the connector to the BICS system
controller are correctly engaged in the
controller when installing the controller. An
audible snap can be heard when the
connector is correctly installed. Try to pull the 2
connector out of the controller, if it cannot be
removed it has been correctly installed [C].
I–2087–1095

1
Installation: Tighten the controller mounting bolts to
80–90 in.–lbs. (9–10 Nm) torque.
P–04707
Reverse the removal procedure to install the controller.

863, 863H Bobcat Loader

Revised Feb.
46299
of 570 –8–8– Service Manual
SEAT BAR SENSOR
Troubleshooting Guide
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system
problems. It is recommended that these procedures be
done by authorized Bobcat Service Personnel only. Check for correct function after adjustments,
repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W–2004–1285

PROBLEM SOLUTION #

Indicator light does not come ON when seat bar is lowered. 1, 2, 3, 4, 5, 6

KEY TO CORRECT THE CAUSE

1. Check controller power indicator light. It must be ON.

2. Check sensor wire connection.

Dealer Copy -- Not for Resale

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

Revised
463 of Feb.
570 99 –8–9– Service Manual
SEAT BAR SENSOR (Cont’d)
Seat Bar Sensor Test
A
Use Sensor Tester (MEL1428) for the following procedure:
1
Disconnect the short adatper test leads if connected.
Disconnect the seat bar sensor connector (Item 1) [A].

P–04702

Connect the Sensor Tester (Item 1) [B] inline, to the seat

bar sensor connectors. See inset [B].
B
Turn the key to the ON position. DO NOT START THE
ENGINE.

The toggle switch (Item 2) [C] can be in either the Absent

or Present position. 1

P–04701

P–04700

If there is no power light (Item 1) [C] on the sensor tester,

check the tester or wiring harness.
C

P–04698
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.
If the above test fails, there is a problem with the seat bar 1
sensor.
Disconnect the Sensor Tester.
Replace the Seat Bar Sensor. (See Page 8–17.)
If the above test passes, run the BICS controller seat bar
circuit test. (See Page 8–18.)

P–04699

863, 863H Bobcat Loader

Revised Feb.
46499
of 570 –8–10– Service Manual
SEAT BAR SENSOR (Cont’d)
Removal And Installation
A
Disconnect the seat bar sensor connector (Item 1) [A].
1

P–04702

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

Dealer Copy -- Not for Resale

Be careful to not overtighten the sensor 2
mounting bolt and nut to prevent breakage of
the sensor. P–03246
I–2088–1095

Installation: Be sure the tabs on the pivot bushing are

positioned in the slotted hole (Item 1) [C] of the operator C
cab as shown.
Pull the seat bar back and remove the assembly as follows:
NOTE: The sensor assembly [D] is shown removed
from the operator cab for clarity purpose only.
The sensor assembly can be removed without 1
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].
Installation: Tighten the pivot bushing mounting bolt to
180–200 in.–lbs. (21–23 Nm) torque.
P–03247
Remove the pivot bushing (Item 3) [D], sensor (Item 4) [D],
magnet (Item 5) [D] and plastic bushing (Item 6) [D] from
the seat bar. D
Inspect all parts for damage and wear and replace if
necessary. 3 6 2 1
Reverse the removal procedure to install the seat bar
sensor.

Left Side
4 5 of Seat Bar

P–03284

863, 863H Bobcat Loader

Revised
465 of Feb.
570 99 –8–11– Service Manual
SEAT BAR SENSOR (Cont’d)
BICS™ Controller Seat Bar Sensor Circuit Test
A
Use Sensor Tester (MEL1428) for the following procedure:
Disconnect the short adatper test leads if connected. 1
Disconnect the seat bar sensor connector (Item 1) [A].
Connect Sensor Tester (Item 1) [B] inline as shown to the P–04701
seat bar sensor connectors. See inset [A].
Turn the key to the ON position. DO NOT START THE
ENGINE.

P–04702

If there is no power light on the sensor tester, check the

tester or wiring harness.
B
When the power light is illuminated, move the toggle switch
(Item 2) [B] on the sensor tester to the Present position.
NOTE: The sensor test light (Item 3) [B] is only 3
activated by the seat bar. It will be off with the
seat bar up or on with the seat bar down.
The seat bar light (Item 1) [C] on the BICS controller should 2
illuminate.

P–04703

Move the toggle switch (Item 1) [D] on the sensor tester to 1

the Absent position.
The Seat Bar light (Item 1) [C] should go off.
If the above test fails, there is a problem with the BICS™
system controller or the wiring harness.
P–04704

P–04699

863, 863H Bobcat Loader

Revised Feb.
46699
of 570 –8–12– Service Manual
SEAT SENSOR
Troubleshooting Guide
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system
problems It is recommended that these procedures be
done by authorized Bobcat Service Personnel only. Check for correct function after adjustments,
repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W–2004–1285

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.

Dealer Copy -- Not for Resale

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
Revised
467 of Feb.
570 99 –8–13– Service Manual
SEAT SENSOR (Cont’d)
Seat Sensor Test
A
Use (MEL1428) Sensor Tester for the following procedure: 2
Disconnect the short adatper test leads if connected.
NOTE: Clean any debris, dirt or objects from under or
behind the operator seat before starting the
test. The rear of the seat must move up and
down.
Raise the operator cab. (See Page 1–1.)
Disconnect the seat sensor connector (Item 1 – Inset) [A].
Connect Sensor Tester (Item 2) [A] inline as shown to the
seat sensor.
Lower the operator cab. (See Page 1–1.)

N–00960 P–04705
Move the toggle switch (Item 1) [B] on the sensor tester to
the Absent position.
Turn the key to the ON position. DO NOT START THE
B
ENGINE.
The power light (Item 2) [B] will illuminate, if the light is not
on, check the tester or wiring harness.
Sit on the operator seat.
1

P–04698
The Sensor Test light (Item 1) [C] should illuminate.
Get off the operator seat. The Sensor Test light (Item 1) [C]
should go off.
C
If the above test passes, run the BICS™ controller seat
sensor circuit test. (See Page 8–16.) 1
If the above test fails, there is a problem with the seat
sensor.
Disconnect the Sensor Tester.
Replace the Seat Sensor. (See Page 8–15.)
If the above test passes, run BICS™ controller seat sensor
circuit test. (See Page 8–16.)
P–04699

863, 863H Bobcat Loader

Revised Feb.
46899
of 570 –8–14– Service Manual
SEAT SENSOR (Cont’d)
Removal And Installation
A
Raise the loader operator cab. (See Page 1–1.)
Locate the seat sensor (Item 1) [A] beneath the operator
cab.

Remove the sensor connector (Item 1) [B] from the holder

and disconnect from the harness.
1
Remove the magnet collar mounting bolt (Item 2) [B] and
washer (Item 1) [C].
Installation: Tighten the bolt to 180–200 in.–lbs. (21–23 P–03987
Nm) torque.

B
2

DO NOT overtighten the magnet mounting 3

bolt to prevent damage to the magnet. 1
I–2089–1095

Dealer Copy -- Not for Resale

Remove the magnet (Item 2) [C] from the sensor (Item 3) 4
[B].
Installation: If the magnet collar (Item 2) [C] is tapered,
install the tapered end to the seat. If the magnet collar (Item
2) [C] is not tapered, install as shown [C]. N–00960

Remove the sensor mounting bolt (Item 4) [B] and nut.

Installation: Tighten the nut and bolt (Item 4) [B] until light C
pressure is applied to the sensor (Item 3) [B]. 5

3
2
1
Be careful to not overtighten the sensor 4
mounting bolt and nut to prevent breakage of
the sensor.
I–2088–1095

Remove the sensor (Item 3) [C]. P–04041

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 D
sensor.
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.

P–04044

863, 863H Bobcat Loader

Revised
469 of Feb.
570 99 –8–15– Service Manual
SEAT SENSOR (Cont’d)
BICS™ Controller Seat Sensor Circuit Test
A
Use Sensor Tester (MEL1428) for the following procedure: 2
Disconnect the short adatper test leads if connected.
NOTE: Clean any debris, dirt or objects from under or
behind the operator seat before starting the
test. The rear of the seat must move up and
down.
Raise the operator cab. (See Page 1–1.)
Disconnect the seat sensor connector (Item 1 – Inset) [A].
Connect MEL1428 Sensor Tester (Item 2) [A] inline, to the
seat sensor.
Lower the operator cab. (See Page 1–1.)
Turn the key to the ON position. DO NOT START THE
ENGINE.

N–00960 P–04705

The power light (Item 1) [B] will illuminate, if the light is not
on, check the tester or wiring harness. B
Move the toggle switch (Item 2) [B] on the sensor tester to
the Present position.
3
NOTE: The sensor test light (Item 3) [B] is only
activated by the seat sensor switch.
2

P–04703

The Seat light (Item 1) [C] on the controller will illuminate.

Move the toggle switch to Absent position, the seat light on C
the controller will go off.
If the above test fails, there is a problem with the BICS
system controller or the wiring harness.

P–04706

863, 863H Bobcat Loader

Revised Feb.
47099
of 570 –8–16– Service Manual
TRACTION LOCK
Troubleshooting Guide
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system
problems. It is recommended that these procedures be
done by authorized Bobcat Service Personnel only. Check for correct function after adjustments,
repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W–2004–1285

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.

Dealer Copy -- Not for Resale

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

Revised
471 of Feb.
570 99 –8–17– Service Manual
TRACTION LOCK (Cont’d)
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–05379
technician. Use only genuine Bobcat parts if
repair is necessary.
W–2165–0195

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

B
2
If the solenoid is being replaced, remove the Do Not
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 correctly. P–05387
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 if P–07926
necessary.
Installation: Thoroughly clean and dry the shaft mounting
bolt (Item 1) [D], the shaft (Item 2) [D] and wedge (Item 3) D
[D]. Use LOCTITE #242 when assembling these parts to 2
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–07964

863, 863H Bobcat Loader

Revised Feb.
47299
of 570 –8–18– Service Manual
TRACTION LOCK CONTROL SYSTEM
(S/N 514427600 & Above; 514525300 & Above; A 1
514625300 & Above)
Inspecting The Traction Lock Control System 2
1. Sit in the operator’s seat. Turn the key ON, lower the 3
seat bar. Press the green PRESS TO OPERATE 4
Button, and disengage the parking brake. Four (4)
of the BICS Controller lights should be ON (Items 5
1,2,3, and 5) [A]. The Traction light (Item 4) [A]
should be OFF.
2. Fasten the Seat Belt, engage the parking brake,
start the engine and press the PRESS TO
OPERATE Button. Disengage the parking brake
and operate at low idle. The Traction light (Item 4) P–10157
[A] should be ON.
Maintenance
B
Check the wire connections at the engine speed sensor
(Item 1) [B].
NOTE: When the Traction Lock Override Button is
activated, the Traction Lock Override Control
System will NOT engage the Traction Lock if
the engine stops. 1
TRACTION LOCK CONTROL SYSTEM

Dealer Copy -- Not for Resale

(S/N 514123809 & Below; 514222299 & Below)
Description
The Traction Lock Control System will lock the traction
drive system when the engine stops. The Traction Lock P–09440
Control System is incorporated into the BICS™ System.
NOTE: When the Traction Lock Override button is
activated, the Traction Lock Control system C
will NOT engage the Traction Lock if the 1
engine stops. The traction light on the BICS
controller [C] will remain OFF until the engine 2
is started and if the parking brake is
disengaged. 3
Inspection 4
Sit in the operator’s seat. Turn the key switch ON, lower the
seat bar and disengage the parking brake. Four lights of the 5
BICS Controller light should be ON (Items 1, 2, 3, & 5) [C].
The traction light should be OFF.
Fasten the seat belt, engage the parking brake and start
the engine. Disengage the parking brake and operate at P–03760
low idle. The traction light should be ON.
Maintenance
Check the wire harness for loose or broken wires. Replace
any parts that are damaged or broken. Use only genuine
Bobcat replacement parts.

863, 863H Bobcat Loader

Revised
473 of Feb.
570 99 –8–19– Service Manual
BOSS® DIAGNOSTIC TOOL
Procedure
A
The tool listed will be needed to do the following procedure: 1
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 &
Maintenance Manual to make service checks of BOSS P–03871
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
TEMPERATURE SENDER
75° F. (24° C.) . . . . . . . . . . . . . . . . . . . . 1075 ± 60 ohms
100° F. (33° C.) . . . . . . . . . . . . . . . . . . . 1198 ± 30 ohms
ENGINE OIL PRESSURE SENDER
5 PSI (34 kPa) . . . . . . . . . . . . . . . . . . . . . . . 3 ohms Max.
6 PSI (41 kPa) . . . . . . . . . . . . . . . . . . . . 5–15 ohms Min.
50 PSI (345 kPa) . . . . . . . . . . . . . . . . . . . . . 34–53 ohms P–05677
100 PSI (690 kPa) . . . . . . . . . . . . . . . . . . . . 64–90 ohms
TRANSMISSION CHARGE PRESSURE SENDER
0 PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0–5 ohms C
400 PSI (2758 kPa) . . . . . . . . . . . . . . . . . . . . . . 90 ohms
FUEL SENDER
Full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ohms
Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 ohms
RPM SENSOR
Adjustment
Continuity Resistance of 3000–3500 ohms.
Disconnect the connector [B] from the engine harness.
Loosen the jam nut (Item 1) [B] on the RPM sensor. P–05675

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 inch (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 Feb.
47499
of 570 –8–20– Service Manual
MONITOR 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 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–2003–1289

SUBJECT DISPLAY READS CONDITION

Engine Coolant Temp. EC–1.1 SHUTDOWN, Engine Temperature
EC–2.1 WARNING, Engine Temperature

Dealer Copy -- Not for Resale

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 Feb. 99
475 of 570 –8–21– 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 Feb.
476 of99
570 –8–22– 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

Dealer Copy -- Not for Resale

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 Feb. 99
477 of 570 –8–23– Service Manual
BOSS® UNIT
Removal And Installation
A
Raise the operator cab. (See Page 1–1.) 1
Loosen the nuts (Item 1) [A] from the sensing system unit
1
(Item 2) [A].
Slide the unit forward in the mounting slots and remove it 2
from the operator cab.

P–04043

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–04042

863, 863H Bobcat Loader

Revised Feb.
47899
of 570 –8–24– Service Manual
BOSS® INSTRUMENT PANEL
Removal And Installation
A
Pry the rubber light mount free from the operator cab (both
sides) [A].

P–03995

Lower the light from the operator cab to locate the three
instrument panel mounting bolts (Item 1) [B] (both sides).
B
1

Dealer Copy -- Not for Resale

P–03955
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–03958
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.

863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.) – System Analysis Part 1 of 2

P–03959

863, 863H Bobcat Loader

Revised
479 of Feb.
570 99 –8–25– 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 Items 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
4 Input from *Auxiliary Hydraulic Switch 9.5
5 Output to Momentary Light 7.5
6 Output to Auxiliary Hydraulic Switch 11.0 MC–02265
7 Output to Detent Light 6.5
8 Input from Key Switch (Bleed position) 12.5
9 Output to **High Flow Solenoid 11.5
Non High Flow Loaders 0 B
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
14 Input from Detent Switch 12.0
15 Input from Rear Aux. Base Switch 11.0
16 Input from Rear Aux. Rod Switch 11.0 2
17 Output to Rear Aux. Diverter Solenoid 10.0 5
18 Output to Aux. Rod Solenoid 0–6.0
19 Output to Aux. Base Solenoid 0–6.0 3
1
*Input signal is present only as Auxiliary Hydraulic Switch
is pushed. 4
N–00562 P–03272
**Output signal goes to High Flow dash panel switch, then
to solenoid. Used only on H models. Zero voltage on Non
High Flow loaders.
Key Switch Item 1 [B]
C DELUXE HANDLES
Auxiliary Hydraulic Switch Item 2 [B]
Momentary Light Item 3 [B]
Detent Light Item 4 [B]
High Flow Switch Item 5 [B] 1
Proportional Flow Switch Item 1 [C] 3 2
Detent Switch Item 2 [C]
Rear Aux. Switch (Base & Rod) Item 3 [C]
Right
Left Steering
Steering Lever
Lever Control
Control
P–02130 P–02129

863, 863H Bobcat Loader

Revised Feb.
48099
of 570 –8–26– Service Manual
PWM MODULE (Cont’d)
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).

Dealer Copy -- Not for Resale

Fig. [A]:
Item Description Volts
1 Input from BICS™ Auxiliary Deactivation 12.0
2 For future use
3 For future use
4 For future use TS–01433

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 8–27.)

863, 863H Bobcat Loader

Revised
481 of Feb.
570 99 –8–27– Service Manual
PWM TROUBLESHOOTING (Cont’d)
Chart
A
The PWM module sends a diagnostic code to the Auxiliary
Hydraulic 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
and then ON (during a proportional flow switch failure). 2
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 Feb.
482 99
of 570 –8–28– 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
White/Black No 4.8–5.2 No
& White Test Ohms Test P–02129

White/Red 1.3–1.5 2.6–2.8 3.8–4.0

& White Ohms Ohms Ohms B
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

Dealer Copy -- Not for Resale

assembly if required.
PWM ELECTRIC SOLENOID
Solenoid Coil Testing
1
The front auxiliary solenoid valves (Item 1) [B] are located N–00076
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
483 of Feb.
570 99 –8–29– Service Manual
 ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
Controls Identification Chart
863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.)–SystemAnalysis

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/

2 8 Female Red
3 6
2 Front Dk. Green/
3 Male Lt. Green
1
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
2
6 6 7 (Bottom) Diverter Yellow
5 3
H 8 (Middle) High Lt. Blue/
1 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

Added Feb.
48499
of 570 –8–30– 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
ENGINE TORQUE
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–12
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 SPECIFICATIONS
Engine (BF4M1011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
(BF4M1011F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Loader Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
STANDARD TORQUE SPECIFICATIONS FOR BOLTS
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–20
TORQUE SPECIFICATIONS FOR LOADER
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–14
U.S. TO METRIC CONVERSION
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–21

863, 863H Bobcat Loader

485 of 570 –9–1– Service Manual
 863, 863H Bobcat Loader
486 of 570 –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)

Dealer Copy -- Not for Resale

‘‘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

487 of 570 –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

488 of 570 –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

489 of 570 –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

490 of 570 –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

491 of 570 –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

492 of 570 –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

493 of 570 –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

494 of 570 –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

495 of 570 –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

496 of 570 –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

Dealer Copy -- Not for Resale

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

497 of 570 –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

498 of 570 –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
is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
B
O–ring in position until the fittings are assembled [A].
Nut Nut
Straight Thread O–ring Fitting
Lubricate the O–ring before installing the fitting. Loosen the Washer Washer
jam nut and install the fitting. Tighten the jam nut until the
washer is tight against the surface [B]. O–ring

Dealer Copy -- Not for Resale

Tubelines And Hoses O–ring

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.

Always use two wrenches when loosening and tightening

C
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
a mark across the flats of both the male and female parts 2
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

863, 863H Bobcat Loader

499 of 570 –9–15– Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS
(Cont’d) A O–ring Flare
O–ring Flare Fitting Primary
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
Tighten the nut until it contacts with the seat. Make a mark Seal
across the flats of both the male and female parts of the P–13009
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.

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 using the hex flat tightening method to tighten a new

* If a torque wrench is used to tighten a new fitting to a fitting to a new hose/tubeline.
used hose/tubeline.
** If using the hex flat tightening method to tighten a new
* If a torque wrench is used to tighten a used fitting to a fitting to a used hose/tubeline.
new hose/tubeline.
*** If using the hex flat tightening method to tighten a used
* If a torque wrench is used to tighten a new fitting to a fitting to a new hose/tubeline.
new hose/tubeline.

863, 863H Bobcat Loader

500 of 570 –9–16– Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS
(Cont’d) 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.

Do not use a O–ring flare fitting when a copper bonnet

orifice is used. When tightened the connection at the 1
bonnet may distort the flare face and prevent it from
sealing.
Use a standard flare fitting (Item 1) [A] as shown.
P–13572
When a O–ring flare fitting is used as a straight thread port
adapter the O–ring flare face is not used to seal. The
O–ring may come off the fitting and enter the system.
B
Always remove the O–ring (Item 1) [B] from the flare
face as shown.
2
An O–ring (Item 2) [B] is added to the flat boss of the fitting
to seal the connection in this application.

Dealer Copy -- Not for Resale

1
P–13573

863, 863H Bobcat Loader

501 of 570 –9–17– Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS
(Cont’d) A
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
If a torque wrench cannot be used, use the following to Fitting
method.
Tighten the nut until it just makes metal to metal contact,
you can feel the resistance. Nut Seals
to Port
Tighten the nut with a wrench no more than one hex flat
maximum.
Do not over tighten the port seal fitting.
NOTE: If a torque wrench cannot be used, use the hex
flat tightening method as an approximate
guideline. Secondary O–ring Seal
NOTE: Port seal fittings are not recommended in all
applications. Use O–ring boss fittings in these
P–13008
applications.
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
fitting and prevent it from sealing.
Port Seal and O–ring Boss
Tightening Torque
Use an O–ring boss fitting (Item 2) [B] as shown.
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)

P–13571

863, 863H Bobcat Loader

502 of 570 –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

503 of 570 –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

504 of 570 –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

Dealer Copy -- Not for Resale

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
505 of 570 –9–21– Service Manual
863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.)–Specifications

863, 863H Bobcat Loader

506 of 570 –9–22– Service Manual
 ADVANCE HAND CONTROL SYSTEM (A.H.C)
Page
Number
ACTUATORS
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–30
Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–31
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–29
ACTUATOR VOLTAGE TEST
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–8
A.H.C. COMPONENTS
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–5
A.H.C./PWM CONTROLLER
Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–17
Decription . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–16
Handle Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–18
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–15
Solenoid Coil Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–18
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–15
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–17
A.H.C. HANDLE
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–27
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–26
A.H.C. STEERING LEVER
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–28
Steering Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–28
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–14
BICS™ VALVE
BICS™ Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–34
Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–33
Lift Arm By–Pass Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–32
Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–33
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–35
HANDLE CONTROL UNIT
Control Unit Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–22
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–19
HANDLE CONTROL UNIT TEST
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–11
HYDRAULIC CONTROL VALVE
Anti–Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–43
Anti–Cavitation/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–42
Auxiliary Electrical Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–49
Auxiliary Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–48
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–40
H–Port Auxiliary Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–51
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–39
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–47 ADVANCED
Lift and Tilt Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–45 HAND CONTROL
Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–40 SYSTEM
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–40
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–41
Port Relief Valve (Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–42
Port Relief Valve (Tilt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–43
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–36
Rubber Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–44
Spool Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–50
Continued On Next Page Continued On Ne

863, 863H Bobcat Loader

Revised
507 of Feb.
570 99 –10–1– Service Manual
 ADVANCE HAND CONTROL SYSTEM (A.H.C)

Page
Number

SWITCH HANDLE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–23
TROUBLESHOOTING (AHC)
Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–6
WIRING SCHEMATICS –
WITH ADVANCED HAND CONTROL OPTIONS . . . . . . . . . . . . . . . . 10–3

863, 863H Bobcat Loader

Revised Feb.
50899
of 570 –10–2– Service Manual
 863, 863H Bobcat Loader
509 of 570 –10–3– Service Manual
 863, 863H Bobcat Loader
510 of 570 –10–4– Service Manual
863 WITHOUT BOSS - WIRING SCHEMATIC
WITH ADVANCED HAND CONTROL OPTION BICS CONTROLLER HARNESS - 6713932

C435 C436
S/N 514425001-39999 C457
TO           THIS SHEET OR

C406
ADVANCED HAND CONTROLS HARNESS - 6710418 BLK 2 2 FRONT AUXILIARY
ROD

(Printed October 1998)
TO ATTACHMENT DGN/LGN 1 1 SOLENOID C302

C406
B YEL/LGN
MC2412
C
A
YEL/RED
RNG/WHT
BLK
DGN/RED
2
1
2
1
FRONT AUXILIARY
BASE
SOLENOID
BICS CONTROLLER

C434
RIGHT HANDLE

14

20

22

23
21

19
15
10

17

18
11
12

16
13
B ADVANCED

2
7

6
4

3
5
8
1
HAND
TO WATER FRONT
KIT AUX.
DBL/WHT D D DBL/WHT PUR/YEL A CONTROLS
ATTACHMENT
DBL/YEL E DBL/YEL DIAGNOSTIC
E

PUR/WHT

PNK/WHT
A

DBL/WHT
PUR/RED

YEL/DGN
RNG CONNECTOR

YEL/RED

LBL/DGN
LBL/RED
YEL/DBL

YEL/BLK

LBL/BLK

YEL/LBL
DBL C C DBL

C439
E

WHT

RNG
DGN
GRY

RED
C440

DBL
BLK

BLK
DETENT DGN B B DGN
B LGN/WHT
RNG/WHT A G PNK/BLK
F

C303
C451
RED 1 1 PNK/RED F F PNK/RED YEL/DBL A A YEL/DBL
C DGN
DGN 3 3 PNK/DGN H H PNK/DGN PUR/WHT B B PUR/WHT
D YEL
TILT BLK 2 2 PNK/BLK G A RNG/WHT PUR/RED C C PUR/RED
SKI
CONTROL POSITION BUCKET
TO RNG BLK LEVEL
ATTACHMENT SOLENOID
C404

C304
RED A A
A DGN/LBL
SEAT
BLK B B
B
TILT ACTUATOR LIFT ACTUATOR SENSOR DGN C C
(IF EQUIPPED)

A
B
M M C307

C413
HYDRAULIC
A A CHARGE
B B PRESSURE

A
B
C305
LEFT HANDLE RED A A
OPENS AT 25 PSI
TO C C SEAT BAR B B

DGN

DGN
BLK

RED

RED
CLOSED AT 29 PSI

RED

RED
C452

BLK

BLK
ATTACHMENT SKI RED 1 1 BRN/RED F F BRN/RED SENSOR

BLK

BLK
C441

CONTROL LIFT DGN C C

B DBL POSITION
DGN 3 3 BRN/DGN H G BRN/BLK

A WHT BLK 2 2 BRN/BLK G H BRN/DGN

8
C438

7
5
6

5
6
2
3

2
3
1

1
4

4
RNG/DBL E E RNG/DBL
HORN
C432 C433 TO ENGINE

C111
RNG D D RNG TRACTION
REAR AUX.
A LOCK
DGN B DGN YEL
B HYDRAULIC OIL

7
8

7
8
5
6

5
6
2
3

2
3
1

1
4

4
C457

B OVERRIDE
A RNG/WHT TURN TEMPERATURE
SIGNAL
BRN C C BRN SWITCH
C YEL/LGN 568-1804 OHMS
YEL

G
YEL A

C
D
B

E
A
A

F
B YEL/RED

BLK

BLK
C437
PUR/BRN
C406 TILT

BRN/WHT
PNK/WHT

LGN/WHT
C301

LGN/RNG
LBL/WHT
TO           THIS SHEET OR

LBL/RNG

BRN/YEL
PNK/YEL

LGN/YEL
DIODE

LBL/YEL
B B PUR/BRN
LIGHTS
C457

LGN
TO ATTACHMENT A A PUR/LBL

LBL
LIFT PUR/LBL B F G C D E A

PNK/WHT
C401

WHT
A DGN/YEL

RNG
DGN
RED
BLK
DBL
B

MAINFRAME CONTROLLER HARNESS -
HYDRAULIC OIL

YEL/BLK
TO OPTIONS FILTER

DGN/WHT
DIFFERENTIAL

PUR/WHT
(RELIEF ADAPTER HARNESS)

BRN/WHT
RNG/WHT

PNK/WHT

LGN/WHT

LGN/RNG

PUR/RED

LGN/RED
LGN/PNK
LBL/WHT
PUR/BRN

LGN/DBL
BRN/DGN

DGN/RED
DBL/WHT

LBL/RNG

BRN/YEL

DGN/LGN
PNK/YEL
6712523

PNK/DGN

LBL/RED
YEL/DBL
DGN/YEL
PUR/LBL

DGN/LBL

PUR/YEL
YEL/RED
YEL/LGN
DBL/YEL
PRESSURE
MANUAL
HYDRAULIC

RNG
DGN
BLK
BRAKE

DBL
YEL
LOCK SWITCH
BRAKE SOLENOID SOLENOID

C306
18
28

25
16

10

29

31

17

23

30
24
14

19
12
15

27

20
13
21
26
22
11
A
B

B
A
A A

4
7

8
1

3
WHT RED
C428 C429 C430 C431

DGN/WHT
RNG/DBL
DGN/YEL

YEL/BRN
B B BLK

YEL/DBL

LGN/RED

LGN/PNK
LGN/DBL

LBL/RED
FILTER HARNESS

RNG
DGN
BRN

BLK
YEL

YEL

RNG
28

25

29

31

23

30
24

19
18

16

12
10

17

14
15

27

20
13

26
22
A
B

B
A

11

21
RNG

2
3
4
5
6
1
BLK

4
7

8
2
1

BLK
(WITHOUT BOSS)-6716642

C308
RED A A

ADVANCED HAND CONTROLS MODULE BLK C C BLK

C
A
B
G
C

H
C

D
C
B
A

B
A

E
B

A
F
F

J
WHT B B

C106 C107 C108 C109 C110 C230

TO TO CAB HARNESS (WITHOUT BOSS) - 6711767
B

G
C

C
A

B
D
A

A
K
F
TO

J
ATTACH. ATTACH. D F E C B A DGN/RED
CONTROLS
(USED W/ HIGH FLOW SWITCH (IF EQUIPPED)

LGN/RED

LGN/PNK
ADVANCED

LGN/DBL

DGN/YEL
RNG/DBL

DGN/YEL
DGN/RED WIRE JUMPER FROM 2 TO 3

LBL/RED
HAND WHEN NOT EQUIPPED WITH HIGH FLOW SWITCH
RNG

BLK
RNG
BLK

BLK

RNG
YEL/DBL
YEL/BRN
RNG

RNG
DGN
RNG

BRN

ACC
BLK

BLK

YEL

YEL
CONTROLS LBL/RED 1
OFF 2
ONLY) ENGINE COOLANT 3 DGN/RED
TO BICS 1075-2231 OHMS
RUN BLK

C111
START
BLK

C119
YEL/LBL A C A D B E 4 WHT/BLK
ENGINE RPM 5
(MAGNETIC B B BLK 6
PICKUP) BLK B D A C B E
A A PUR/WHT

SO
MODE RNG/DBL BLK
LIGHT DETENT B
ENGINE OIL RED/WHT
PRESSURE SWITCH LIGHT ST HORN (IF EQUIPPED)
HERE OR HERE OR RED/WHT
AUXILIARY HYDRAULIC SWITCH
RNG

TO OPTIONS TO OPTIONS
YEL/DGN (IF EQUIPPED)
(K TO P DIVERTER (K TO P DIVERTER BUCKET LEVEL
HARNESS) HARNESS) SWITCH (IF EQUIPPED)

C113 C112
FUSE 6
RNG

I 1
BLK B B
25A
C105

TO OPTIONS REAR AUXILIARY FUEL LEVEL WHT/BLK

RNG 2
DGN/YEL A A RELIEF (IF 33-246 OHMS YEL/DBL A U IGNITION SWITCH 3

C117
SV2

C202
RNG EQUIPPED) 4 WHT/BLK
B B BLK YEL/BRN K T
RED

LBL/DGN 5
PUR/WHT P M WHT 6
BLK B B A A PUR
TO OPTIONS YEL/DGN F L WHT/BLK
YEL A A  DIVERTER
J BLK SV1 (IF EQUIPPED) PUR N G RED/WHT
FUSE 8 FUSE 2
G RNG RNG RED RED RNG RNG C W LBL/RED
25A 10A TO OPTIONS
F BRN RNG/DBL X X RNG/DBL
(FRONT WIPER)
E
C104

BRN/DGN RNG V V RNG

C204
D BRN/YEL LBL/RED W B RED/WHT RED/WHT 1

C114
C DBL DBL H D BLK BLK 2
B PNK PNK R F YEL/DGN
A RED/WHT RED/WHT E J LBL/BLK LBL/BLK 1
RED/WHT
H DBL/WHT S C RNG 2
3
K DBL/BLK WHT/BLK L A YEL/DBL 4

TO OPTIONS
RED/WHT B E RED/WHT 6 5
(WIPER/WASHER BOTTLE) AUXILIARY WHT M S DBL/WHT GLOW PLUG SWITCH
C102 C103

HOURMETER AND
A DBL/BLK HARNESS (IF EQUIPPED) T H DBL
DIODE
B BLK
BLK h RNG
STARTER RELAY GLOW PLUG RELAY LBL/RNG
U
J
R
P
PNK
PUR/WHT
ENGINE WARNING LIGHT
TO OPTIONS YEL/DGN
(BACK-UP ALARM SWITCHES) RED/WHT G N PUR
RNG

C201
RED/WHT

RED/WHT

RNG BLK D K YEL/BRN

A
B

GLOW RNG
RNG/DGN
C121
85 86 86 85
h RNG

C116
SWITCHED POWER RELAY WHT BLK BLK LBL/RNG PLUGS

HERE OR 87 87 BLK BLK HOURMETER YEL/DBL

BLK
A

WHT/LGN LBL/RNG HR
B

TO OPTIONS) 87A 30 30
FUSE 4
FUSE 3
WHT/BLK

30 87A RED RED 87A

BACKUP RNG C F RNG/DGN
25A
25A

TRANSMISSION WARNING LIGHT
RNG

RED BLK HR
ALARM
BLK

87 BLK
RNG/DGN F C RNG RED
BLK HR FUEL GAUGE BLK
G G 85 86
C101

RNG BLK PUR

E B GND

C205
BLK BLK HR
S GRY
PNK A D BRN/DGN
LGHT GRY
LGN/WHT

D E BRN/YEL DBL/WHT
I RNG DBL
DBL/WHT H A PNK GRY
RED

RNG
BLK B H DBL/WHT
FUSE 5 ENGINE RNG
FUSE 1

LEFT RIGHT
FUEL SHUTOFF SOLENOID RED/WHT TEMPERATURE HEAD
HEAD
10A

15A GAUGE LIGHT LIGHT

S PUR/WHT

C206
LGN/WHT BLK (IF EQUIPPED) (IF EQUIPPED)
RED/DBL BLK
BRAKE RELAY GND
DBL/WHT

DBL/WHT

BLK BLK BLK

RNG

LGN I RNG
87A
BLK

BLK

FUSE 7 LGHT GRY

PNK
BLK

A
B

1
PNK
BLK

30 RED/WHT
RED/WHT
87
C118 RED
RED
RED 25A WHT VOLTMETER RNG
RNG
BLK
BLK
3
2

86 85

C207
S RED BLK PNK/WHT I
A
B

M V
RED BLK

G
RED GND
RIGHT RED RED BLK DBL/WHT DBL/WHT
LEFT WHT/LGN RED 4
TAILLIGHT TAILLIGHT LEFT RIGHT LGHT PNK
PUR RED S B GRY
WORK WORK B 5
EXC DBL
LIGHT LIGHT BATTERY GRY 6

REAR LIGHT HARNESS - 6714350 BLK B B BLK

LIGHT SWITCH (IF EQUIPPED)

C115
STARTER
ALTERNATOR
WHT C C WHT
PNK/WHT D D PNK/WHT
RNG A A RNG

ENGINE HARNESS (WITHOUT BOSS) - 6715947 OR 6718070

RED = RED
RNG = ORANGE
BICS
WIRES CONNECT BY SOME CONNECTOR BLK = BLACK
ENGINE

LBL = LIGHT BLUE
FUSE 1 10A
FUSE 5 LETTER ACROSS BODIES NOT SHOWN
15A

DBL = DARK BLUE
CONNECTORS FOR DRAWING CLARITY LGN = LIGHT GREEN
DGN = DARK GREEN
BOSS

A B YEL = YELLOW
10A

FUSE 2 25A FUSE 6

B A PNK = PINK
PWM WHT = WHITE
BRN = BROWN
LIGHT
TAN = TAN
FUSE 3
BRAKE

25A FUSE 7 PUR = PURPLE

25A

GRY = GREY
ACCESSORY

FUSE 8
25A

FUSE 4
ACCESSORY
25A
MC2412 (10-28-99)
FUSE BLOCK
511 of 570
512 of 570
 863 BOSS - WIRING SCHEMATIC
WITH ADVANCED HAND CONTROL OPTION
BICS CONTROLLER HARNESS - 6713932

C435 C436
C457
S/N 514425001-39999 ADVANCED HAND CONTROLS HARNESS - 6710418
TO           THIS SHEET OR
BLK 2 2 FRONT AUXILIARY
ROD
C406
(Printed October 1998)
TO ATTACHMENT DGN/LGN 1 1 SOLENOID C302

C406
MC2408 B YEL/LGN
C
A
YEL/RED
RNG/WHT DGN/RED
BLK 2
1
2
1
FRONT AUXILIARY
BASE
SOLENOID
BICS CONTROLLER

C434
RIGHT HANDLE

20

23
21
14

19
15
10

17

18
11
12
22
16
13
B ADVANCED

6
4

3
5
8
2

1
HAND
TO TW0 FRONT
SPEED AUX.
DBL/WHT D D DBL/WHT PUR/YEL A CONTROLS
ATTACHMENT
DBL/YEL E DBL/YEL DIAGNOSTIC
E

PUR/WHT

PNK/WHT
A

DBL/WHT
PUR/RED

YEL/DGN
RNG CONNECTOR

YEL/RED

LBL/DGN
LBL/RED
YEL/DBL

YEL/BLK

LBL/BLK

YEL/LBL
DBL C C DBL

C439
E

WHT

RNG
GRY

DGN
RED
C440

DBL
BLK

BLK
DETENT DGN B B DGN
B LGN/WHT
RNG/WHT A G PNK/BLK
F

C303
C451
RED 1 1 PNK/RED F F PNK/RED YEL/DBL A A YEL/DBL
C DGN
DGN 3 3 PNK/DGN H H PNK/DGN PUR/WHT B B PUR/WHT
D YEL
TILT BLK 2 2 PNK/BLK G A RNG/WHT PUR/RED C C PUR/RED
SKI
CONTROL POSITION BUCKET
TO RNG BLK LEVEL
ATTACHMENT SOLENOID
C404

C304
RED A A
A DGN/LBL
SEAT
BLK B B
B
TILT ACTUATOR LIFT ACTUATOR SENSOR DGN C C
(IF EQUIPPED)

A
B
M M C307

A
B
C305
LEFT HANDLE RED A A
TO SEAT BAR B B

DGN

DGN
BLK

RED

RED
RED

RED
C452

BLK

BLK
ATTACHMENT SKI RED 1 1 BRN/RED F F BRN/RED SENSOR

BLK

BLK
C441

CONTROL LIFT DGN C C

B DBL POSITION
DGN 3 3 BRN/DGN H G BRN/BLK

A WHT BLK 2 2 BRN/BLK G H BRN/DGN

7
8

7
8
C438

5
6

5
6
2
3

2
3
1

1
4

4
RNG/DBL E RNG/DBL
HORN
E
BOSS CHARGE HARNESS - 6717131 C432 C433 TO ENGINE

C111
RNG D D RNG TRACTION
REAR AUX.
A LOCK
DGN B B DGN

7
8

7
8
5
6

5
6
C455

2
3

2
3
1

1
4

4
C457

A RNG/WHT C C HYDRAULIC B OVERRIDE

TURN CHARGE
SIGNAL
BRN C C BRN SWITCH
C YEL/LGN A A PRESSURE

G
YEL A YEL

C
D
B

E
A
A

F
B YEL/RED B B 5-90 OHMS

BLK

BLK
C437
PUR/BRN
C406 TILT

BRN/WHT
PNK/WHT

LGN/WHT
C301

LGN/RNG
LBL/WHT
TO           THIS SHEET OR

LBL/RNG

BRN/YEL
PNK/YEL

LGN/YEL
DIODE

LBL/YEL
B B PUR/BRN
LIGHTS
C457

LGN
TO ATTACHMENT A A PUR/LBL

LBL
LIFT PUR/LBL B F G C D E A

PNK/WHT
C401

DGN
BLK

WHT
A DGN/YEL

RNG
DGN
RED
BLK
DBL
B

MAINFRAME CONTROLLER HARNESS -

B
A
TO OPTIONS HYDRAULIC OIL TEMPERATURE

DGN/WHT
BRN/WHT

PUR/WHT
(RELIEF ADAPTER HARNESS)

RNG/WHT

LGN/WHT
PNK/WHT

LGN/RNG

PUR/RED

LGN/RED
LGN/PNK
LBL/WHT
PUR/BRN

DBL/WHT

LBL/RNG
568-1804 OHMS

BRN/YEL

LGN/DBL
BRN/DGN

DGN/RED
6712523

PNK/DGN

DGN/LGN
PNK/YEL

LBL/RED
YEL/DBL
C413

DGN/YEL
PUR/LBL

PUR/YEL
YEL/RED
DGN/LBL

YEL/LGN
DBL/YEL
MANUAL
HYDRAULIC

RNG
DGN
BRAKE

BLK

DBL
YEL
LOCK SWITCH

A
B
BRAKE SOLENOID SOLENOID
HYDRAULIC OIL FILTER

C306
DIFFERENTIAL PRESSURE

28

25

29

31

17

23

30
24

19
18

16

12
10

14
15

27

20
13

26
22
11

21
A
B

B
A
A A

4
7

8
1

3
WHT RED
C428 C429 C430 C431

DGN/WHT
RNG/DBL
DGN/YEL

YEL/BRN
B B BLK

YEL/DBL
FILTER HARNESS

LGN/RED

LGN/PNK
YEL/LBL

LGN/DBL

LBL/RED
RNG
DGN
BRN

BLK

BLK
YEL

YEL

RNG
29

23

30
24
18
28

25
16

12
10

31

17

14

19
15

27

20

26
B

11

13
21

22
RNG

A
2
3
4
5
6
1
BLK

8
2

7
1

3
(BOSS) -

BLK

C308
RED A A

6716643 ADVANCED HAND CONTROLS MODULE BLK C C BLK

C
D
B
G

E
F
C

H
C

D
C
B
A

E
B

A
B
F
F

J
WHT B B

C106 C107 C108 C109 C110 C117 C119 C230

DGN/RED
TO TO TO
G
*  PIN NUMBER = 30 PIN CONNECTOR BOSS # PIN NUMBER = 18 PIN CONNECTOR
B
A

C
D
B
A

B
A

E
A

A
F

F
D F E C B A

J
ATTACH. ATTACH. CONTROLS
(USED W/ FUEL SHUTOFF

* G1
SOLENOID

* C1

# C1

* D1

* H1

* G2
* G3

* D1
* E1
* B1

# B1

* A1

* K1

# E1
# A1
* H2
* C3
* C2
* D3
# C3
# C2

# D1
# D2
# D3
* D2

* H3

* F1

# F1
* B2
# A2
# A3
# B2
# B3

* E2
* E3

* B3
# E3

*  J1

# E2

* K2
* A3
* A2
* F3

* F2

# F3
# F2
* J2
* J3

LGN/RED

LGN/PNK
DGN/YEL
ADVANCED

LGN/DBL
RNG/DBL

DGN/YEL
LBL/RED

YEL/BRN

YEL/DBL
DBL/YEL
YEL/LBL
HAND
RNG

RNG

RNG
BLK

BLK

ACC
CONTROLS
RNG

RNG

RNG
DGN
BRN
BLK

BLK

YEL

YEL
BLK

BLK

BLK
OFF
ONLY)

RNG/WHT
RNG/WHT
WHT/RNG

PUR/WHT
RUN

PUR/RED
LBL/WHT

RNG/DBL
YEL/DGN
YEL/BRN
DBL/YEL
YEL/DBL

YEL/LBL

YEL/LBL

PUR/RED
START

YEL/RED
C A D B E

RNG
RNG
PUR

RED
BLK

BLK

BLK

BLK

BLK

BLK
DIODE

BLK
BLK

BLK
D A C B E

DGN/YEL SO
MODE
SHUTDOWN RELAY B
FUEL LEVEL LIGHT DETENT RED/WHT DBL/WHT DBL
DIODE LIGHT
33-246 OHMS ST

86 85 AUXILIARY HYDRAULIC SWITCH LEFT
RNG

ENGINE COOLANT RIGHT
BLK (IF EQUIPPED) HEAD HEAD
HERE OR TO OPTIONS 1075-2231 OHMS
HERE OR TO OPTIONS (K TO P HARNESS) 87 LIGHT LIGHT

C113 C112
(K TO P HARNESS) (IF EQUIPPED)
FUSE 6

RED/DBL

Dealer Copy -- Not for Resale

RNG

ENGINE OIL 30 I (IF EQUIPPED)
RNG
B B PRESSURE
25A

BLK 87A BLK

C105

TO OPTIONS REAR AUXILIARY
3-90 OHMS
DGN/YEL A A RELIEF (IF
RNG SV2 EQUIPPED) ENGINE RPM IGNITION SWITCH
(MAGNETIC PICKUP) TO BICS BLK

C111
AIR FILTER
RED

YEL/LBL YEL/LBL A RNG C M WHT

BLK B B
TO OPTIONS DIVERTER RNG F L WHT/BLK WHT/BLK
YEL A A (IF EQUIPPED) BLK BLK B
J BLK SV1 PUR/RED N G RED/WHT
FUSE 8 FUSE 2
G RNG RNG RED RED RNG/WHT PUR/WHT P R PNK
25A 10A S DBL/WHT
F BRN RNG/DBL X
E H DBL
C104

BRN/DGN RNG V
E RED/WHT RED/WHT 1
D BRN/YEL LBL/RED W
W LBL/RED BLK 2
C DBL DBL H
3
B PNK PNK R X RNG/DBL BLK

A E B RED/WHT

C114
RED/WHT RED/WHT
H DBL/WHT S V RNG DBL/WHT
4
PNK

K DBL/BLK WHT M C RNG DBL/WHT

5
WHT/BLK L F RNG DBL
6
TO OPTIONS
(WIPER/WASHER BOTTLE) AUXILIARY RED/WHT B P PUR/WHT
LIGHT SWITCH (IF EQUIPPED)
C102 C103

HOURMETER AND N PUR/RED
A DBL/BLK K
HARNESS (IF EQUIPPED) DIODE
B BLK LBL/RNG J D BLK

TO OPTIONS
BLK h RNG U A BLK
J
RED/WHT

RED/WHT

(BACK-UP ALARM SWITCHES) BLK D HIGH FLOW SWITCH (IF EQUIPPED)

DGN/RED WIRE JUMPER FROM 2 TO 3
RNG BLK A U WHEN NOT EQUIPPED WITH HIGH FLOW SWITCH
RNG/DGN RED/WHT G T LBL/RED 1
2
STARTER RELAY GLOW PLUG RELAY K 3 DGN/RED
T BLK
B
A

FUSE 4
FUSE 3

HERE OR
TO OPTIONS BLK

C116
25A

C121
25A

86 4 WHT/BLK
BACKUP RNG C F RNG/DGN 85 86 85 5
WHT BLK BLK LBL/WHT GLOW BLK 6
ALARM PLUGS BLK
RNG/DGN F C RNG
B
A

SWITCHED POWER RELAY 87 87
G G WHT/LGN 30 LBL/RNG BLK HR
30
C101

87A RED RED 87A HORN (IF EQUIPPED)

E B BLK 87A BLK
WHT/BLK

HR
BLK
RNG

PNK A D BRN/DGN 30 DIAGNOSTIC PORT

RED
D E BRN/YEL RED 87 BLK HR 1 RED RNG/DBL BLK

C202
DBL/WHT H A PNK 86 2 PUR/RED
RED

85 BLK HR
RNG BLK
BLK B H DBL/WHT 3 PUR/WHT
FUSE 5 TO OPTIONS
4 BLK (FRONT WIPER)
FUSE 1

RED/WHT
10A

C204
15A
RED/WHT 1
LGN/WHT BLK
BOSS DISPLAY 2
BRAKE RELAY
DBL/WHT

DBL/WHT

RNG

LGN B PUR/RED
BLK

BLK

87A BUCKET LEVEL
FUSE 7 PUR/WHT
PNK

C
BLK

A
B

SWITCH (IF EQUIPPED)
PNK
BLK

30

C201
RED/WHT A RNG
87
C118 S
RED
RED
RED 25A WHT
E RNG
1 2
WHT/BLK
86 85 BLK RNG
RED BLK PNK/WHT D 3
A
B

WHT/BLK

M
RED 4

G
RED DGN/WHT
LEFT RIGHT RED RED 5
WHT/LGN RED DGN/WHT 6
TAILLIGHT TAILLIGHT LEFT RIGHT PUR RED S B
WORK WORK B
EXC
LIGHT LIGHT BATTERY

REAR LIGHT HARNESS - 6714350 BLK B B BLK

CAB HARNESS (BOSS) - 6711774

C115
STARTER
ALTERNATOR
WHT C C WHT
PNK/WHT D D PNK/WHT
RNG A A RNG

ENGINE HARNESS (BOSS) - 6715948 OR 6718071

RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
BICS
WIRES CONNECT BY SOME CONNECTOR DGN = DARK GREEN
ENGINE

FUSE 1 10A
FUSE 5 LETTER ACROSS BODIES NOT SHOWN YEL = YELLOW
15A

PNK = PINK
CONNECTORS FOR DRAWING CLARITY WHT = WHITE
BRN = BROWN
BOSS

A B
10A

FUSE 2 25A FUSE 6 TAN = TAN

PWM
B A PUR = PURPLE
GRY = GREY
LIGHT
FUSE 3
BRAKE

25A FUSE 7
25A
ACCESSORY

FUSE 8
25A

FUSE 4 25A
ACCESSORY MC2408 (10-29-99)
FUSE BLOCK
513 of 570
514 of 570
 863 WITHOUT BOSS - WIRING SCHEMATIC
HIGH FLOW ADVANCED HAND CONTROLS HARNESS - 6716541 BICS CONTROLLER HARNESS - 6713932

C434 C435 C436

WITH HIGH FLOW AND ADVANCED HAND CONTROL OPTION BLK 2 2 FRONT AUXILIARY
S/N 514425001-39999 C457
TO           THIS SHEET OR ROD
DGN/LGN 1 1 SOLENOID
TO ATTACHMENT C406
(Printed October 1998)
BLK 2 2
C302
FRONT AUXILIARY

C406
MC2413 B YEL/LGN
1 1 BASE

BICS CONTROLLER
DGN/RED
C YEL/RED SOLENOID
A RNG/WHT
B ADVANCED HAND CONTROL
RIGHT HANDLE DIAGNOSTIC

20

23
21
14

19
15
10

17

18
11
12
22
16
13
PUR/YEL A

6
4

3
5
8
2

1
CONNECTOR
TO WATER FRONT
KIT AUX.
DBL/WHT D D DBL/WHT
ATTACHMENT
DBL/YEL E E DBL/YEL

PUR/WHT

PNK/WHT
A

DBL/WHT
PUR/RED

YEL/DGN
RNG

YEL/RED

LBL/DGN
LBL/RED
YEL/DBL

YEL/BLK

LBL/BLK

YEL/LBL
DBL C C DBL

C439
E

WHT

RNG
GRY

DGN
RED
C440

DBL
BLK

BLK
DETENT DGN B B DGN
B LGN/WHT
RNG/WHT A G PNK/BLK
F

C303
C451
RED 1 1 PNK/RED F F PNK/RED YEL/DBL A A YEL/DBL
C DGN
DGN 3 3 PNK/DGN H H PNK/DGN PUR/WHT B B PUR/WHT
D YEL
TILT BLK 2 2 PNK/BLK G A RNG/WHT PUR/RED C C PUR/RED
SKI
CONTROL POSITION
TO BUCKET
ATTACHMENT RNG BLK LEVEL DIVERTER
C404 SOLENOID

C304
SOLENOID RED A A
A DGN/LBL

C444
SEAT
BLK B B
B TILT ACTUATOR LIFT ACTUATOR BLK B B

C447 C446
YEL/LGN SENSOR DGN C C
A A YEL A A (IF EQUIPPED)

A
B
REAR BASE
SOLENOID B B BLK M M

REAR AUXILIARY
C307

A
B
RELIEF SOLENOID

C305
LEFT HANDLE RED A A

DGN

DGN
RED

RED
A A YEL/RED

RED

RED

C443
BLK

BLK
BLK

BLK
TO REAR ROD SEAT BAR BLK B B
B B BLK BLK B B

C452

C401
ATTACHMENT SKI RED 1 1 BRN/RED F F BRN/RED SOLENOID SENSOR
C441

CONTROL LIFT A DGN/YEL A A DGN C C

B DBL POSITION
DGN 3 3 BRN/DGN H G BRN/BLK

7
8

7
8
5
6

5
6
3

3
2

2
B

1
4

4
A WHT BLK 2 2 BRN/BLK G H BRN/DGN

C438
RNG/DBL E E RNG/DBL C432 C433 TO OPTIONS
TO ENGINE
HORN

C111
(RELIEF ADAPTER HARNESS)

7
8

7
8
5
6

5
6
TRACTION

2
3

2
3
RNG RNG

1
4

4
D D A

C413
REAR AUX. HYDRAULIC LOCK
DGN B B DGN A A CHARGE
C457

A RNG/WHT B OVERRIDE
TURN
SIGNAL
BRN C C BRN B B PRESSURE SWITCH
C YEL/LGN OPENS AT 25 PSI

BLK

BLK
C C

G
YEL A YEL

C
D
B

E
A
A

F
B CLOSED AT 29 PSI

BRN/WHT
PNK/WHT

LGN/WHT
YEL/RED

LGN/RNG
LBL/WHT

LBL/RNG

BRN/YEL
PNK/YEL

LGN/YEL
LBL/YEL
C437
PUR/BRN
C406
TO           THIS SHEET OR
TILT
C301

LGN
LBL
B B PUR/BRN
LIGHTS
TO ATTACHMENT C457 LIFT PUR/LBL
A A PUR/LBL
DIODE B F G C D E A
YEL
HYDRAULIC OIL
TEMPERATURE

PNK/WHT
568-1804 OHMS

WHT

RNG
DGN
RED
BLK
DBL
YEL/BLK
TO
MAINFRAME CONTROLLER HARNESS -

DGN/WHT
ATTACHMENT

PUR/WHT
RNG/WHT

BRN/WHT
PNK/WHT

LGN/WHT

LGN/RNG

PUR/RED

LGN/RED
LGN/PNK
LBL/WHT
PUR/BRN

LGN/DBL
BRN/DGN

DGN/RED
DBL/WHT

LBL/RNG

BRN/YEL
PNK/DGN

DGN/LGN
PNK/YEL

LBL/RED
YEL/DBL
DGN/YEL
PUR/LBL

DGN/LBL

PUR/YEL
YEL/RED
YEL/LGN
C442

DBL/YEL
A LBL/RED 6712523 MANUAL

RNG
DGN
HYDRAULIC

BLK

DBL

YEL
BRAKE
B LOCK SWITCH
BRAKE SOLENOID SOLENOID

C306
29

23

30
28

25
16

12
10

31

17

24
14
19

18
15

20

26
11
27

13
21

22
B

B
A

A
HYDRAULIC OIL

8
2

7
1

3
FILTER WHT RED
A A
C428 C429 C430 C431

DGN/WHT
RNG/DBL

YEL/BRN
B B BLK

YEL/DBL
LBL/RED

LGN/RED

LGN/PNK
DIFFERENTIAL

LGN/DBL

LBL/RED
PRESSURE

RNG
DGN
BRN

BLK
YEL

RNG
29

23

30
24
28

25
16

12
10

31

17

14
19

18
15

27

20

26
22
B

11

13
21
RNG

A
2
3
4
5
6
1
C445

BLK

8
2

7
1

BLK
A A LBL/RED

C308
HIGH FLOW B B BLK RED A A
SOLENOID

FILTER HARNESS ADVANCED HAND CONTROLS MODULE BLK C C BLK

C
B
G

A
C

D
C
B
A

B
A

E
B

A
F
F

J
WHT B B

C106 C107 C108 C109 C110 (WITHOUT BOSS)-6716642 C230

TO TO CAB HARNESS (WITHOUT BOSS) - 6711767

C
B
A

D
B
A

B
A

B
A

A
F
TO

J
ATTACH. ATTACH. D F E C B A DGN/RED
CONTROLS
(USED W/ HIGH FLOW SWITCH (IF EQUIPPED)

LGN/RED

LGN/PNK
ADVANCED

DGN/YEL
RNG/DBL

LGN/DBL
DGN/YEL
DGN/RED WIRE JUMPER FROM 2 TO 3

LBL/RED
HAND WHEN NOT EQUIPPED WITH HIGH FLOW SWITCH
RNG

BLK
RNG
BLK

BLK

RNG
YEL/DBL
YEL/BRN
RNG

RNG

RNG
DGN
BRN
BLK

BLK ACC

YEL

YEL
CONTROLS LBL/RED 1
OFF 2
ONLY) ENGINE COOLANT 3 DGN/RED
TO BICS 1075-2231 OHMS
RUN BLK

C111
START
BLK

C119
YEL/LBL A C A D B E 4 WHT/BLK
ENGINE RPM 5
(MAGNETIC B B BLK 6
PICKUP) BLK B D A C B E
A A PUR/WHT

SO
MODE RNG/DBL BLK
LIGHT DETENT B
ENGINE OIL RED/WHT
PRESSURE SWITCH LIGHT ST HORN (IF EQUIPPED)
HERE OR HERE OR RED/WHT
AUXILIARY HYDRAULIC SWITCH
RNG

TO OPTIONS TO OPTIONS
YEL/DGN (IF EQUIPPED)
(K TO P DIVERTER (K TO P DIVERTER BUCKET LEVEL
HARNESS) HARNESS) SWITCH (IF EQUIPPED)

C113 C112
Dealer Copy -- Not for Resale
FUSE 6
RNG

I 1
BLK B B
25A
C105

TO OPTIONS REAR AUXILIARY FUEL LEVEL WHT/BLK

RNG 2
DGN/YEL A A RELIEF (IF 33-246 OHMS YEL/DBL A U IGNITION SWITCH 3

C117
SV2

C202
RNG EQUIPPED) 4 WHT/BLK
B B BLK YEL/BRN K T
RED

LBL/DGN 5
PUR/WHT P M WHT 6
BLK B B A A PUR
TO OPTIONS YEL/DGN F L WHT/BLK
YEL A A  DIVERTER
J BLK SV1 (IF EQUIPPED) PUR N G RED/WHT
FUSE 8 FUSE 2
G RNG RNG RED RED RNG RNG C W LBL/RED
25A 10A TO OPTIONS
F BRN RNG/DBL X X RNG/DBL
(FRONT WIPER)
E
C104

BRN/DGN RNG V V RNG

C204
D BRN/YEL LBL/RED W B RED/WHT RED/WHT 1

C114
C DBL DBL H D BLK BLK 2
B PNK PNK R F YEL/DGN
A RED/WHT RED/WHT E J LBL/BLK LBL/BLK 1
RED/WHT
H DBL/WHT S C RNG 2
3
K DBL/BLK WHT/BLK L A YEL/DBL 4

TO OPTIONS
RED/WHT B E RED/WHT 6 5
(WIPER/WASHER BOTTLE) AUXILIARY WHT M S DBL/WHT GLOW PLUG SWITCH
C102 C103

HOURMETER AND
A DBL/BLK HARNESS (IF EQUIPPED) T H DBL
DIODE
B BLK
BLK h RNG
STARTER RELAY GLOW PLUG RELAY LBL/RNG
U
J
R
P
PNK
PUR/WHT
ENGINE WARNING LIGHT
TO OPTIONS YEL/DGN
(BACK-UP ALARM SWITCHES) RED/WHT G N PUR
RNG

C201
RED/WHT

RED/WHT

RNG BLK D K YEL/BRN

A
B

RNG
h
86 86 GLOW
RNG/DGN 85 85 RNG

C116
HERE OR
C121 SWITCHED POWER RELAY WHT BLK BLK LBL/RNG PLUGS

YEL/DBL
87 87 BLK BLK HOURMETER
BLK
A

WHT/LGN LBL/RNG HR
B

TO OPTIONS) 87A 30 30
FUSE 4
FUSE 3
WHT/BLK

30 87A RED RED 87A

BACKUP RNG C F RNG/DGN
25A
25A

BLK TRANSMISSION WARNING LIGHT
RNG

RED HR
ALARM
BLK

87 BLK
RNG/DGN F C RNG RED
BLK HR FUEL GAUGE BLK
G G 85 86
C101

RNG BLK PUR

E B GND

C205
BLK BLK HR
S GRY
PNK A D BRN/DGN
LGHT GRY
LGN/WHT

D E BRN/YEL DBL/WHT
I RNG
DBL/WHT H A PNK DBL GRY
RED

RNG
BLK B H DBL/WHT
FUSE 5 ENGINE RNG
FUSE 1

LEFT RIGHT
FUEL SHUTOFF SOLENOID RED/WHT TEMPERATURE HEAD
HEAD
10A

15A GAUGE LIGHT LIGHT

S PUR/WHT

C206
LGN/WHT BLK (IF EQUIPPED) (IF EQUIPPED)
RED/DBL
BRAKE RELAY GND BLK
DBL/WHT

DBL/WHT

BLK BLK BLK

RNG

LGN I RNG
BLK

BLK

87A
FUSE 7 LGHT GRY
PNK
BLK

A
B

1
PNK
BLK

30 RED/WHT
RED/WHT
87
C118 RED
RED
RED 25A WHT VOLTMETER RNG
RNG
BLK
BLK
3
2

86 85

C207
S RED BLK PNK/WHT I
A
B

M V
RED BLK

G
RED GND
RIGHT RED RED BLK DBL/WHT DBL/WHT
LEFT WHT/LGN RED 4
TAILLIGHT TAILLIGHT LEFT RIGHT LGHT PNK
PUR RED S B GRY
WORK WORK B 5
EXC DBL
LIGHT LIGHT BATTERY GRY 6

REAR LIGHT HARNESS - 6714350 BLK B B BLK

LIGHT SWITCH (IF EQUIPPED)

C115
STARTER
ALTERNATOR
WHT C C WHT
PNK/WHT D D PNK/WHT
RNG A A RNG

ENGINE HARNESS (WITHOUT BOSS) - 6715947 OR 6718070

RED = RED
RNG = ORANGE
BICS
WIRES CONNECT BY SOME CONNECTOR BLK = BLACK
ENGINE

LBL = LIGHT BLUE
FUSE 1 10A
FUSE 5 LETTER ACROSS BODIES NOT SHOWN
15A

DBL = DARK BLUE
CONNECTORS FOR DRAWING CLARITY LGN = LIGHT GREEN
DGN = DARK GREEN
BOSS

A B YEL = YELLOW
10A

FUSE 2 25A FUSE 6

B A PNK = PINK
PWM WHT = WHITE
BRN = BROWN
LIGHT
TAN = TAN
FUSE 3
BRAKE

25A FUSE 7 PUR = PURPLE

25A

GRY = GREY
ACCESSORY

FUSE 8
25A

FUSE 4
ACCESSORY
25A
MC2413 (10-29-99)
FUSE BLOCK
515 of 570
516 of 570
 863 BOSS - WIRING SCHEMATIC
HIGH FLOW ADVANCED HAND CONTROLS HARNESS - 6716541 BICS CONTROLLER HARNESS - 6713932

C434 C435 C436

WITH HIGH FLOW AND ADVANCED HAND CONTROL OPTION BLK 2 2 FRONT AUXILIARY
S/N 514425001-39999 C457
TO           THIS SHEET OR
1
ROD
DGN/LGN 1 SOLENOID
TO ATTACHMENT C406
(Printed October 1998) BLK 2 2
C302
FRONT AUXILIARY

C406
MC2409 B YEL/LGN
1 1 BASE

BICS CONTROLLER
DGN/RED
C YEL/RED SOLENOID
A RNG/WHT
B ADVANCED HAND CONTROL
RIGHT HANDLE DIAGNOSTIC

21
14

19
15
10
20
17

18

12
22
16
13
23
11
PUR/YEL A

2
7

6
4

3
5
8
1
CONNECTOR
TO WATER FRONT
KIT AUX.
DBL/WHT D D DBL/WHT
ATTACHMENT
DBL/YEL E E DBL/YEL

PUR/WHT

PNK/WHT
A

DBL/WHT
PUR/RED

YEL/DGN
RNG

YEL/RED

LBL/DGN
LBL/RED
YEL/DBL

YEL/BLK

LBL/BLK

YEL/LBL
DBL C C DBL

C439
E

WHT

RNG
DGN
GRY

RED
C440

DBL
BLK

BLK
DETENT DGN B B DGN
B LGN/WHT
RNG/WHT A G PNK/BLK
F

C303
C451
RED 1 1 PNK/RED F F PNK/RED YEL/DBL A A YEL/DBL
C DGN
DGN 3 3 PNK/DGN H H PNK/DGN PUR/WHT B B PUR/WHT
D YEL
TILT BLK 2 2 PNK/BLK G A RNG/WHT PUR/RED C C PUR/RED
SKI
CONTROL POSITION
TO BUCKET
ATTACHMENT RNG BLK LEVEL DIVERTER
SOLENOID
C404

C304
SOLENOID RED A A
A DGN/LBL

C444
SEAT
BLK B B
TILT ACTUATOR LIFT ACTUATOR B B

C447 C446
B BLK
A A YEL/LGN SENSOR DGN C C
YEL A A (IF EQUIPPED)

A
B
REAR BASE
SOLENOID B B BLK M M

REAR AUXILIARY
C307
RELIEF SOLENOID

A
B
C305
LEFT HANDLE RED A A

DGN

DGN
RED

RED
A A YEL/RED

RED

RED

C443
BLK

BLK
BLK

BLK
TO REAR ROD SEAT BAR BLK B B
B B BLK B B

C452
BLK

C401
ATTACHMENT SKI RED 1 1 BRN/RED F BRN/RED SOLENOID SENSOR
F
C441

CONTROL LIFT A DGN/YEL A A DGN C C

B DBL POSITION
DGN 3 3 BRN/DGN H G BRN/BLK

8
7

7
5
6

5
6
2
3

2
3
1

1
B

4
A WHT BLK 2 2 BRN/BLK G H BRN/DGN

C438
RNG/DBL E E RNG/DBL C432 C433
BOSS CHARGE HARNESS - 6717131
TO OPTIONS
HORN TO ENGINE

C111
(RELIEF ADAPTER HARNESS)

7
8

7
8
6

6
TRACTION

5
RNG RNG

2
3

2
3
1

1
4

4
D D A
REAR AUX. LOCK
DGN B B DGN
C457

B OVERRIDE
A RNG/WHT

C455
TURN C C HYDRAULIC
SIGNAL
BRN C C BRN SWITCH
C YEL/LGN CHARGE
A A

BLK

BLK
A YEL

G
YEL

C
D
B

E
A
F
A PRESSURE
B

BRN/WHT
PNK/WHT

LGN/WHT
YEL/RED

LGN/RNG
LBL/WHT
B B

LBL/RNG
5-90 OHMS

BRN/YEL
PNK/YEL

LGN/YEL
LBL/YEL
C437
PUR/BRN
C406
TO           THIS SHEET OR
TILT
C301

LGN
LBL
B B PUR/BRN
LIGHTS
TO ATTACHMENT C457 LIFT PUR/LBL
A A PUR/LBL
DIODE B F G C D E A

PNK/WHT
DGN
BLK

WHT

RNG
DGN
RED
BLK
DBL
MAINFRAME CONTROLLER HARNESS -

A
B
TO
HYDRAULIC OIL TEMPERATURE

DGN/WHT
ATTACHMENT

BRN/WHT

PUR/WHT
RNG/WHT

PNK/WHT

LGN/WHT

LGN/RNG

PUR/RED

LGN/RED
LGN/PNK
LBL/WHT
PUR/BRN

DBL/WHT

LBL/RNG

BRN/YEL

LGN/DBL
BRN/DGN

DGN/RED
PNK/YEL
PNK/DGN

DGN/LGN

LBL/RED
YEL/DBL
DGN/YEL
PUR/LBL

DGN/LBL

PUR/YEL
YEL/RED
YEL/LGN
C442

568-1804 OHMS

DBL/YEL
A LBL/RED C413 6712523 MANUAL

RNG
DGN
HYDRAULIC

BLK

DBL

YEL
BRAKE
B LOCK SWITCH

A
B
BRAKE SOLENOID SOLENOID
HYDRAULIC OIL FILTER

C306
DIFFERENTIAL PRESSURE

28

25

10

29

31

17

23

30
24
14
19
16

12

18
15

27

20
13

26
22
11

21
A
B

B
A

4
7

8
1

3
WHT RED
A A
C428 C429 C430 C431

DGN/WHT
RNG/DBL
B B BLK

YEL/BRN
FILTER HARNESS

YEL/DBL
LBL/RED

LGN/RED

LGN/PNK
YEL/LBL

LGN/DBL

LBL/RED
RNG
DGN
BRN

BLK

BLK
YEL

RNG
28

25
16

10

29

31

17

23

30
24
14
19

18
12
15

27

20
13
21
26
22
RNG

A
B

B
A

11
3
4
5
6
2
1
C445

BLK

4
7

8
1
(BOSS) -

BLK
A A LBL/RED

C308
HIGH FLOW B B BLK RED A A
SOLENOID
6716643 ADVANCED HAND CONTROLS MODULE BLK C C BLK

C
D
A
B

E
G

D
C
C

D
B
A

A
B
A

K
F

F
J
WHT B B

C106 C107 C108 C109 C110 C117 C119 C230

DGN/RED
TO *  PIN NUMBER = 30 PIN CONNECTOR BOSS # PIN NUMBER = 18 PIN CONNECTOR

G
TO TO
B
A

C
D
B
A

B
A

A
B

E
D F E C B A

F
J
ATTACH. ATTACH. CONTROLS
(USED W/ FUEL SHUTOFF

* G1
SOLENOID

* C1

# C1

* D1

* H1

* G3

* D1
* E1
* B1

# B1

* A1

* G2

* K1

# E1
# A1
* C3
* D3
# C3

# D3

* H3

* F1

# F1
* H2

* C2

# C2

* B2

# A3
# B2
# B3
# D1
# D2

* D2
* E3

* B3
# E3

* A3
* F3

# A2

* E2

* F2

* J1

# F3
# E2
# F2

* K2
* A2
* J2
* J3

LGN/RED

LGN/PNK
LGN/DBL

DGN/YEL
ADVANCED

RNG/DBL

DGN/YEL
LBL/RED

YEL/BRN

YEL/DBL
DBL/YEL
YEL/LBL
HAND
RNG

RNG

RNG
BLK

BLK

CONTROLS ACC
RNG

RNG

RNG
DGN
BRN
BLK

BLK

BLK
YEL

YEL

BLK

BLK
OFF
ONLY)

RNG/WHT
RNG/WHT
WHT/RNG

PUR/WHT
RUN

PUR/RED

RNG/DBL
LBL/WHT
YEL/DGN
YEL/BRN
DBL/YEL
YEL/DBL

YEL/LBL

YEL/LBL

PUR/RED
START

YEL/RED

RNG
RNG
C A D B E

PUR

RED
BLK

BLK

BLK

BLK

BLK

BLK
DIODE

BLK
BLK

BLK
D A C B E

DGN/YEL SO
MODE
SHUTDOWN RELAY B
FUEL LEVEL LIGHT DETENT RED/WHT DBL/WHT DBL
DIODE LIGHT
33-246 OHMS ST

86 85 AUXILIARY HYDRAULIC SWITCH LEFT
RNG

ENGINE COOLANT RIGHT
BLK (IF EQUIPPED) HEAD
HERE OR TO OPTIONS 1075-2231 OHMS HEAD
HERE OR TO OPTIONS (K TO P HARNESS) 87 LIGHT LIGHT

C113 C112
(K TO P HARNESS) (IF EQUIPPED)
FUSE 6

RED/DBL
RNG

ENGINE OIL 30 I (IF EQUIPPED)
RNG
B B
25A

BLK PRESSURE 87A BLK

C105

TO OPTIONS REAR AUXILIARY
3-90 OHMS
DGN/YEL A A RELIEF (IF
RNG SV2 EQUIPPED) ENGINE RPM IGNITION SWITCH
(MAGNETIC PICKUP) TO BICS BLK

C111
AIR FILTE
RED

YEL/LBL YEL/LBL A RNG C M WHT

BLK B B
TO OPTIONS DIVERTER RNG F L WHT/BLK WHT/BLK
YEL A A (IF EQUIPPED) BLK BLK B
J BLK SV1 PUR/RED N G RED/WHT
FUSE 8 FUSE 2
G RNG RNG RED RED RNG/WHT PUR/WHT P R PNK
25A 10A S DBL/WHT
F BRN RNG/DBL X
H DBL
C104

E BRN/DGN RNG V
E RED/WHT RED/WHT 1
D BRN/YEL LBL/RED W
W LBL/RED BLK 2
C DBL DBL H
3
B PNK PNK R X RNG/DBL BLK

A E B RED/WHT

C114
RED/WHT RED/WHT
H DBL/WHT S V RNG DBL/WHT
4
PNK

K DBL/BLK WHT M C RNG DBL/WHT

5
WHT/BLK L F RNG DBL
6
TO OPTIONS
(WIPER/WASHER BOTTLE) AUXILIARY RED/WHT B P PUR/WHT
LIGHT SWITCH (IF EQUIPPED)
C102 C103

HOURMETER AND N PUR/RED
A DBL/BLK K
HARNESS (IF EQUIPPED) DIODE
B BLK LBL/RNG J D BLK

TO OPTIONS
BLK h RNG U A BLK
J
RED/WHT

RED/WHT

(BACK-UP ALARM SWITCHES) BLK D HIGH FLOW SWITCH (IF EQUIPPED)

DGN/RED WIRE JUMPER FROM 2 TO 3
RNG BLK A U WHEN NOT EQUIPPED WITH HIGH FLOW SWITCH
RNG/DGN RED/WHT G T LBL/RED 1 2
STARTER RELAY GLOW PLUG RELAY K 3 DGN/RED
T BLK
B
A

FUSE 4
FUSE 3

HERE OR
TO OPTIONS BLK

C116
C121
25A
25A

86 4 WHT/BLK
BACKUP RNG C F RNG/DGN 85 86 85 5
WHT BLK BLK LBL/WHT GLOW BLK 6
ALARM PLUGS BLK
RNG/DGN F C RNG
B
A

SWITCHED POWER RELAY 87 87
G G WHT/LGN 30 LBL/RNG BLK HR
30
C101

87A RED RED 87A HORN (IF EQUIPPED)

E B BLK 87A BLK
WHT/BLK

HR
BLK
RNG

PNK A D BRN/DGN 30 DIAGNOSTIC PORT

RED
D E BRN/YEL RED 87 BLK HR 1 RED RNG/DBL BLK

C202
DBL/WHT H A PNK 86 2 PUR/RED
RED

85 BLK HR
RNG BLK
BLK B H DBL/WHT 3 PUR/WHT
FUSE 5 TO OPTIONS
RED/WHT 4 BLK (FRONT WIPER)
FUSE 1

10A

C204
15A
RED/WHT 1
LGN/WHT BLK
BOSS DISPLAY 2
BRAKE RELAY
DBL/WHT

DBL/WHT

RNG

LGN B PUR/RED
87A
BLK

BLK

FUSE 7 PUR/WHT BUCKET LEVEL

PNK

C
BLK

B
A

SWITCH (IF EQUIPPED)
PNK
BLK

30

C201
RED/WHT A RNG
87
C118 S
RED
RED
RED 25A WHT
E RNG
1 2
WHT/BLK
86 85 BLK RNG
RED BLK PNK/WHT D 3
B
A

WHT/BLK

M
RED 4

G
RED DGN/WHT
RIGHT RED RED 5
LEFT WHT/LGN RED DGN/WHT 6
TAILLIGHT TAILLIGHT LEFT RIGHT PUR RED S B
WORK WORK EXC B
LIGHT LIGHT BATTERY

REAR LIGHT HARNESS - 6714350 BLK B B BLK

CAB HARNESS (BOSS) - 6711774

C115
STARTER
ALTERNATOR
WHT C C WHT
PNK/WHT D D PNK/WHT
RNG A A RNG

ENGINE HARNESS (BOSS) - 6715948 OR 6718071

RED = RED
RNG = ORANGE
BICS
WIRES CONNECT BY SOME CONNECTOR BLK = BLACK
ENGINE

LBL = LIGHT BLUE
FUSE 1 10A
FUSE 5 LETTER ACROSS BODIES NOT SHOWN
15A

DBL = DARK BLUE
CONNECTORS FOR DRAWING CLARITY LGN = LIGHT GREEN
DGN = DARK GREEN
BOSS

A B YEL = YELLOW
10A

FUSE 2 25A FUSE 6

B A PNK = PINK
PWM WHT = WHITE
BRN = BROWN
LIGHT
TAN = TAN
FUSE 3
BRAKE

25A FUSE 7 PUR = PURPLE

25A

GRY = GREY
ACCESSORY

FUSE 8
25A

FUSE 4 25A
ACCESSORY MC2409 (10-29-99)
FUSE BLOCK
517 of 570
518 of 570
A.H.C. COMPONENTS
Identification
A
Steering Lever/Handle Control (Item1) [A]. 1
Handle Control Unit (Item 2) [A].

N–17376 N–17378

Control Valve Actuators (Item 1) [B].

B

Dealer Copy -- Not for Resale

1
N–17387
A.H.C./PWM Controller (Item 1) [C].

N–17375
B.I.C.S. Controller (Item 1) [D].
D

P–10157

863, 863H Bobcat Loader

Revised
519 of Feb.
570 99 –10–5– Service Manual
TROUBLESHOOTING (A.H.C.)
Chart
The Advance Hand Control System (A.H.C.) has a built–in diagnostic function which uses the two lights on the left handle to
indicate the condition of the A.H.C. System. The left light is lift and the right light is tilt.
The control module continually checks the system in the order listed. The checks start with the lift handle controller and then
the lift actuator. If no problems are present, it will then check the tilt handle controller and the tilt actuator. The system will stop
its check at the first problem and then flash the code. If the problem is in the tilt controller or actuator, the lift indicator light
will be ON and the tilt light flashing a code.
The system starts its diagnostics and calibration when the ignition key is turned ON. The left light will be ON for 0.5 second
and remain ON, then both lights will be ON for another 0.5 second. (This indicates the handles are wired properly and both
lights are working.)
LOADERS PRIOR TO PRESS TO OPERATE BUTTON–At this time one of the following will happen:
1. Both lights will continue to stay ON. (Normal Operation.)
2. Both lights go out, with no flashing code. (No BICS Signal, BICS Controller Not Satisfied)
3. The System goes into a flashing code. (See chart below for the problem.)
LOADER WITH PRESS TO OPERATE BUTTON–At this time one of the following will happen:
1. Both lights will be OFF until the PRESS TO OPERATE BUTTON is engaged. (Normal Operation.)
2. The System goes into a flashing code. (See chart below for the problem.)
The following list shows the probable causes and troubleshooting procedures when the lights are flashing.
The system will continually flash the code signal with the key in the RUN position.

NUMBER PROBLEM CAUSE SOLUTION

OF FLASHES (Page 10–5 )

1 Handle not calibrated Handle controller not in neutral during start–up. 1

Mechanical handle controller malfunction. 4
Electrical handle controller problem. 6
2 Actuator not calibrated Control valve spool sticking or not centered during 5
shutdown.
Faulty actuator. 8
3 Handle Control Wiring Fault Disconnected connector or wire. 2
Broken wire. 3
Electrical handle controller problem. 6
4 Actuator Wiring Fault Disconnected connector or wire. 2
Broken wire. 3
Faulty actuator. 2,4,7
*5 Actuator Fault Faulty actuator. –

*Actuator fault (5 flashes) will only occur while the loader is in operation. The controller sensed the actuator was out of sync
with the hand controller unit. Normally this is caused from dust build up in the actuator motor, which causes a poor connection
at the motor brush. This fault will cause a loss of power to the actuators. When the loader control unit is reset (The loader
key is turned to the OFF position then back to the ON position) you will not get an actuator fault (5 flashes), the system will
reset and say the system is OK or signal an alarm (2 or 4 flashes). When actuator faults (5 flashes) alarm becomes more
frequent replace the actuator.

863, 863H Bobcat Loader

Revised Feb.
52099
of 570 –10–6– Service Manual
TROUBLESHOOTING (A.H.C.) (Cont’d)
Chart (Cont’d)

SOLUTION

1. Turn the key OFF, put the hand controller in neutral position, turn the key ON. (The engine
does not have to be running for system recalibration or diagnostics).
2. Check wire connections for loose connector body, loose or bent pins in connectors.
3. Check for broken or damaged wire.
4. Check for stuck or sticky handle controller mechanism.
5. Turn the key OFF check to ensure spool moves freely, returns to neutral, turn the key ON.
6. Check the signal voltage from the handle controller unit. (See Page 10–8)
7. Check the signal voltage from the lift or tilt spool actuator. (See Page 10–6)
8. Check to insure the actuator moves freely on the actuator mounting bolt.

Dealer Copy -- Not for Resale

NOTE: If during operation one or both indicator light(s) goes out, this represents a reduced performance state. This
is caused by the actuator not being able to reach (full stoke) as commanded by the handle controller. When
the handle controller is returned to neutral and the actuator reaches neutral, the condition will clear itself
and the light will come back ON. Reduced speed in the lift or tilt circuits may be noticed. This will not disable
the loader, but may be an indication that an actuator is going bad.
When the wrong BICS™ controller, (Black face instead of Green face) is installed in an Advanced Hand
Control loader, and the key is turned to the ON position, the left light will come on for 0.5 seconds and remain
ON, then both lights will stay ON for an additional 0.5 seconds, then both lights will go out with no flashing
code, because there is no signal from the BICS to the control module. The BICS™ controller lights will be
ON, but the Advanced Hand Controller will not allow the loader hydraulics to function.

863, 863H Bobcat Loader

Revised
521 of Feb.
570 99 –10–7– Service Manual
ACTUATOR VOLTAGE TEST
Procedure
A
With Test Harness;
The test harness (MEL1554) and a digital multimeter are
necessary to complete the following procedure. 1
Disconnect the actuator wire connector (Item 1) [A] for the
tilt or (Item 2) [A] for the lift circuit from the controls 2
harness.
NOTE: Each actuator has to be checked separately.
Install the test harness (Item 1) [B].
N–17387
Turn the key to the ON position with engine OFF.
With a digital multimeter, take a voltage reading at the four
prong terminal connector (Item 2) [B]. B
The sensor supply voltage between terminal 1 (ground)
and terminal 3 [C] should be 4.3 ± 0.1 volts.
1
The signal voltage reading between terminal 1 (ground)
and terminal 2 [C] should be from 1.55 to 1.85 volts.
NOTE: Terminal 4 [C] is an open terminal not used at
this time.
2

Without Test Harness;

A digital multimeter is necessary to complete this test.
P–13755
The wiring harness connectors must remain connected to
complete this test.
If the test harness (MEL1554) is not available the sensor
C
supply voltage test (4.3 ± 0.1 volts) can be taken between
terminal 1 and terminal 3 on the tilt control harness (Item
1) [D] and the lift control harness (Item 2) [D].
The signal voltage reading (1.72 volts) can be taken
between terminal 1 and terminal 2 on the tilt control harness
(Item 1) [D] and the lift control harness (Item 2) [D].
Wire Code For Tilt Control Harness: (Item 1) [D]
1
Terminal 1 .... Light Blue/Yellow 4 3 2
Terminal 2 .... LIght Blue/White
Terminal 3 .... Light Blue
Terminal 4 .... Open P–13754
Terminal 5 .... Pink/White
Terminal 6 .... Light Blue/Red
Terminal 7
Terminal 8
....
....
Black
Pink/Yellow
D
Wire Code For Lift Control Harness: (Item 2) [A] 1
Terminal 1 .... Light Green/Yellow
Terminal 2 .... Light Green/White
Terminal 3 .... Light Green
Terminal 4 .... Open
Terminal 5 .... Brown/White 2
Terminal 6 .... Light Green/Orange
Terminal 7 .... Black
Terminal 8 .... Brown/Yellow

N–17387

863, 863H Bobcat Loader

Revised Feb.
52299
of 570 –10–8– Service Manual
ACTUATOR VOLTAGE TEST (Cont’d)
Procedure (Cont’d)
Diagnosis Results For Tilt Actuator (top) Sensor Supply Voltage Test;

If the sensor supply voltage is 4.3 ± 0.1 volts, continue on and check the signal voltage.
If the sensor supply voltage is less than 4.3 ± 0.1 volts or 0 volts, check the PWM fuse, check for shorts or opens in the wiring
harness. If there are no apparent shorts or opens change the AHC/PWM controller. (See Page 10–15.)

If the sensor supply voltage is more than 4.3 ±0.1 volts check for a short of the power wires in the wiring harness. If there
are no apparent shorts change the AHC/PWM controller. (See Page 10–15.)
Diagnosis Results For Tilt Actuator Signal Voltage Test;
If the signal voltage is in the range of 1.55 to 1.85 volts, the system is functioning properly. The nominal voltage reading is
1.72 volts.
If the signal voltage is not in the range of 1.55 to 1.85 volts check the hydraulic control valve spools for a centering problem
or replace the actuators. (See Page 10–29.)
Handle Out (Toward Side Screen):
1. Stop engine. Raise operator cab.
2. Connect the remote start switch (MEL1429A) to the loader.
3. Turn key to ON position with engine OFF to get a code indication from the indicator lights on the left control handle.

Dealer Copy -- Not for Resale

4. Check the sensor supply voltage. (See Page 10–10.)
5. Check the system to make sure it is functional, with no blinking indicator lights.
6. Move right AHC handle toward the side screen to full stroke. Hold in position and and take a voltage reading.
The voltage reading must be 0.13 volts or greater.
If the voltage reading is less than 0.13 volts, replace the actuator. (See Page 10–29.)
While holding the handle toward the side screen turn the key to OFF position and wait five seconds..
7. Continue to hold the handle toward the side screen and turn the key to the ON position. Take a voltage reading.
(You will have a one blink alarm on the right indicator light.)
The voltage reading should be between 1.55 to 1.85 volts.
If the voltage is above 1.85 volts, repeat steps 5 thru 7, if the voltage is still above 1.85 volts change the actuator.
If the voltage is below 1.55 volts complete the following tests: (See Step 11 Below; Tests a & b.)
Handle In (Toward Center Of Cab):
8. Turn the key to OFF position and wait five seconds, then turn key to ON position. Check the system to make sure it
is functional, with no blinking indicator lights.
9. Move right AHC handle toward the center of the cab to full stroke. Hold in position and take a voltage reading.
The voltage reading must be 3.2 volts or less.
If the voltage reading is more than 3.2 volts, check for shorts in the electrical connections, or replace the actuator.
(See Page 10–29.)
10. While the handle is held toward the center of the cab, turn the key to OFF position and wait five seconds.
11. Continue to hold the handle toward the center of the cab and turn the key to the ON position. Take a voltage reading.
(You will have a one blink alarm on the right indicator light.)
The voltage reading should be between 1.55 to 1.85 volts.
If the voltage is below 1.55 volts, repeat steps 8 thru 11 if the voltage is still below 1.55 volts change the actuator.
If the voltage is above 1.85 volts complete the following tests:
a. Remove the pin from the actuator to the control spool. Watch the spool, if the spool continues to move toward
neutral after the pin is removed, replace the actuator. Also check the mounting hardware on the actuators and
control valve for wear and correct torque.
b. If the spool does not move, check the control valve for a sticky spool or sticky centering mechanism. Also check
the mounting hardware on the actuators and control valve for wear and correct torque.

863, 863H Bobcat Loader

Revised
523 of Feb.
570 99 –10–9– Service Manual
ACTUATOR VOLTAGE TEST (Cont’d)
Procedure (Cont’d)
Diagnosis Results For Lift Actuator (bottom) Sensor Supply Voltage Test;

If the sensor supply voltage is 4.3 ± 0.1 volts, continue on and check the signal voltage.
If the sensor supply voltage is less than 4.3 ± 0.1 volts or 0 volts, check the PWM fuse, check for shorts or opens in the wiring
harness. If there are no apparent shorts or opens change the AHC/PWM controller. (See Page 10–15.)

If the sensor supply voltage is more than 4.3 ± 0.1 volts check for a short of the power wires in the wiring harness. If there
are no apparent shorts change the AHC/PWM controller. (See Page 10–15.)
Diagnosis Results For Lift Actuator Signal Voltage Test;
If the signal voltage is in the range of 1.55 to 1.85 volts, the system is functioning properly. The nominal voltage reading is
1.72 volts.
If the signal voltage is not in the range of 1.55 to 1.85 volts check the hydraulic control valve spools for a centering problem
or replace the actuators. (See Page 10–29.)
Handle Out (Toward Side Screen):
1. Stop engine. Raise operator cab.
2. Connect the remote start switch (MEL1429A) to the loader.
3. Turn key to ON position with engine OFF to get a code indication from the indicator lights on the left control handle.
(See Page 10–6.)
4. Check the sensor supply voltage. (See Page 10–10.)
5. Check the system to make sure it is functional, with no blinking indicator lights.
6. Move left AHC handle toward the side screen to full stroke. Hold in position and take a voltage reading.
The voltage reading must be 0.13 volts or greater.
If the voltage reading is less than 0.13 volts, replace the actuator. (See Page 10–29.)
7. While holding the handle toward the side screen turn the key to OFF position.
8. Wait five seconds, then put the handle to the float position. Turn the key to ON position and take a voltage reading.
(You will have a one blink alarm on the left indicator light.)
The voltage reading should be between 1.55 to 1.85 volts.
If the voltage is above 1.85 volts, repeat steps 5 thru 8, if still above 1.85 volts, change the actuator.
If the voltage is below 1.55 volts complete the following tests: (See Step 12 Below; Tests a & b.)
Handle In (Toward Center Of Cab):
9. Turn the key to OFF position and wait five seconds, then turn key to ON position. Check the system to make sure it
is functional, with no blinking indicator lights.
10. Move left AHC handle toward the center of the cab to full stroke, in float position. Take a voltage reading.
The voltage reading must be 4.17 volts or less.
If the voltage reading is more than 4.17 volts, check for shorts in the electrical connections, or replace the actuator.
(See Page 10–29.)
11. While the handle is in float position, turn the key to OFF position. Wait for five seconds.
12. Continue to keep the handle in the float position. Turn the key to ON position. Take a voltage reading.
(You will have a one blink alarm on the left indicator light.)
The voltage reading should be between 1.55 to 1.85 volts.
If the voltage is below 1.55 volts, repeat steps 9 thru 12, if the voltage is still below 1.55 volts change the actuator.
If the voltage is above 1.85 volts complete the following tests:

a. Remove the pin from the actuator to the control spool. Watch the spool, if the spool continues to move toward
neutral after the pin is removed, replace the actuator. Also check the mounting hardware on the actuators and
control valve for wear and correct torque.
b. If the spool does not move, check the control valve for a sticky spool or sticky centering mechanism. Also check
the mounting hardware on the actuators and control valve for wear and correct torque.

863, 863H Bobcat Loader

Revised Feb.
52499
of 570 –10–10– Service Manual
HANDLE CONTROL UNIT TEST
Procedure
A
Right Handle Test With Test Harness; 1
Raise the operator cab. (See Page 1–1.)
Connect the remote start switch. (See Page 1–1.)
The test harness (MEL1555) and a digital multimeter are
necessary to complete the following procedure.
Disconnect the handle control harness (Item 1) [A].
Install the test harness (Item 1) [B].
N–17387
Move handle to the neutral position.
Turn the key to the ON position with the engine OFF.
B
With a digital multimeter take a voltage reading at the four
prong terminal connector (Item 2) [B].
1
The sensor supply voltage between ground, terminal 1 and
terminal 3 [C] should be 4.3 ± 0.1 volts.

The signal voltage reading between the ground, terminal 1 2

and terminal 2 [C] should be 1.7 to 2.1 volts.

Dealer Copy -- Not for Resale

NOTE: Terminal 4 [C] is an open terminal not used at
this time.
Right Handle Test Without Test Harness;
P–13756
A digital multimeter is necessary to complete this test.
For the switch handle harness connector color code. (See
Page 10–24.) C
The test must be run at the eight pin switch handle
connector (Item 1) [A]. The wiring harness connectors
must remain connected to complete this test.

Check the sensor supply voltage (4.3 ± 0.1 volts) between

terminal G (Pink/Black) and terminal F (Pink/Red).
Check the signal voltage between terminal G (Pink/Black)
and terminal H (Pink/Green). The voltage should be
between 1.7 to 2.1 volts. 1
4 3 2
Diagnosis Results for both Tests;
P–13754
If the sensor supply voltage is 4.3 ± 0.1 volts, continue on
and check the signal voltage.

If the sensor supply voltage is less than 4.3 ± 0.1 volts or

0 volts, check the PWM fuse, check for shorts or opens in
the wiring harness. If there are no apparent shorts or opens
change the AHC/PWM controller. (See Page 10–15.)

If the sensor supply voltage is more than 4.3 ± 0.1 volts

check for a short to a power wire in the wiring harness. If
there are no apparent shorts, change the AHC/PWM
controller. (See Page 10–15.)
If the signal voltage is in the range of 1.7 to 2.1 volts the
system is functioning properly. The nominal voltage
reading is 1.89 volts. If the signal voltage is not in the range
of 1.7 to 2.1 volts change the handle controller.

863, 863H Bobcat Loader

Revised
525 of Feb.
570 99 –10–11– Service Manual
HANDLE CONTROL UNIT TEST (Cont’d)
Procedure (Cont’d)
A
Left Handle Test With Test Harness; 1
Raise the operator cab. (See Page 1–1.)
Connect the remote start switch. (See Page 1–1.)
The test harness (MEL1555) and a digital multimeter are
necessary to complete the following procedure.
Disconnect the handle control harness (Item 1) [A].
Install the test harness (Item 1) [B].
N–17375
Move handle to the neutral position.
Turn the key to the ON position with the engine OFF.
B
With a digital multimeter take a voltage reading at the four
prong terminal connector (Item 2) [B].

The sensor supply voltage between ground, terminal 1 and

terminal 3 [C] should be 4.3 ± 0.1 volts.
1
The signal voltage reading between the ground, terminal 1
and terminal 2 [C] should be 1.7 to 2.1 volts.
NOTE: Terminal 4 [C] is an open terminal not used at
this time. 2
Left Handle Test Without Test Harness;
P–13757
A digital multimeter is necessary to complete this test.
For the switch handle harness connector color code. (See
Page 10–24.) C
The test must be run at the eight pin switch handle
connector (Item 1) [A]. The wiring harness connectors
must remain connected to complete this test.

Check the sensor supply voltage (4.3 ± 0.1 volts) between

terminal G (Brown/Black) and terminal F (Brown/Red).
Check the signal voltage between terminal G
(Brown/Black) and terminal H (Brown/Green). The voltage 1
should be between 1.7 to 2.1 volts. 4 3 2
Diagnosis Results for both Tests;
P–13754
If the sensor supply voltage is 4.3 ± 0.1 volts, continue on
and check the signal voltage.

If the sensor supply voltage is less than 4.3 ± 0.1 volts or

0 volts, check the PWM fuse, check for shorts or opens in
the wiring harness. If there are no apparent shorts or opens
change the AHC/PWM controller. (See Page 10–13.)

If the sensor supply voltage is more than 4.3 ± 0.1 volts

check for a short to a power wire in the wiring harness. If
there are no apparent shorts, change the AHC/PWM
controller. (See Page 10–13.)
If the signal voltage is in the range of 1.7 to 2.1 volts the
system is functioning properly. The nominal voltage
reading is 1.89 volts. If the signal voltage is not in the range
of 1.7 to 2.1 volts change the handle controller.

863, 863H Bobcat Loader

Revised Feb.
52699
of 570 –10–12– Service Manual
HANDLE CONTROL UNIT TEST (Cont’d)
Procedure (Cont’d)
Right Handle (Tilt) Full Stroke Voltage Test
1. Turn the key to the ON position with engine OFF.
2. Check the Sensor Supply Voltage. (See Page 10–10.)
3. Move right AHC handle out or toward the side screen, hold and take a voltage reading. The voltage should be 0.13 or
greater. If the voltage is less than 0.13 volts change the handle controller.
4. Allow the handle to go to neutral. Take a voltage reading. The voltage should be 1.7 to 2.1 volts. If the voltage reading
is either higher or lower, check for loose mounting hardware, or a bad handle controller.
5. Move the right AHC handle in toward the center of the cab to full stroke. Hold in position and take a voltage reading.
The voltage reading should be 4.17 volts or less. If the voltage reading is higher, change the handle controller unit. (See
Page 10–19.)
6. Release the handle and allow it to go to neutral. Take a voltage reading. The voltage should be 1.7 to 2.1 volts.
If the voltage is either higher or lower, check for loose mounting hardware, or a bad handle controller.
Left Handle (Lift) Full Stroke Voltage Test
1. Turn the key to the ON position with engine OFF.
2. Check the Sensor Supply Voltage. (See Page 10–10.)
3. Move left AHC handle out or toward the side screen, hold and take a voltage reading. The voltage should be 0.13 or
greater. If the voltage is less than 0.13 volts change the handle controller.

Dealer Copy -- Not for Resale

4. Allow the handle to go to neutral. Take a voltage reading. The voltage should be 1.7 to 2.1 volts. If the voltage reading
is either higher or lower, check for loose mounting hardware, or a bad handle controller.
5. Move the left AHC handle in toward the center of the cab to float and take a voltage reading. The voltage reading should
be 3.2 volts or less. If the voltage reading is higher, change the handle controller unit. (See Page 10–19.)
6. Release the control handle and allow it to go to neutral from the float position. Take a voltage reading. The voltage
should be 1.7 to 2.1 volts. If the voltage is either higher or lower, check for loose mounting hardware, or a bad handle
controller.

863, 863H Bobcat Loader

Revised
527 of Feb.
570 99 –10–13– 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.

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

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.

ADVANCED HAND CONTROLS (AHC)

Indicator Effect on Loader Operation
Light Light OFF When Light is OFF Cause
Valve Control Valve cannot be used. Lift, tilt and traction AHC has detected a diagnostic
functions will not operate. condition OR Hand Controls not in
neutral when engine was started.

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 Feb. 99570
528 of –10–14– Service Manual
A.H.C./PWM CONTROLLER
Removal and Installation
A 2 2

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

At the left fender, remove the four motor cover mounting
bolts, and remove the motor cover (Item 1) [A].
Remove the four mounting bolts (Item 2) [A] from the
controller.

N–17463

Disconnect the wiring harness connectors from the

controller (Item 1) [B].
B
Remove the controller from the loader.
Test

• The wiring harness connectors must be connected to

the controller [B].

Dealer Copy -- Not for Resale

• Take voltage measurements by probing into wires near
the controller shown in figure [B]. All connectors must
remain plugged into their respectful harness.
1
• Turn the key to the ON position (Item 1) [C] with the
engine OFF.
N–17464

• Turn the switches ON to get their appropriate readings.

(See chart listed below for switch locations.)
C
• Press the auxiliary hydraulic switch (Item 2) [C] twice.
Both Green lights will be ON.

• For individual voltage readings see Page 10–14. 5

Key Switch Item 1 [C] 2
Auxiliary Hydraulic Switch Item 2 [C] 3
Momentary Light Item 3 [C]
Detent Light Item 4 [C]
High Flow Switch Item 5 [C] 1
4
Proportional Flow Switch Item 1 [D]
Detent Switch Item 2 [D]
Rear Aux. Switch (Base & Rod) Item 3 [D] N–16959 P–10466

1
3
Right
Left Steering
Steering Lever
Lever 2 Control
Control
P–13255 P–13254

863, 863H Bobcat Loader

Revised
529 of Feb.
570 99 –10–15– Service Manual
 A

*Schematic Connector Number MC–02420

A.H.C./PWM CONTROLLER (Cont’d)

Description
Connector No. Pin No. Description Voltage Comments
C 430* A Battery Power 12.0
B Ground 0
C 428* 1 Power 12.0
2 Model Input 0
3 Model Select–Input A Not Used
4 Model Select–Input B Not Used
5 Model Select–Input C Not Used
6 Open 0
C 429* A Diagnostic Light 4.0–11.0 Light ON–Light OFF
B Diagnostic Light 4.0–11.0 Light ON–Light OFF
C 431* 1 Attachment Control Signal 0 or 12.0
2 Signal from Lift Control Input Handle 0.80–1.89–2.90 Low–Neutral–High
3 Return from Aux. Module Switch Input 9.5
4 Signal from Tilt Control Input Handle 0.80–1.89–2.90 Low–Neutral–High
5 Power to Tilt Spool Actuator Not Used
6 Signal from Lift Actuator Feedback Input 0.40–1.72–3.0 Low–Neutral–High
7 Return from Aux. Detent Switch Input 12.0
8 Power to Lift Spool Actuator Not Used
9 Signal from Tilt Actuator Feedback Input 0.40–1.72–3.0 Low–Neutral–High
10 Return from Aux. Rear Base Switch Input 11.0
11 BICS Status Input 0 or 12.0 Bar UP–Bar DOWN
12 Return from Aux. Rear Rod Switch Input 12.0
13 High Flow Solenoid Output 0 or 12.0
14 Diagnostic Input No function
15 Low Reference to Resistive Inputs Ground
16 Signal from Aux. Resistive Inputs 0.98–2.24–3.24 Low–Neutral–High
17 Lift Actuator Reverse Motor Output 0 to 12.0
18 Diverter Solenoid Output 12.0
19 BICS Aux. Lock Input 0 or 11.0 Bar UP–Bar DOWN
20 Auxiliary Relief Input 12.0 Key Left
21 Aux. Switch Module Detent Light 3.5 between 8.5 Light ON–Light OFF
22 Aux. Switch Module Momentary Light 3.5–8.5 Light ON–Light OFF
23 Lift Actuator Forward Motor Output 0 to 12.0
24 Aux. Spool Base End Output 0–6.0 Key Left (12 Volt)
25 High Reference to Resistive Inputs 4.3 ± 0.1
26 Power to Aux. Switch Module 9.99–10.68
27 AHC Status Output 0 or 12.0 Bar UP–Bar DOWN
28 Switch Power 12.0 Key On
29 Tilt Actuator Reverse Motor Output 0 to 12.0
30 Aux. Spool Rod End Output 0–6.0
31 Tilt Actuator Forward Motor Output 0 to 12.0
863, 863H Bobcat Loader
530 of 570
Revised Feb. 99 –10–16– Service Manual
A.H.C./PWM CONTROLLER (Cont’d)
Conditions
A
• Auxiliary Hydraulic Switch lights will not come ON.
Check the following:

PWM fuse
Wires disconnected, shorted, or open.
Auxiliary hydraulic switch failure.
Module failure.
1
Use the voltage tests in the wire identification
section to determine the cause. (See Page 10–16.)
2
Troubleshooting Chart P–03272

The controller sends a diagnostic code to the Auxiliary

Hydraulic 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
blinking.
• Continuous flow (detent) can be engaged if alternate

Dealer Copy -- Not for Resale

blinking lights are OFF after the key switch is turned OFF
and then ON (during a proportional flow switch failure).

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 Open
• Solenoid failed. Perform solenoid
coil test.
• PWM module failed.
Light Off Light Blinking Rod End Solenoid or Wiring • Wires Disconnected
• Wires Shorted
• Wires Open
• Solenoid failed. Perform solenoid
coil test.
• PWM module failed.
Light Blinking Light Blinking Diverter Solenoid or Wiring • Wires Disconnected
• Wires Shorted
• Wires Open
• Solenoid failed. Perform solenoid
coil test.
• PWM module failed.
*Blinking/OFF *OFF/Blinking Proportional Flow Switch • Wires Disconnected
(Right Handle) • Wires Shorted
• Wires Open
• Proportional flow switch failed.
Check voltage to switch.
Perform handle test.
• PWM module failed.

*Alternate Blinking Lights

863, 863H Bobcat Loader

Revised
531 of Feb.
Revised Feb. 99
570 99 –10–17– Service Manual
AHC/PWM CONTROLLER (Cont’d)
Handle Testing
A
The right side steering lever handle switch (Item 1) [A]
controls the proportional flow to front auxiliary. Use a Ohm
meter to test the switch.
1
Disconnect the handle switch harness from the controls
harness (Item 1) [B]. Use the chart below to test the handle
switch.

Handle Switch Position

Test between
handle wires Full Left Center Full Right
Dk. Blue & 4.5–5.5 4.5–5.5 4.5–5.5 P–02129
Dk. Blue/White K–Ohms K–Ohms K–Ohms
Dk. Blue/Yellow 0.5–1.5
& Dk. Blue/White K–Ohms
2.3–2.7
K–Ohms
3.5–4.5
K–Ohms
B
Dk. Blue/Yellow 3.5–4.5 2.3–2.7 0.5–1.5 1
& Dk. Blue K–Ohms K–Ohms K–Ohms
One K–Ohm is equal to 1000 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.
Solenoid Coil Testing
N–17387
The front auxiliary solenoid coils (Item 1) [C] are located in
the hydraulic control valve. Test the solenoid coils with a
Ohm test meter.
C
Disconnect the coil from the controls harness. The correct
reading is 1–5 Ohms.

1
N–17493

863, 863H Bobcat Loader

Revised Feb.
53299
of 570 –10–18– Service Manual
HANDLE CONTROL UNIT
Removal And Installation
A
To remove the handle control unit.
Slide the rubber handle cover (Item 1) [A] up the handle.
Remove the two mounting bolts (Item 2) [A] from the
control cover.
Remove the control cover.
1

Dealer Copy -- Not for Resale

N–17376

Disconnect the loader control harness (Item 1) [B] from the

handle control harness.
B

N–17378

863, 863H Bobcat Loader

533 of 570 –10–19– Service Manual
HANDLE CONTROL UNIT (Cont’d)
Removal And Installation (Cont’d)
A
Using a small screwdrive remove the handle control
electrical connector from the clip [A].

P–13737

Using an allen wrench, remove the two mounting screws

(Item 1) [B] from the control unit. B
NOTE: A small screwdriver (Item 2) [B] in the control
unit may be needed to hold the center spacer
from turning.

1
1

N–17379

863, 863H Bobcat Loader

534 of 570 –10–20– Service Manual
HANDLE CONTROL UNIT (Cont’d)
Removal And Installation (Cont’d)
A
Remove the mounting bolt and nut (Item 1) [A] from the
control handle and shaft.
Remove the control unit (Item 2) [A] from the control
handle.

Dealer Copy -- Not for Resale

2

N–17380

NOTE: The control unit (Item 1) [B] can only be

replaced as a complete assembly. B 2
3
Check the spacer (Item 2) [B] and screws (Item 3) [B] and
replace as needed.

N–17392

Installation: When installing the control unit into the

steering handle, check the routing of the switch handle wire
C
harness (Item 1) [C] to assure proper return of the control
handle to neutral.

N–17470

863, 863H Bobcat Loader

535 of 570 –10–21– Service Manual
HANDLE CONTROL UNIT (Cont’d)
Control Unit Connector
A
The wire connector (Item 1) [A] can be removed from the
handle control unit wires, use the following procedure.

1
N–17392

Remove the wedge (Item 1) [B] from the connector.

B

1
1

P–13725 P–13732

With a pointed tool, lift the tab (Item 1) [C] and pull the wire
from the connector. C
Assembly: Install the wires into the connector as listed
below [C]:
2
1–Terminal – Red 3
1
2–Terminal – Black
3–Terminal – Green 1

P–17333

863, 863H Bobcat Loader

536 of 570 –10–22– Service Manual
SWITCH HANDLE
Removal And Installation
A
Remove the handle control unit from the steering lever.
(See Page 10–19.)

To remove the connector (Item 1) [A] from the switch

handle wires, use the following procedure:

Dealer Copy -- Not for Resale

N–17381

Remove the wedge (Item 1) [B] from the connector.

B

1
P–13725 P–13732
Using a pointed tool, press down on the tab (Item 1) [C] and
pull the wire from the connector.
C
Installation: Install the wires into the connector as listed
below [C]:
Right Steering Lever Switch Handle
1–Terminal – Pink/Red
2–Terminal – Pink/Green 2
3–Terminal – Pink/Black
1
3
Left Steering Lever Switch Handle
1–Terminal – Brown/Red
2–Terminal – Brown/Black
3–Terminal – Brown/Green
1
P–17335

863, 863H Bobcat Loader

537 of 570 –10–23– Service Manual
SWITCH HANDLE (Cont’d)
Removal And Installation (Cont’d)
A
Disconnect the left switch handle connectors (Item 1, 2 & 1
3) [A] from the loader wiring harness connectors.
Disconnect the right switch handle connectors (Item 1 & 2)
[B] from loader wiring harness connectors.
Remove the connector locks and connectors from the
wires to remove the switch handle from the steering
handle.
2
Installation:The wire colors of the steering lever harness
are as follows: 3
N–17375
Left Switch Handle
Eight–Pin Connector
A–Terminal – Yellow B
B–Terminal – Green
C–Terminal – Brown
D–Terminal – Orange
E–Terminal – Orange/Blue
F–Terminal – Brown/Red 2
G–Terminal – Brown/Black
H–Terminal – Brown/Green 1
Three–Pin Connector
A–Terminal – Orange/White
B–Terminal – Yellow/Red
C–Terminal – Yellow/Green
Two–Pin Connector N–17387
A–Terminal – Purple
B–Terminal – Purple/Blue
Two–Pin Connector (Water Kit)
A–Terminal – White
B–Terminal – Blue
Right Switch Handle
Eight–Pin Connecter
A–Terminal – Dk. Orange/White
B–Terminal – Green
C–Terminal – Dk. Blue
D–Terminal – Dk. Blue/White
E–Terminal – Dk. Blue/Yellow
F–Terminal – Pink/Red
G–Terminal – Pink/Black
H–Terminal – Pink/Gray
Six–Pin Connector
A–Terminal – Orange
B–Terminal – Lt. Green/White
C–Terminal – Lt. Green
D–Terminal – Yellow
E–Terminal – Blank
F–Terminal – Blank

863, 863H Bobcat Loader

538 of 570 –10–24– Service Manual
SWITCH HANDLE (Cont’d)
Removal And Installation (Cont’d)
A
Roll the pistol grip handle cover (Item 1) [A] down.
Using a small screwdriver, lift the handle tabs (Item 2) [A]
and slightly rotate the switch handle. 2
2

N–17382

Pull the switch handle and wiring harness assembly (Item

1) [B] from the steering lever.
B

Dealer Copy -- Not for Resale

N–17383

Installation: When installing the switch handle and wiring

harness assembly into the steering handle, rout the
harness (Item 1) [C] to assure proper return of the control C
handle to neutral position.
863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.) – Advanced Hand Control Section Part 1 of 3

N–17471

863, 863H Bobcat Loader

539 of 570 –10–25– Service Manual
A. H. C. HANDLE
Removal And Installation
A
Remove the handle control unit. (See Page 10–19.) 1
Remove the switch handle. (See Page 10–23.)
Remove the rubber handle cover (Item 1) [A] from the
handle.

N–17384

Using a small screwdriver, hold the handle spacer (Item 1)

[B] and remove the allen head screws (Item 2) [B] from the
handle assembly. B
1

2 2

N–17385

Remove the handle from the steering lever assembly [C].

C

N–17386

863, 863H Bobcat Loader

540 of 570 –10–26– Service Manual
A.H.C. HANDLE (Cont’d)
Disassembly And Assembly
A
Remove the handle sleeve (Item 1) [A] and bushings (Item
2) [A] from the handle.
Check all parts for wear and replace as needed.

2
1
N–17394

Check the mounting bolt (Item 1) [B] that connects the

handle to the handle control unit for wear, replace as
needed. B

Dealer Copy -- Not for Resale

N–17393

863, 863H Bobcat Loader

541 of 570 –10–27– Service Manual
A.H.C. STEERING LEVER
Removal And Installation
A
Remove the handle control unit. (See Page 10–19.)
1
Remove the switch handle from the steering lever. (See
Page 10–23.)
Remove the handle from the steering lever. (See Page
10–26.)
Loosen the two u–clamps (Item 1) [A] nuts.
Remove the steering lever from the cross shaft and control
panel.
N–17389
The steering lever (Item 1) [B] must be replace as a
complete unit.
The connector clip (Item 2) [B] can be replaced separately B
from the steering lever.

P–13734
Steering Lever Boot
Disconnect the switch handle harness connectors from the
loader wiring harness connectors. (See Page 10–24.) C 1
1
Remove the connectors from the switch handle wiring
harness. (See Page 10–24.)
Remove the steering lever from the control panel. (See
Page 10–27.)
Remove the four pop rivets from the boot retainer (Item 1)
[C] and control panel.
Remove the steering lever boot.

N–17391

863, 863H Bobcat Loader

542 of 570 –10–28– Service Manual
ACTUATORS
Removal And Installation
A
NOTE: For correction installation of the actuator,
mark all the wire connections (Item 1) [A]
before disconnecting them.
Disconnect the wiring harness connectors (Item 1) [A] from 1
the actuator connectors.

1
N–17387

Remove the right side motor cover.

Remove the two mounting bolts (Item 1) [B] from the B
control valve mounting plate and actuator mounting block.
Installation: Tighten the mounting bolts to 30 ft.–lbs. (40,7
Nm) torque.
1

Dealer Copy -- Not for Resale

P–13736

Remove the pins (Item 1) [C] from the actuator couplers.

C
Remove the actuators and mounting block through the
right side motor cover hole.
1

1
N–17403
Installation: To install the pins in the actuator couplers,
move the bottom actuator shaft (Item 1) [D] out to the end
of its stroke. Install the pin into the actuator coupler and
valve spool. Move the top actuator shaft (Item 2) [D] out to
D
the end of the stroke and install the pin into the coupler and
valve spool, before installing and tightening the actuator
mount bolts.
2

N–17414

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543 of 570 –10–29– Service Manual
ACTUATORS (Cont’d)
Disassembly And Assembly
A
Remove the two mounting bolts (Item 1) [A] from the
actuator mounting block.
Installation: Tighten the mount bolts to 10–12 ft.–lbs.
(13,5–16,2 Nm) torque.
NOTE: There must be a small amount of free play 1 1
between the actuators and the mount block
when properly installed.

N–17412

Check the mounting block (Item 1) [B] and bolts for wear
and replace as needed. B

N–17415

Remove the rubber boot (Item 1) [C] and tie strap from the
actuator shaft. C
Check the rubber boot (Item 1) [C] for wear and replace as
needed.

N–17468

Check the actuator wiring harness connector (Item 1) [D]

and replace if broken.
D
Installation: Install the wires into the connector as listed
below:
Lift and Tilt Actuator
1 – Terminal–Red–Larger diameter wires (16 gauge)
2 – Terminal–Green–Larger diameter wires(16 gauge)
3 – Terminal–Black–Larger diameter wires(16 gauge)
4 – Terminal–Open
5 – Terminal–Red–Smaller diameter wires(18 gauge)
6 – Terminal–Open 1
7 – Terminal–Open
8 – Terminal–Black–Smaller diameter wires(18 gauge) N–17469

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544 of 570 –10–30– Service Manual
ACTUATORS (Cont’d)
Mounting Plate
A
To remove and install the control valve/actuator mounting
plate, use the following procedure:
Remove the actuators and actuator mounting blocking
from the mounting plate. (See Page 10–29.)
Support the control valve with a chain hoist [A].

N–17406

At the right side motor cover hole, remove the two control
valve mounting bolts (Item 1) [B]. B
1
Installation: Tighten the two 3/8 x 1–1/4 inch mounting
bolts to 30 ft.–lbs. (40,7 Nm) torque.

Dealer Copy -- Not for Resale

1
N–17292

Remove the tubeline clamp (Item 1) [C] mounting bolt.

C 2
2
Remove the two mounting bolts (Item 2) [C].
Remove the control valve/actuator mounting plate through
the right side motor cover hole. 1

N–17404

863, 863H Bobcat Loader

545 of 570 –10–31– Service Manual
BICS™ VALVE
Lift Arm By–Pass Orifice
A 2
To remove, replace or check the orifice for the lift arm
by–pass function, use the following procedure.

When repairing hydrostatic and hydraulic

systems, clean the work area before
disassembly and keep all parts clean. Always N–17293
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888 B
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.
Remove the orifice from the valve.

N–17294

Clean and inspect the orifice (Item 1) [C]. Replace as

needed. C
1

P–13727

863, 863H Bobcat Loader

546 of 570 –10–32– Service Manual
BICS™ VALVE (Cont’d)
Check Valve
A
Loosen and remove the check valve (Item 1) [A].
3
Installation: Tighten the check valve to 20 ft.–lbs. (27 Nm)
torque.

N–17271

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.

Lock Valve

Dealer Copy -- Not for Resale

There are two lock valves on the BICS valve, lift lock valve
(Item 2) [A] and tilt lock valve (Item 3) [A]. 1

P–13728

Loosen and remove the lock valve (Item 1) [C] from the
valve. C 1

Installation: Tighten the lock valve(s) to 25 ft.–lbs. (34 Nm)

torque. Replace all the O–rings and back–up washers
before installation.
Inspect the lock valve(s) for damage.
Replace the lock valve(s) if necessary.

N–17295

863, 863H Bobcat Loader

547 of 570 –10–33– Service Manual
BICS™ VALVE (Cont’d)
BICS™ Valve Solenoid
A
Loosen the mounting nut (Item 1) [A] at the solenoid. 1

N–17271

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

coil (Item 3) [B], O–ring (Item 4) [B]. B 3
Remove the solenoid cartridge (Item 5) [B] from the valve.
4
Installation: Tighten the cartridge to 20 ft.–lbs. (27 Nm) 1
torque. 5
2

N–17298

Inspect the solenoid cartridge (Item 1) [C] for damage.

Replace all the O–rings and back–up washers before C 1
installation.
Replace the solenoid cartridge as needed.

N–17299

863, 863H Bobcat Loader

548 of 570 –10–34– Service Manual
BICS™ VALVE (Cont’d)
Removal And Installation
A
Loosen the six mounting bolts (Item 1) [A] at the BICS
valve.
Remove the mounting bolts (Item 1) [A].
1
1

N–17271

Remove the BICS valve assembly (Item 1) [B] from the top
of the control valve (Item 2) [B].
B 1
Installation: Always replace the four large O–rings (Item
3) [B] and small O–ring (Item 4) [B].

3
3

Dealer Copy -- Not for Resale

4
2

N–17302

Installation: The chart below lists the correct torque

specifications and tightening sequence [C] when
reinstalling the BICS™ valve assembly to the hydraulic C
control valve. Thoroughly clean and dry bolts and threads
in valve. Use liquid adhesive LOCTITE #242.

Step Torque ♦Sequence 3 6

1 110–130 in.–lbs. 1 2
(12,4–14,7 Nm)
5 4
2 190–210 in.–lbs.
(21,5–23,7 Nm) 1, 2, 3, 4, 5 & 6
3* 190–210 in.–lbs.
(21,5–23,7 Nm)
P–09587

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

every bolt or the complete ♦sequence must be repeated.

863, 863H Bobcat Loader

549 of 570 –10–35– Service Manual
HYDRAULIC CONTROL VALVE
Removal And Installation
A

1 1

When repairing hydrostatic and hydraulic 2

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–17406
I–2003–0888

Raise the lift arms and install an approved lift arm support
B
device. (See Page 1–1.) 2
1
Stop the engine. Raise the seat bar.
Raise the operator cab. (See Page 1–1.)
Clean the area around the control valve.
Drain the hydraulic fluid reservoir. (See Page 2–1.)
Remove the advance hand control actuators. (See Page
10–29.)
Support the hydraulic control valve with a chain hoist [A]. N–17407

Remove the mounting plate for the control valve/actuators

assembly. (See Page 10–31.) C
Disconnect the wire harness connectors (Item 1) [A] from 2
the auxiliary solenoid connectors.
Disconnect the harness connector (Item 2) [A] from the
BICS valve solenoid connector.
Disconnect the hose (Item 1) [B] which goes from the
control valve to the oil cooler.
Disconnect the right side steering shock (Item 2) [B].
1
Disconnect the hydraulic hoses (Item 1 & 2) [C] from the
tee–fitting on the lift lock valve.
N–17408

Disconnect the hydraulic hose (Item 1) [D] from the lift lock
valve to the BICS block on the control valve. D

N–17409

863, 863H Bobcat Loader

550 of 570 –10–36– Service Manual
HYDRAULIC CONTROL VALVE
Removal And Installation (Cont’d)
A
NOTE: Install caps on all control valve fittings when
disconnecting tubelines to protect the Flare–O 1
fitting O–rings.
Remove the right side motor cover.
Disconnect the inlet tubeline (Item 1) [A] from the bottom
of the control valve.

N–17401

Remove the tubeline clamp mounting bolt (Item 1) [B] from

the control valve mount plate. B
1

Dealer Copy -- Not for Resale

N–17404

At the left side of the engine compartment, loosen the

auxiliary tubeline mounting bolt (Item 1) [C]. C 1

N–17405

Remove the tubeline mounting bolt and clamp (Item 1) [D]

from the tubeline at the hydraulic filter. D

N–17397

863, 863H Bobcat Loader

551 of 570 –10–37– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Removal And Installation (Cont’d)
A
Disconnect the auxiliary tubelines (Item 1) [A].
1
Disconnect the charge pressure hose (Item 2) [A] from the
control valve.

N–17410

Disconnect the tilt circuit tubelines (Item 1) [B].

B
1 1

N–17411

Disconnect the lift circuit tubelines (Item 1) [C] and (Item

1) [D].
C 1
Remove the control valve from the loader.

P–13738

P–13739

863, 863H Bobcat Loader

552 of 570 –10–38– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Identification Chart
A H3
H2
H1

Item 863 A.H.C. Loader

A1 Lift Cylinder Base End/Restrictor

C4
A2 Tilt Cylinder Base End
B3 A3
G3 D3
A3 Auxiliary Hydraulics
C3
D2
B1 Lift Cylinder Rod End G2 B2 A2 E2
C2
B2 Tilt Cylinder Rod End F2 D1
G1 B1 A1 E1
B3 Auxiliary Hydraulics
F1 C1
C1 Load Check Valve/Lift Function MR

C2 Load Check Valve/Tilt Function

MC–02419
C3 Orificed Load Check Valve/Auxiliary Function
C4 Outlet Fluid Flow
D1 Lift Spool Centering Spring
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 Valve
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

553 of 570 –10–39– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Disassembly And Assembly
A
Remove the BICS valve assembly from the control valve.
(See Page 10–35.)
Remove the four large O–rings (Item 1) [A] and small 1
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 2
parts. (See Page 10–39.)

N–17275

B 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 1
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0284

Mark each valve section, spool and related parts so that

they will be returned to its original valve location during
assembly. N–17276
Load Check Valve
Loosen the load check valve plug (Item 1) [B]. C
Installation: Always use new O–ring. Tighten the plug to
35–40 ft.–lbs. (47–54 Nm) torque.
1
Remove the load check plug (Item 1) [C].
Remove the spring (Item 2) [C] and poppet (Item 3) [C].

3
2

N–17274

The auxiliary section (Item 1) [D] uses an orifice load check D 1

poppet.
Lift Base End Restrictor 2
Remove the restrictor (Item 2) [D] from the lift section base
end port.

Check for damage and replace as needed.

N–17273

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554 of 570 –10–40– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Main Relief Valve
A
Loosen the main relief valve (Item 1) [A].
Installation: Tighten the main relief to 35–40 ft.–lbs..
(47–54 Nm) torque.

N–17276

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

Dealer Copy -- Not for Resale

1

N–17272

Remove the O–rings, sleeve, and glide ring from the main
relief valve [C]. C
Installation: Always use new O–rings. sleeve, and glide
ring.
NOTE: See Page 2–1 for setting the pressure at the
main relief valve after the control valve is
installed in the loader.

N–17297

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555 of 570 –10–41– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Port Relief Valve (Lift)
A
Loosen the port relief valve (Item 1) [A] (Port E1).
Installation: Tighten port relief to 35–40 ft.–lbs. (47–54
Nm) torque.

2
1

N–17283

Remove the port relief valve from the control valve [B].
B
Remove the O–rings and back–up washer from the port
relief valve.

Installation: Always use new O–rings and back–up

washers.

Anti–Cavitation/Port Relief Valve

Loosen the anti–cavitation valve/port relief (Item 2) [A]
(Port E2).
Installation: Tighten cartridge to 35–40 ft.–lbs. (47–54
Nm) torque. N–17284

Remove the anti–cavitation valve/port relief from the

control valve [C].
C
Remove the O–rings and back–up washer from the
anti–cavitation/port relief.
Installation: Always use new O–rings and back–up
washers.

N–17285

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556 of 570 –10–42– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Port Relief Valve (Tilt)
A
Loosen the anti–cavitation/port relief valve (Item 1) [A] 1
(Port F2).
2
Installation: Tighten the anti–cavitation/port relief valve to
35–40 ft.–lbs. (47–54 Nm) torque.

N–17276

Remove the anti–cavitation/port relief from the control

valve [B]. B
Remove the O–rings from the anti–cavitation/port relief
valve.
Installation: Always use new O–rings and back–up
washers.

Dealer Copy -- Not for Resale

N–17278
Anti–Cavitation Valve
Loosen the anti–cavitation valve (Item 2) [A] (Port F1).
C
Installation: Tighten the anti–cavitation valve to 35–40
ft.–lbs. (47–54 Nm) torque.
Remove the anti–cavitation valve from the control valve
[C].
Remove the O–rings from the anti–cavitation valve.
Installation: Always use new O–rings and back–up
washers.

N–17277

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557 of 570 –10–43– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Rubber Boot
A
Remove the two screws (Item 1) [A] on the rubber boot 1
retainer.
Installation: Tighten the screws to 90–100 in.–lbs.
(10,2–11,3 Nm) torque.

N–17279

Remove the rubber boot (Item 1) [B] and retainer (Item 2)

[B].
B
Remove the seal retainer (Item 3) [B] and O–ring (Item 4)
[B].

1 3
2
N–17280

863, 863H Bobcat Loader

558 of 570 –10–44– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Lift And Tilt Spool
A
Remove the rubber boot from the other end of the spool.
(See Page 10–44.) 1
Remove the two screws (Item 1) [A] from the end cap (lift
or tilt).
Installation: Tighten the screws to 90–100 in.–lbs.
(10,2–11,3 Nm) torque.
2
Remove the end cap (Item 2) [A] (lift or tilt).
1
N–17286

Remove the spool (Item 1) [B], centering spring, back–up

washer and seal from the control valve. B

Dealer Copy -- Not for Resale

1
2

N–17288

At the other end of the spool bore, remove the spool seal
(Item 1) [C] and O–ring (Item 2) [C]. C
NOTE: To install new spool seal (Item 2) [B], remove 1
the centering spring or See Page 10–50 for seal
replacement without removing the centering
spring.

N–17492

Installation: If both spools are removed at the same time,

mark the lift spool (Item 1) [D] and tilt spool (Item 2) [D] so
they will be put in their original bore.
D
2

N–17261

863, 863H Bobcat Loader

559 of 570 –10–45– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Lift And Tilt Spool (Cont’d)
A 2

The tool listed will be needed to do the following procedure;

MEL1285 – Spring Tool
Put the linkage end of the spool in the vice [A].
Install the spring tool (Item 1) [A] over the centering spring. 1
NOTE: Be careful when removing the bolt from the
centering spring, because there is spring
pressure.
Loosen the bolt (Item 2) [A] holding the centering spring to
the spool.
Installation: Tighten the bolt to 90–100 in.–lbs. (10,2–11,3
Nm) torque.

N–17287

Remove the adapter (Item 1) [B], spring cap (Item 2) [B],

spring (Item 3) [B], and washer (Item 4) [B] from the spool. B
2
3

4
1

N–17290

863, 863H Bobcat Loader

560 of 570 –10–46– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Lift And Tilt Spool (Cont’d)
A O–ring

Lift Spool Only: To remove the plastic plug from the lift
spool:
Make a center point in the plug using a 1/16 inch drill.
Drill a hole all the way through the plug using a 7/64 inch
tap drill.
Plastic
Turn a 6–32 tap into the plug. Pull the tap and plug out of
the spool. Be careful, do not break the tap. Plug
0.60 inch
(15,2 mm)
Clean all the debris from the inside of the spool bore.
MC–02421
Installation: Slide the O–ring over the nipple on the plastic
plug. Install the plastic plug in the spool. Install the bolt so
that the end of the plug is about 0.60 inch (15,2 mm) from
the end of the spool [A]. B
NOTE: During installation of the centering spring to
the spool, make sure the adapter is centered in
the washer hole (Item 1) [B]. If the adapter is
not centered, it can cause the bolt to break
during installation.
Inspection

Dealer Copy -- Not for Resale

Check the spools for wear or scratches.
1
Check that the spools are not loose in their bore.
Check that the centering springs are not broken.
N–17260
Check that the load check valve seats are not worn.
Check the load check poppet for damage.
Check the rubber boots and retainers that they are not worn
or damage.
Replace all parts as needed.

863, 863H Bobcat Loader

561 of 570 –10–47– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Auxiliary Spool
A 2
Remove the end cap screws (Item 1) [A] & [B].
Installation: Tighten the screws to 90–100 in.–lbs. 1 3
(10,2–11,3 Nm) torque.

6
5

4
N–17281

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 2
(Item 5) [A] & [B].
Remove the spring retainer (Item 6) [A] & [B]. 3 1

6
5

4
N–17264

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

C
1

N–17263

863, 863H Bobcat Loader

562 of 570 –10–48– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Auxiliary Electrical 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–17265

Remove the metal housing (Item 1) [B], coil (Item 2) [B],

and end plate (Item 3) [B]. B
4
Remove the electric solenoid valve (Item 4) [B].
3
Installation: Tighten the solenoid valve to 96–144 in.–lbs. 2
(10,8–16,3 Nm) torque.
1

Dealer Copy -- Not for Resale

N–17267

Installation: Always install new O–rings and back–up

washers on the solenoid valve [C]. C

N–17269

863, 863H Bobcat Loader

563 of 570 –10–49– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Spool Seal Installation
A
To install new spool seals when the centering spring is 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–17491

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.
Remove the plastic material. 1
Install the spool into the control valve.

CD–15080
Install the linkage end spool seal [C] into the control valve
(Item 1) [D].
Be careful not to damage the spool seal.
C

P–13746
Install the O–ring (Item 2) [D].
Continue assembling the control valve. D
863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.) – Advanced Hand Control Section Part 2 of 3
1

N–17492

863, 863H Bobcat Loader

564 of 570 –10–50– Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
H–Port Auxiliary Section
A
Loosen the plug (Item 1) [A]. 1
Installation: Tighten the plug to 35–40 ft.–lbs. (47–54 Nm)
torque.

N–17265

Remove the plug from the control valve [B].

B

Dealer Copy -- Not for Resale

N–17266

Depending on the application of the auxiliaries, the control

valve may be equipped with a port relief valve (Item 1) [C].
C

N–17474
If so equipped, remove the port relief from the control valve
[D].
D
Installation: Replace the O–rings and back–up washers.
Tighten the port relief valve 35–40 ft.–lbs. (47–54 Nm)
torque.

N–17284

863, 863H Bobcat Loader

565 of 570 –10–51– Service Manual
863,863HServiceManual#6900648(S/N514425001&Abv.,514525001&Abv.,514625001&Abv.) – Advanced Hand Control Section Part 3 of 3

863, 863H Bobcat Loader

566 of 570 –10–52– Service Manual
 863/863H–1
Revision Number

2 February 1999
SERVICE MANUAL Date

REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER X
SERVICE MANAGER
Model 863/863H SALES MANAGER
Manual No. 6900648 (10–98)

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
Maintenance Safety Page thru Section 1
(This includes Maintenance Safety Page,
Alphabetical Index, i thru viii & Section 1)
PUT IN
Maintenance Safety Page thru Section 1
(This includes Maintenance Safety Page,
Alphabetical Index, i thru viii & Section 1)

2–3 thru 2–4 2–3 thru 2–4

2–23 thru 2–26 2–23 thru 2–26
2–33 thru 2–34 2–33 thru 2–34
2–51 thru 2–52 2–51 thru 2–52
2–59 thru 2–60 2–59 thru 2–60
2–71 thru 2–74 2–71 thru 2–74
DO NOT REMOVE the Hydraulic Schematics
in Section 2
Section 3 Section 3
Section 4 Section 4
6–5 thru 6–6 6–5 thru 6–6
6–19 thru 6–20 6–19 thru 6–20
7–1 thru 7–8 7–1 thru 7–8
7–25 thru 7–26 7–25 thru 7–26
7–47 thru 7–50 7–47 thru 7–50
7–121 thru 7–122 7–121 thru 7–122
Section 8 Section 8
10–1 thru 10–18 10–1 thru 10–18
DO NOT REMOVE Advanced Hand Control Wiring
Schematics in Section 10

567 of 570
568 of 570
 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: 863-2

Date: 28 July 2010
Product: Bobcat Loader
Model: 863
Manual No: 6900648 (7-10)

The following Pages are a revision to the above Service Manual.

COVER
MAINTENANCE SAFETY

7-31

Printed in U.S.A.
569 of 570
 2
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