Bobcat 864, 864H Skid-Steer Loader Repair Service Manual - 6900945

(S/N: 518911001 - 518914999 - S/N: 516811001 - 516814999 - S/N: 517511001 - 517514999) 
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This workshop repair service manual PDF download for the 864, 864H 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, 864H 
HIGH FLOW
S/N: 518911001 - 518914999
S/N: 516811001 - 516814999
S/N: 517511001 - 517514999


TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS 
FIRE PREVENTION
SERIAL NUMBER LOCATIONS 
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM 
HYDROSTATIC SYSTEM 
DRIVE SYSTEM 
MAIN FRAME 
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE 
HEATING, VENTILATION, AIR CONDITIONING 
SPECIFICATIONS
SERVICE MANUAL REVISION


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6900945 (7-10)
Total Pages : 809


This 864, 864H 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 !!!! 

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
    FOREWORD
    SAFETY INSTRUCTIONS
    FIRE PREVENTION
        Maintenance
        Operation
        Electrical
        Hydraulic System
        Fueling
        Starting
        Spark Arrestor Exhaust System
        Welding And Grinding
        Fire Extinguishers
    SERIAL NUMBER LOCATIONS
        Loader Serial Number
        Engine Serial Number
    DELIVERY REPORT
    BOBCAT LOADER IDENTIFICATION
    
SAFETY AND MAINTENANCE
    LIFTING AND BLOCKING THE LOADER
        Procedure
    LIFT ARM SUPPORT DEVICE
        Engaging The Lift Arm Support Device
        Disengaging The Lift Arm Support Device
    OPERATOR CAB
        Raising The Operator Cab
        Lowering The Operator Cab
        Emergency Exit
    TRANSPORTING THE BOBCAT LOADER
        Procedure
    TOWING THE LOADER
        Procedure
    REMOTE START
        Procedure For Loader Without Attachments Control Harness
        Procedure For Loader With Attachments Control Harness
    SERVICE SCHEDULE
        Chart
    AIR CLEANER SERVICE
        Replacing Filter Element
    ENGINE COOLING SYSTEM
        Cleaning The Cooling System
    FUEL SYSTEM
        Fuel Specifications
        Filling The Fuel Tank
        Fuel Filter
        Removing Air From The Fuel System
    ENGINE LUBRICATION SYSTEM
        Checking Engine Oil
        Replacing Oil And Filter
    HYDRAULIC/HYDROSTATIC SYSTEM
        Checking And Adding Fluid
        Hydraulic/Hydrostatic Filter Replacement
        Replacing Hydraulic Fluid
    FAN GEARBOX
        Checking And Adding Oil
    BOB-TACH
        Inspection And Maintenance
    POWER BOB-TACH (OPTION)
        Inspection And Maintenance
    LUBRICATING THE LOADER
        Procedure
        
HYDRAULIC SYSTEM
    HYDRAULIC / HYDROSTATIC SCHEMATICS
    HYDRAULIC SYSTEM INFORMATION
        Glossary Of Hydraulic/Hydrostatic Symbols For Loaders
        Troubleshooting
        Tighten Procedures
    CYLINDER (LIFT)
        Checking
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    CYLINDER (TILT)
        Checking
        Removal And Installation
        Rod End Seal
        Parts Identification
        Disassembly
        Assembly
    CYLINDER (POWER BOB-TACH)
        Checking
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    MAIN RELIEF VALVE (FOOT CONTROL)
        Checking The Main Relief Valve At Front Auxiliary Hydraulics
        Checking The Main Relief Valve Without Front Auxiliaries
        Removal And Installation
        Adjustment
    MAIN RELIEF VALVE (AHC)
        Checking The Main Relief Valve At Front Auxiliary Hydraulics
        Checking The Main Relief Valve Without Front Auxiliaries
        Removal and Installation
        Adjustment
    HYDRAULIC CONTROL VALVE (FOOT CONTROL)
        Removal And Installation
        BICS™ Valve, Removal And Installation
        BICS™ Valve, Lift Arm Bypass Orifice Disassembly And Assembly
        BICS™ Valve, Check Valve Disassembly And Assembly
        BICS™ Valve, Lock Valve Disassembly And Assembly
        BICS™ Valve, Solenoid Disassembly And Assembly
        BICS™ Valve, Solenoid Testing
        Identification Chart
        Load Check Valve
        Main Relief Valve
        Port Relief Valve, Tilt Spool (Linkage End)
        Port Relief Valve, Lift Spool (Bonnet End)
        Anti-Cavitation Valve/Port Relief Valve, Tilt Spool (Bonnet End)
        Anti-Cavitation Valve, Lift Spool (Linkage End)
        Rubber Boot
        Lift And Tilt Lock Block
        Lift Spool and Detent
        Tilt Spool Removal And Installation
        Auxiliary Spool Removal And Installation (Bonnet End)
        Auxiliary Spool Removal And Installation (Linkage End)
        Auxiliary Plug Removal And Installation
        Auxiliary Electric Solenoid Disassembly
        Port Relief-Auxiliary Section Disassembly
        Cleaning And Inspection
    HYDRAULIC CONTROL VALVE (ADVANCE HAND
    CONTROL) (AHC), ADVANCE CONTROL SYSTEM (ACS)
        Actuator Removal And Installation (In Loader)
        Removal And Installation
        Actuator Removal And Installation (Out Of Loader)
        BICS™ Valve, Removal And Installation
        BICS™ Valve, Lift Arm Bypass Orifice Disassembly And Assembly
        BICS™ Valve, Check Valve Disassembly And Assembly
        BICS™ Valve, Lock Valve Disassembly And Assembly
        BICS™ Valve, Solenoid Disassembly And Assembly
        BICS™ Valve, Solenoid Testing
        Identification Chart
        Identification Chart
        Lift Base End Restrictor
        Load Check Valve
        Main Relief Valve
        Port Relief Valve
        Anti-Cavitation Valve/Port Relief Valve
        Anti-Cavitation Valve
        Lift Spool Removal
        Lift Spool Removal And Installation
        Lift and Tilt Spool Disassembly And Assembly
        Auxiliary Spool Removal And Installation
        Auxiliary Electric Solenoid Disassembly
        Port-Auxiliary Section Disassembly
        Cleaning And Inspection
    LIFT ARM BYPASS CONTROL VALVE
        Inspecting
        Additional Inspection For Loaders With Advanced Hand Controls
        Removal And Installation
        Disassembly And Assembly
    HYDRAULIC PUMP (SINGLE GEAR)
        Checking The Output Of The Pump
        Removal And Installation
        Parts Identification
        Disassembly
        Inspection
        Assembly
    HYDRAULIC PUMP (HI-FLOW)
        Checking The Output Of The High Flow Pump
        Removal And Installation
        Parts Identification
        Disassembly
        Inspection
        Assembly
    HYDRAULIC/HYDROSTATIC FILTER
        Housing Removal And Installation
        Mount Removal And Installation
    HYDRAULIC FLUID RESERVOIR
        Draining The Hydraulic Fluid Reservoir
        Removal And Installation
        Hydraulic Fluid Screen
    CONTROLS
        Control Pedal Removal And Installation
        Control Pedal Adjustment
        Crossbar Linkage Removal And Installation
        Crossbar Linkage Inspection
        Control Foot Sensor (ACS) Removal And Installation
        Control Pedal (ACS) Removal And Installation
        Control Pedal Linkage (ACS) Disassembly And Assembly
    BUCKET POSITION VALVE
        Solenoid Removal And Installation
        Solenoid Testing
        Removal And Installation
        Disassembly And Assembly
    REAR AUXILIARY DIVERTER
        Disassembly
        Inspection
        Solenoid Testing
        Assembly
    SELECT VALVE
        Checking The High Flow Pump Relief Valve
        Removal And Installation
        Disassembly And Assembly
        Solenoid Testing
    REAR AUXILIARY DIVERTER VALVE (SINGLE SHUTTLE)
        Removal And Installation
        Disassembly
        Inspection
        Solenoid Testing
        Assembly
    POWER BOB-TACH BLOCK
        Removal And Installation
        Disassembly And Assembly
    AUXILIARY PRESSURE RELEASE (ACCUMULATOR)
        Removal and Installation
        Disassembly And Assembly
        
HYDROSTATIC SYSTEM
    HYDROSTATIC SYSTEM INFORMATION
        Troubleshooting Chart
        Replenishing Valve Function
    CONTROL PANEL
        Removal and Installation
    STEERING
        Lever Removal And Installation
        Lever Disassembly And Assembly
        Linkage Removal And Installation
        Linkage Neutral Adjustment
    STEERING (ADVANCED HAND CONTROL) (AHC)
        Components Identification
        Handle Control Unit Removal And Installation
        Switch Handle Removal And Installation
        Handle Removal And Installation
        Handle Disassembly And Assembly
        Steering Lever Removal And Installation
        Steering Lever Boot
    STEERING (ADVANCED HAND CONTROL) (AHC) W/ PUSH BUTTON FLOAT
        Components Identification
        Handle Sensor Removal And Installation
        Control Handle Removal and Installation
        Control Handle Disassembly and Assembly
        Control Lever Removal and Installation
        Control Lever Boot
    STEERING (ADVANCED CONTROL SYSTEM) (ACS)
        Components Identification
        Handle Sensor Removal And Installation
        Control Handle Removal and Installation
        Control Handle Disassembly and Assembly
        Control Lever Removal and Installation
        Control Lever Boot
    HYDROSTATIC MOTOR
        Removal And Installation
        Parts Identification
        Disassembly
        Inspection
        Assembly
        Filling
    CHARGE PRESSURE SENDER
        Removal and Installation
    HYDROSTATIC PUMP
        Removal And Installation
        Replenishing/High Pressure Relief Valve(s)
        Charge Pressure Relief Valve
        Parts Identification (Right Half)
        Parts Identification (Left Half)
        Hydraulic Pump Removal And Installation
        Disassembly
        Assembly
    DRIVE BELT
        Shield Removal And Installation
        Adjustment
        Replacement
        Tensioner Pulley Removal And Installation
        Tensioner Pulley Disassembly And Assembly
        Tensioner Pulley Tension Spring
    OIL COOLER
        Removal and Installation
        Removal And Installation With STC (Seal Tight Connector)
        
DRIVE SYSTEM
    BRAKE
        Pedal Removal And Installation
        Pedal Disassembly And Assembly
        Switch Operated Parking Brake
        Block Removal And Installation
        Block Disassembly And Assembly
        Traction Lock Bypass Knob
    DRIVE COMPONENTS
        Track Checking
        Track Adjustment
        Track Removal And Installation
        Track Idler (Front) Removal And Installation
        Track Idler (Front) Parts Identification
        Track Idler (Front) Disassembly
        Track Idler (Front) Assembly
        Track Idler (Rear) Removal And Installation
        Track Idler (Rear) Parts Identification
        Track Idler (Rear) Disassembly
        Track Idler (Rear) Assembly
        Track Roller Removal And Installation
        Track Roller Parts Identification
        Track Roller Disassembly
        Track Roller Assembly
        Track Housing Removal And Installation
        Track Damage Identification
        
MAINFRAME
    SEAT BAR
        Removal And Installation
        Assembling Components
        Compression Spring Disassembly And Assembly
    OPERATOR CAB
        Gas Cylinder Removal And Installation
        Gas Cylinder Disassembly And Assembly
        Removal And Installation
    OPERATOR SEAT
        Removal And Installation
        Seat Belt Removal And Installation
    OPERATOR SEAT (SUSPENSION)
        Removal And Installation
        Slide Rail Removal And Installation
        Cushion Removal And Installation
        Back Removal And Installation
        Shock Removal And Installation
    BOB-TACH
        Inspection And Maintenance
        Bob-Tach Lever And Wedge
        Removal And Installation
        Pivot Pin Bushing And Seal Replacement
    POWER BOB-TACH
        Inspection And Maintenance
        Power 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 & ANALYSIS
    ELECTRICAL SCHEMATICS
    ELECTRICAL SYSTEM INFORMATION
        Troubleshooting Chart
        Description
        Fuse Location
        Relay Switch Location
        Solenoid Test
    BATTERY
        Removal And Installation
        Servicing The Battery
        Using A Booster Battery
    ALTERNATOR (55 AMP)
        Adjusting The Alternator Belt
        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
    ALTERNATOR (90 AMP)
        Adjusting The Alternator Belt
        Alternator Identification
        Charging System Check
        Alternator Voltage Test
        Low Voltage Test
        High Voltage Test
        Removal And Installation
        Rectifier Continuity (Diode) Test
        Alternator Regulator Test
        Disassembly
        Stator Continuity Test
        Stator Ground Test
        Rotor Continuity Test
        Rotor Ground Test
        Assembly
    STARTER
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
        External Pinion
        Inspection And Repair
        No Load Test
    INSTRUMENT PANEL
        Left Panel (Standard)
        Right Panel-Standard Instrument Panel (With Key Switch) [Figure 60-50-2]
        Right Panel (Deluxe) (With Keyless Start) [Figure 60- 50-3]
        Right Panel Setup Display Options (Deluxe)
        Passwords
        Option And Field Accessory Panels
        Standard Panel Removal And Installation (Right Side)
        Deluxe Panel Removal And Installation (Right Side)
        Standard And Deluxe Panel Removal And Installation (Left Side)
        Front Accessory Panel Removal And Installation
    LIGHTS
        Front Removal And Installation
        Rear Removal And Installation
    BOBCAT CONTROLLER
        Identification Chart
        Removal And Installation
    DIAGNOSTICS SERVICE CODES
        Display
    BICS™ SYSTEM
        Inspecting The BICS™ Controller (Engine STOPPED - Key ON)
        Inspecting 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 Bypass Control
        Additional Inspection For Loaders With Advanced Hand Controls (AHC)
        Troubleshooting Chart
        Troubleshooting Guide
    SEAT BAR SENSOR
        Troubleshooting Chart
        Test
        Removal And Installation
        BICS™ Circuit Test
    TRACTION LOCK
        Description Of The Control System
        Inspecting The Control System
        Parking Brake Solenoid Removal And Installation
        Traction Lock Bypass Knob
    ADVANCE HAND CONTROL (AHC) SYSTEM
        Components Identification
        Troubleshooting Guide
        Parts Identification
        AHC Controller Removal And Installation
        Handle Control Unit Connector
        Switch Handle Removal and Installation
        Actuators Disassembly and Assembly
    ADVANCED HAND CONTROL (AHC) SYSTEM (W/ PUSH BUTTON FLOAT) (CONT’D)
        Components Identification
        Troubleshooting Guide
        Controller Connector And Wire Identification
        AHC Controller Removal And Installation
        Handle Sensor Removal And Installation
        Handle Sensor Connector
        Switch Handle Removal and Installation
        Actuators Disassembly and Assembly
    ADVANCED CONTROL SYSTEM (ACS)
        Components Identification
        Troubleshooting Guide
        Controller, Connector And Wire Identification
        ACS Controller Removal And Installation
        Handle Sensor Connector
        Switch Handle Removal
        Switch Handle Installation
        Actuators Disassembly and Assembly
        Handle Lock Solenoid Removal And Installation
        Handle Lock Solenoid Disassembly And Assembly
        Handle Lock Solenoid Connector
        Calibration Of The ACS System
        Switchable Hand/Foot Controls Calibration Procedure
        Hand Controls Only Calibration Procedure
        Foot Sensor Disassembly And Assembly
        Foot Sensor Connector
        Foot Lock Solenoid Removal And Installation
        Foot Lock Solenoid Connector
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
        Controls Identification Chart
        
ENGINE SERVICE
    TROUBLESHOOTING
        Chart
    ENGINE SPEED CONTROL
        Removal And Installation
        Speed Control Cable
        Speed Control Linkage
    MUFFLER
        Removal And Installation
    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 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 And 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
        
HEATING, VENTILATION, AIR CONDITIONING
    AIR CONDITIONING SYSTEM FLOW
        Principals
        Chart
    COMPONENTS
        Identification
    SAFETY
        Safety Equipment
    REGULAR MAINTENANCE
        Filter Elements Removal And Installation
        Compressor Drive Belt Inspection
        Cleaning The Condenser
    BASIC TROUBLESHOOTING
        Poor A/C Performance
        Cleaning The A/C Evaporator Coil & Heater Coil
        Receiver/Drier Sight Glass Inspection
        Compressor Drive Belt Inspection:
        Checking The Electrical System
        Engine Coolant Bypassing The Heater Valve
        Heater Valve Not Opening Or Closing
    GENERAL AIR CONDITIONING SERVICE GUIDELINES
        Compressor Oil
        Compressor Oil Check
        Component Replacement And Refrigeration Leaks
    SYSTEM TROUBLESHOOTING CHART
        Gauge Pressure Related Troubleshooting
    TEMPERATURE/PRESSURE
        Chart
    ELECTRICAL
        Chart
    AIR CONDITIONING SERVICE
        Chart
    RECOMMENDED SERVICE TOOLS
        Full Service A/C Tools
        Basic Field Diagnostic Tools
    SYSTEM CHARGING AND RECLAMATION
        Reclamation Procedure
        Charging Procedure With A Manifold Gauge Set
        Charging Procedure
    COMPRESSOR
        Removal And Installation
        Compressor Clutch Disassembly
    CONDENSER
        Removal And Installation
    RECEIVER/DRIER
        Removal And Installation
    PRESSURE RELIEF VALVE
        Removal And Installation
    PRESSURE SWITCH
        Removal And Installation
    THE EVAPORATOR/HEATER UNIT
        Removal And Installation
        Disassembly And Assembly
    THERMOSTAT
        Removal And Installation
    THE EXPANSION VALVE
        Removal And Installation
    THE EVAPORATOR
        Removal And Installation
    HEATER COIL
        Removal And Installation With A/C
        Removal And Installation Without A/C
    HEATER/AC FAN
        Removal And Installation
        Disassembly And Assembly
        Wire Connector Removal and Installation
    HEATER VALVE
        Removal and Installation
        Disassembly And Assembly
        
SPECIFICATIONS
    LOADER SPECIFICATIONS
        Loader Dimensions
        Performance
        Controls
        Engine
        Hydraulic System
        Electrical
        Drive System
        Capacities
        Tracks
        Ground Pressure
    ENGINE SPECIFICATIONS
        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
    LOADER TORQUE
        Specifications
    TORQUE SPECIFICATIONS FOR BOLTS
        Torque For General SAE Bolts
        Torque For General Metric Bolts
    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
        Specifications
    CONVERSIONS
        Decimal And Millimeter Equivalents
        U.S. To Metric Conversion
        
SERVICE MANUAL REVISION
    864/864H-1
    864/864H-2
    864/864H-3
    864/864H-4
    864/864H-5
    
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