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.

• MAINTENANCE SAFETY
• ALPHABETICAL INDEX
• CONTENTS
• FOREWORD
• SAFETY INSTRUCTIONS
• SERIAL NUMBER LOCATIONS
• LOADER SERIAL NUMBER
• ENGINE SERIAL NUMBER
• DELIVERY REPORT
• BOBCAT LOADER IDENTIFICATION
• 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
• 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 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
• 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
• TROUBLESHOOTING
• 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
• HYDROSTATIC MOTOR (S/N 514427762 & Above; 514525304 & Above; 514625302 & Above)
• Removal And Installation
• Parts Identification
• Disassembly
• Inspection
• Assembly
• HYDROSTATIC MOTOR (S/N 514427761 & Below; 514525303 & Below; 514625301 & Below)
• 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 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
• DRIVE CHAIN
• Removal And Installation
• CHAINCASE FLUID
• Removing The Fluid From The Chaincase
• MAIN FRAME
• SEAT BAR
• 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
• 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
• 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 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
• 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
• FRONT COVER
• 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)
• 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
• TRACTION LOCK CONTROL SYSTEM (S/N 514427600 & Above; 514525300 & Above; 514625300 & Above)
• Inspecting The Traction Lock Control System
• Maintenance
• TRACTION LOCK CONTROL SYSTEM (S/N 514123809 & Below; 514222299 & Below)
• 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 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
• 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 SCHEMATICS
• 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
• HYDRAULIC CONTROL VALVE
• 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
• 863/863H–1
• 863-2