6900648 (10–98) Printed in U.S.A. © Melroe Company 1998
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS
TM
)
Service
Manual
S/N 514425001 & Above
S/N 514525001 & Above
S/N 514625001 & Above HIGH FLOW
MAINTENANCE SAFETY
WARNING
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s 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. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
Never service the Bobcat Skid-
Steer Loader without instructions.
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.
Stop, cool and clean engine of
flammable materials before
checking fluids.
Never service or adjust loader
with the engine running unless
instructed to do so in the
manual.
Avoid contact with leaking
hydraulic fluid or diesel fuel
under pressure. It can penetrate
the skin or eyes.
Never fill fuel tank with engine
running, while smoking or when
near open flame.
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.
Keep body, jewelry and clothing
away from moving parts,
electrical contact, hot parts and
exhaust.
Wear eye protection to guard
from battery acid, compressed
springs, fluids under pressure
and flying debris when engines
are running or tools are used.
Use eye protection approved for
type of welding.
Keep rear door closed except for
service. Close and latch door
before operating the loader.
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.
Lead-acid batteries produce
flammable and explosive gases.
Keep arcs, sparks, flames and
lighted tobacco away from
batteries.
Batteries contain acid which
burns eyes or skin on contact.
Wear protective clothing. If acid
contacts body, flush well with
water. For eye contact flush well
and get immediate medical
attention.
Use the correct procedure to lift or
lower operator cab.
Cleaning and maintenance are
required daily.
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.
MSW01-0805
WRONG
B-6590
WRONG
B-16102
B-6580
WRONG
B-16102
B-6589
WRONG
B-15280
WRONG
B-15231
WRONG
B-11799
B-10731a
CORRECT
B-12365
CORRECT
B-7469
CORRECT
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
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 7–1 . . . . . . . . . . . . . . . . . . . . . . .
CHAINCASE FLUID 4–1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGE PUMP 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING ROD 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL PEDALS 2–1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL ROD GUIDE BUSHING 7–1 . . . . . . . . . . . . . .
CONTROL TOWER (M46 Pump & AHC) 3–1 . . . . . . . . .
COOLING SYSTEM 1–1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRABKSHAFT GEAR MOUNTING BOLT 7–1 . . . . . . . .
CYLINDER HEAD 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER LINERS 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
DECIMAL & MILLIMETER EQUIVALENTS 9–1 . . . . . . .
DEUTZ ENGINE TOOLS 7–1 . . . . . . . . . . . . . . . . . . . . . . .
DRIVE BELT 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE BELT SHIELD 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE BELT TENSIONER PULLEY 3–1 . . . . . . . . . . . . .
DRIVE CHAIN 4–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELEC./HYD. CONTROLS REFERENCE 8–1 . . . . . . . . .
ELECTRICAL SYSTEM INFORMATION 6–1 . . . . . . . . .
ENGINE 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE LUBRICATION SYSTEM 1–1 . . . . . . . . . . . . . . .
ENGINE MOUNTS 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE MUFFLER 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL COOLER 7–1 . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SPECIFICATIONS 9–1 . . . . . . . . . . . . . . . . . . . .
ENGINE SPEED CONTROL 7–1 . . . . . . . . . . . . . . . . . . . .
ENGINE TORQUE 9–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALPHABETICAL INDEX
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 . . . . . .
HYDRAULIC/HYDROSTATIC SYSTEM 1–1 . . . . . . . . . . .
HYDROSTATIC FILTER HOUSING 2–1 . . . . . . . . . . . . . . .
HYDROSTATIC MOTOR 3–1 . . . . . . . . . . . . . . . . . . . . . . . .
HYDROSTATIC PUMP 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDROSTATIC SYSTEM INFORMATION 3–1 . . . . . . . . .
LIFT ARM BY–PASS CONTROL VALVE 2–1 . . . . . . . . . .
LIFT ARMS 5–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIFT ARM SUPPORT DEVICE 1–1 . . . . . . . . . . . . . . . . . . .
LIFT CYLINDER(S) 2–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIFTING AND BLOCKING THE LOADER 1–1 . . . . . . . . .
LOADER SPECIFICATIONS 9–1 . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE LOADER 1–1 . . . . . . . . . . . . . . . . . . .
MAIN RELIEF VALVE 2–1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
MONITOR SERVICE CODE 8–1 . . . . . . . . . . . . . . . . . . . . .
MOTOR CARRIER 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL COOLER 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION SENSING SYSTEM UNIT 8–1 . . . . . . . . . . .
OPERATOR CAB 1–1 & 5–1 . . . . . . . . . . . . . . . . . . . . . . . .
OPERATOR CAB GAS CYLINDER 5–1 . . . . . . . . . . . . . . .
OPERATOR SEAT 5–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARKING BRAKE DISC 4–1 . . . . . . . . . . . . . . . . . . . . . . . .
PARKING BRAKE PEDAL 4–1 . . . . . . . . . . . . . . . . . . . . . . .
PEDAL INTERLOCK LINKAGE 2–1 . . . . . . . . . . . . . . . . . .
PISTON AND PISTON PIN 7–1 . . . . . . . . . . . . . . . . . . . . . .
PWM CONTROL HANDLE 8–1 . . . . . . . . . . . . . . . . . . . . . .
PWM ELECTRIC SOLENOID 8–1 . . . . . . . . . . . . . . . . . . . .
PWM MODULE 8–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PWM TROUBLESHOOTING 8–1 . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Continued On Next Page
Revised Feb. 99
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 . . . . . . . . . . . . . . . . .
ALPHABETICAL INDEX (Cont’d)
Revised Feb. 99
2
ADVANCED
HAND CONTROL
SYSTEM
PREVENTIVE
MAINTENANCE
HYDRAULIC
SYSTEM
HYDROSTATIC
SYSTEM
DRIVE
SYSTEM
MAIN
FRAME
ELECTRICAL
SYSTEM
ENGINE
SERVICE
SPECIFICATIONS
SYSTEMS
ANALYSIS
863, 863H Bobcat Loader
i Service Manual
CONTENTS
FOREWORD ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY INSTRUCTIONS v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERIAL NUMBER LOCATIONS vii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DELIVERY REPORT vii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOBCAT LOADER IDENTIFICATION viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREVENTIVE MAINTENANCE 1–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC SYSTEM 2–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDROSTATIC SYSTEM 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SYSTEM 4–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN FRAME 5–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM 6–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SERVICE 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEMS ANALYSIS 8–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 9–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADVANCED HAND CONTROL SYSTEM 10–1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the State of California
to cause cancer, birth defects and other
reproductive harm.
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
(Including sidescreens) is in
good condition and is not
modified.
2. Check that ROPS mounting
hardware is tightened and is
Melroe approved.
3. The seat belt must be correctly
installed, functional and in
good condition.
4. The seat bar and pedal
interlocks must be correctly
adjusted, clean and lubricated.
5. Check lift arm support device,
replace if damaged.
6. Machine signs must be legible
and in the correct location.
7. Steering levers and foot pedals
must return to neutral.
8. Check for correct function of
the work lights.
9. The parking brake must
function correctly.
10. Enclosure door latches must
open and close freely.
11. Bob–Tach wedges and
linkages must function
correctly and be in good
condition.
12. Safety treads must in good
condition.
13. Check for correct function of
indicator lamps (Optional on
some models).
14. Check hydraulic fluid level,
engine oil level and fuel supply.
15. Inspect for fuel, oil or hydraulic
fluid leaks.
16. Lubricate the loader.
Revised Feb. 99
WARNING
ii
863, 863H Bobcat Loader
Service Manual
24. Check for correct function of
the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.
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.
Recommend to the owner that all
necessary corrections be made
before the machine is returned to
service.
17. Check the condition of the
battery and cables.
Revised Feb. 99
863, 863H Bobcat Loader
iii Service Manual
iv
863, 863H Bobcat Loader
Service Manual
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Bobcat 863 High Flow 514425001 + Factory Service & Work Shop Manual
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Description
Upon purchasing this manual, you will receive a .PDF file containing an email contact. After contacting us, you will receive a reply with a link to access the manual for your Bobcat 863 High Flow 514425001 +.
This comprehensive manual covers every aspect of your machine, providing detailed guidance for tasks ranging from an oil change to a transmission swap. With hundreds of pages, it includes numerous illustrations and easy-to-follow instructions, making it valuable for both professional mechanics and DIY enthusiasts. The manual features a search function for easy navigation and allows for the printing of specific pages as needed.
Designed as a Factory Service Repair Manual, it offers a step-by-step approach to maintenance and repair, equipping owners with the knowledge typically possessed by factory-trained technicians. By utilizing the information within this manual, owners can confidently make informed decisions regarding the upkeep and repair of their machine.
Our commitment extends beyond delivering a high-quality service manual; we also provide exceptional customer service, ensuring your satisfaction with your purchase.
