Service

Manual
S/N 514425001 & Above
S/N 514525001 & Above
HIGH FLOW S/N 514625001 & Above

EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICSTM) 6900648 (10–98) Printed in U.S.A. © Melroe Company 1998
 MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING 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

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.

CORRECT CORRECT CORRECT

B-10731a B-12365 B-7469

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG

B-11799 B-15231 B-15280

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.
WRONG
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.
WRONG
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.
WRONG

B-6590 B-6580 B-6589

B-16102 B-16102
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
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
 ALPHABETICAL INDEX
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 . . . . . . . . . . . . . . . . . . . . . . .
CHAINCASE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL ROD GUIDE BUSHING . . . . . . . . . . . . . .
CONTROL TOWER (M46 Pump & AHC) . . . . . . . . .
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRABKSHAFT GEAR MOUNTING BOLT . . . . . . . .
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER LINERS . . . . . . . . . . . . . . . . . . . . . . . . . . .
DECIMAL & MILLIMETER EQUIVALENTS . . . . . . .
DEUTZ ENGINE TOOLS . . . . . . . . . . . . . . . . . . . . . . .
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE BELT SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE BELT TENSIONER PULLEY . . . . . . . . . . . . .
DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELEC./HYD. CONTROLS REFERENCE . . . . . . . . .
ELECTRICAL SYSTEM INFORMATION . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . .
ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .
ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . .
ENGINE TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Continued On Next Page
Revised Feb. 99
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
7–1 HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . 1–1
HYDROSTATIC FILTER HOUSING . . . . . . . . . . . . . . . 2–1
4–1 HYDROSTATIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3–1 HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
7–1 HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . 3–1
2–1
7–1 LIFT ARM BY–PASS CONTROL VALVE . . . . . . . . . . 2–1
3–1 LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
1–1 LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . 1–1
LIFT CYLINDER(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
7–1 LIFTING AND BLOCKING THE LOADER . . . . . . . . . 1–1
7–1 LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 9–1
7–1 LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . 1–1
7–1
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
9–1 MONITOR SERVICE CODE . . . . . . . . . . . . . . . . . . . . . 8–1
7–1 MOTOR CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3–1 OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3–1 OPERATION SENSING SYSTEM UNIT . . . . . . . . . . . 8–1
3–1 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . 1–1 & 5–1
4–1 OPERATOR CAB GAS CYLINDER . . . . . . . . . . . . . . . 5–1
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
8–1
6–1 PARKING BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . 4–1
7–1 PARKING BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . 4–1
PEDAL INTERLOCK LINKAGE . . . . . . . . . . . . . . . . . . 2–1
1–1 PISTON AND PISTON PIN . . . . . . . . . . . . . . . . . . . . . . 7–1
7–1 PWM CONTROL HANDLE . . . . . . . . . . . . . . . . . . . . . . 8–1
7–1 PWM ELECTRIC SOLENOID . . . . . . . . . . . . . . . . . . . . 8–1
7–1 PWM MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
9–1 PWM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 8–1
7–1
9–1 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
 ALPHABETICAL INDEX (Cont’d)

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

Revised Feb. 99
 CONTENTS PREVENTIVE
MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii HYDRAULIC
BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii SYSTEM
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 HYDROSTATIC
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 SYSTEM
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
SYSTEMS ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
ADVANCED HAND CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1 DRIVE
SYSTEM

MAIN
CALIFORNIA FRAME
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. ELECTRICAL
SYSTEM

ENGINE
SERVICE

SYSTEMS
ANALYSIS

SPECIFICATIONS

ADVANCED
HAND CONTROL
SYSTEM

863, 863H Bobcat Loader

i Service Manual
 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 9. The parking brake must

(Including sidescreens) is in function correctly.
good condition and is not
modified.

2. Check that ROPS mounting 10. Enclosure door latches must

hardware is tightened and is open and close freely.
Melroe approved.

3. The seat belt must be correctly 11. Bob–Tach wedges and

installed, functional and in linkages must function
good condition. correctly and be in good
condition.

4. The seat bar and pedal 12. Safety treads must in good
interlocks must be correctly condition.
adjusted, clean and lubricated.

5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps (Optional on
some models).

6. Machine signs must be legible WARNING 14. Check hydraulic fluid level,
and in the correct location. engine oil level and fuel supply.

7. Steering levers and foot pedals 15. Inspect for fuel, oil or hydraulic
must return to neutral. fluid leaks.

8. Check for correct function of 16. Lubricate the loader.

the work lights.

863, 863H Bobcat Loader

Revised Feb. 99 ii Service Manual
17. Check the condition of the
battery and cables.

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.

24. Check for correct function of

the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.

Recommend to the owner that all

necessary corrections be made
before the machine is returned to
service.

863, 863H Bobcat Loader

Revised Feb. 99 iii Service Manual
SAFETY INSTRUCTIONS

Instructions are necessary before operating or servicing machine. Read and understand the Operation &
Maintenance Manual, 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. Failure to follow instructions can cause injury or death.
W–2003–1298

The following publications provide information on the safe use and maintenance of the loader and attachments:

• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine
is in safe operating condition.

• The Operation & Maintenance Manual delivered with the loader gives operating information as well as routine
maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement
Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.

• The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are
shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.

• The loader has a plastic Operator’s Handbook fastened to the operator cab. Its brief instructions are convenient to the
operator. The Handbook is available from your dealer in an English edition or one of many other languages. See your
Bobcat dealer for more information on translated versions.

• The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and
repair work.

• The Skid–Steer Loader Operator Training Course is available through your local dealer. This course is intended to provide
rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish version.

• The Service Safety Training Course is available from your Bobcat dealer. This course provides information for safe and
correct service procedures for Bobcat Skid–Steer loaders.

• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.

Warnings on the machine and in the This notice identifies procedures

manuals are for your safety. Failure to which must be followed to avoid
obey warnings can cause injury or damage to the machine.
death. I–2019–0284
W–2044–1285

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.

SI05–1298

863, 863H Bobcat Loader

Revised Feb. 99 v Service Manual
SAFETY INSTRUCTIONS (Cont’d)

• Wear tight fitting clothing. Always wear safety glasses when maintaining or servicing loader. Safety glasses, hearing
protection or loader special applications kit are required for some work. See your dealer for Melroe Safety equipment.

• Know where fire extinguisher and first aid kit are located and how to use them.
• Do not use the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive
dust or gases.

• The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent
fire hazard and overheating.

• Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any
damaged part.

• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check
for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for
cleaning parts. Use commercial nonflammable solvents.

• Follow any environmental safety regulations when disposing of used fluids such as engine oil, grease or anti–freeze.
• Do not use ether or starting fluids on engines which have glow plugs. These starting aids can cause explosion and injure
you or bystanders.

• Always clean the loader and disconnect the battery before doing any welding. Cover rubber hoses, battery and all other
flammable parts. Keep a fire extinguisher near the loader when welding. Have good ventilation when grinding or welding
painted parts. Wear dust mask when grinding painted parts. Toxic dust or gas can be produced.

• Stop the engine and let it cool before adding fuel. No smoking!
• Use the procedure in the Operation & Maintenance or Service Manuals for connecting the battery.
A fire extinguisher is available from your local dealer. The fire extinguisher can be installed in the location shown [A].

SI06–0398 P–3705

863, 863H Bobcat Loader

Revised Feb. 99 vi Service Manual
SERIAL NUMBER LOCATIONS
Always use the serial number of the loader when
A
requesting service information or when ordering parts.
Early or later models (identification made by serial number)
may use different parts, or it may be necessary to use a
different procedure in doing a specific service operation.
LOADER SERIAL NUMBER
The loader serial number plate is located on the inside of
the left upright, above the grill [A].
Explanation of loader Serial Number:

XXXX XXXXX
P–07612
Module 2. – Production
Sequence (Series)
Module 1. – Model/Engine
B
Combination
The four digit Model/Engine Combination module number
identifies the model number and engine combination. This
number (in parenthesis beside the model number) is used
in the Service Manual to more easily identify the standard,
optional and field accessory equipment included or
available for each specific model.
The five digit Production Sequence Number identifies the
order which the loader is produced.
ENGINE SERIAL NUMBER
P–07619
The serial number is located on the valve cover at the right
side of the engine [B].

DELIVERY REPORT C
The Delivery Report must be filled out by the dealer and
signed by the owner or operator when the Bobcat loader is
delivered. An explanation of the form must be given to the
owner. Make sure it is filled out completely [C].

863, 863H Bobcat Loader

vii Service Manual
 BOBCAT LOADER IDENTIFICATION
863,863H(S/N514425001&Abv.,514525001&Above,514625001&Abv.)ServiceManual#6900648–ContentsSection

FRONT LIGHTS
(OPTIONAL)
OPERATOR SEAT

GRAB REAR AUXILIARY

HANDLES QUICK COUPLERS
(OPTIONAL)

SEAT BELT

TILT CYLINDER

BUCKET
FRONT AUXILIARY
QUICK COUPLERS
(OPTIONAL)
SAFETY TREAD
BUCKET STEPS
OPERATOR CAB
(ROPS & FOPS)
SEAT BAR
REAR GRILL LIFT ARM

LIFT ARM
SUPPORT DEVICE

REAR LIGHT
(OPTIONAL)

LIFT CYLINDER
REAR DOOR TAIL LIGHT
(OPTIONAL) B–15016
TIRES* B–15017

* TIRES – Flotation tires are shown. Optional tires are available.

BUCKET – Several different buckets and other attachments are available for the Bobcat loader.
ROPS, FOPS – Roll Over Protective Structure, per SAE J1040 and ISO 3471 and Falling Object Protective
Structure per SAE J1043 and ISO 3449 Level I. Level ll FOPS is available for protection from heavy falling
objects. The Bobcat loader is base–equipped with a standard operator cab as shown. Extra insulated cab is
available as an option (Reduced noise level).
863, 863H Bobcat Loader
Revised Feb. 99 viii Service Manual
 PREVENTIVE MAINTENANCE PREVENTIVE
MAINTENANCE

AIR CLEANER SERVICE

Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14
ALTERNATOR BELT
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19

BOB–TACH
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–27
COOLING SYSTEM
Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18

ENGINE LUBRICATION SYSTEM

Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17
Replacing Of Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17

FAN GEARBOX
Checking And Maintaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–26
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23
Removing Oil From The Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23

FUEL SYSTEM
Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 1–16

HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20
Replacing Hydraulic/Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . . . . . 1–20
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21

LIFT ARM SUPPORT DEVICE

To Install The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . 1–6
To Remove The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . 1–7

LIFTING AND BLOCKING THE LOADER

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
LUBRICATING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–24

OPERATOR CAB
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9

REMOTE START SWITCH

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–28

Continued On Next Page

863, 863H Bobcat Loader

Revised Feb. 99 –1–1– Service Manual
 PREVENTIVE MAINTENANCE (Cont’d)

SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONROLS)

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13

SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
SEAT BAR RESTRAINT SYSTEM (MECHANICAL HAND CONTROLS)
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
SERVICE SCHEDULE
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

TIRE MAINTENANCE
Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–22
Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–22
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–22

TOWING THE LOADER

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
TRANSPORTING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5

863, 863H Bobcat Loader

Revised Feb. 99 –1–2– Service Manual
SERVICE SCHEDULE
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat loader.

Instructions are necessary before operating or servicing machine.

Read and understand the Operation & Maintenance Manual,
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. Failure to follow instructions can cause injury or death.
W–2003–1298

◊
ITEM SERVICE REQUIRED 8–10 50 250 500 1000 3000
Engine Oil Check the oil level and add oil as needed.
Engine Air Cleaner Check condition indicator or display panel. Service only
when required.
Engine Cooling System Clean debris from oil cooler radiator and grill.
Lift Arms, Cyl., Bob–Tach Lubricate with multi–purpose lithium based grease
Pivot Pins and Wedges (12 places).
Engine Air System Check for leaks and damaged components.
Tires Check for damaged tires and correct air pressure.
Seat Belt, Seat Bar & Pedal Check the condition of seat belt. Check the seat bar and foot
Interlocks pedal interlocks for correct operation. Clean dirt and debris from
moving parts.
Bobcat Interlock Control Check BICS™ functions. Clean dirt, debris or objects from
System (BICSTM) under or behind seat and around brake pedal as required.
Safety Signs and Safety Check for damaged signs (decals) and safety treads. Replace
Treads any signs or safety treads that are damaged or worn.
Operator Cab Check the fastening bolts, washers and nuts. Check the
condition of cab.
Fuel Filter Remove the trapped water.
Hyd. Fluid, Hoses and Check fluid level and add as needed. Check for damage and
Tubelines leaks. Repair or replace as needed.
Final Drive Trans.(Chaincase) Check oil level.
Battery Check cables, connections and electrolyte level. Add distilled
water as needed.
Foot Pedals and Steering Check for correct operation. Repair or adjust as needed.
Wheel Nuts Check for loose wheel nuts and tighten to 105–115 ft.–lbs.
(142–156 Nm) torque.
Parking Brake Check operation of the brake.
Alternator Belt Check tension and adjust as needed.
Engine/Hydro. Drive Belt * Check for wear or damage. Check idler arm stop.
Fuel Filter Replace filter element.
Steering Shaft Grease three fittings.
Hydraulic Reservoir Replace the reservoir breather cap.
Breather Cap
Hyd./Hydro. Filter Replace the filter element.
Engine Oil and Filter Replace oil and filter. Use CD or better grade oil and Melroe filter.
Final Drive Trans. Replace the oil in the chaincase.
Hydraulic Reservoir Clean or replace the fluid.
Hydraulic Motors Clean or replace the case drain filters.
Bobcat Interlock Control Check lift arm by–pass control.
System (BICSTM)
Fan Drive Gearbox Check gear lube level.
Engine Valves ∞ Adjust the engine valves.
Engine Timing Belt ◊ Replace the timing belt and belt tensioner assy.
Check wheel nut torque every 8 hours for the first 24 hours.
Also replace hydraulic/hydrostatic filter element when the transmission warning light comes ON.
Or every 12 months.
* Inspect the new belt after first 50 hours.
After the first 50 hours.
∞ After the first 500 hours on new engine, adjust engine valves; 1000 hours thereafter. (See Page 7–1 for
procedure.)
◊ Or every 5 years.
863, 863H Bobcat Loader
Revised Feb. 99 –1–3– Service Manual
 A

Instructions are necessary before operating or

servicing machine. Read and understand the
Operation & Maintenance Manual, 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. Failure to follow instructions
can cause injury or death.
W–2003–1298

Read the Removal & Installation, Disassembly &

Assembly, etc. completely to become familiar with the
procedure before beginning [A].
B–07023
LIFTING AND BLOCKING THE LOADER

Procedure
Always park the loader on a level surface.

Put jackstands under the front axles and rear

corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
B
death.
W–2017–0286

Put floor jack under the rear of the loader [B].

Lift the rear of the loader and install jackstands [B].

P–07703

Put the floor jack under the front of the loader [C].
C
Lift the front of the loader and put jackstands under the axle
tubes [C].
NOTE: Make sure the jackstands do not touch the
tires. Make sure tires clear floor or any
obstacles.

P–07704

863, 863H Bobcat Loader

Revised Feb. 99 –1–4– Service Manual
TRANSPORTING THE BOBCAT LOADER
Procedure
A

Adequately designed ramps of sufficient

strength are needed to support the weight of
the machine when loading onto a transport
vehicle. Wood ramps can break and cause Support
personal injury. P–10458
W–2058–0494

A loader with an empty bucket or no attachment must be

loaded backward onto the transport vehicle [A].
B
The rear of the trailer must be blocked or supported when
loading or unloading the loader to prevent the front end of
the trailer from raising up. Some ramps provide support
[A].
Be sure the transport and towing vehicles are of adequate
size and capacity (See SPECIFICATIONS Section Page
9–1, for weight of loader.) P–10462 P–10464

Use the following procedure to fasten the Bobcat loader to

the transport vehicle to prevent the loader from moving
during sudden stops or when going up or down slopes [B].
Lower the bucket or attachment to the floor. Stop the
engine. Engage the parking brake. Install chains at the
front and rear loader tie down positions [B]. Fasten each
end of the chain to the transport vehicle.
TOWING THE LOADER
To prevent damage to the loaders hydrostatic system, the
loader must be towed only a short distance at slow speed.
(Example: Moving the loader onto a transport vehicle).
The towing chain (or cable) must be rated at 1 & 1/2 times
the weight of the loader. (See SPECIFICATIONS Section,
Page 9–1.)
• Turn the key switch to ON and press the Traction
Lock Override button.
• Tow the Bobcat at 2 MPH (3,2 km/hr) or less for not
more than 25 feet (7,6 meters).
If the electrical system is not functioning, part of the brake 6707867 P–10460
system must be disassembled to move the loader.

863, 863H Bobcat Loader

–1–5– Service Manual
LIFT ARM SUPPORT DEVICE
To Install The Lift Arm Support Device
A

1
P–10829

B 1

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved
lift arm support device. Failure to use an
approved lift arm support device can allow the
lift arms or attachment to fall and cause injury
or death. W–2059–0598

Maintenance and service work can be done with the lift

arms lowered. If the lift arms must be raised for service, use
the following procedure:
P–10830
Put jackstands under the rear corners of the loader.
Disconnect the spring from the retaining pin (Item 1) [A],
hold onto the approved lift arm support device (Item 2) [A]
and remove the retaining pin.
Lower the lift arm support device on top of the lift cylinder.
Hook the free end of the spring (Item 1) [B] to the lift arm
support device so there will be no interference with the
support device engagement.
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine.

Service lift arm support device if damaged or if

parts are missing. Using a damaged lift arm
support or with missing parts can cause lift
arms to drop causing injury or death.
W–2271–1197

863, 863H Bobcat Loader

Revised Feb. 99 –1–6– Service Manual
LIFT ARM SUPPORT DEVICE (Cont’d)
To Install The Lift Arm Support Device (Cont’d)
A
Raise the lift arms, until the lift arm support device drops
onto the lift cylinder rod [A].
Lower the lift arms slowly until the support device is held
between the lift arm and the lift cylinder. Stop the engine.
Raise the seat bar.
(Foot Pedal Controls) Move both pedals until both lock. 1
(Mechanical Hand Controls) Move the hand control until
both lock.
(Advanced Hand Controls) Move the hand controls to the P–07659
NEYTRAL POSITION to make sure that both lift and tilt
functions are deactivated.
Install pin (Item 1) [A] into the rear of the lift arm support B
device below the cylinder rod.
To Remove The Lift Arm Support Device
Remove the pin from the lift arm support device (Item 1)
[A]. 1

Connect the spring (Item 1) [B] from the lift arm support
device to the bracket below the lift arms.
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine.
Raise the lift arms a small amount and the spring will lift the P–07656
support device off the lift cylinder rod. Lower the lift arms.
Stop the engine.
Raise the seat bar. C
(Foot Pedal Controls) Move both pedals until both lock.
(Mechanical Hand Controls) Move the hand control until
both lock.
(Advanced Hand Controls) Move the hand controls to the
NEYTRAL POSITION to make sure that both lift and tilt
functions are deactivated.
Disconnect the spring from the bracket.
Raise the support device into storage position and insert 1
pin through lift arm support device and bracket [C]. P–10829
Connect spring to the retaining pin (Item 1) [C].

863, 863H Bobcat Loader

Revised Feb. 99 –1–7– Service Manual
OPERATOR CAB
The Bobcat loader has an operator cab (ROPS and FOPS)
A
as standard equipment to protect the operator from rollover
and falling objects. Check with your dealer if the operator
cab has been damaged.
ROPS/FOPS – Roll Over Protective Structure per SAE
J1040 and ISO 3471, and Falling Object Protective
Structure per SAE J1043 and ISO 3449, Level l. Level ll is
available.
Level l – Protection from falling bricks, small concrete
blocks and hand tools encountered in operations such as
highway maintenance, landscaping, and other
construction site services.
Level ll – Protection from falling trees, rocks; for machines P–10887 P–10888
involved in site clearing, overhead demolition or forestry.

Never modify operator cab by welding,

grinding, drilling holes or adding attachments
unless instructed to do so by Melroe Company.
Changes to the cab can cause loss of operator
protection from rollover and falling objects,
and result in injury or death.
W–2069–1285

Raising The Operator Cab

Stop the loader on a level surface. Lower the lift arms. Stop P–03470
the engine. If the lift arms must be up while raising the
operator cab, install the lift arm support device. (See Page
1–6.) C
Install jackstands under the rear of the loader frame (Inset)
[C].
Loosen the nut (both sides) at the front corner of the
operator cab [A].
Remove the nut and plate (both sides) [A].
Mechanical Hand controls Only: Disconnect the control
linkage joint from the bottom hole (work position) and move
to the TOP hole on the control handle (both sides) [B].Both
control handles must be in the vertical position so there will
be no cab interference with the steering levers when the
operator cab is raised or lowered.
P–10449 P–10826
Advanced Hand Controls Only: Hold the steering levers
forward so that the cab does not hit the levers when raising
the cab.
Lift on the grab handle and bottom of the operator cab
slowly until the cab latching mechanism engages and the
cab is all the way up [C].

Before the cab or the lift arms are raised for

service, jackstands must be put under the rear
corners of the frame. Failure to use jackstands
Use care when raising or lowering the operator can allow the machine to tip backward causing
cab to prevent damaging the shaft of the lift injury or death.
lock by–pass valve. W–2014–0895
I–2070–0495

863, 863H Bobcat Loader

Revised Feb. 99 –1–8– Service Manual
OPERATOR CAB (Cont’d)
Lowering the Operator Cab
A
NOTE: Make sure the seat bar is fully raised or
lowered when lowering the cab. Always use
the grab handles to lower the cab.
Advanced Hand Controls Only: Hold the steering levers
forward so that the cab does not hit the levers when
lowering the cab.
Pull down on the bottom of the operator cab until it stops
at the latching mechanism.
Release the latching mechanism and pull the cab all the
way down [A]. P–10825

Install the plate and nut (both sides) [B].

B
Tighten the nuts to 40–50 ft.–lbs. (54–68 Nm) torque.

Use care when raising or lowering the operator

cab to prevent damaging the shaft of the lift
lock by–pass valve.
I–2070–0495

P–10888 P–10887

Mechanical Hand Controls Only

Move the control linkage from the top hole to the BOTTOM C
hole (work position) on the control handle (both sides) [C].

P–03561

863, 863H Bobcat Loader

Revised Feb. 99 –1–9– Service Manual
OPERATOR CAB (Cont’d)
Emergency Exit
A
The front opening on the operator cab and rear window
provide exits.
To exit through the rear window, use the following
procedure:
Pull on the tag on the top of the rear window to remove the
rubber cord [A].

P–10168

Push the rear window out of the rear of the operator cab.
B
Exit through the rear of the operator cab [B].

P–10810

NOTE: When an Operator Cab Enclosure Kit is

installed, the window of the front door can be C
used as an emergency exit [C].
Pull the plastic loop at the top of the window in the front door
to remove the rubber cord [C].

P–09216

Push the window out with your foot [D].

D
Exit through the front door.

P–09217

863, 863H Bobcat Loader

–1–10– Service Manual
SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)
Description
A
Clean
The seat bar restraint system has a pivoting, spring assist (Both Sides)
seat bar with arm rests and has spring loaded interlocks for
the lift and tilt control functions.
The operator controls the use of the seat bar. The seat bar
in the down position helps to keep the operator in the seat.
The interlocks require the operator to lower the seat bar in
order to operate the hand controls.
When the seat bar is up, the lift and tilt control functions are
locked when returned to the NEUTRAL POSITION.

P–10361

AVOID INJURY OR DEATH

The Seat Bar System must lock the lift and tilt
foot pedals or hand controls in neutral when the AVOID INJURY OR DEATH
Seat Bar is up. Service the system if controls do
not lock correctly. Never operate loader without interlock shield
W–2263–0597 6705474 on both interlocks. Shields prevent
foot from unlocking interlocks when leaving
loader seat. W–2158–0594
Seat Bar Inspection
Sit in the seat and fasten the seat belt. Engage the parking
brake. Pull the seat bar all the way down. Start the engine.
Loaders without seat sensors press the green PRESS TO
OPERATE Button. Operate each foot pedal to check both
the lift and tilt functions. Raise the lift arms until the bucket
is about 2 feet (600 mm) off the ground. B
Raise the seat bar. Try to move each foot pedal. Pedals
must be firmly locked in neutral position. There must be no
motion of the lift arms or tilt (bucket) when the pedals are
pushed.
Pull the seat bar down. Loaders without seat sensors press
the green PRESS TO OPERATE Button. Lower the lift
arms. Operate the lift pedals. While the lift arms are going
up, raise the seat bar and the lift arms must stop.
Lower the seat bar. Loaders without seat sensors press the
green PRESS TO OPERATE Button. Lower the lift arms
and put the bucket flat on the ground. Stop the engine. Interlock
Interlock
Raise the seat bar and operate the foot pedals to be sure Shield
Shield
that the pedals are firmly locked in the neutral position.
Unbuckle the seat belt.
Clean
Seat Bar Maintenance1.See the SERVICE SCHEDULE (Both Sides)
Page 1–3 and on the loader for correct service interval.
Clean any debris or dirt from the moving parts [A] & [B].
Inspect the linkage bolts and nuts for tightness. The correct
torque is 25–28 ft.–lbs. (34–38 Nm).
If the seat bar system does not function correctly, check for
free movement of each linkage part. Check for excessive
wear. Adjust pedal control linkage. Replace parts that are
worn or damaged. Use only genuine Bobcat replacement
parts.

P–10821

863, 863H Bobcat Loader

Revised Feb. 99 –1–11– Service Manual
SEAT BAR RESTRAINT SYSTEM (MECHANICAL
HAND CONTROLS) A
Description Clean
(Both Sides)
The seat bar restraint system has a pivoting, spring assist
seat bar with arm rests and has spring loaded interlocks for
the lift and tilt control functions.
The operator controls the use of the seat bar. The seat bar
in the down position helps to keep the operator in the seat.
The interlocks require the operator to lower the seat bar in
order to operate the hand controls.
When the seat bar is up, the lift and tilt control functions are
locked when returned to the NEUTRAL POSITION.
P–10361

AVOID INJURY OR DEATH

The Seat Bar System must lock the lift and tilt
foot pedals or hand controls in neutral when the AVOID INJURY OR DEATH
Seat Bar is up. Service the system if controls do Never operate loader without interlock shield
not lock correctly. 6705474 on both interlocks. Shields prevent
W–2263–0597 foot from unlocking interlocks when leaving
loader seat. W–2158–0594
Seat Bar Inspection
Sit in the seat and fasten the seat belt. Engage the parking
brake. Pull the seat bar all the way down. Loaders without
seat sensors press the green PRESS TO OPERATE
Button. Start the engine. Operate each hand control to
check both the lift and tilt functions. Raise the lift arms until
the bucket is about 2 feet (600 mm) off the ground. B
Raise the seat bar. Try to move each hand control. The
controls must be firmly locked in NEUTRAL POSITION.
There must be no motion of the lift arms or tilt (bucket) when
the controls are moved.
Interlock
Interlock
Pull the seat bar down. Loaders without seat sensors press Shield
Shield
the green PRESS TO OPERATE Button. Lower the lift
arms. Operate the lift control. While the lift arms are going Clean
up, raise the seat bar and the lift arms must stop. (Both Sides)

Lower the seat bar. Loaders without seat sensors press the
green PRESS TO OPERATE Button. Lower the lift arms
and put the bucket flat on the ground. Stop the engine.
Raise the seat bar and operate the hand controls to be sure
that the controls are firmly locked in the NEUTRAL
POSITION. Unbuckle the seat belt.
Seat Bar Maintenance
See the SERVICE SCHEDULE Page 1–3 for correct
service interval.
Clean any debris or dirt from the moving parts [A] & [B].
Inspect the linkage bolts and nuts for tightness. The correct
torque is 25–28 ft.–lbs. (34–38 Nm).
If the seat bar system does not function correctly, check for
free movement of each linkage part. Check for excessive
wear. Adjust hand control linkage. Replace parts that are
worn or damaged. Use only genuine Bobcat replacement
parts.
P–09671

863, 863H Bobcat Loader

Revised Feb. 99 –1–12– Service Manual
SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND
CONTROLS) A
Description
The seat bar restraint system has a pivoting seat bar (Item
1) [A] with arm rests. 1
The operator controls the use of the seat bar. The seat bar
in the down position helps to keep the operator in the seat.
When the seat bar is down and the green PRESS TO
OPERATE Button is activated, the lift, tilt, and traction drive
functions can be operated.
When the seat bar is up, the lift, tilt, and traction drive
functions are deactivated. P–13721

Seat Bar Inspection

Sit in the operator’s seat. Turn the key ON, lower the seat B
bar and press the green PRESS TO OPERATE Button.
Clean
Both lights on the left handle should be ON.
(Both Sides)
Move each hand control back and forth. You should hear
the zip,zip sound of the lift and tilt actuators moving the
control valve spools (under the seat).
Raise the seat bar fully. Both lights on the left handle should
be OFF.
Move each hand control back and forth. There must be no
zip–zip sound of the lift or tilt actuators. If either actuator
makes a sound while the seat bar is raised, contact your
dealer for service. P–10361

Seat Bar Maintenance

See the SERVICE SCHEDULE Page 1–3 for correct
service interval.
Clean any debris or dirt from the moving parts [B].
If the seat bar system does not function correctly replace
parts that are worn or damaged. Use only genuine Bobcat
replacement parts.
Before you leave the operator’s seat:
• Lower the lift arms, put the attachment flat on
the ground.
• Stop the engine.
• Engage the parking brake.
• Raise seat bar.
• (Advanced Hand Controls) Move the hand
controls to the NEUTRAL POSITION to make
sure that both lift and tilt functions are
deactivated.
The seat bar system must deactivate the lift
and tilt control functions when the seat bar is
up. Service the system if hand controls do
not deactivate.
W–2321–0698

863, 863H Bobcat Loader

–1–13– Service Manual
AIR CLEANER SERVICE
Replacing Filter Element
A 2

Without BOSS®: Replace the outer filter element only

when the red ring shows in the window of the condition
indicator (Item 1) [A].
NOTE: Before replacing the filter element, push the 1
button on the condition indicator (Item 2) [A].
Start the engine, then stop the engine. If the
red ring does not show, do not replace the filter
element.
Replace the inner filter every third time the outer filter is
replaced or when the red ring still shows in the indicator
window after the outer filter has been replaced. P–10799

With BOSS®: It is important to change the air filter element

only when the service codes (on the BOSS® option
instrument panel) shows the symbols AF.2 [B].
B

MC–02322

Service the air cleaner as follows:

Release the three dust cover fasteners (Item 1) [C].
C
1
Remove the dust cover.

P–10800

863, 863H Bobcat Loader

–1–14– Service Manual
AIR CLEANER SERVICE (Cont’d)
Replacing Filter Element (Cont’d)
A
Remove the outer filter element [A].
NOTE: Make sure all sealing surfaces are free of dirt
and debris.
Install the new outer filter element.
Only replace the inner filter element under the following
conditions [B]:
Replace the inner filter every third time the outer filter
is replaced or when the red ring still shows in the
indicator window after the outer filter has been P–10798
replaced.
When the service codes on the instrument panel
shows symbol AF.2 during full engine speed, replace
the inner filter element only after the outer filter
B
element has been changed.
Align the tab on the cover with one of the slots on air cleaner
housing (Item 1) [B]. The evacuator (Item 1) [C] must be
at the bottom.
Push dust cover into place and secure with wire fasteners.
1
Check the air intake hose for damage. Check the air
cleaner housing for damage. Check to make sure all
connections are tight.

P–10802

P–10800

863, 863H Bobcat Loader

Revised Feb. 99 –1–15– Service Manual
FUEL SYSTEM
Fuel Specifications
A
Use only clean, high quality diesel fuel, Grade No. 1 or
Grade No. 2 .
The following is one suggested blending guideline which
should prevent fuel gelling problems:
Temp. F° (C°) No. 2 No.1
1
+15°(9°) 100% 0%
Down to –20° (–29°) 50% 50%
Below –20° (29°) 0% 100%
We recommend an operator contact their fuel supplier for
local recommendations. P–10819

Filling the Fuel Tank

B WRONG

Stop and cool the engine before adding fuel.

NO SMOKING! Failure to obey warnings can
cause an explosion or fire.
W–2063–0887

Remove the fuel fill cap (Item 1) [A].

Use a clean, approved safety container to add fuel of the
correct specifications. Add fuel only in an area that has free B–13456
movement of air and no open flames or sparks. NO
SMOKING! [B].
Install and tighten the fuel fill cap [A]. C
Fuel Filter
See the SERVICE SCHEDULE, Page 1–3 for the 2
recommended service interval when to remove the water
from the fuel filter.
Loosen the drain (Item 1) [C] at the bottom of the filter
element to drain any water from the filter.
See the SERVICE SCHEDULE, Page 1–3 for the
recommended service interval when to replace the fuel
filter.
To replace the fuel filter element, use a filter wrench to
remove the filter element [C].
Clean the area around the filter housing. Put oil on the seal 1
of the new filter element. Install the fuel filter, and hand
tighten. Remove the air from the fuel system.
Removing Air From The Fuel System
After replacing the fuel filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel
system prior to starting the engine. 3
Loosen the air vent plug (Item 2) [C] at the top of the fuel
filter.
Operate the priming bulb (Item 3) [C] until fuel flows from
the vent.
Tighten the air vent plug.
P–10803

863, 863H Bobcat Loader

Revised Feb. 99 –1–16– Service Manual
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
A
Check the engine oil level every day.
Before starting the engine for the work shift, open the rear 3
door. Remove the dipstick (Item 1) [A].
Keep the oil level between the marks on the dipstick.
Use a good quality motor oil that meets API Service
Classification of CC, CD or CE.
1
RECOMMENDED SAE VISCOSITY NUMBER
C° (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)
–40 –34 –29 –23 –18 –13 –7 –1 +4 +10 +15 +21 +27 +32 +38 +43 +49

SAE 40W or 20W–50

SAE 10W–30

SAE 15W–40

SAE 30W

* SAE 5W–30
SAE 20W–20

SAE 10W 2

SYNTHETIC OIL Use recommendation from Synthetic Oil Mfgr.

P–10803
–40 –30 –20 –10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120
F°
TEMPERATURE RANGE ANTICIPATED
BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API B
CLASSIFICATION CD, CF4, CG4 )
* Can be used ONLY when available with appropriate diesel rating.

Replacement Of Oil And Filter

See the SERVICE SCHEDULE, Page 1–3 for the service 1
interval for replacing the engine oil and filter.
Run the engine until it is at operating temperature. Stop the
engine.
Open the rear door. Remove the drain plug (Item 2) [A].
Drain the oil into container.
P–10801

Remove the oil filter (Item 1) [B].

Clean the filter housing surface. Put clean oil on the new oil
filter gasket. Install the filter and hand tighten only.
Install and tighten the drain plug.
Remove the filler cap (Item 3) [A]. Always clean up spilled fuel or oil. Keep heat,
flames, sparks or lighted tobacco away from
Put 10 qts. (9,5 L) of oil in the engine. fuel and oil. Failure to use care around
combustibles can cause explosion or fire
Start the engine and let it run for several minutes. Stop the which can result in injury or death.
engine. Check for leaks and check the oil level. Add oil as W–2103–1285
needed if it is not at the top mark on the dipstick.

863, 863H Bobcat Loader

Revised Feb. 99 –1–17– Service Manual
COOLING SYSTEM
Cleaning The Cooling System
A
Check the cooling system every day to prevent
over–heating, loss of performance or engine damage.

Wear safety glasses to prevent eye injury when

any of the following conditions exist: P–07614
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running. B
• Tools are being used.
W–2019–1285

Raise the rear grill [A].

Use air pressure or water pressure to clean the top
hydraulic/hydrostatic system oil cooler (Item 1) [A].
1
Remove the hair pin (Item 1) [B] (both sides) so the oil
cooler can be raised.
Raise the oil cooler, use air pressure or water pressure to
clean the top of the engine oil cooler (Item 1) [C].
P–07618

P–07617

863, 863H Bobcat Loader

Revised Feb. 99 –1–18– Service Manual
ALTERNATOR BELT
Adjusting The Alternator Belt
A
Stop the engine.
Loosen the alternator mounting bolt (Item 1) [A]. 1

P–10357

Loosen the adjustment bolt (Item 1) [B].

B
Move the alternator until the belt has 5/16 inch (8,0 mm)
movement at the middle of the belt span with 15 lbs. (66 N)
of force [A] or [B].
Tighten the adjustment and mounting bolts.

P–10358

863, 863H Bobcat Loader

Revised Feb. 99 –1–19– Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid
A
Use only recommended fluid in the hydraulic system. (See
SPECIFICATIONS Page 9–1.)
To check the reservoir, use the following procedure:
Put the Bobcat loader on a level surface. Lower the lift arms
2
and tilt the Bob–Tach fully back.
Stop the engine.
Remove the dipstick (Item 1) [A].
1
P–07671

The fluid level must be between the marks on the dipstick

[B]. B
If fluid is needed, remove the fill cap (Item 2) [A].

Add fluid as needed to bring the level to the top mark on the
dipstick [B].

P–07673

Replacing The Hydraulic/Hydrostatic Filter

C
See the SERVICE SCHEDULE, Page 1–3 for the correct
service interval.
Raise the operator cab. (See Page 1–8.)
Use a filter wrench to remove the filter element (Items 1)
[C].
Clean the surface of the filter housing where the element
seal contacts the housing. Put clean oil on the rubber seal 1
of the filter elements.
Install and hand tighten the filter elements.
N–17395

863, 863H Bobcat Loader

Revised Feb. 99 –1–20– Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)
Replacing The Hydraulic Fluid
A
See the SERVICE SCHEDULE Page 1–3 for the service
interval.
Replace the fluid if it becomes contaminated or after major
repair.
Also clean the two hydrostatic motor case drain filters
thoroughly after a major repair.
Remove the fill cap. Remove the screen from the reservoir
[A]. Wash the screen in clean solvent and air dry.
Raise the operator cab. (See Page 1–8.) P–07672

Disconnect the hose (Item 1) [B] from the hydraulic fluid

reservoir and drain the fluid into a container.
B LEFT CASE DRAIN
FILTER
Replace the filter element. (See Page 1–17.)
Remove the case drain filters (Item 2) [B] & (Item 1) [C] and
clean thoroughly with clean solvent.
Install the case drain filters and tighten all the hoses.

1
Add the correct fluid to the reservoir until the fluid level is
to the top mark on the dipstick. (See Page 1–17.)

Diesel fuel or hydraulic fluid under pressure 2

can penetrate skin or eyes, causing serious
injury or death. Fluid leaks under pressure may
not be visible. Use a piece of cardboard or wood
to find leaks. Do not use your bare hand. Wear
safety goggles. If fluid enters skin or eyes, get
immediate medical attention from a physician
familiar with this injury.
W–2072–0496
Always clean up spilled fuel or oil. Keep heat,
flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around N–17398
combustibles can cause explosion or fire
which can result in injury or death.
W–2103–1285
C RIGHT CASE DRAIN
FILTER
Lower the operator cab. Start the engine and operate the
loader hydraulic controls. Stop the engine. Check for leaks.
Check the fluid level in the reservoir and add as needed.
1

N–17397

863, 863H Bobcat Loader

–1–21– Service Manual
TIRE MAINTENANCE
Wheel Nuts
A
See the SERVICE SCHEDULE Page 1–3 for the service
interval to check the wheel nuts. The correct torque is
105–115 ft.–lbs. (142–156 Nm) torque [A].
Tire Rotation
Check the tires regularly for pressure, wear and damage.
Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
capability. Check for the correct pressure before operating
the loader. Inflate to maximum pressure shown on sidewall
of tire. P–07649

Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires to
the front [B]. B
It is important to keep the same size tires on each side of
the loader. If different sizes are used, each tire will be
turning at a different rate and cause excessive wear. The
tread bars of all the tires must face the same direction.
Tire Mounting
Tires are to be repaired only by an authorized person using
the proper procedures and safety equipment. Tires and
rims must always be checked for correct size before
mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust. The tire B–09976
bead and rim flange must be lubricated with a rubber
lubricant before mounting the tire, avoid excessive
pressure which can rupture the tire and cause serious
injury or death. During inflation of the tire, check the tire
pressure frequently to avoid over inflation.

Do not inflate tires above specified pressure.

Failure to use correct tire mounting procedure
can cause an explosion which can result in
injury or death. W–2078–1285

Inflate tires to the MAXIMUM pressure shown

on the sidewall of the tire. DO NOT mix brands
of tires used on the same loader.
I–2057–0794

863, 863H Bobcat Loader

Revised Feb. 99 –1–22– Service Manual
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
A
The chaincase contains the final drive sprockets and 1
chains and uses the same type of oil as the
hydraulic/hydrostatic system. (See SPECIFICATIONS
Page 9–1.)
To check the chaincase oil level, use the following
procedure:
Drive the loader on a level surface. Stop the engine.
Remove the plug (Item 1) [A] from the front of the
chaincase housing.
P–07610
If oil can be reached with the tip of the your finger through
the hole the oil level is correct.
If the level is low, add oil through the check plug hole until B
the oil flows from the hole. Install and tighten the plug.
Removing Oil From The Chaincase
To drain the oil from the chaincase, remove the cover (Item
1) [B] over the drain plug at the rear of the chaincase.

P–01616

Remove the drain plug (Item 1) [C] and drain the oil into a
container.
C
NOTE: When installing the drain plug into the
chaincase, always use a NEW drain plug.

P–01619

863, 863H Bobcat Loader

Revised Feb. 99 –1–23– Service Manual
LUBRICATION OF THE BOBCAT LOADER
Procedure
A
Lubricate the loader as specified in the SERVICE
SCHEDULE Page 1–3 for the best performance of the
loader.
1
Record the operating hours each time you lubricate the
Bobcat loader.
Always use a good quality lithium based multi–purpose
grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Lubricate the following locations on the loader:
P–07655
1. Rod End Lift Cylinder (Both Sides) [A].

2. Base End Lift Cylinder (Both Sides) [B]. B

P–10815

3. Lift Arm Pivot Pin (Both Sides) [C].

C

P–07631

4. Base End Tilt Cylinder [D].

D
4

P–07641

863, 863H Bobcat Loader

Revised Feb. 99 –1–24– Service Manual
LUBRICATION OF THE BOBCAT LOADER (Cont’d)
Procedure (Cont’d)
A
5. Rod End Tilt Cylinder [A].
5
6. Bob–Tach Pivot Pin (Both Sides) [A].
7. Bob–Tach Wedge (Both Sides) [A].

6
7
P–07653

8. 250 Hours: Steering Lever Shaft (2) [B &C]. B 8

9. 250 Hours: Centering bracket pivot pin [B].

N–17497

P–13767

10. 250 Hours: Steering Linkage Pivot [D] (If Equipped).

D
863,863H(S/N514425001&Abv.,514525001&Above,514625001&Abv.)ServiceManual#6900648–PreventiveMaintenanceSectionPart1of2

10

N–17398

863, 863H Bobcat Loader

Revised Feb. 99 –1–25– Service Manual
Please click here and go
back to our website.

BUY NOW
Then Instant Download the
Complete Manual.
Thank you very much!
Have questions.
Please write to me.
aservicemanuapdf@yahoo.com