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

(S/N: 516911001 & Above) 
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This workshop repair 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 !!!! 

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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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