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Bobcat 864 HIGH FLOW Skid-Steer Loader Repair Service Manual - 6900627


(S/N: 516911001 & Above)
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This service manual PDF download for the 864 Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

Bobcat Loader 864
HIGH FLOW
S/N: 516911001 & Above


TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION
PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE
SYSTEMS ANALYSIS
SPECIFICATIONS
ADVANCED HAND CONTROL SYSTEM
SERVICE MANUAL REVISION


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6900627 (7–10)
Total Pages : 534


This 864 Bobcat Loader Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
SERIAL NUMBER LOCATIONS
LOADER SERIAL NUMBER
ENGINE SERIAL NUMBER
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION
PREVENTIVE MAINTENANCE
SERVICE SCHEDULE
LIFTING AND BLOCKING THE LOADER
Procedure
TRANSPORTING THE BOBCAT LOADER
Procedure
TOWING THE LOADER
Procedure (Without Coupler)
Procedure (With Coupler)
LIFT ARM SUPPORT DEVICE
Engaging The Lift Arm Support Device
Disengaging The Lift Arm Support Device
REMOTE START SWITCH
Procedure
OPERATOR CAB
Description
Raising The Operator Cab
Lowering The Operator Cab
Emergency Exit
SEAT BAR RESTRAINT SYSTEM
Description
Inspecting The Seat Bar
Maintaining The Seat Bar
SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)
Description
FUEL SYSTEM
Fuel Specifications
Filling the Fuel Tank
Fuel Filter
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Replacing The Oil And Filter
ENGINE COOLING SYSTEM
Cleaning The Cooling System
HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid
Hydraulic/Hydrostatic Filter Replacement
Replacing The Hydraulic Fluid
LUBRICATING THE LOADER
Procedure
HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
TROUBLESHOOTING
LIFT CYLINDER
Checking The Lift Cylinder(s)
Removal And Installation
TILT CYLINDER
Checking The Tilt Cylinder(s)
Removal And Installation
Rod End Seal
HYDRAULIC CYLINDER
Lift Cylinder Identification
Tilt Cylinder Identification
Disassembly
Assembly
MAIN RELIEF VALVE
Checking The Main Relief Valve At The Front Auxiliary Hydraulics
Checking The Main Relief Valve Without Auxiliaries
Removal And Installation
Adjustment
BICS™ VALVE
Lift Arm By–Pass Orifice
Check Valve
Lock Valve
BICS™ Valve Solenoid
Removal And Installation
HYDRAULIC CONTROL VALVE
Auxiliary Pressure Relief Block (864H)
Removal And Installation
Identification Chart
Disassembly and Assembly
Load Check Valve
Lift Base End Restrictor
Main Relief Valve
Port Relief Valve
Anti–Cavitation Valve/Port Relief Valve
Anti–Cavitation Valve
Rubber Boot
Lift Spool and Detent
Tilt Spool and Centering Spring
Auxiliary Spool
Auxiliary Electric Solenoid
H Port – Auxiliary Section
Inspection
Spool Seal Installation
LIFT ARM BY–PASS CONTROL VALVE
Removal And Installation
LIFT ARM BY–PASS CONTROL VALVE MOUNT BRACKET
Removal And Installation
Disassembly And Assembly
HYDRAULIC PUMP
Checking The Output Of The Pump
Removal and Installation
Parts Identification
Disassembly
Inspection
Assembly
HYDRAULIC PUMP (Double Gear)
Checking The Output Of The High Flow Pump
Removal and Installation
Disassembly
Parts Identification
Inspection
Assembly
HYDRAULIC/HYDROSTATIC FILTER HOUSING
Removal and Installation
HYDRAULIC FLUID RESERVOIR
Draining The Hydraulic Fluid Reservoir
Removal And Installation
CONTROL PEDALS
Pedal Adjustment
Removal and Installation
PEDAL INTERLOCK LINKAGE
Pedal Interlock Linkage Adjustment
Removal and Installation
CROSSBAR LINKAGE
Removal And Installation
Inspection
REAR AUXILIARY DIVERTER–864 STANDARD FLOW
Disassembly
Inspection
Solenoid Testing
Assembly
SELECT VALVE (864H)
Checking The High Flow Pump Relief Valve
Removal And Installation
Disassembly And Assembly
Solenoid Testing
BUCKET POSITION VALVE
Solenoid Removal And Installation
Solenoid Testing
Removal And Installation
Disassembly And Assembly
HYDROSTATIC SYSTEM
TROUBLESHOOTING
HYDROSTATIC SYSTEM INFORMATION
Replenishing Valve Function
CHARGE PRESSURE
Charge Pressure Sender
CONTROL PANEL
Removal and Installation
STEERING LEVERS
Removal And Installation
Disassembly And Assembly
STEERING LINKAGE
Removal And Installation
Neutral Adjustment
HYDROSTATIC MOTOR
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
HYDROSTATIC PUMP
Removal And Installation
Replenishing/High Pressure Relief Valve
Charge Pressure Relief Valve
Parts Identification (Right Half)
Parts Identification (Left Half)
Hydraulic Pump Removal
Disassembly
Assembly
DRIVE BELT SHIELD
Removal And Installation
DRIVE BELT
Adjusting The Drive Belt
Replacing The Drive Belt
DRIVE BELT TENSIONER PULLEY
Removal And Installation
Disassembly And Assembly
Tension Spring
OIL COOLER
Removal and Installation
DRIVE SYSTEM
PARKING BRAKE PEDAL
Removal And Installation
Disassembly And Assembly
BRAKE BLOCK
Removal And Installation
Disassembly And Assembly
Traction Lock By–Pass Knob
TRACK
Checking Track Tension
Adjusting Track Tension
Removal And Installation
TRACK IDLER (Front)
Removal And Installation
Parts Identification
Disassembly
Assembly
TRACK IDLER (Rear)
Removal And Installation
Parts Identification
Disassembly
Assembly
TRACK ROLLER
Removal And Installation
Parts Identification
Disassembly
Assembly
TRACK HOUSING
Removal And Installation
TRACK DAMAGE IDENTIFICATION
Cutting Of Steel Cords
Abrasion Of Embedded Metals
Separation Of Embedded Metals
Cuts On The Lug Side Rubber
Separation Of Embedded Metals Due To Corrosion
Lug Abrasion
Cracks And Cuts On The Lug Side Rubber
Cracks On The Lug Side Rubber Due To Fatigue
Abrasion Of The Track Roller Side
Cuts On The Edges Of Track Roller Side
MAIN FRAME
SEAT BAR
Removal And Installation
Assembling Components
Compression Spring Disassembly And Assembly
OPERATOR CAB GAS CYLINDER
Removal And Installation
Disassembly And Assembly
OPERATOR CAB
Removal And Installation
OPERATOR SEAT
Removal And Installation
BOB–TACH
Inspection And Maintenance
Bob–Tach Lever And Wedge
Removal And Installation
Pivot Pin Bushing And Seal Replacement
LIFT ARMS
Removal And Installation
REAR GRILL
Removal And Installation
REAR DOOR
Removal And Installation
Adjusting The Rear Door Latch
FUEL TANK
Removal And Installation
Fuel Level Sender
Fuel Pick–up Screen/Check Valve
ELECTRICAL SYSTEM
ELECTRICAL SCHEMATICS
TROUBLESHOOTING
ELECTRICAL SYSTEM INFORMATION
Description
Fuse Location
Solenoid Testing
BATTERY
Removal And Installation
Servicing The Battery
Using A Booster Battery
ALTERNATOR BELT
Adjusting The Alternator Belt
ALTERNATOR
Alternator Output Test
Rectifier (Diode) Test
Alternator Regulator Test
Removal And Installation
Disassembly
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
Rectifier Continuity (Diode) Test
Assembly
STARTER
Removal And Installation
Parts Identification
Disassembly And Assembly
External Pinion
Inspection And Repair
Magnetic Switch Test
No Load Test
STANDARD INSTRUMENT PANEL
Removal And Installation
FRONT LIGHTS
Removal And Installation
RELAY SWITCHES
Location
ENGINE SERVICE
TROUBLESHOOTING
ENGINE SPEED CONTROL
Removal And Installation
Speed Control Linkage
Speed Control Cable
ENGINE MUFFLER
Removal And Installation
AIR CLEANER
Replacing Filter Element
AIR CLEANER
Housing, Removal And Installation
RADIATOR
Oil Cooler, Removal And Installation
COOLING FAN
Drive Tension Pulley, Removal And Installation
Gearbox/Blower Housing, Removal And Installation
Blower, Removal And Installation
Gearbox, Checking And Maintaining
Gearbox, Parts Identification
Gearbox, Disassembly
Gearbox, Assembly
Gearbox, Checking Backlash
ENGINE COMPONENTS AND TESTS
Engine Compression, Checking
Glow Plug, Checking
Fuel Shut–Off Solenoid, Checking
Fuel Shut–Off Solenoid Removal and Installation
Fuel Injection Pump, Removal
Fuel Injection Pump Timing
Fuel Injection Pump Installation
Fuel Injector Removal and Installation
Fuel Injector Checking
Fuel Injector Disassembly
Fuel Injector Assembly
Timing Belt, Inspection
Timing Belt, Removal
Timing Belt, Installation
Timing Belt, Replacement In the Loader
Valve Clearance Adjustment
Valve Timing, Checking
Thermostat, Oil Pressure Control Valves & Heater Connections
ENGINE AND ENGINE MOUNTS
Removal And Installation
Engine Mount Replacement
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Ring Gear Removal And Installation
Flywheel Housing Removal And Installation
RECONDITIONING THE ENGINE
Deutz Engine Tools Identification Chart
Disassembly
Assembly
Cylinder, Checking
Camshaft Bearing, Checking
Camshaft Bearing, Removal And Installation
Control Rod Guide Bushing, Removal
Control Rod Guide Bushing, Installation
Rear Cover Seal, Removal And Installation
Crankshaft, Checking
Connecting Rod, Checking
Piston, Checking
Piston Pin, Checking
Piston Rings, Installation
Piston Installation On the Connecting Rod
Cylinder Head, Disassembly
Valves, Checking
Valve Seats, Checking
Valve Spring, Checking
Cylinder Head, Assembly
Rocker Arm and Bracket, Checking
Front Cover, Disassembly
Front Cover, Assembly
Turbo Charger, Removal and Installation
Crankshaft Gear Mounting Bolt Torque Procedure
SYSTEMS ANALYSIS
BICS™
Inspecting The BICS™ Controller (Engine STOPPED – Key ON)
Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
Inspecting The Seat Bar Sensor (Engine RUNNING)
Inspecting The Traction Lock (Engine RUNNING)
Inspecting The Lift Arm By–Pass Control
Additional Inspection For Loaders With Advanced Hand Controls
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
Troubleshooting Chart
BICS SYSTEM CONTROLLER
Troubleshooting Guide
Removal And Installation
SEAT BAR SENSOR
Troubleshooting Guide
Seat Bar Sensor Test
Removal And Installation
BICS™ Controller Seat Bar Sensor Circuit Test
TRACTION LOCK
Troubleshooting Guide
Removal And Installation
BOSS® DIAGNOSTIC TOOL
Procedure
SENDER AND SENSOR
Service Checks
Components
RPM SENSOR
Adjustment
MONITOR SERVICE CODES
TROUBLESHOOTING THE BOSS® & LCD DISPLAY
BOSS®UNIT
Removal And Installation
BOSS® INSTRUMENT PANEL
Removal And Installation
PWM MODULE
Description
PWM TROUBLESHOOTING
Conditions
Chart
PWM CONTROL HANDLE
Handle Testing
PWM ELECTRIC SOLENOID
Solenoid Coil Testing
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
Controls Identification Chart
SPECIFICATIONS
LOADER SPECIFICATIONS
LOADER DIMENSIONS
PERFORMANCE
CONTROLS
ENGINE
HYDRAULIC SYSTEM
ELECTRICAL
DRIVE SYSTEM
CAPACITIES
TRACKS
GROUND PRESSURE
ENGINE SPECIFICATIONS (BF4M1011)
General
Fuel System
Valve And Valve Guide And Seat Insert
Piston And Rings
Connecting Rod
Cylinder Head And Block
Crankshaft And Main Bearings
Camshaft And Bearings
Oil Pump
ENGINE SPECIFICATIONS (BF4M1011F)
General
Fuel System
Valve And Valve Guide And Seat Insert
Piston And Rings
Connecting Rod
Cylinder Head And Block
Crankshaft And Main Bearings
Camshaft And Bearings
Oil Pump
ENGINE TORQUE
TORQUE SPECIFICATIONS FOR LOADER
HYDRAULIC CONNECTION SPECIFICATIONS
O–ring Face Seal Connection
Straight Thread O–ring Fitting
Tubelines And Hoses
Flare Fitting
O–ring Flare Fitting
Port Seal Fitting
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
STANDARD TORQUE SPECIFICATIONS FOR BOLTS
DECIMAL AND MILLIMETER EQUIVALENTS
U.S. TO METRIC CONVERSION
ADVANCE HAND CONTROL SYSTEM (A.H.C)
ADVANCE HAND CONTROL ELECTRICAL SCHEMATICS
A.H.C. COMPONENTS
Identification
TROUBLESHOOTING (A.H.C.)
ACTUATOR VOLTAGE TEST
Procedure
HANDLE CONTROL UNIT TEST
Procedure
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
Troubleshooting Chart
A.H.C./PWM CONTROLLER
Removal And Installation
Test
Description
Conditions
Troubleshooting Chart
Handle Testing
Solenoid Coil Testing
HANDLE CONTROL UNIT
Removal And Installation
Control Unit Connector
SWITCH HANDLE
Removal And Installation
A. H. C. HANDLE
Removal And Installation
Disassembly And Assembly
A.H.C. STEERING LEVER
Removal And Installation
Steering Lever Boot
ACTUATORS
Removal And Installation
Disassembly And Assembly
Mounting Plate
BICS™ VALVE
Lift Arm By–Pass Orifice
Check Valve
Lock Valve
BICS™ Valve Solenoid
Removal And Installation
HYDRAULIC CONTROL VALVE
Removal And Installation
Identification Chart
Disassembly And Assembly
Load Check Valve
Lift Base End Restrictor
Main Relief Valve
Port Relief Valve (Lift)
Anti–Cavitation/Port Relief Valve
Port Relief Valve (Tilt)
Anti–Cavitation Valve
Rubber Boot
Lift And Tilt Spool
Inspection
Auxiliary Spool
Auxiliary Electrical Solenoid
Spool Seal Installation
H–Port Auxiliary Section
SERVICE MANUAL REVISION
864-1

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