Bobcat 863 & 863H Skid Steer Loader Service Repair Manual (High Flow) – PDF Download

Description

Bobcat 863 & 863H Skid Steer Loader Service Repair Manual (High Flow)

This Bobcat 863 and 863H Skid Steer Loader Service Repair Manual is the complete workshop reference for the standard 863 and the High Flow 863H. Across 506 pages it documents every major system on these machines — hydraulic, hydrostatic, drive, main frame, electrical and engine — along with full specifications, torque values, service schedules and diagnostic procedures. Whether you are servicing a single machine or running a fleet of these skid steers, this is the reference the shop floor actually needs.

File Details

• Manual Type: Complete Service Repair Manual
• Brand: Bobcat
• Models Covered: 863, 863H (High Flow)
• Serial Number Ranges: 514411001–514424999, 514511001–514524999, 514611001–514624999
• Language: English
• Page Count: 506 pages
• File Format: PDF
• Document Number: 6724799 (4-96)
• Publication Date: April 1996, updated by revisions through July 2010
• Printed in: U.S.A.

Chapters Covered

The Bobcat 863 and 863H service manual is organised into nine numbered sections, each one a full subsystem reference on its own:

• Section 1 – Safety and Maintenance: Service Schedule, Lifting and Blocking the Loader, Lift Arm Support Device, Operator Cab (raising/lowering, emergency exit), Seat Bar Restraint System, Air Cleaner Service, Fuel System (specs, filter, bleeding), Engine Lubrication (oil and filter), Cooling System, Alternator Belt, Hydraulic/Hydrostatic Fluid and Filters, Wheel Nuts and Tire Rotation, Final Drive Transmission (Chaincase), Lubricating the Loader, Fan Gearbox, Remote Start Switch
• Section 2 – Hydraulic System: Hydraulic Cylinders (lift and tilt — disassembly, assembly, seals), BICS Control Valve (lock valve, check valve, solenoid, lift arm by-pass orifice), Hydraulic Control Valve (load check, main relief, port relief, anti-cavitation, spools, seals, rubber boot), Main Relief Valve (checking, adjusting, removal), Select Valve 863H (high flow relief, disassembly, solenoid testing), Lift Arm By-Pass Control Valve, Hydraulic Pump (output check, disassembly, inspection, assembly), Double Gear Pump 863H, Hydraulic Filter Housings, Hydraulic Fluid Reservoir, Control Pedals and Pedal Interlock Linkage, Rear Auxiliary Diverter
• Section 3 – Hydrostatic System: Front Panel (solid and cable steering linkage), Steering Levers, Control Tower, Hydrostatic Motor (removal, disassembly, inspection, assembly), Hydrostatic Pump (removal, separation, charge pump, disassembly, inspection, assembly), Steering Neutral Adjustment (solid linkage and cable), Wheel RPM Forward vs Reverse, Left vs Right Adjustment, Swashplate Neutral Adjustment, Displacement Control Servo, Drive Belt and Tensioner Pulley, Drive Belt Shield, Oil Cooler
• Section 4 – Drive System: Parking Brake Pedal and Disc, Front and Rear Chaincase Covers, Axle Seal, Axle/Sprocket/Bearings, Motor Carrier (removal, disassembly, assembly, shaft seal), Drive Chain, Chaincase Fluid Drain
• Section 5 – Main Frame: Seat Bar (gas spring and compression spring versions), Operator Cab, Operator Cab Gas Cylinder, Operator Seat, Bob-Tach (lever, wedge, stops, pivot pin bushing and seals), Lift Arms, Rear Grill, Rear Door (one-piece and two-piece), Fuel Tank and Level Sender
• Section 6 – Electrical System: Alternator (output test, regulator test, rectifier/diode test, disassembly, assembly), Battery (removal, servicing, booster battery use), Starter (disassembly, external pinion, inspection and repair, magnetic switch test, no-load test), Standard Instrument Panel, Front Lights, Relay Switches
• Section 7 – Engine Service: Engine Speed Control, Engine Muffler, Air Cleaner Housing, Blower Housing / Fan Gearbox, Blower Fan, Fan Drive Tension Pulley, Flywheel and Ring Gear, Glow Plugs, Valve Clearance Adjustment, Fuel Injection Pump (removal, timing, installation), Fuel Injector (check, disassembly, assembly), Timing Belt (inspection, removal, installation, belt replacement in loader), Valve Timing, Reconditioning the Engine (full disassembly and assembly), Cylinder Liners, Camshaft Bearings, Control Rod Guide Bushing, Rear Cover Seal, Crankshaft, Connecting Rod, Pistons and Piston Pin, Cylinder Head, Rocker Arm and Bracket, Front Cover, Turbocharger, Positive Crankcase Ventilation System, Oil Cooler, Crankshaft Gear Mounting Bolt Torque Procedure
• Section 8 – Systems Analysis: Bobcat Interlock Control System (BICS) — inspection, maintenance, troubleshooting chart, troubleshooting guide; BICS System Controller (removal, controller test); Seat Bar Sensor and Seat Sensor (removal, test); Traction Lock; BOSS Diagnostic Tool; Service Codes (alphabetical and numeric); BOSS Instrument Panel; Operation Sensing System Unit; PWM Module (description, voltage table, troubleshooting chart); PWM Control Handle and PWM Electric Solenoid; Electrical/Hydraulic Controls Reference Chart
• Section 9 – Specifications: Loader Specifications (performance, controls, engine, dimensions, capacities, tires), Engine Specifications for the BF4M1011 and BF4M1011F (general, fuel system, valves, pistons and rings, connecting rod, crankshaft and main bearings, camshaft, oil pump), Engine Torque Specifications, Torque Specifications for Loader, Hydraulic Connection Specifications (flare, O-ring flare, O-ring face seal, port seal, straight thread O-ring, tubelines and hoses), Hydraulic/Hydrostatic Fluid Specifications, Standard Torque Specifications for Bolts, Decimal and Millimeter Equivalents, U.S. to Metric Conversion Chart

What This Manual Enables You To Do

This Bobcat 863 863H skid steer loader service repair manual goes far beyond routine maintenance. The hydraulic and hydrostatic sections cover every pump, motor, cylinder, control valve and relief valve in the circuit, with step-by-step removal, disassembly, inspection and reassembly procedures plus the correct torque values for each fastener. The engine section covers the full Deutz BF4M1011 and BF4M1011F service envelope — valve clearance, injector testing, injection pump timing and installation, timing belt replacement, cylinder head work, crankshaft and bearing measurement, turbocharger rebuild and full engine reconditioning. The drive section handles the chaincase, axles, sprockets, bearings, motor carrier and parking brake, and the electrical section includes alternator, starter and battery diagnostics with output, regulator and no-load tests. Systems Analysis gives you the BICS and BOSS diagnostic material: fault code charts, sensor tests and controller diagnostics so electrical and interlock faults can be isolated quickly rather than guessed at.

Covered Serial Numbers

This manual applies to three serial number ranges: S/N 514411001–514424999, S/N 514511001–514524999, and S/N 514611001–514624999. Always confirm your machine’s serial number against these ranges before ordering parts or following a procedure, since early and later machines within a model line can use different components or require a different procedure for the same operation.

Who This Bobcat 863 & 863H Service Manual Is For

This is a workshop-grade service manual written for the mechanic who is actually working on the machine. Independent shops, fleet maintenance departments, farm and construction owners who run their own repairs, and anyone maintaining a Bobcat 863 or 863H skid steer will find the procedures, clearances, torque figures and diagnostic charts they need in one place. The manual assumes the reader has basic mechanical ability and access to common hand tools and measuring equipment; specialised tools are called out by their Bobcat tool numbers where a procedure requires them, so you know in advance when a job needs a specific puller, driver, seal installer or testing kit.

Hydraulic, Hydrostatic and Engine Coverage in Depth

The hydraulic system section covers the complete circuit on both models, including the High Flow select valve unique to the 863H. You get the main relief valve check and adjustment, port relief and anti-cavitation valve service, load check valves, all three spools (lift, tilt and auxiliary) with their detents and centering springs, the BICS control valve with its lock valves and lift arm by-pass orifice, and the lift arm by-pass control valve. The hydraulic pump and the double gear pump used on the High Flow model both have output testing, disassembly, inspection and assembly procedures, along with the case drain filters and the hydraulic fluid reservoir. On the hydrostatic side, the tandem piston pump and the hydrostatic motor are treated as full rebuild candidates, and the manual walks through swashplate neutral adjustment, steering neutral setting, and the forward vs reverse / left vs right wheel RPM balance procedure that keeps these loaders tracking straight. On the engine side, the manual covers the Deutz BF4M1011 and BF4M1011F completely: fuel injection pump timing and installation depth (with shim selection), injector opening pressure and spray pattern checks, timing belt alignment and tension, valve clearance, cylinder head and valve seat inspection, piston and ring measurement, crankshaft and main bearing clearances, camshaft and bearing service, and turbocharger disassembly, inspection and assembly with axial and radial play limits.

Systems Analysis and Diagnostics

The Systems Analysis section is what separates this manual from a basic repair guide. It documents the Bobcat Interlock Control System (BICS) with a full troubleshooting chart and troubleshooting guide for the seat sensor, seat bar sensor, valve output and traction lock circuits; the BICS controller test procedure; the BOSS diagnostic tool procedure; the BOSS and LCD display troubleshooting chart; the full service code list (both numeric and alphabetic) with what each code means; the PWM module voltage table and PWM troubleshooting chart with blinking-light diagnostic codes for the base end, rod end and diverter solenoids; the PWM control handle switch test values; and the operation sensing system unit. If you have ever chased an intermittent BICS light or a random traction lock fault on one of these loaders, this is the material that lets you test the right circuit in the right order instead of replacing parts on suspicion.

Specifications Section

The Specifications section is a complete reference in its own right. It includes rated operating capacity, tipping load, operating weight, breakout force, axle torque, travel speed, engine model, horsepower, governed RPM, torque, displacement, bore and stroke, low and high idle, hydraulic pump capacity, system relief pressure, cylinder bore and rod diameters, hydraulic function times, alternator output, battery rating, starter rating, drive system reduction ratio, axle size and wheel bolt size. It also carries the engine torque tables for the BF4M1011 and BF4M1011F (cylinder head, main bearing, connecting rod, camshaft, flywheel, timing belt tensioner, injector, glow plug and more), the loader torque specification table, standard torque specifications for bolts by grade, hydraulic fitting tightening torque charts for flare, O-ring flare, O-ring face seal and port seal connections, decimal and millimeter equivalents, and U.S. to metric conversion factors.

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With this Bobcat 863 and 863H skid steer loader service manual you can perform routine maintenance on schedule, diagnose hydraulic, hydrostatic and electrical faults systematically, rebuild cylinders, pumps, motors and the engine to specification, and torque every critical fastener correctly the first time. Correct procedures and the correct specifications matter on machines like these — an over-torqued fitting, a missed shim or an incorrectly tensioned drive belt can turn a routine job into a repeat repair, and the diagnostic charts save hours of guesswork on the BICS and BOSS systems. The manual is delivered as an instant PDF download after payment, with no shipping and no waiting. Read it on a laptop or tablet in the shop, print the pages you need for the job in front of you, and keep the file as a permanent reference for the machine. Once you own it, you have the same service information for the life of the loader.