Bobcat 863, 863 High Flow Skid Steer Loader Service Manual
570 pages · Publication 6900648_7_10
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- Models
- 863, 863 High Flow
- Serial coverage
- SN 514425001 & above, SN 514525001 & above, SN 514625001 & above
- Manual type
- Service Manual
- Pages
- 570
- Publication
- 6900648_7_10
- Condition
- Brand new
What's inside
From the manual's own table of contents: 23 sections, 560 entries. See sample pages (PDF, 457 KB)
MAINTENANCE SAFETY
ALPHABETICAL INDEX
FOREWORD6 topics
- SAFETY INSTRUCTIONS
- SERIAL NUMBER LOCATIONS
- LOADER SERIAL NUMBER
- ENGINE SERIAL NUMBER
- DELIVERY REPORT
- BOBCAT LOADER IDENTIFICATION
PREVENTIVE MAINTENANCE
SERVICE SCHEDULE57 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
- Raising The Operator Cab
- Lowering The Operator Cab
- Emergency Exit
- SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)
- Description
- Seat Bar Inspection
- Seat Bar Maintenance
- SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS)
- Description
- Seat Bar Inspection
- Seat Bar Maintenance
- SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)
- Description
- Seat Bar Maintenance
- Seat Bar Inspection
- AIR CLEANER SERVICE
- Replacing Filter Element
- FUEL SYSTEM
- Fuel Specifications
- Filling The Fuel Tank
- Fuel Filter
- Removing Air From The Fuel System
- ENGINE LUBRICATION SYSTEM
- Checking Engine Oil
- Replacement Of Oil And Filter
- COOLING SYSTEM
- Cleaning The Cooling System
- ALTERNATOR BELT
- Adjusting The Alternator Belt
- HYDRAULIC/HYDROSTATIC SYSTEM
- Replacing The Hydraulic/Hydrostatic Filter
- Checking And Adding Fluid
- Replacing The Hydraulic Fluid
- TIRE MAINTENANCE
- Wheel Nuts
- Tire Rotation
- Tire Mounting
- FINAL DRIVE TRANSMISSION (CHAINCASE)
- Checking And Adding Oil
- Removing Oil From The Chaincase
- LUBRICATION OF THE BOBCAT LOADER
- Procedure
- FAN GEARBOX
- Checking And Maintaining
- BOB–TACH
- Inspection And Maintenance
- REMOTE START SWITCH
- Procedure
HYDRAULIC SYSTEM
HYDRAULIC/HYDROSTATIC 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
- MAIN RELIEF VALVE (Advanced Hand Control)
- Adjustment
- SELECT VALVE 863H
- Checking The High Flow Pump Relief Valve
- Removal And Installation
- Disassembly And Assembly
- Solenoid Testing
- LIFT ARM BY–PASS CONTROL VALVE
- Removal And Installation
- Disassembly And Assembly
- BICS™ CONTROL VALVE
- Removal And Installation
- BICS™ VALVE ASSEMBLY
- Lift Arm By–Pass Orifice
- Check Valve
- Lock Valve
- BICS™ Valve Solenoid
- HYDRAULIC CONTROL VALVE
- Removal And Installation
- Identification Chart
- Disassembly And Assembly
- Load Check Valve
- Lift Base End Restrictor
- Main Relief Valve
- Port Relief Valve
- Anti–Cavitation/Port Relief Valve
- Rubber Boot
- Lift Spool And Detent
- Tilt Spool And Centering Spring
- Auxiliary Spool
- Auxiliary Electric Solenoid
- H Port – Auxiliary Section
- Inspection
- Spool Seal Installation
- HYDRAULIC PUMP
- Checking The Output Of The Pump
- Removal And Installation
- Parts Identification
- Disassembly
- Inspection
- Assembly
- HYDRAULIC PUMP (Double Gear) 863H
- Checking The Output Of The High Flow Pump
- Removal And Installation
- Parts Identification
- Disassembly
- Inspection
- Assembly
- HYDRAULIC FLUID RESERVOIR
- Removal And Installation
- HYDROSTATIC FILTER HOUSING
- Removal And Installation
- Hydrostatic Charge Pressure Sender
- CONTROL PEDALS
- Removal And Installation
- Pedal Adjustment
- PEDAL INTERLOCK LINKAGE
- Removal And Installation
- Pedal Interlock Linkage Adjustment
- REAR AUXILIARY DIVERTER
- Disassembly
- Inspection
- Solenoid Testing
- Assembly
HYDROSTATIC SYSTEM
TROUBLESHOOTING73 topics
- HYDROSTATIC SYSTEM INFORMATION
- Replenishing Valve Function
- FRONT PANEL (M46 Pump & AHC)
- Removal And Installation
- FRONT PANEL (M44 Hydraulic Pump)
- Removal And Installation
- STEERING LEVERS (M46 Pumps & AHC)
- Disassembly And Assembly
- STEERING LEVERS (M44 Pumps)
- Removal And Installation
- Disassembly And Assembly
- CONTROL TOWER (M46 Pump & AHC)
- Removal And Installation
- Disassembly And Assembly
- SOLID STEERING LINKAGE NEUTRAL ADJUSTMENT (M46 Pump)
- Procedure
- STEERING LINKAGE (M44 Pump)
- Removal And Installation
- Steering Linkage Adjustment
- Removal And Installation
- Parts Identification
- Disassembly
- Inspection
- Assembly
- Removal And Installation
- Parts Identification
- Disassembly
- Inspection
- Assembly
- MOTOR CARRIER
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- HYDROSTATIC PUMP (M46)
- Removal And Installation
- Replenishing/High Pressure Relief Valve
- Charge Pressure Relief Valve
- Parts Identification (Right Half)
- Parts Identification (Left Half)
- Hydraulic Pump Removal
- Hydrostatic Pump Separation
- Charge Pump Disassembly
- Disassembly
- Inspection
- Assembly
- Charge Pump Assembly
- Hydrostatic Pump Connection
- Hydraulic Pump Installation
- Swashplate Neutral Adjustment
- Displacement Control Servo (Solid Linkage)
- HYDROSTATIC PUMP (M44)
- Parts Identification (Right Half)
- Parts Identification (Left Half)
- Replenishing/High Pressure Relief Valve
- Charge Pressure Relief Valve
- Hydraulic Pump Removal
- Hydraulic Pump Separation
- Charge Pump Disassembly
- Disassembly
- Assembly
- CHARGE PUMP (M44)
- Assembly
- DRIVE BELT SHIELD
- Removal And Installation
- DRIVE BELT
- Adjusting The Drive Belt
- Replacing The Drive Belt
- DRIVE BELT TENSIONER PULLEY
- Removal And Installation
- Tension Spring
- HYDRAULIC/HYDROSTATIC OIL COOLER
- Removal And Installation
DRIVE SYSTEM
PARKING BRAKE PEDAL16 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
- DRIVE CHAIN
- Removal And Installation
- CHAINCASE FLUID
- Removing The Fluid From The Chaincase
MAIN FRAME
SEAT BAR25 topics
- 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 Lever And Wedge
- Bob–Tach Stops
- Removal And Installation
- Pivot Pin Bushing And Seal Replacement
- LIFT ARMS
- Removal And Installation
- REAR GRILL
- Removal And Installation
- REAR DOOR
- Removal And Installation
- Door Latch And Catch Adjustment
- FUEL TANK
- Removal And Installation
- Fuel Level Sender
- Fuel Pick–Up Screen/Check Valve
- Inlet Screen
ELECTRICAL SYSTEM
ELECTRICAL 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 SERVICE88 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
- Replacement
- FLYWHEEL
- Removal And Installation
- Flywheel Ring Gear
- FLYWHEEL HOUSING
- Removal And Installation
- GLOW PLUG
- Checking The Glow Plug
- VALVE CLEARANCE
- Adjustment
- FUEL INJECTION PUMP
- Description
- Removal
- Injection Pump Timing
- Installation
- FUEL INJECTOR
- Removal and Installation
- Checking
- Disassembly
- Assembly
- TIMING BELT
- Inspection
- Removal
- Installation
- Belt Replacement In Loader
- VALVE TIMING
- Checking
- DEUTZ ENGINE TOOLS
- Identification Chart
- RECONDITIONING THE ENGINE
- Disassembly
- Assembly
- CYLINDER LINERS
- Checking The Cylinder Liners
- CAMSHAFT BEARINGS
- Checking
- Removal And Installation
- CONTROL ROD GUIDE BUSHING
- Removal
- Installation
- REAR COVER SEAL
- Removal And Installation
- CRANKSHAFT
- Checking The Crankshaft
- CONNECTING ROD
- Checking The Connecting Rod
- PISTON AND PISTON PIN
- Checking the Piston
- Installing Piston Rings
- CYLINDER HEAD
- Disassembly
- Checking The Valves
- Checking Valve Seats
- Valve Spring
- Assembly
- ROCKER ARM AND BRACKET
- Checking
- Disassembly
- Assembly
- TURBOCHARGER
- Removal and Installation
- Disassembly
- Inspection
- Assembly
- ENGINE OIL COOLER
- Removal And Installation
- CRANKSHAFT GEAR MOUNTING BOLT
- Torque Procedure
SYSTEMS ANALYSIS
BICS™ (With Press To Operate Button)57 topics
- Inspecting The BICS™ Controller (Engine STOPPED– Key ON)
- Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
- Inspecting The Seat Bar Sensor (Engine RUNNING)
- Inspecting The Traction Lock (Engine RUNNING)
- Inspecting The Lift Arm By–Pass Control
- Additional Inspection For Loaders With Advanced Hand Controls
- Troubleshooting Chart
- BICS™ (Without Press To Operate Button)
- Inspecting The BICS™ Controller (Engine STOPPED– Key ON)
- Inspecting Deactivation of the Auxiliary HydraulicsSystem (Engine STOPPED – Key ON)
- Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)
- Inspecting The Traction Lock (Engine RUNNING)
- Inspecting The Lift Arm By–Pass Control
- Maintenance
- Troubleshooting Chart
- SEAT SENSOR OVERRIDE ONLY (If Equipped)
- BICS SYSTEM CONTROLLER
- Removal And Installation
- SEAT BAR SENSOR
- Troubleshooting Guide
- Seat Bar Sensor Test
- Removal And Installation
- BICS™ Controller Seat Bar Sensor Circuit Test
- SEAT SENSOR
- Troubleshooting Guide
- Seat Sensor Test
- Removal And Installation
- BICS™ Controller Seat Sensor Circuit Test
- TRACTION LOCK
- Troubleshooting Guide
- Removal And Installation
- Inspecting The Traction Lock Control System
- Maintenance
- Description
- Inspection
- Maintenance
- BOSS® DIAGNOSTIC TOOL
- Procedure
- SENDER AND SENSOR
- Service Checks
- RPM SENSOR
- Adjustment
- MONITOR SERVICE CODES
- TROUBLESHOOTING THE BOSS® & LCD DISPLAY
- BOSS® UNIT
- Removal And Installation
- BOSS® INSTRUMENT PANEL
- Removal And Installation
- PWM MODULE
- Description
- PWM TROUBLESHOOTING
- Chart
- PWM CONTROL HANDLE
- Handle Testing
- PWM ELECTRIC SOLENOID
- Solenoid Coil Testing
- ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
SPECIFICATIONS
LOADER SPECIFICATIONS44 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
- Cylinder Head And Block
- Crankshaft And Main Bearings
- Camshaft And Bearings
- Oil Pump
- ENGINE TORQUE
- Specifications
- Torque For General Metric Bolts
- TORQUE SPECIFICATIONS FOR LOADER
- HYDRAULIC CONNECTION SPECIFICATIONS
- O–ring Face Seal Connection
- Straight Thread O–ring Fitting
- Tubelines And Hoses
- Flare Fitting
- O–ring Flare Fitting
- Port Seal Fitting
- HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
- STANDARD TORQUE SPECIFICATIONS FOR BOLTS
- DECIMAL AND MILLIMETER EQUIVALENTS
- U.S. TO METRIC CONVERSION
ADVANCE HAND CONTROL SYSTEM (A.H.C)
ADVANCE HAND CONTROL ELECTRICAL SCHEMATICS54 topics
- A.H.C. COMPONENTS
- Identification
- TROUBLESHOOTING (A.H.C.)
- ACTUATOR VOLTAGE TEST
- Procedure
- HANDLE CONTROL UNIT TEST
- Procedure
- BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
- Troubleshooting Chart
- A.H.C./PWM CONTROLLER
- Removal and Installation
- Test
- Description
- Conditions
- Troubleshooting Chart
- Handle Testing
- Solenoid Coil Testing
- HANDLE CONTROL UNIT
- Removal And Installation
- Control Unit Connector
- SWITCH HANDLE
- Removal And Installation
- A. H. C. HANDLE
- Removal And Installation
- Disassembly And Assembly
- A.H.C. STEERING LEVER
- Removal And Installation
- Steering Lever Boot
- ACTUATORS
- Removal And Installation
- Disassembly And Assembly
- Mounting Plate
- BICS™ VALVE
- Lift Arm By–Pass Orifice
- Check Valve
- Lock Valve
- BICS™ Valve Solenoid
- Removal And Installation
- Identification Chart
- Disassembly And Assembly
- Load Check Valve
- Lift Base End Restrictor
- Main Relief Valve
- Port Relief Valve (Lift)
- Anti–Cavitation/Port Relief Valve
- Port Relief Valve (Tilt)
- Anti–Cavitation Valve
- Rubber Boot
- Lift And Tilt Spool
- Inspection
- Auxiliary Spool
- Auxiliary Electrical Solenoid
- Spool Seal Installation
- H–Port Auxiliary Section
SERVICE MANUAL REVISIONS
Inside this manual
Real pages from this service manual (570 pages). Open the sample pages (PDF, 456 KB)
- Diagram, page 81: SELECT VALVE (863H) (Cont’d)
- Specifications, page 433: FRONT COVER (Cont’d)
- Troubleshooting, page 521: TROUBLESHOOTING (A.H.C.) (Cont’d)
- Foldout diagram: RED = RED
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 6900648_7_10$69.53
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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, 570 pages
Quantity one is the manual described above.
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Other editions and similar models
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