Bobcat 864, 864 High Flow Skid Steer Loader Service Manual
534 pages · Publication 6900627_7_10
Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3 or morePay by credit or debit card or with PayPal. No PayPal account needed.
Added to your cart. View cart
- Models
- 864, 864 High Flow
- Serial coverage
- SN 516911001 & above
- Manual type
- Service Manual
- Pages
- 534
- Publication
- 6900627_7_10
- Condition
- Brand new
What's inside
From the manual's own table of contents: 23 sections, 508 entries. See sample pages (PDF, 558 KB)
MAINTENANCE SAFETY
ALPHABETICAL INDEX
FOREWORD7 topics
- SAFETY INSTRUCTIONS
- FIRE PREVENTION
- SERIAL NUMBER LOCATIONS
- LOADER SERIAL NUMBER
- ENGINE SERIAL NUMBER
- DELIVERY REPORT
- BOBCAT LOADER IDENTIFICATION
PREVENTIVE MAINTENANCE
SERVICE SCHEDULE39 topics
- 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 SCHEMATICS92 topics
- 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
TROUBLESHOOTING38 topics
- 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 PEDAL38 topics
- 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 BAR25 topics
- Removal And Installation
- Assembling Components
- Compression Spring Disassembly And Assembly
- OPERATOR CAB GAS CYLINDER
- Removal And Installation
- Disassembly And Assembly
- 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 SCHEMATICS36 topics
- 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 SERVICE72 topics
- ENGINE SPEED CONTROL
- Removal And Installation
- Speed Control Linkage
- Speed Control Cable
- ENGINE MUFFLER
- Removal And Installation
- AIR CLEANER
- Replacing Filter Element
- 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™43 topics
- 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 SPECIFICATIONS43 topics
- 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 SCHEMATICS52 topics
- A.H.C. COMPONENTS
- Identification
- TROUBLESHOOTING (A.H.C.)
- ACTUATOR VOLTAGE TEST
- Procedure
- HANDLE CONTROL UNIT TEST
- Procedure
- 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
- Lift Arm By–Pass Orifice
- Check Valve
- Lock Valve
- BICS™ Valve Solenoid
- 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
Inside this manual
Real pages from this service manual (534 pages). Open the sample pages (PDF, 556 KB)
- Diagram, page 264: REAR DOOR
- Specifications, page 384: RECONDITIONING THE ENGINE (Cont’d)
- Troubleshooting, page 448: 12 volt supply and
- Foldout diagram, page 482
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual 6900627_7_10$69.83
Added to your cart. View cart
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 534 pages
Quantity one is the manual described above.
Fast free USA shipping
Ships in 1 business day.
60-day returns
Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy
Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).