Page 1

86 4 86 4

Service Manual S/N 516911001 & Above

HIGH FLOW

EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM)

6900627 (7–99)

© Melroe Company 1999 Printed in U.S.A.


MAINTENANCE SAFETY WARNING

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow W-2003-0903 instructions can cause injury or death.

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

CORRECT

CORRECT

B-10731a

B-15248

Never service the Bobcat Compact Track Loader without instructions.

Use the correct procedure to lift or lower operator cab.

CORRECT

B-15247

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B-15246

B-15275

B-15279

Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced. Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed.

WRONG

B-15665

Stop, cool and clean engine of flammable materials before checking fluids. Never service or adjust loader with the engine running unless instructed to do so in the manual. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes. Never fill fuel tank with engine running, while smoking or when near open flame.

Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device. Replace it if damaged.

Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged. Never modify equipment or add attachments not approved by Bobcat Company.

WRONG

B-15663 B-16102 Keep body, jewelry and clothing

away from moving parts, electrical contact, hot parts and exhaust. Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding. Keep rear door closed except for service. Close and latch door before operating the loader.

WRONG

B-6589 B-16102

Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries. Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer. MSW06-0805


ALPHABETICAL INDEX ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1 ACTUATOR VOLTAGE TEST . . . . . . . . . . . . . . . . . . 10–1 A.H.C./PWM CONTROLLER . . . . . . . . . . . . . . . . . . 10–1 A.H.C. HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1 A.H.C. STEERING LEVER . . . . . . . . . . . . . . . . . . . . 10–1 AIR CLEANER HOUSING . . . . . . . . . . . . . . . . . . . . . . 7–1 AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . 7–1 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

FAN DRIVE TENSION PULLEY . . . . . . . . . . . . . . . . . . FAN GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . FRONT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 BICS™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 BICS™ VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1, 10–1 BLOWER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 BLOWER HOUSING/FAN GEARBOX . . . . . . . . . . . 7–1 BICS™ SYSTEM CONTROLLER . . . . . . . . . . . 8–1, 10–1 BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 BOSS® DIAGNOSTIC TOOL . . . . . . . . . . . . . . . . . . . 8–1 BOSS® INSTRUMENT PANEL . . . . . . . . . . . . . . . . . 8–1 BOSS® UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 BRAKE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . 2–1

GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . . . . . CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . CHARGE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL ROD GUIDE BUSHING . . . . . . . . . . . . . . CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT GEAR MOUNTING BOLT . . . . . . . . CROSSBAR LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER LINERS . . . . . . . . . . . . . . . . . . . . . . . . . . .

7–1 3–1 3–1 7–1 2–1 3–1 7–1 7–1 7–1 2–1 7–1 7–1

DECIMAL & MILLIMETER EQUIVALENTS . . . . . . . DEUTZ ENGINE TOOLS . . . . . . . . . . . . . . . . . . . . . . . DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE BELT SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE BELT TENSIONER PULLEY . . . . . . . . . . . . .

9–1 7–1 3–1 3–1 3–1

ELEC./HYD. CONTROLS REFERENCE . . . . . . . . . ELECTRICAL SYSTEM INFORMATION . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . ENGINE TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8–1 6–1 7–1 1–1 1–1 7–1 7–1 9–1 7–1 9–1

7–1 7–1 7–1 7–1 7–1 6–1 7–1 7–1 1–1 5–1

HANDLE CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . 10–1 HANDLE CONTROL UNIT TEST . . . . . . . . . . . . . . . . 10–1 HYDRAULIC CONNECTION SPECIFICATIONS . . . 9–1 HYDRAULIC CONTROL VALVE . . . . . . . . . . . 2–1, 10–1 HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . 2–1 HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . 2–1 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 HYDRAULIC PUMP (Double Gear) 863H . . . . . . . . . . 2–1 HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . 2–1 HYDRAULIC/HYDROSTATIC FILTER HOUSING . . . 2–1 HYDRAULIC/HYDROSTATIC FLUID SPECS . . . . . . 9–1 HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . 1–1 HYDROSTATIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 3–1 HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . 3–1 LIFT ARM BY–PASS CONTROL VALVE . . . . . . . . . . LIFT ARM BY–PASS CONTROL VALVE MOUNT BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . LIFT CYLINDER(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFTING AND BLOCKING THE LOADER . . . . . . . . . LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . .

2–1 2–1 5–1 1–1 2–1 1–1 9–1 1–1

MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 MONITOR SERVICE CODE . . . . . . . . . . . . . . . . . . . . . 8–1 OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1, 7–1 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . 1–1 & 5–1 OPERATOR CAB GAS CYLINDER . . . . . . . . . . . . . . . 5–1 OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 PARKING BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . PEDAL INTERLOCK LINKAGE . . . . . . . . . . . . . . . . . . PISTON AND PISTON PIN . . . . . . . . . . . . . . . . . . . . . . PWM CONTROL HANDLE . . . . . . . . . . . . . . . . . . . . . . PWM ELECTRIC SOLENOID . . . . . . . . . . . . . . . . . . . . PWM MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PWM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . .

4–1 2–1 7–1 8–1 8–1 8–1 8–1

REAR AUXILIARY DEVERTER–864 STD. FLOW . . REAR COVER SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECONDITIONING THE ENGINE . . . . . . . . . . . . . . . . RELAY SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOTE START SWITCH . . . . . . . . . . . . . . . . . . . . . . ROCKER ARM AND BRACKET . . . . . . . . . . . . . . . . . . RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–1 7–1 5–1 5–1 7–1 6–1 1–1 7–1 8–1

Continued On Next Page


ALPHABETICAL INDEX (Cont’d) SEAT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . 1–1 SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 SELECT VALVE 864H . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 SENDER AND SENSOR . . . . . . . . . . . . . . . . . . . . . . . 8–1 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 STANDARD INSTRUMENT PANEL . . . . . . . . . . . . . . 6–1 STANDARD TORQUE SPECS. FOR BOLTS . . . . . 9–1 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 STEERING LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 SWITCH HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1 TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 TOWING THE BOBCAT LOADER . . . . . . . . . . . . . . . 1–1 TORQUE SPECIFICATIONS FOR LOADER . . . . . . 9–1 TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 TRACK DAMAGE IDENTIFICATION . . . . . . . . . . . . . 4–1 TRACK HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 TRACK IDLER (Front & Rear) . . . . . . . . . . . . . . . . . . 4–1 TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 TRANSPORTING THE LOADER . . . . . . . . . . . . . . . . 1–1 TROUBLESHOOTING . . . . . 2–1, 3–1, 6–1, 7–1 & 10–1 TROUBLESHOOTING THE BOSS® & L.C.D. DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 U.S. TO METRIC CONVERSION . . . . . . . . . . . . . . . . 9–1 VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 WIRING SCHEMATICS . . . . . . . . . . . . . . . . . . . 6–1, 10–1


PREVENTIVE MAINTENANCE

CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 SYSTEMS ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1 ADVANCED HAND CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1

HYDRAULIC SYSTEM

HYDROSTATIC SYSTEM

DRIVE SYSTEM

MAIN FRAME

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

ELECTRICAL SYSTEM

ENGINE SERVICE

SYSTEMS ANALYSIS

SPECIFICATIONS

ADVANCED HAND CONTROL SYSTEM

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864 Bobcat Loader Service Manual


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. A general inspection of the following items must be made after the loader has had service or repair: 9. The parking brake function correctly.

1. Check that the ROPS/FOPS (Including sidescreens) is in good condition and is not modified.

must

2. Check that ROPS mounting hardware is tightened and is Melroe approved.

10. Enclosure door latches must open and close freely.

3. The seat belt must be correctly installed, functional and in good condition.

11. Bob–Tach wedges and linkages must function correctly and be in good condition.

4. The seat bar and pedal interlocks must be correctly adjusted, clean and lubricated.

12. Safety treads must in good condition.

5. Check lift arm support device, replace if damaged.

13. Check for correct function of indicator lamps (Optional on some models).

6. Machine signs must be legible and in the correct location.

14. Check hydraulic fluid level, engine oil level and fuel supply.

WARNING

7. Steering levers and foot pedals must return to neutral.

15. Inspect for fuel, oil or hydraulic fluid leaks.

8. Check for correct function of the work lights.

16. Lubricate the loader.

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864 Bobcat Loader Service Manual


17. Check the condition of the battery and cables.

18. Inspect the air cleaner for damage or leaks. Check the condition of the element.

19. Check the electrical charging system.

20. Check tracks for wear.

21. Inspect for loose or broken parts or connections.

22. Operate the loader and check all functions.

23. Check for any field modification not completed.

24. Check for correct function of the Bobcat Interlock Control System (BICS™) before the machine is returned to the customer. Recommend to the owner that all necessary corrections be made before the machine is returned to service.

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864 Bobcat Loader Service Manual


SAFETY INSTRUCTIONS

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. W–2003–0299

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.

Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.

This notice identifies procedures which must be followed to avoid damage to the machine. I–2019–0284

W–2044–1285

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

SI05–0299

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864 Bobcat Loader Service Manual


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].

A

P–10650

SI03–0398

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864 Bobcat Loader Service Manual


SERIAL NUMBER LOCATIONS

A

Always use the serial number of the loader when requesting service information or when ordering parts. Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation. LOADER SERIAL NUMBER The loader serial number plate is located on the inside of the left upright, above the grill [A]. Explanation of loader Serial Number: XXXX

XXXXX P–07612

Module 2. – Production Sequence (Series)

B

Module 1. – Model/Engine Combination The four digit Model/Engine Combination module number identifies the model number and engine combination. This number (in parenthesis beside the model number) is used in the Service Manual to more easily identify the standard, optional and field accessory equipment included or available for each specific model. The five digit Production Sequence Number identifies the order which the loader is produced. ENGINE SERIAL NUMBER The serial number is located on the valve cover at the right side of the engine [B].

P–07619

C

DELIVERY REPORT The Delivery Report must be filled out by the dealer and signed by the owner or operator when the Bobcat loader is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely [C].

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864 Bobcat Loader Service Manual


BOBCAT LOADER IDENTIFICATION 864ServiceManual#6900627–ContentsSection

◊ FRONT LIGHTS

OPERATOR SEAT

GRAB HANDLES STEERING LEVER SEAT BELT ◊ REAR AUXILIARY QUICK COUPLERS

TILT CYLINDER

BUCKET ◊ FRONT AUXILIARY QUICK COUPLERS SAFETY TREAD BUCKET STEPS

OPERATOR CAB (ROPS & FOPS)

◊ REAR WINDOW

SEAT BAR LIFT ARM

REAR GRILL

LIFT ARM SUPPORT DEVICE LIFT CYLINDER ◊ REAR LIGHT ◊ TAIL LIGHT

REAR DOOR * TRACKS

B–15217 B–15218

◊ OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment) BUCKET – Several different buckets and other attachments are available for the Bobcat loader. ROPS, FOPS – Roll Over Protective Structure, Falling Object Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level l. Level ll is available. The Bobcat loader is base–equipped with a standard operator cab as shown. Extra insulated cab is available as an option (Reduced noise level).

viii

864 Bobcat Loader Service Manual


PREVENTIVE MAINTENANCE

PREVENTIVE MAINTENANCE Page Number

ENGINE COOLING SYSTEM Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18 ENGINE LUBRICATION SYSTEM Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17 Replacing The Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17 FUEL SYSTEM Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–16 1–16 1–16 1–16

HYDRAULIC/HYDROSTATIC SYSTEM Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19 Hydraulic/Hydrostatic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 1–19 Replacing The Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20 LIFT ARM SUPPORT DEVICE Disengaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . 1–9 Engaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 LIFTING AND BLOCKING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 LUBRICATING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21 OPERATOR CAB Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–12 1–13 1–12 1–13

REMOTE START SWITCH Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10 SEAT BAR RESTRAINT SYSTEM Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14 Inspecting The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14 Maintaining The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14 SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS) Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15

Continued On Next Page

–1–1–

864 Bobcat Loader Service Manual


PREVENTIVE MAINTENANCE (Cont’d) Page Number SERVICE SCHEDULE Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 TOWING THE LOADER Procedure (Without Coupler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 Procedure (With Coupler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 TRANSPORTING THE BOBCAT LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5

–1–2–

864 Bobcat Loader Service Manual


SERVICE SCHEDULE Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat loader. Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. W–2003–0199

SERVICE SCHEDULE ITEM Engine Oil Engine Air Filter and Air System Engine Cooling System Lift Arms, Cyl. Bob–Tach Pivot Pins and Wedges

Seat Belt, Seat Bar and Pedal Interlocks Bobcat Interlock Control System (BICS™) Safety Signs and Safety Treads Operator Cab Tracks Fuel Filter Hyd. Fluid, Hoses & Tubelines Battery Foot Pedals or Hand Controls & Steering Parking Brake Alternator Belt Engine/Hydro. Drive Belt Fuel Filter Steering Shaft Hyd. Reservoir Breather Cap Hyd./Hydro. Filter Engine Oil and Filter Hydraulic Reservoir Hydrostatic Motors

SERVICE REQUIRED

8-10

50

n

n

n

250

500

1000

3000

Check the oil level and add oil as needed. Check condition indicator or display panel. Service only when required. Check for leaks and damaged components. Clean debris from oil cooler radiator & grill. Check coolant level cold, add premixed coolant as needed. Lubricate with multi–purpose lithium based grease (12 places). Check the condition of seat belt. Check the seat bar, and foot pedal interlocks for correct operation. Clean dirt and debris from moving parts. Check BICS functions. Check for damaged signs (decals) and safety treads. Replace any signs or safety treads that are damaged or worn. Check the fastening bolts, washers and nuts. Check the condition of cab. } Check for damaged tracks and correct tension. Remove the trapped water. Check fluid level and add as needed. Check for damage and leaks. Repair and replace as needed. Check cables connections and electrolyte level. Add distilled water as needed. Check for correct operation. Repair or adjust as needed. Check operation of the brake. Check tension and adjust as needed. * Check for wear or damage. Check idler arm stop. Replace filter element. Grease three fittings. Replace the reservoir breather cap. D Replace the filter element. {Replace oil & filter. Use CD or better grade oil and Melroe filter. Clean or replace the fluid. Clean or replace the case drain filters.

Hydrostatic Motor Carrier Bobcat Interlock Control System (BICSt) Fan Drive Gearbox Engine Valves Track Rollers and Idlers

Replace oil. Use SAE 10W–40. Check lift arm by–pass control.

Engine Timing Belt

◊ Replace the timing belt and belt tensioner assy.

D J * { ∞ ◊ }

HOURS

Check gear lubrication level. ∞ Adjust the engine valves. Replace oil. Use SAE 10W–40. (Rollers–70cc, Idlers–100cc)

Also replace hydraulic/hydrostatic filter element when the transmission warning light comes ON. Or every 12 months. Inspect the new belt after first 50 hours. Replace break–in filter and engine oil at 50 hours on a new loader; 100 hours thereafter. After the first 500 hours on new engine, adjust engine valves; 1000 hours thereafter. (See Page 7–1 for procedure.) Or every 5 years. Check every 8–10 hours for the first 50 hours. Then at 50 hour intervals. –1–3–

864 Bobcat Loader Service Manual


A Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. W–2003–0199 Read the Removal & Installation, Disassembly & Assembly, etc. completely to become familiar with the procedure before beginning [A]. B–07023

LIFTING AND BLOCKING THE LOADER Procedure Always park the loader on a level surface.

Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death.

B

W–2017–0286

Put floor jack under the rear of the loader [B]. Lift the rear of the loader and install jackstands [B].

N–18271

Put the floor jack under the front of the loader [C].

C

Lift the front of the loader and put jackstands under the loader frame [C]. NOTE: Make sure the jackstands do not touch the tracks. Make sure tracks clear floor or any obstacles.

N–18267

–1–4–

864 Bobcat Loader Service Manual


TRANSPORTING THE BOBCAT LOADER

A

Procedure

Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury.

Support

W–2058–0494 N–18274

A loader with an empty bucket or no attachment must be loaded backward onto the transport vehicle [A].

B

The rear of the trailer must be blocked or supported when loading or unloading the loader to prevent the front end of the trailer from raising up. Some ramps provide support [A]. Be sure the transport and towing vehicles are of adequate size and capacity (See SPECIFICATIONS Section Page 9–1, for weight of loader.) P–13807

P–13808

Use the following procedure to fasten the Bobcat loader to the transport vehicle to prevent the loader from moving during sudden stops or when going up or down slopes [B]. Lower the bucket or attachment to the floor. Stop the engine. Engage the parking brake. Install chains at the front and rear loader tie down positions [B]. Fasten each end of the chain to the transport vehicle.

6718401

–1–5–

N–18275

864 Bobcat Loader Service Manual


TOWING THE LOADER

A

Procedure (Without Coupler)

1 N–18673

Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W–2059–0598

Raise the operator cab. (See Page 1–1.) Remove the hydraulic hose (Item 1) [A] from the lift arm by–pass valve. Cap the fitting on the lift arm by–pass valve. Connect a Port–a–Power to the hydraulic hose (Item 1) [A]. Operate the Port–a–Power to 400 PSI (2758 kPa) to release the brake. Lower the operator cab and tow the loader. Before operating the loader again, disconnect the Port–a–Power and connect all hydraulic hoses.

–1–6–

864 Bobcat Loader Service Manual


TOWING THE LOADER (Cont’d)

A

Procedure (With Coupler)

1

N–18674

B

Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W–2059–0598 Raise the operator cab. (See Page 1–1.) Disengage the parking brake solenoid valve by pushing IN on the red Traction Lock By–Pass Knob (Item 1) [A] and turning it 1/4 TURN counterclockwise. The knob will come out to release the solenoid valve.

1 N–18906

Connect a Port–a–Power to the coupler (Item 1) [B]. Operate the Port–a–Power to 400 PSI (2758 kPa) to release the brake [C].

C

Lower the operator cab and tow the loader. Before operating the loader again, disconnect the Port–a–Power.

Engage the parking brake solenoid valve, by pushing IN on the red Traction Lock By–Pass Knob (Item 1) [A] and turning it 1/4 TURN clockwise. N–18907

Unexpected loader movement. Can cause serious injury or death. Push in and turn red Traction Lock By–Pass Knob clockwise to engaged position before operating loader. Read Operation instructions.

&

Maintenance

Manual

for more 6803932

–1–7–

864 Bobcat Loader Service Manual


LIFT ARM SUPPORT DEVICE

A 2

Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W–2059–0598

1

Engaging The Lift Arm Support Device

N–17992

Maintenance and service work can be done with the lift arms lowered. If the lift arms are raised, use the following procedure to install the lift arm support device:

B

Install jackstands under the rear of the loader frame.

1

Disconnect the spring from the pin (Item 1) [A]. Hold the lift arm support device (Item 2) [A] up and remove the pin. Lower the lift arm support device on top of the lift cylinder. Hook the free end of the spring (Item 1) [B] to the lift arm support device so it does not interfere with the support device engagement. Sit in the seat, fasten the seat belt and lower the seat bar. Start the engine.

N–17993

Raise the lift arms until the lift arm support device drops onto the lift cylinder rod (inset) [C]

C

Lower the lift arms slowly until the support device is held between the lift arm and the lift cylinder. Stop the engine. Raise the seat bar and move foot pedals until both lock.

1

Exit the cab.

N–17997

Install pin (Item 1) [D] into the rear of the lift arm support device below the cylinder rod. N–17994

D Service lift arm support device if damaged or if parts are missing. Using a damaged lift arm support or with missing parts can cause lift arms to drop causing injury or death. W–2271–1197

N–17998

–1–8–

864 Bobcat Loader Service Manual


LIFT ARM SUPPORT DEVICE (Cont’d)

A

Disengaging The Lift Arm Support Device Remove the pin from the lift arm support device. Connect the spring (Item 1) [A] from the lift arm support device to the bracket below the lift arms.

1 1

Enter the cab. Sit in the seat, fasten the seat belt and lower the seat bar. Start the engine. Raise the lift arms a small amount and the spring will lift the support device off the lift cylinder rod [A].

N–17995

N–17996

Lower the lift arms.

B

Stop the engine. Raise the seat bar. (Foot Pedal controls) Move both pedals until both lock. (Advanced Hand Controls) Move the hand controls to the NEUTRAL POSITION to make sure that both lift and tilt functions are deactivated. Exit the cab. Disconnect the spring from the bracket. Raise the support device into storage position and insert pin through lift arm support device and bracket (Item 1) [B]. Connect spring to pin (Item 2) [B].

1

2

N–17999

–1–9–

864 Bobcat Loader Service Manual


REMOTE START SWITCH

A

Procedure The tool listed will be needed to do the following procedure: MEL1429 A – Remote Start Switch The Remote Start Switch is required when the service technician is adjusting the steering linkage, checking the hydraulic/hydrostatic system. Lift and block the loader. (See Page 1–4.) Raise the lift arms and install an approved lift arm support device. (See Page 1–7.)

1 P–07101

Raise the operator cab. (See Page 1–11.)

NOTE: On current model loaders, the connector on the BICS harness is round (7–pin) connector, not a rectangular (8–pin) connector. Use the adapter harness (Item 1) [A] to connect the remote start switch to the loader harness.

B 1

Disconnect the operator cab wire harness (Item 1) [B] from the engine wire harness.

P–04732

Connect the remote start switch to the engine harness connectors (Item 1) [C].

C

Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death.

W–2017–0286

1

1

Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W–2059–0598

P–04758

–1–10–

864 Bobcat Loader Service Manual


REMOTE START SWITCH (Cont’d)

A

Procedure (Cont’d)

1

Put the traction lock override switch (Item 1) [A] in the ON position so the traction function is locked. The wheels are not able to turn. Turn the key to the right and start the engine.

P–04713

Move the traction lock override switch (Item 1) [B] to the OFF position so the traction function is unlocked. The wheels are now able to turn.

B 1

The auxiliary mode switch (Item 2) [B] is used to turn the front auxiliary quick couplers ON and OFF during relief pressure and flow tests.

2 P–04714

–1–11–

864 Bobcat Loader Service Manual


OPERATOR CAB

A

Description The Bobcat loader has an operator cab (ROPS and FOPS) as standard equipment to protect the operator from rollover and falling objects. Check with your dealer if the operator cab has been damaged.

P–10887

Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Melroe Company. Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death.

B

W–2069–1285

ROPS/FOPS – Roll–Over Protection Structure per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level I. Level II is available. LEVEL I – Protection from falling bricks, small concrete blocks, and hand tools encountered in operations such as highway maintenance, landscaping, and other construction site services. LEVEL II – Protection from falling trees, rocks; for machines involved in site clearing, overhead demolition or forestry.

P–10888

C

Raising The Operator Cab Stop the loader on a level surface. Lower the lift arms. If the lift arms must be up while raising the operator cab, install the lift arm support device. (See Page 1–7.) Loosen the nut (both sides) at the front corner of the operator cab [A]. Remove the nut and plate (both sides) [B]. Lift on the grab handle and bottom of the operator cab. Raise slowly until the cab latching mechanism engages and the cab is all the way up [C].

Use care when raising or lowering the operator cab to prevent damaging the shaft of the lift lock by–pass valve. I–2070–0495

N–17986

–1–12–

864 Bobcat Loader Service Manual


OPERATOR CAB (Cont’d)

A

Lowering The Operator Cab NOTE: Make sure the seat bar is fully raised or lowered when lowering the cab. Push the rear window out of the rear of the operator cab. Pull down on the bottom of the operator cab until it stops at the latching mechanism. Release the latching mechanism and pull the cab all the way down [A].

N–17987

Install the plate and nut (both sides) [B].

B

Tighten the nuts to 40–50 ft.–lbs. (54–68 Nm) torque.

P–10888

P–10887

C

Emergency Exit The front opening on the operator cab and rear window provide exits. To exit through the rear window, use the following procedure: Pull on the tag on the top of the rear window to remove the rubber cord [C].

P–00660

Push the rear window out of the rear of the operator cab.

D

Exit through the rear of the operator cab [D].

N–17988

–1–13–

864 Bobcat Loader Service Manual


OPERATOR CAB (Cont’d)

A

Emergency Exit (Cont’d) NOTE: When an Operator Cab Enclosure Kit (optional) is installed, the window of the front door can be used as an emergency exit [A]. Pull the plastic loop at the top of the window in the front door. Push the window out with your foot. SEAT BAR RESTRAINT SYSTEM Description The seat bar restraint system has a pivoting seat bar with arm rests and has spring loaded interlocks for the lift and tilt control pedals. The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat. The interlocks require the operator to lower the seat bar in order to operate the foot pedal controls. When the seat bar is up, the lift and tilt pedals are locked when returned to the neutral position.

6707852

B

AVOID INJURY OR DEATH The seat bar system must lock the lift and tilt control pedals in neutral when the seat bar is up. Service the system if pedals do not lock correctly. W–2105–1285

P–10361

C

Interlock Shield

Inspecting The Seat Bar Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Start the engine. Operate each foot pedal to check both the lift and tilt functions. Raise the lift arms until the bucket is about 2 feet (600 mm) off the ground.

Clean

Raise the seat bar. Try to move each foot pedal. Pedals must be firmly locked in neutral position. There must be no motion of the lift arms or tilt (bucket) when the pedals are pushed. Pull the seat bar down, lower the lift arms. Operate the lift pedals. While the lift arms are going up, raise the seat bar and the lift arms should stop.

P–01640

Lower the seat bar, lower the lift arms and place the bucket flat on the ground. Stop the engine. Raise the seat bar and operate the foot pedals to be sure that the pedals are firmly locked in the neutral position. Unbuckle the seat belt. Maintaining The Seat Bar See the SERVICE SCHEDULE Page 1–3 for correct service interval. Clean any debris or dirt from the moving parts [B] & [C]. Inspect the linkage bolts and nuts for tightness. The correct torque is 25–28 ft.–lbs. (34–38 Nm).

AVOID INJURY OR DEATH Never operate loader without pedal lock shield 6705474 on both interlocks. Shields prevent foot from unlocking interlocks when leaving loader seat. W–2162–1194

If the seat bar system does not function correctly, check for free movement of each linkage part. Check for excessive wear. Adjust pedal control linkage. Replace parts that are worn or damaged. Use only genuine Melroe replacement parts. –1–14–

864 Bobcat Loader Service Manual


SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)

A

Description The seat bar restraint system has a pivoting seat bar (Item 1) [A] with arm rests.

1

The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat. When the seat bar is down, and the green PRESS TO OPERATE Button is activated, the lift, tilt, and traction drive functions can be operated. When the seat bar is up, the lift, tilt, and traction drive functions are deactivated.

P–13721

AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly. • The seat bar must be lowered. • Keep your feet on the foot rests. W–2179–0694

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground. • Stop the engine. • Engage the parking brake. • Raise seat bar. • Move the hand controls to the NEUTRAL POSITION to make sure that both lift and tilt functions are deactivated. The seat bar system must deactivate the lift and tilt control functions when the seat bar is up. Service the system if hand controls do not deactivate. W–2302–0698

See SEAT BAR RESTRAINT SYSTEM Inspection & Maintenance, Page 1–13.

–1–15–

864 Bobcat Loader Service Manual


FUEL SYSTEM

A

Fuel Specifications Use only clean, high quality diesel fuel, Grade No. 1 or Grade No. 2 . The following is one suggested blending guideline which should prevent fuel gelling problems: Temp. F° (C°) No. 2 +15°(9°) 100% 0% Down to –20° (–29°) Below –20° (29°)

No.1

1 50% 0%

50% 100%

We recommend an operator contact their fuel supplier for local recommendations.

N–18269

Filling the Fuel Tank

B

WRONG

Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire. W–2063–0887

Remove the fuel fill cap (Item 1) [A]. Use a clean, approved safety container to add fuel of the correct specifications. Add fuel only in an area that has free movement of air and no open flames or sparks. NO SMOKING! [B]. Install and tighten the fuel fill cap [A]. Fuel Filter

B–13456

C 2

See the SERVICE SCHEDULE, Page 1–3 for the recommended service interval when to remove the water from the fuel filter. Loosen the drain (Item 1) [C] at the bottom of the filter element to drain any water from the filter. See the SERVICE SCHEDULE, Page 1–3 for the recommended service interval when to replace the fuel filter. To replace the fuel filter element, use a filter wrench to remove the filter element [C].

1

Clean the area around the filter housing. Put oil on the seal of the new filter element. Install the fuel filter, and hand tighten. Remove the air from the fuel system. Removing Air From The Fuel System After replacing the fuel filter element or when the fuel tank has run out of fuel, the air must be removed from the fuel system prior to starting the engine.

3

Loosen the air vent plug (Item 2) [C] at the top of the fuel filter. Operate the priming bulb (Item 3) [C] until fuel flows from the vent. P–10803

Tighten the air vent plug. –1–16–

864 Bobcat Loader Service Manual


ENGINE LUBRICATION SYSTEM

A

Checking Engine Oil Check the engine oil level every day. Before starting the engine for the work shift, open the rear door. Remove the dipstick (Item 1) [A].

3

Keep the oil level between the marks on the dipstick. Use a good quality motor oil that meets API Service Classification of CC, CD or CE.

1

RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)

C° –40

–34

–29

–23

–18

–13

–7

–1

+4

+10

+15

+21

+27

+32

+38

+43 +49

SAE 40W or 20W–50 SAE 10W–30 SAE 15W–40 SAE 30W

* SAE 5W–30 SAE 20W–20

2

SAE 10W SYNTHETIC OIL Use recommendation from Synthetic Oil Mfgr.

P–10803 –40 –30

–20

–10

0

+10

+20

+30

+40

+50

+60

+70

+80

+90 +100 +110 +120

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API CLASSIFICATION CD, CF4, CG4 )

B

* Can be used ONLY when available with appropriate diesel rating. Replacing The Oil And Filter See the SERVICE SCHEDULE, Page 1–3 for the service interval for replacing the engine oil and filter.

1

Run the engine until it is at operating temperature. Stop the engine. Open the rear door. Remove the drain plug (Item 2) [A]. Drain the oil into container. P–10801

Remove the oil filter (Item 1) [B]. Clean the filter housing surface. Put clean oil on the new oil filter gasket. Install the filter and hand tighten only. Install and tighten the drain plug. Remove the filler cap (Item 3) [A]. Put 10 qts. (9,5 L) of oil in the engine. Start the engine and let it run for several minutes. Stop the engine. Check for leaks and check the oil level. Add oil as needed if it is not at the top mark on the dipstick.

–1–17–

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death. W–2103–1285

864 Bobcat Loader Service Manual


ENGINE COOLING SYSTEM

A

Cleaning The Cooling System Check the cooling system every day to prevent over–heating, loss of performance or engine damage.

1

Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure. • Flying debris or loose material is present. • Engine is running. • Tools are being used.

P–07614

B

W–2019–1285

Raise the rear grill [A]. Use air pressure or water pressure to clean the top hydraulic/hydrostatic system oil cooler (Item 1) [A].

1 Remove the hair pin (Item 1) [B] (both sides) so the oil cooler can be raised.

P–07618

Raise the oil cooler, use air pressure or water pressure to clean the top of the engine oil cooler (Item 1) [C].

C

1

P–07617

–1–18–

864 Bobcat Loader Service Manual


HYDRAULIC/HYDROSTATIC SYSTEM

A

Checking And Adding Fluid Use only recommended fluid in the hydraulic system. (See SPECIFICATIONS Page 9–1.) To check the reservoir, use the following procedure:

2

Put the Bobcat loader on a level surface. Lower the lift arms and tilt the Bob–Tach fully back. Stop the engine. Remove the dipstick (Item 1) [A].

1 The fluid level must be between the marks on the dipstick [B].

P–07671

B

If fluid is needed, remove the fill cap (Item 2) [A]. Add fluid as needed to bring the level to the top mark on the dipstick [B].

P–07673

Hydraulic/Hydrostatic Filter Replacement

C

See the SERVICE SCHEDULE, Page 1–3 for the correct service interval. Raise the operator cab. (See Page 1–11.) Use a filter wrench to remove the filter element (Item 1) [C]. Clean the surface of the filter housing where the element seal contacts the housing. Put clean oil on the rubber seal of the filter elements.

1

Install and hand tighten the filter elements. N–18289

–1–19–

864 Bobcat Loader Service Manual


HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

A

Replacing The Hydraulic Fluid See the SERVICE SCHEDULE Page1–3 for the correct service interval. Replace the fluid if it becomes contaminated or after major repair. Remove the fill cap. Remove the screen from the reservoir [A]. Wash the screen in clean solvent and air dry. NOTE: Be sure the rubber gasket is installed on the fill cap. Also replace the two hydrostatic motor case drain filters thoroughly after a major repair. Raise the cab. (See Raising the Operator Cab Page 1–11.) Disconnect the hose (Item 1) [B] from the hydraulic fluid reservoir and drain the fluid into a container.

P–07672

B

Replace both hydrostatic motor case drain filters (Item 1) [C] & [D]. Install the case drain filters and tighten all the hoses.

1

Replace the hydraulic/hydrostatic filter element. (See Page 1–18.) Add the correct fluid to the reservoir until the fluid level is between the marks on the dipstick. (See Page 1–18.) DO NOT fill above the top mark on the dipstick. N–18100

C

RIGHT CASE DRAIN FILTER

Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin and cause serious injury and possibly death if proper medical treatment by a physician familiar with this injury is not received immediately. W–2145–0290

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

1 N–18100

W–2103–1285

Lower the cab. (See Lowering The Operator Cab, Page 1–12.)

D

LEFT CASE DRAIN FILTER

Start the engine and operate the loader hydraulic controls. Stop the engine and check for leaks. Check the fluid level in the reservoir and add as needed.

1

N–18099

–1–20–

864 Bobcat Loader Service Manual


LUBRICATING THE LOADER

A

Procedure Lubricate the loader as specified in the SERVICE SCHEDULE Page 1–3 for the best performance of the loader.

1

Record the operating hours each time you lubricate the Bobcat loader. Always use a good quality lithium based multi–purpose grease when you lubricate the loader. Apply the lubricant until extra grease shows. Lubricate the following locations on the loader:

P–07655

1. Rod End Lift Cylinder (Both Sides) [A].

B

2. Base End Lift Cylinder (Both Sides) [B].

2

N–18068

C

3. Lift Arm Pivot Pin (Both Sides) [C].

3

P–07631

D

4. Base End Tilt Cylinder [D].

4

P–07641

–1–21–

864 Bobcat Loader Service Manual


LUBRICATING THE LOADER (Cont’d)

A

Procedure (Cont’d) 5. Rod End Tilt Cylinder [A]. 6. Bob–Tach Pivot Pin (Both Sides) [A]. 7. Bob–Tach Wedge (Both Sides) [A].

5 6

7

N–18266

B

8. 250 Hours: Steering Lever Shaft (2) [B].

8

9. 250 Hours: Centering bracket pivot pin [B].

9

P–13815

–1–22–

864 Bobcat Loader Service Manual


HYDRAULIC SYSTEM Page Number BICS™ VALVE BICS™ Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift Arm By–Pass Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–27 2–25 2–24 2–26 2–28

BUCKET POSITION VALVE Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–91 2–90 2–89 2–89

HYDRAULIC SYSTEM

CONTROL PEDALS Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–76 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–76 CROSSBAR LINKAGE Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–79 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–79 HYDRAULIC CONTROL VALVE Anti–Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti–Cavitation/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Pressure Relief Block (864H) . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Electric Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H Port – Auxiliary Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift Spool And Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rubber Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spool Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tilt Spool And Centering Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–41 2–40 2–32 2–49 2–48 2–38 2–50 2–37 2–50 2–38 2–43 2–38 2–39 2–40 2–33 2–42 2–51 2–47

HYDRAULIC CYLINDER Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift Cylinder Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tilt Cylinder Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–18 2–16 2–14 2–15

HYDRAULIC FLUID RESERVOIR Draining The Hydraulic Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . 2–75 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–75 Continued On Next Page

–2–1–

864 Bobcat Loader Service Manual


HYDRAULIC SYSTEM (Cont’d) PAGE Number HYDRAULIC PUMP Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking The Output Of The Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–60 2–54 2–57 2–59 2–56 2–55

HYDRAULIC PUMP (Double Gear) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking The Output Of The High Flow Pump . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–71 2–62 2–66 2–70 2–65 2–63

HYDRAULIC SYSTEM INFORMATION Glossary Of Hydraulic/Hydrostatic Symbols For Loaders . . . . . . . . . . . . 2–5 HYDRAULIC/HYDROSTATIC FILTER HOUSING Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–74 LIFT ARM BY–PASS CONTROL VALVE Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–52 LIFT ARM BY–PASS CONTROL VALVE MOUNT BRACKET Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–53 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–53 LIFT CYLINDER Checking The Lift Cylinder(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10 MAIN RELIEF VALVE Checking The Main Relief Valve At The Front Auxiliary Hydraulics . . . Checking The Main Relief Valve Without Auxiliaries . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–21 2–22 2–23 2–23

PEDAL INTERLOCK LINKAGE Pedal Interlock Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–77 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–77 REAR AUXILIARY DIVERTER–864 STANDARD FLOW Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–81 2–81 2–81 2–81

Continued On Next Page

–2–2–

864 Bobcat Loader Service Manual


HYDRAULIC SYSTEM (Cont’d) PAGE Number SELECT VALVE 864H Checking The High Flow Pump Relief Valve . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–82 2–84 2–83 2–88

TILT CYLINDER Checking The Tilt Cylinder(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12 Rod End Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13 TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9 TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 9) UNLESS OTHERWISE SPECIFIED.

–2–3–

864 Bobcat Loader Service Manual


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BOBCAT 864 COMPACT TRACK LOADER Service Repair Manual SN 516911001 & Above  
BOBCAT 864 COMPACT TRACK LOADER Service Repair Manual SN 516911001 & Above  
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