Bobcat 864 & 864 High Flow Loader Service Manual SN 516911001 & Above – PDF DOWNLOAD

Description

Bobcat 864 & 864 High Flow Loader Service Manual SN 516911001 & Above – PDF DOWNLOAD

FILE DETAILS:

Bobcat 864 & 864 High Flow Loader Service Manual SN 516911001 & Above – PDF DOWNLOAD

Language : English
Pages : 536
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 864 & 864 High Flow Loader Service Manual SN 516911001 & Above – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 8
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 12
SERIAL NUMBER LOCATIONS 13
LOADER SERIAL NUMBER 13
ENGINE SERIAL NUMBER 13
DELIVERY REPORT 13
BOBCAT LOADER IDENTIFICATION 14
PREVENTIVE MAINTENANCE 15
SERVICE SCHEDULE 17
LIFTING AND BLOCKING THE LOADER 18
Procedure 18
TRANSPORTING THE BOBCAT LOADER 19
Procedure 19
TOWING THE LOADER 20
Procedure (Without Coupler) 20
Procedure (With Coupler) 21
LIFT ARM SUPPORT DEVICE 22
Engaging The Lift Arm Support Device 22
Disengaging The Lift Arm Support Device 23
REMOTE START SWITCH 24
Procedure 24
OPERATOR CAB 26
Description 26
Raising The Operator Cab 26
Lowering The Operator Cab 27
Emergency Exit 27
SEAT BAR RESTRAINT SYSTEM 28
Description 28
Inspecting The Seat Bar 28
Maintaining The Seat Bar 28
SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS) 29
Description 29
FUEL SYSTEM 30
Fuel Specifications 30
Filling the Fuel Tank 30
Fuel Filter 30
Removing Air From The Fuel System 30
ENGINE LUBRICATION SYSTEM 31
Checking Engine Oil 31
Replacing The Oil And Filter 31
ENGINE COOLING SYSTEM 32
Cleaning The Cooling System 32
HYDRAULIC/HYDROSTATIC SYSTEM 33
Checking And Adding Fluid 33
Hydraulic/Hydrostatic Filter Replacement 33
Replacing The Hydraulic Fluid 34
LUBRICATING THE LOADER 35
Procedure 35
HYDRAULIC SYSTEM 37
HYDRAULIC / HYDROSTATIC SCHEMATICS 42
HYDRAULIC SYSTEM INFORMATION 45
TROUBLESHOOTING 49
LIFT CYLINDER 50
Checking The Lift Cylinder(s) 50
Removal And Installation 50
TILT CYLINDER 52
Checking The Tilt Cylinder(s) 52
Removal And Installation 52
Rod End Seal 53
HYDRAULIC CYLINDER 54
Lift Cylinder Identification 54
Tilt Cylinder Identification 55
Disassembly 56
Assembly 58
MAIN RELIEF VALVE 61
Checking The Main Relief Valve At The Front Auxiliary Hydraulics 61
Checking The Main Relief Valve Without Auxiliaries 62
Removal And Installation 63
Adjustment 63
BICS™ VALVE 64
Lift Arm By–Pass Orifice 64
Check Valve 65
Lock Valve 66
BICS™ Valve Solenoid 67
Removal And Installation 68
HYDRAULIC CONTROL VALVE 72
Auxiliary Pressure Relief Block (864H) 72
Removal And Installation 73
Identification Chart 77
Disassembly and Assembly 78
Load Check Valve 78
Lift Base End Restrictor 78
Main Relief Valve 79
Port Relief Valve 80
Anti–Cavitation Valve/Port Relief Valve 80
Anti–Cavitation Valve 81
Rubber Boot 82
Lift Spool and Detent 83
Tilt Spool and Centering Spring 87
Auxiliary Spool 88
Auxiliary Electric Solenoid 89
H Port – Auxiliary Section 90
Inspection 90
Spool Seal Installation 91
LIFT ARM BY–PASS CONTROL VALVE 92
Removal And Installation 92
LIFT ARM BY–PASS CONTROL VALVE MOUNT BRACKET 93
Removal And Installation 93
Disassembly And Assembly 93
HYDRAULIC PUMP 94
Checking The Output Of The Pump 94
Removal and Installation 95
Parts Identification 96
Disassembly 97
Inspection 99
Assembly 100
HYDRAULIC PUMP (Double Gear) 102
Checking The Output Of The High Flow Pump 102
Removal and Installation 103
Disassembly 106
Parts Identification 105
Inspection 110
Assembly 111
HYDRAULIC/HYDROSTATIC FILTER HOUSING 114
Removal and Installation 114
HYDRAULIC FLUID RESERVOIR 115
Draining The Hydraulic Fluid Reservoir 115
Removal And Installation 115
CONTROL PEDALS 116
Pedal Adjustment 116
Removal and Installation 116
PEDAL INTERLOCK LINKAGE 117
Pedal Interlock Linkage Adjustment 117
Removal and Installation 117
CROSSBAR LINKAGE 119
Removal And Installation 119
Inspection 119
REAR AUXILIARY DIVERTER–864 STANDARD FLOW 121
Disassembly 121
Inspection 121
Solenoid Testing 121
Assembly 121
SELECT VALVE (864H) 122
Checking The High Flow Pump Relief Valve 122
Removal And Installation 123
Disassembly And Assembly 124
Solenoid Testing 128
BUCKET POSITION VALVE 129
Solenoid Removal And Installation 129
Solenoid Testing 129
Removal And Installation 130
Disassembly And Assembly 131
HYDROSTATIC SYSTEM 133
TROUBLESHOOTING 135
HYDROSTATIC SYSTEM INFORMATION 136
Replenishing Valve Function 136
CHARGE PRESSURE 136
Charge Pressure Sender 136
CONTROL PANEL 137
Removal and Installation 137
STEERING LEVERS 139
Removal And Installation 139
Disassembly And Assembly 139
STEERING LINKAGE 141
Removal And Installation 141
Neutral Adjustment 144
HYDROSTATIC MOTOR 149
Removal And Installation 149
Parts Identification 152
Disassembly 154
Inspection 163
Assembly 164
HYDROSTATIC PUMP 173
Removal And Installation 173
Replenishing/High Pressure Relief Valve 175
Charge Pressure Relief Valve 176
Parts Identification (Right Half) 178
Parts Identification (Left Half) 180
Hydraulic Pump Removal 182
Disassembly 183
Assembly 191
DRIVE BELT SHIELD 199
Removal And Installation 199
DRIVE BELT 200
Adjusting The Drive Belt 200
Replacing The Drive Belt 200
DRIVE BELT TENSIONER PULLEY 201
Removal And Installation 201
Disassembly And Assembly 202
Tension Spring 203
OIL COOLER 204
Removal and Installation 204
DRIVE SYSTEM 205
PARKING BRAKE PEDAL 207
Removal And Installation 207
Disassembly And Assembly 208
BRAKE BLOCK 209
Removal And Installation 209
Disassembly And Assembly 210
Traction Lock By–Pass Knob 210
TRACK 211
Checking Track Tension 211
Adjusting Track Tension 212
Removal And Installation 213
TRACK IDLER (Front) 216
Removal And Installation 216
Parts Identification 218
Disassembly 219
Assembly 220
TRACK IDLER (Rear) 223
Removal And Installation 223
Parts Identification 223
Disassembly 224
Assembly 225
TRACK ROLLER 227
Removal And Installation 227
Parts Identification 227
Disassembly 228
Assembly 229
TRACK HOUSING 232
Removal And Installation 232
TRACK DAMAGE IDENTIFICATION 233
Cutting Of Steel Cords 233
Abrasion Of Embedded Metals 234
Separation Of Embedded Metals 235
Cuts On The Lug Side Rubber 237
Separation Of Embedded Metals Due To Corrosion 236
Lug Abrasion 239
Cracks And Cuts On The Lug Side Rubber 239
Cracks On The Lug Side Rubber Due To Fatigue 238
Abrasion Of The Track Roller Side 240
Cuts On The Edges Of Track Roller Side 241
MAIN FRAME 243
SEAT BAR 245
Removal And Installation 245
Assembling Components 248
Compression Spring Disassembly And Assembly 248
OPERATOR CAB GAS CYLINDER 249
Removal And Installation 249
Disassembly And Assembly 250
OPERATOR CAB 251
Removal And Installation 251
OPERATOR SEAT 253
Removal And Installation 253
BOB–TACH 254
Inspection And Maintenance 254
Bob–Tach Lever And Wedge 255
Removal And Installation 257
Pivot Pin Bushing And Seal Replacement 259
LIFT ARMS 260
Removal And Installation 260
REAR GRILL 263
Removal And Installation 263
REAR DOOR 264
Removal And Installation 264
Adjusting The Rear Door Latch 265
FUEL TANK 266
Removal And Installation 266
Fuel Level Sender 269
Fuel Pick–up Screen/Check Valve 269
ELECTRICAL SYSTEM 271
ELECTRICAL SCHEMATICS 273
TROUBLESHOOTING 281
ELECTRICAL SYSTEM INFORMATION 282
Description 282
Fuse Location 282
Solenoid Testing 282
BATTERY 283
Removal And Installation 283
Servicing The Battery 284
Using A Booster Battery 285
ALTERNATOR BELT 286
Adjusting The Alternator Belt 286
ALTERNATOR 287
Alternator Output Test 287
Rectifier (Diode) Test 287
Alternator Regulator Test 288
Removal And Installation 289
Disassembly 290
Stator Continuity Test 290
Stator Ground Test 290
Rotor Continuity Test 291
Rotor Ground Test 291
Rectifier Continuity (Diode) Test 291
Assembly 292
STARTER 292
Removal And Installation 292
Parts Identification 293
Disassembly And Assembly 294
External Pinion 298
Inspection And Repair 299
Magnetic Switch Test 302
No Load Test 302
STANDARD INSTRUMENT PANEL 303
Removal And Installation 303
FRONT LIGHTS 304
Removal And Installation 304
RELAY SWITCHES 305
Location 305
ENGINE SERVICE 307
TROUBLESHOOTING 309
ENGINE SPEED CONTROL 310
Removal And Installation 310
Speed Control Linkage 311
Speed Control Cable 311
ENGINE MUFFLER 312
Removal And Installation 312
AIR CLEANER 313
Replacing Filter Element 313
AIR CLEANER 315
Housing, Removal And Installation 315
RADIATOR 316
Oil Cooler, Removal And Installation 316
COOLING FAN 317
Drive Tension Pulley, Removal And Installation 317
Gearbox/Blower Housing, Removal And Installation 318
Blower, Removal And Installation 320
Gearbox, Checking And Maintaining 321
Gearbox, Parts Identification 322
Gearbox, Disassembly 323
Gearbox, Assembly 328
Gearbox, Checking Backlash 333
ENGINE COMPONENTS AND TESTS 336
Engine Compression, Checking 336
Glow Plug, Checking 338
Fuel Shut–Off Solenoid, Checking 339
Fuel Shut–Off Solenoid Removal and Installation 340
Fuel Injection Pump, Removal 341
Fuel Injection Pump Timing 342
Fuel Injection Pump Installation 343
Fuel Injector Removal and Installation 345
Fuel Injector Checking 346
Fuel Injector Disassembly 347
Fuel Injector Assembly 348
Timing Belt, Inspection 350
Timing Belt, Removal 350
Timing Belt, Installation 351
Timing Belt, Replacement In the Loader 355
Valve Clearance Adjustment 360
Valve Timing, Checking 361
Thermostat, Oil Pressure Control Valves & Heater Connections 362
ENGINE AND ENGINE MOUNTS 365
Removal And Installation 365
Engine Mount Replacement 371
FLYWHEEL AND HOUSING 372
Flywheel Removal And Installation 372
Ring Gear Removal And Installation 372
Flywheel Housing Removal And Installation 372
RECONDITIONING THE ENGINE 373
Deutz Engine Tools Identification Chart 373
Disassembly 374
Assembly 378
Cylinder, Checking 393
Camshaft Bearing, Checking 394
Camshaft Bearing, Removal And Installation 394
Control Rod Guide Bushing, Removal 396
Control Rod Guide Bushing, Installation 398
Rear Cover Seal, Removal And Installation 402
Crankshaft, Checking 403
Connecting Rod, Checking 404
Piston, Checking 406
Piston Pin, Checking 407
Piston Rings, Installation 407
Piston Installation On the Connecting Rod 408
Cylinder Head, Disassembly 410
Valves, Checking 410
Valve Seats, Checking 411
Valve Spring, Checking 411
Cylinder Head, Assembly 411
Rocker Arm and Bracket, Checking 413
Front Cover, Disassembly 414
Front Cover, Assembly 419
Turbo Charger, Removal and Installation 429
Crankshaft Gear Mounting Bolt Torque Procedure 430
SYSTEMS ANALYSIS 433
BICS™ 435
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 435
Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 435
Inspecting The Seat Bar Sensor (Engine RUNNING) 435
Inspecting The Traction Lock (Engine RUNNING) 435
Inspecting The Lift Arm By–Pass Control 435
Additional Inspection For Loaders With Advanced Hand Controls 435
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 436
Troubleshooting Chart 436
BICS SYSTEM CONTROLLER 437
Troubleshooting Guide 437
Removal And Installation 438
SEAT BAR SENSOR 439
Troubleshooting Guide 439
Seat Bar Sensor Test 440
Removal And Installation 441
BICS™ Controller Seat Bar Sensor Circuit Test 442
TRACTION LOCK 443
Troubleshooting Guide 443
Removal And Installation 444
BOSS® DIAGNOSTIC TOOL 445
Procedure 445
SENDER AND SENSOR 445
Service Checks 445
Components 445
RPM SENSOR 445
Adjustment 445
MONITOR SERVICE CODES 446
TROUBLESHOOTING THE BOSS® & LCD DISPLAY 448
BOSS®UNIT 449
Removal And Installation 449
BOSS® INSTRUMENT PANEL 450
Removal And Installation 450
PWM MODULE 451
Description 451
PWM TROUBLESHOOTING 452
Conditions 452
Chart 453
PWM CONTROL HANDLE 454
Handle Testing 454
PWM ELECTRIC SOLENOID 454
Solenoid Coil Testing 454
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE 455
Controls Identification Chart 455
SPECIFICATIONS 457
LOADER SPECIFICATIONS 459
LOADER DIMENSIONS 459
PERFORMANCE 459
CONTROLS 459
ENGINE 459
HYDRAULIC SYSTEM 460
ELECTRICAL 460
DRIVE SYSTEM 460
CAPACITIES 460
TRACKS 460
GROUND PRESSURE 460
ENGINE SPECIFICATIONS (BF4M1011) 461
General 461
Fuel System 461
Valve And Valve Guide And Seat Insert 461
Piston And Rings 462
Connecting Rod 462
Cylinder Head And Block 462
Crankshaft And Main Bearings 463
Camshaft And Bearings 463
Oil Pump 463
ENGINE SPECIFICATIONS (BF4M1011F) 464
General 464
Fuel System 464
Valve And Valve Guide And Seat Insert 464
Piston And Rings 465
Connecting Rod 465
Cylinder Head And Block 465
Crankshaft And Main Bearings 466
Camshaft And Bearings 466
Oil Pump 466
ENGINE TORQUE 467
TORQUE SPECIFICATIONS FOR LOADER 469
HYDRAULIC CONNECTION SPECIFICATIONS 470
O–ring Face Seal Connection 470
Straight Thread O–ring Fitting 470
Tubelines And Hoses 470
Flare Fitting 470
O–ring Flare Fitting 471
Port Seal Fitting 473
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 474
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 475
DECIMAL AND MILLIMETER EQUIVALENTS 476
U S TO METRIC CONVERSION 476
ADVANCE HAND CONTROL SYSTEM (A H C) 477
ADVANCE HAND CONTROL ELECTRICAL SCHEMATICS 479
A H C COMPONENTS 485
Identification 485
TROUBLESHOOTING (A H C ) 486
ACTUATOR VOLTAGE TEST 488
Procedure 488
HANDLE CONTROL UNIT TEST 491
Procedure 491
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 494
Troubleshooting Chart 494
A H C /PWM CONTROLLER 495
Removal And Installation 495
Test 496
Description 497
Conditions 498
Troubleshooting Chart 498
Handle Testing 499
Solenoid Coil Testing 499
HANDLE CONTROL UNIT 500
Removal And Installation 500
Control Unit Connector 503
SWITCH HANDLE 504
Removal And Installation 504
A H C HANDLE 507
Removal And Installation 507
Disassembly And Assembly 508
A H C STEERING LEVER 509
Removal And Installation 509
Steering Lever Boot 509
ACTUATORS 510
Removal And Installation 510
Disassembly And Assembly 511
Mounting Plate 512
BICS™ VALVE 513
Lift Arm By–Pass Orifice 513
Check Valve 514
Lock Valve 514
BICS™ Valve Solenoid 515
Removal And Installation 516
HYDRAULIC CONTROL VALVE 517
Removal And Installation 517
Identification Chart 520
Disassembly And Assembly 521
Load Check Valve 521
Lift Base End Restrictor 521
Main Relief Valve 522
Port Relief Valve (Lift) 523
Anti–Cavitation/Port Relief Valve 523
Port Relief Valve (Tilt) 524
Anti–Cavitation Valve 524
Rubber Boot 525
Lift And Tilt Spool 526
Inspection 528
Auxiliary Spool 529
Auxiliary Electrical Solenoid 530
Spool Seal Installation 531
H–Port Auxiliary Section 532
SERVICE MANUAL REVISION 533
864-1 533
864-2 535

DESCRIPTION:

Bobcat 864 & 864 High Flow Loader Service Manual SN 516911001 & Above – PDF DOWNLOAD

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.

SAFETY INSTRUCTIONS:
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.

FIRE PREVENTION:

• The loader has several components that are at high temperature under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.
• Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it will increase the fire hazard. The loader must be cleaned as often as necessary to avoid this accumulation. Flammable debris in the engine compartment is a fire hazard when the loader is parked with a hot engine.

The spark arrestor muffler is designed to control the emission of hot particles from the engine and exhaust system, but the
muffler and the exhaust gases are still hot.
• 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.
• Do not use ether or starting fluids on this engine. It has 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 Manual for connecting the battery.
• Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler.
• Know where fire extinguishers and first aid kits are located and how to use them.
A fire extinguisher is available from your Bobcat dealer. The fire extinguisher can be installed in the location shown [A].

Contact us: [email protected]

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.V