Bobcat 863, 863 High Flow Skid Steer Loader Service Manual
506 pages · Publication 6724799_7_10
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- Models
- 863, 863 High Flow
- Serial coverage
- (SN 514411001–514424999), (SN 514511001–514524999), (SN 514611001–514624999)
- Manual type
- Service Manual
- Pages
- 506
- Publication
- 6724799_7_10
- Condition
- Brand new
What's inside
From the manual's own table of contents: 20 sections, 478 entries. See sample pages (PDF, 491 KB)
MAINTENANCE SAFET
FOREWORD6 topics
- SAFETY INSTRUCTIONS
- SERIAL NUMBER LOCATIONS
- LOADER SERIAL NUMBER
- DELIVERY REPORT
- BOBCAT LOADER IDENTIFICATION
- OPTIONS AND ACCESSORIES
PREVENTIVE MAINTENANCE
SERVICE SCHEDULE48 topics
- LIFTING AND BLOCKING THE LOADER
- Procedure
- TRANSPORTING THE BOBCAT LOADER
- Procedure
- TOWING THE LOADER
- LIFT ARM SUPPORT DEVICE
- To Install The Lift Arm Support Device
- To Remove The Lift Arm Support Device
- OPERATOR CAB
- Description
- Raising The Operator Cab
- Lowering The Operator Cab
- Emergency Exit
- SEAT BAR RESTRAINT SYSTEM
- Description
- Seat Bar Inspection
- Seat Bar Maintenance
- AIR CLEANER SERVICE
- Replacing Filter Element
- FUEL SYSTEM
- Fuel Specifications
- Filling The Fuel Tank
- Fuel Filter
- Removing Air From The Fuel System
- ENGINE LUBRICATION SYSTEM
- Checking Engine Oil
- Replacement Of Oil And Filter
- COOLING SYSTEM
- Cleaning The Cooling System
- ALTERNATOR BELT
- Adjusting The Alternator Belt
- HYDRAULIC/HYDROSTATIC SYSTEM
- Checking And Adding Fluid
- Replacing The Hydraulic/Hydrostatic Filter
- Replacing The Hydraulic Fluid
- TIRE MAINTENANCE
- Wheel Nuts
- Tire Rotation
- Tire Mounting
- FINAL DRIVE TRANSMISSION (CHAINCASE)
- Checking And Adding Oil
- Removing Oil From The Chaincase
- LUBRICATION OF THE BOBCAT LOADER
- Procedure
- FAN GEARBOX
- Checking And Maintaining
- REMOTE START SWITCH
- Procedure
HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS84 topics
- TROUBLESHOOTING
- HYDRAULIC SYSTEM INFORMATION
- Tighten Procedures
- LIFT CYLINDER(S)
- Checking The Lift Cylinder(s)
- Removal And Installation
- TILT CYLINDER
- Checking The Tilt Cylinder
- Removal And Installation
- Rod End Seal
- HYDRAULIC CYLINDER
- Lift Cylinder Identification
- Tilt Cylinder Identification
- Disassembly
- Assembly
- MAIN RELIEF VALVE
- Checking The Main Relief Valve
- Checking The Main Relief Valve Without Auxiliaries
- Removal And Installation
- Adjustment
- SELECT VALVE 863H
- Checking The High Flow Pump Relief Valve
- Removal And Installation
- Disassembly And Assembly
- Solenoid Testing
- LIFT ARM BY–PASS CONTROL VALVE
- Removal And Installation
- Disassembly And Assembly
- BICS™ CONTROL VALVE
- Removal And Installation
- BICS™ VALVE ASSEMBLY
- Lift Arm By–Pass Orifice
- Check Valve
- Lock Valve
- BICS™ Valve Solenoid
- HYDRAULIC CONTROL VALVE
- Removal And Installation
- Identification Chart
- Disassembly And Assembly
- Load Check Valve
- Lift Base End Restrictor
- Main Relief Valve
- Port Relief Valve
- Anti–Cavitation/Port Relief Valve
- Rubber Boot
- Lift Spool And Detent
- Tilt Spool And Centering Spring
- Auxiliary Spool
- Auxiliary Electric Solenoid
- H Port – Auxiliary Section
- Inspection
- Spool Seal Installation
- HYDRAULIC PUMP
- Checking The Output Of The Pump
- Removal And Installation
- Parts Identification
- Disassembly
- Inspection
- Assembly
- HYDRAULIC PUMP (Double Gear) 863H
- Checking The Output Of The High Flow Pump
- Removal And Installation
- Parts Identification
- Disassembly
- Inspection
- Assembly
- HYDRAULIC FLUID RESERVOIR
- Removal And Installation
- HYDROSTATIC FILTER HOUSING
- Removal And Installation
- Hydrostatic Charge Pressure Sender
- HYDRAULIC FILTER HOUSING
- Removal And Installation
- CONTROL PEDALS
- Removal And Installation
- Pedal Adjustment
- PEDAL INTERLOCK LINKAGE
- Removal And Installation
- Pedal Interlock Linkage Adjustment
- REAR AUXILIARY DIVERTER
- Disassembly
- Inspection
- Solenoid Testing
- Assembly
HYDROSTATIC SYSTEM
TROUBLESHOOTING51 topics
- HYDROSTATIC SYSTEM INFORMATION
- Replenishing Valve Function
- FRONT PANEL (SOLID STEERING LINKAGE)
- Removal And Installation
- FRONT PANEL (CABLE STEERING LINKAGE)
- Removal And Installation
- STEERING LEVERS
- Disassembly And Assembly
- CONTROL TOWER (SOLID STEERING LINKAGE)
- Removal And Installation
- Disassembly And Assembly
- SOLID STEERING LINKAGE NEUTRAL ADJUSTMENT
- Procedure
- CABLE STEERING LINKAGE NEUTRAL ADJUSTMENT
- Pre–Adjustment Checks
- Adjusting Lever Freeplay
- Adjusting The Wheel RPM Forward Compared to Reverse Travel
- Adjusting The Steering Neutral Setting
- Adjusting The Wheel RPM Left Compared To Right Side
- HYDROSTATIC MOTOR
- Removal And Installation
- Parts Identification
- Disassembly
- Inspection
- Assembly
- HYDROSTATIC PUMP
- Removal And Installation
- Replenishing/High Pressure Relief Valve
- Parts Identification
- Hydraulic Pump Removal
- Hydrostatic Pump Separation
- Charge Pump Disassembly
- Disassembly
- Inspection
- Assembly
- Charge Pump Assembly
- Hydrostatic Pump Connection
- Hydraulic Pump Installation
- Swashplate Neutral Adjustment
- Displacement Control Servo (Solid Linkage)
- Displacement Control Servo (Cable Linkage)
- DRIVE BELT SHIELD
- Removal And Installation
- DRIVE BELT
- Adjusting The Drive Belt
- Replacing The Drive Belt
- DRIVE BELT TENSIONER PULLEY
- Removal And Installation
- Tension Spring
- OIL COOLER
- Removal And Installation
DRIVE SYSTEM
PARKING BRAKE PEDAL22 topics
- Removal And Installation
- Disassembly And Assembly
- PARKING BRAKE DISC
- Removal And Installation
- FRONT CHAINCASE COVER
- Removal And Installation
- REAR CHAINCASE COVER
- Removal And Installation
- AXLE SEAL
- Removal And Installation
- AXLE, SPROCKET AND BEARINGS
- Removal And Installation
- MOTOR CARRIER
- Shaft Seal Replacement
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- DRIVE CHAIN
- Removal And Installation
- CHAINCASE FLUID
- Removing The Fluid From The Chaincase
MAIN FRAME
SEAT BAR (W/GAS SPRING)37 topics
- Removal And Installation
- Seat Bar Pivot Assembly
- Compressing The Gas Cylinder
- Assembly
- SEAT BAR (W/COMPRESSION SPRING)
- Removal And Installation
- Assembling Components
- Compression Spring Disassembly And Assembly
- OPERATOR CAB GAS CYLINDER
- Removal And Installation
- Disassembly And Assembly
- Removal And Installation
- OPERATOR SEAT
- Removal And Installation
- BOB–TACH
- Bob–Tach Lever And Wedge
- Bob–Tach Stops
- Removal And Installation
- Pivot Pin Bushing And Seal Replacement
- LIFT ARMS
- Removal And Installation
- REAR GRILL
- Removal And Installation
- REAR DOOR (ONE PIECE)
- Removal And Installation
- Door Latch And Catch Adjustment
- REAR DOOR
- Removal And Installation
- Hood Removal And Installation
- Bumper Removal And Installation
- Door Latch Removal And Installation
- Door Latch And Catch Adjustment
- FUEL TANK
- Removal And Installation
- Fuel Level Sender
- Fuel Pick–Up Screen/Check Valve
- Inlet Screen
ELECTRICAL SYSTEM
ELECTRICAL SCHEMATICS33 topics
- ELECTRICAL SYSTEM INFORMATION
- Description
- Fuse Location
- BATTERY
- Removal And Installation
- Servicing The Battery
- Using A Booster Battery
- ALTERNATOR
- Alternator Output Test
- Rectifier (Diode) Test
- Alternator Regulator Test
- Removal And Installation
- Disassembly
- Stator Continuity Test
- Stator Ground Test
- Rotor Continuity Test
- Rotor Ground Test
- Rectifier Continuity (Diode) Test
- Assembly
- STARTER
- Removal And Installation
- Parts Identification
- Disassembly And Assembly
- External Pinion
- Inspection And Repair
- Magnetic Switch Test
- No Load Test
- STANDARD INSTRUMENT PANEL
- Removal And Installation
- FRONT LIGHTS
- Removal And Installation
- RELAY SWITCHES
- Location
ENGINE SERVICE91 topics
- ENGINE SPEED CONTROL
- Removal And Installation
- Speed Control Cable
- Speed Control Linkage
- ENGINE MUFFLER
- Removal And Installation
- AIR CLEANER HOUSING
- Removal And Installation
- BLOWER HOUSING/FAN GEARBOX
- Removal And Installation
- FAN DRIVE TENSION PULLEY
- Removal And Installation
- BLOWER FAN
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- Checking Backlash
- ENGINE
- Removal And Installation
- ENGINE MOUNTS
- Replacement
- FLYWHEEL
- Removal And Installation
- Flywheel Ring Gear
- FLYWHEEL HOUSING
- Removal And Installation
- GLOW PLUG
- Checking The Glow Plug
- VALVE CLEARANCE
- Adjustment
- FUEL INJECTION PUMP
- Description
- Removal
- Installation
- FUEL INJECTOR
- Removal And Installation
- Checking
- Disassembly
- Assembly
- TIMING BELT
- Inspection
- Removal
- Installation
- Belt Replacement In Loader
- VALVE TIMING
- Checking
- DEUTZ ENGINE TOOLS
- Identification Chart
- RECONDITIONING THE ENGINE
- Disassembly
- Assembly
- CYLINDER LINERS
- Checking The Cylinder Liners
- CAMSHAFT BEARINGS
- Checking
- Removal And Installation
- CONTROL ROD GUIDE BUSHING
- Removal
- Installation
- REAR COVER SEAL
- Removal And Installation
- CRANKSHAFT
- Checking The Crankshaft
- CONNECTING ROD
- Checking The Connecting Rod
- PISTON AND PISTON PIN
- Checking The Piston
- Checking Piston Pin
- Installing Piston Rings
- CYLINDER HEAD
- Disassembly
- Checking The Valves
- Checking Valve Seats
- Valve Spring
- Assembly
- ROCKER ARM AND BRACKET
- Checking
- Disassembly
- Assembly
- TURBOCHARGER
- Removal And Installation
- Disassembly
- Inspection
- Assembly
- Description
- Inspection
- Module Removal And Installation
- Removal And Installation
- CRANKSHAFT GEAR MOUNTING BOLT
- Torque Procedure
SYSTEMS ANALYSIS
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)43 topics
- Inspecting The BICS™ Controller (Engine STOPPED – Key ON)
- Inspecting Deactivation Of The Auxiliary HydraulicsSystem (Engine STOPPED – Key ON)
- Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)
- Inspecting The Traction Lock (Engine RUNNING)
- Inspecting The Lift Arm By–Pass Control
- Maintenance
- Troubleshooting Chart
- SEAT SENSOR OVERRIDE ONLY (If Equipped)
- Troubleshooting Guide
- BICS SYSTEM CONTROLLER
- BICS™ SYSTEM CONTROLLER
- Removal And Installation
- Controller Test
- SEAT BAR SENSOR
- Removal And Installation
- Seat Bar Sensor Test
- SEAT SENSOR
- Removal And Installation
- Seat Sensor Test
- TRACTION LOCK
- Removal And Installation
- BOSS® DIAGNOSTIC TOOL
- Procedure
- SENDER AND SENSOR
- Service Checks
- Components
- RPM SENSOR
- Adjustment
- MONITOR SERVICE CODES
- TROUBLESHOOTING THE BOSS® & LCD DISPLAY
- OPERATION SENSING SYSTEM UNIT
- Removal And Installation
- BOSS® INSTRUMENT PANEL
- Removal And Installation
- PWM MODULE
- Description
- Troubleshooting Chart
- PWM CONTROL HANDLE
- Handle Testing
- PWM ELECTRIC SOLENOID
- Solenoid Coil Testing
- ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
- Controls Identification Chart
SPECIFICATIONS
LOADER SPECIFICATIONS43 topics
- LOADER DIMENSIONS
- PERFORMANCE
- CONTROLS
- ENGINE
- HYDRAULIC SYSTEM
- ELECTRICAL
- DRIVE SYSTEM
- CAPACITIES
- TIRES
- ENGINE SPECIFICATIONS (BF4M1011)
- General
- Fuel System
- Valve And Valve Guide And Seat Insert
- Piston And Rings
- Connecting Rod
- Cylinder Head And Block
- Crankshaft And Main Bearings
- Camshaft And Bearings
- Oil Pump
- ENGINE SPECIFICATIONS (BF4M1011F)
- General
- Fuel System
- Valve And Valve Guide And Seat Insert
- Piston And Rings
- Connecting Rod
- Crankshaft And Main Bearings
- Camshaft And Bearings
- Oil Pump
- ENGINE TORQUE
- Specifications
- Torque For General Metric Bolts
- TORQUE SPECIFICATIONS FOR LOADER
- HYDRAULIC CONNECTION SPECIFICATIONS
- O–ring Face Seal Connection
- Straight Thread O–ring Fitting
- Tubelines And Hoses
- Flare Fitting
- O–ring Flare Fitting
- Port Seal Fitting
- HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
- STANDARD TORQUE SPECIFICATIONS FOR BOLTS
- DECIMAL AND MILLIMETER EQUIVALENTS
- U.S. TO METRIC CONVERSION
SERVICE MANUAL REVISIONS
Inside this manual
Real pages from this service manual (506 pages). Open the sample pages (PDF, 490 KB)
- Troubleshooting, page 289: TROUBLESHOOTING
- Diagram, page 338: ENGINE
- Specifications, page 443: BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
- Foldout diagram, page 270
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 863, 863 High Flow are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual 6724799_7_10$69.91
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 506 pages
Quantity one is the manual described above.
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Ships in 1 business day.
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Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).