Description
Bobcat 863, 863 HIGH FLOW Skid Steer Loader Service Manual
Condition: Brand New
Language: English
Manufacturer: Bobcat
Models Covered: 863, 863 HIGH FLOW
Serial Numbers Covered: (SN 514411001Â514424999), (SN 514511001Â514524999), (SN 514611001Â514624999)
Manual Type: Service Manual
Manufacturer Part Number: 6724799_7_10
Pages: 506
Format: PDF Instant View+Download
A Service Manual (sometimes referred to as a Repair, Technical, Workshop
or Shop Manual) is often
large and broken down in to sections for different parts of your equipment.
Service
manuals cover absolutely every aspect of your machine unless mentioned
otherwise. Sometimes, the
engine is covered in a separate service manual that is written specifically for
the
engine. Most of the time though, it’s included in the main service manual. A
service manual will
arm you with the same exact information that your local service center has and
includes
electrical and hydraulic diagrams and which are usually color and or large
foldout pages.
Most OEM service manuals will also include troubleshooting flow charts, error
codes and
exploded views of components which are a great help for disassembly and
re-assembly.
An Operator’s Manual typically describes basic equipment operation and
maintenance. This
is the manual distributed with your equipment at the time of purchase from the
dealer.
A Parts Catalog is often large and broken down in to sections for
different parts of your
equipment. Parts Catalogs cover absolutely every aspect of your machine unless
mentioned
otherwise. Sometimes, the engine is covered in a separate parts catalog that is
written
specifically for the engine. Most of the time though, it’s included in the main
parts
catalog. A parts catalog will arm you with the same exact information that your
local
service center has and includes exploded views of assemblies that are a great
help with
disassembly and re-assembly. Parts catalogs also include all part numbers for
every part
of your machine which makes for easy ordering of parts.
PDF Contents:
- MAINTENANCE SAFET
- CONTENTS
- FOREWORD
- SAFETY INSTRUCTIONS
- SERIAL NUMBER LOCATIONS
- LOADER SERIAL NUMBER
- DELIVERY REPORT
- BOBCAT LOADER IDENTIFICATION
- OPTIONS AND ACCESSORIES
- PREVENTIVE MAINTENANCE
- SERVICE SCHEDULE
- 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 SCHEMATICS
- 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 BYâPASS CONTROL VALVE
- Removal And Installation
- Disassembly And Assembly
- BICS⢠CONTROL VALVE
- Removal And Installation
- BICS⢠VALVE ASSEMBLY
- Lift Arm ByâPass 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
- AntiâCavitation/Port Relief Valve
- Rubber Boot
- Lift Spool And Detent
- Tilt Spool And Centering Spring
- Auxiliary Spool
- Auxiliary Electric Solenoid
- H Port â 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
- TROUBLESHOOTING
- 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
- PreâAdjustment 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 PEDAL
- 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)
- 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
- OPERATOR CAB
- Removal And Installation
- OPERATOR SEAT
- Removal And Installation
- BOBâTACH
- BobâTach Lever And Wedge
- BobâTach 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 PickâUp Screen/Check Valve
- Inlet Screen
- ELECTRICAL SYSTEM
- ELECTRICAL SCHEMATICS
- TROUBLESHOOTING
- 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 SERVICE
- TROUBLESHOOTING
- 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
- FAN GEARBOX
- 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
- FRONT COVER
- Disassembly
- Assembly
- TURBOCHARGER
- Removal And Installation
- Disassembly
- Inspection
- Assembly
- POSITIVE CRANKCASE VENTILATION SYSTEM(S/N 514415609, 514611152, 514511106 & Below)
- Description
- Inspection
- Module Removal And Installation
- OIL COOLER
- Removal And Installation
- CRANKSHAFT GEAR MOUNTING BOLT
- Torque Procedure
- SYSTEMS ANALYSIS
- BOBCAT INTERLOCK CONTROL SYSTEM (BICSâ¢)
- Inspecting The BICS⢠Controller (Engine STOPPED â Key ON)
- Inspecting Deactivation Of The Auxiliary HydraulicsSystem (Engine STOPPED â Key ON)
- Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)
- Inspecting The Traction Lock (Engine RUNNING)
- Inspecting The Lift Arm ByâPass Control
- Maintenance
- Troubleshooting Chart
- SEAT SENSOR OVERRIDE ONLY (If Equipped)
- Troubleshooting Guide
- BICS SYSTEM CONTROLLER
- TRACTION LOCK
- SEAT SENSOR
- SEAT BAR SENSOR
- LIFT ARM BYâPASS VALVE
- 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 SPECIFICATIONS
- 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
- Oâring Face Seal Connection
- Straight Thread Oâring Fitting
- Tubelines And Hoses
- Flare Fitting
- Oâring 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
- 863â001
- 863â002
- 863â003
- 863â004
- 863â005
- 863â006
- 863â007
- 863â008
- 863â009
- 863-10
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