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Bobcat T870 Compact Track Loader Service Manual 6987487 - PDF DOWNLOAD

Bobcat T870 Compact Track Loader Service Manual 6987487 – PDF DOWNLOAD

Name: Bobcat T870 Compact Track Loader Service Manual 6987487 - PDF DOWNLOAD
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Bobcat T870 Compact Track Loader Service Manual 6987487 – PDF DOWNLOAD

S/N A3PG11001 & Above
S/N A3PH11001 & Above

Category: Bobcat Tags: BOBCAT T870 COMPACT TRACK LOADER SERVICE, Bobcat T870 Compact Track Loader Service Manual 6987487, Bobcat T870 Compact Track Loader Service Manual 6987487 - PDF DOWNLOAD Vendor: Sensor Docs

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Description

Description

Bobcat T870 Compact Track Loader Service Manual 6987487 – PDF DOWNLOAD

FILE DETAILS:

Bobcat T870 Compact Track Loader Service Manual 6987487 – PDF DOWNLOAD

Language : English
Pages : 1224
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Bobcat T870 Compact Track Loader Service Manual 6987487 – PDF DOWNLOAD

S/N A3PG11001 & Above
S/N A3PH11001 & Above

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:

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

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

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

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

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

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

7. Steering levers, hand controls and foot pedals must return to neutral (as applicable).

8. Check for correct function of the work lights.

9. The parking brake must function correctly.

10. Enclosure door latches must open and close freely.

11. Bob-Tach® attachment mounting system wedges and linkages must function correctly and be in good condition.

12. Safety treads must be in good condition.

13. Check for correct function of indicator lamps.

14. Check all machine fluid levels.

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

SAFETY INSTRUCTIONS:

The following publications provide information on the safe use and maintenance of the Bobcat machine 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 machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.

• Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.

• An Operator’s Handbook fastened to the operator cab. It’s 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 AEM Safety Manual delivered with the machine gives general safety information.

• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.

TABLE OF CONTENTS:

Bobcat T870 Compact Track Loader Service Manual 6987487 – PDF DOWNLOAD

MAINTENANCE SAFETY................................................................................... 3
CONTENTS............................................................................................. 5
FOREWORD............................................................................................. 7
FOREWORD......................................................................................... 9
SAFETY INSTRUCTIONS.............................................................................. 11
FIRE PREVENTION.................................................................................. 13
Maintenance.................................................................................. 13
Operation.................................................................................... 13
Electrical................................................................................... 13
Hydraulic System............................................................................. 13
Fueling...................................................................................... 13
Starting..................................................................................... 13
Spark Arrester Exhaust System................................................................ 13
Welding And Grinding......................................................................... 14
Fire Extinguishers........................................................................... 14
SERIAL NUMBER LOCATIONS.......................................................................... 15
Loader Serial Number......................................................................... 15
Engine Serial Number......................................................................... 15
DELIVERY REPORT.................................................................................. 16
LOADER IDENTIFICATION............................................................................ 17
SAFETY AND MAINTENANCE............................................................................... 19
LIFTING AND BLOCKING THE LOADER.................................................................. 23
Procedure.................................................................................... 23
LIFT ARM SUPPORT DEVICE.......................................................................... 25
Installing................................................................................... 25
Removing..................................................................................... 26
OPERATOR CAB..................................................................................... 27
Description.................................................................................. 27
Raising...................................................................................... 28
Lowering..................................................................................... 29
Cab Door Sensor.............................................................................. 30
Special Applications Kit..................................................................... 31
Special Applications Kit Inspection And Maintenance.......................................... 31
Forestry Door And Window Kit................................................................. 32
Forestry Door And Window Kit Inspection And Maintenance...................................... 32
TRANSPORTING THE LOADER ON A TRAILER............................................................. 33
Loading And Unloading........................................................................ 33
Fastening.................................................................................... 33
TOWING THE LOADER................................................................................ 35
Procedure.................................................................................... 35
REMOTE START TOOL KIT - MEL1563.................................................................. 37
Remote Start Tool - MEL1563.................................................................. 37
Service Tool Harness Communicator - MEL1566.................................................. 39
Remote Start Procedure....................................................................... 39
REMOTE START TOOL (SERVICE TOOL) KIT - 7217666................................................... 43
Description.................................................................................. 43
Remote Start Tool (Service Tool) - 7022042................................................... 44
Loader Service Tool Harness - 6689747........................................................ 45
Computer Service Tool Harness - 6689746...................................................... 46
Remote Start Procedure....................................................................... 47
SERVICE SCHEDULE................................................................................. 51
Maintenance Intervals........................................................................ 51
AIR CLEANER SERVICE.............................................................................. 53
Replacing Filter Elements.................................................................... 53
ENGINE COOLING SYSTEM............................................................................ 55
Maintenance Platform......................................................................... 55
Cooling System Identification................................................................ 55
Cleaning (Earlier Models).................................................................... 56
Cleaning (Later Models)...................................................................... 58
Checking Level............................................................................... 60
Removing And Replacing Coolant............................................................... 60
FUEL SYSTEM...................................................................................... 61
Fuel Specifications.......................................................................... 61
Biodiesel Blend Fuel......................................................................... 61
Filling The Fuel Tank........................................................................ 62
Fuel Filter.................................................................................. 63
Removing Air From The Fuel System............................................................ 63
ENGINE LUBRICATION SYSTEM........................................................................ 65
Checking And Adding Engine Oil............................................................... 65
Engine Oil Chart............................................................................. 65
Removing And Replacing Oil And Filter........................................................ 66
HYDRAULIC / HYDROSTATIC SYSTEM................................................................... 67
Checking And Adding Fluid.................................................................... 67
Hydraulic / Hydrostatic Fluid Chart.......................................................... 67
Removing And Replacing Hydraulic Fluid....................................................... 68
Hydraulic / Hydrostatic Filter Identification................................................ 70
Removing And Replacing Hydraulic / Hydrostatic Filter (Earlier Models)....................... 71
Removing And Replacing Hydraulic / Hydrostatic Filter (Later Models)......................... 72
Removing And Replacing Hydraulic Charge Filter............................................... 73
Breather Cap................................................................................. 75
BOB-TACH (HAND LEVER)............................................................................ 77
Inspection And Maintenance................................................................... 77
BOB-TACH (POWER)................................................................................. 79
Inspection And Maintenance................................................................... 79
LUBRICATING THE LOADER........................................................................... 81
Lubrication Locations........................................................................ 81
SPARK ARRESTER MUFFLER........................................................................... 85
Cleaning Procedure........................................................................... 85
PIVOT PINS....................................................................................... 87
Inspection And Maintenance................................................................... 87
LOADER STORAGE AND RETURN TO SERVICE............................................................. 89
Storage...................................................................................... 89
Return To Service............................................................................ 89
STOPPING THE ENGINE AND LEAVING THE LOADER....................................................... 91
Procedure.................................................................................... 91
EMERGENCY EXIT................................................................................... 93
Rear Window Identification................................................................... 93
Rear Window Removal (Latches)................................................................ 93
Rear Window Removal (Rubber Cord)............................................................ 94
External Access (Rear Window With Latches)................................................... 94
External Access (Rear Window With Rubber Cord)............................................... 95
Front Door................................................................................... 95
SEAT BELT........................................................................................ 97
Inspection And Maintenance................................................................... 97
HYDRAULIC SYSTEM..................................................................................... 99
HYDRAULIC / HYDROSTATIC SCHEMATICS............................................................... 107
HYDRAULIC SYSTEM INFORMATION..................................................................... 119
Glossary Of Hydraulic / Hydrostatic Symbols.................................................. 119
Troubleshooting.............................................................................. 123
CYLINDER (LIFT).................................................................................. 125
Testing...................................................................................... 125
Removal And Installation..................................................................... 126
Parts Identification (Earlier Models)........................................................ 130
Parts Identification (Later Models).......................................................... 131
Disassembly.................................................................................. 132
Assembly..................................................................................... 134
CYLINDER (TILT).................................................................................. 137
Testing...................................................................................... 137
Removal And Installation..................................................................... 138
Base End Pivot Pin Removal And Installation.................................................. 140
Parts Identification (Earlier Models)........................................................ 141
Parts Identification (Later Models).......................................................... 142
Disassembly.................................................................................. 143
Assembly..................................................................................... 146
CYLINDER (BOB-TACH).............................................................................. 151
Testing...................................................................................... 151
Removal And Installation..................................................................... 152
Parts Identification......................................................................... 153
Disassembly.................................................................................. 154
Assembly..................................................................................... 155
MAIN RELIEF VALVE (S/N A3PG11001 - A3PG12799 AND S/N A3PH11001 - A3PH12325)...................... 159
Description.................................................................................. 159
Testing...................................................................................... 160
Adjusting.................................................................................... 162
Removal And Installation..................................................................... 162
MAIN RELIEF VALVE (S/N A3PG12800 & ABOVE AND S/N A3PH12326 & ABOVE).............................. 165
Description.................................................................................. 165
Testing...................................................................................... 165
Main Relief Valve Adjustment................................................................. 168
Main Relief Valve Removal And Installation................................................... 168
Auxiliary Relief Valve Adjustment............................................................ 169
Auxiliary Relief Valve Removal And Installation.............................................. 170
HYDRAULIC CONTROL VALVE (SJC) (S/N A3PG11001 - A3PG12799 AND S/N A3PH11001 - A3PH12325).......... 171
Description.................................................................................. 171
Removal And Installation..................................................................... 172
Actuator Removal And Installation (In Loader)................................................ 176
Actuator Removal And Installation (Out Of Loader)............................................ 178
Identification Chart......................................................................... 181
Mount Bracket Removal And Installation....................................................... 182
Lift Load Check Valve Removal And Installation............................................... 182
Load Check Valve Removal And Installation (Tilt And Auxiliary)............................... 183
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)............................... 184
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................ 184
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................ 185
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)................. 185
Port Relief Valve Removal And Installation................................................... 186
Plug Removal And Installation................................................................ 187
End Cap Block Removal And Installation....................................................... 188
Lift Spool Removal And Installation.......................................................... 188
Lift Spool Disassembly And Assembly.......................................................... 190
Tilt Spool Removal And Installation.......................................................... 192
Auxiliary Spool Removal And Installation..................................................... 194
Auxiliary Solenoid Removal And Installation.................................................. 195
Solenoid Removal And Installation............................................................ 196
Lock Valve Removal And Installation.......................................................... 197
Lift Arm Bypass Orifice Removal And Installation............................................. 198
Main Relief Valve Removal And Installation................................................... 198
Check Valve Removal And Installation......................................................... 199
HYDRAULIC CONTROL VALVE (SJC) (S/N A3PG12800 & ABOVE AND S/N A3PH12326 & ABOVE).................. 201
Description.................................................................................. 201
Removal And Installation..................................................................... 202
Actuator Removal And Installation (In Loader)................................................ 206
Actuator Removal And Installation (Out Of Loader)............................................ 207
Identification Chart......................................................................... 210
Mount Bracket Removal And Installation....................................................... 211
Lift Load Check Valve Removal And Installation............................................... 211
Load Check Valve Removal And Installation (Tilt And Auxiliary)............................... 212
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)............................... 213
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................ 213
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................ 214
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)................. 214
Port Relief Valve Removal And Installation................................................... 215
Plug Removal And Installation................................................................ 217
End Cap Block Removal And Installation....................................................... 218
Lift Spool Removal And Installation.......................................................... 218
Lift Spool Disassembly And Assembly.......................................................... 220
Tilt Spool Removal And Installation.......................................................... 221
Auxiliary Spool Removal And Installation..................................................... 223
Auxiliary Solenoid Removal And Installation.................................................. 224
Solenoid Removal And Installation............................................................ 225
Lock Valve Removal And Installation.......................................................... 226
Lift Arm Bypass Orifice Removal And Installation............................................. 228
Main Relief Valve Removal And Installation................................................... 228
Auxiliary Relief Valve Removal And Installation.............................................. 229
Check Valve Removal And Installation......................................................... 229
HYDRAULIC CONTROL VALVE (SCPA) (S/N A3PG11001 - A3PG12799 AND S/N A3PH11001 - A3PH12325)......... 231
Description.................................................................................. 231
Removal And Installation..................................................................... 232
Mount Bracket Removal And Installation....................................................... 236
Identification Chart......................................................................... 237
Lift Load Check Valve Removal And Installation............................................... 238
Load Check Valve Removal And Installation (Tilt And Auxiliary)............................... 239
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)............................... 240
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................ 240
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................ 241
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)................. 241
Port Relief Valve Removal And Installation................................................... 242
Plug Removal And Installation................................................................ 243
Rubber Boot Removal And Installation......................................................... 244
End Cap Block Removal And Installation....................................................... 245
Lift Spool And Detent Removal And Installation............................................... 246
Tilt Spool Removal And Installation.......................................................... 256
Auxiliary Spool Removal And Installation..................................................... 258
Auxiliary Solenoid Removal And Installation.................................................. 260
Solenoid Removal And Installation............................................................ 261
Lock Valve Removal And Installation.......................................................... 262
Lift Arm Bypass Orifice Removal And Installation............................................. 264
Main Relief Valve Removal And Installation................................................... 264
Check Valve Removal And Installation......................................................... 265
HYDRAULIC CONTROL VALVE (SCPA) (S/N A3PG12800 & ABOVE AND S/N A3PH12326 & ABOVE)................. 267
Description.................................................................................. 267
Removal And Installation..................................................................... 268
Mount Bracket Removal And Installation....................................................... 271
Identification Chart......................................................................... 272
Lift Load Check Valve Removal And Installation............................................... 273
Load Check Valve Removal And Installation (Tilt And Auxiliary)............................... 274
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)............................... 275
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................ 275
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................ 276
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)................. 276
Port Relief Valve Removal And Installation................................................... 277
Plug Removal And Installation................................................................ 279
Rubber Boot Removal And Installation......................................................... 280
End Cap Block Removal And Installation....................................................... 280
Lift Spool And Detent Removal And Installation............................................... 281
Tilt Spool Removal And Installation.......................................................... 289
Auxiliary Spool Removal And Installation..................................................... 291
Auxiliary Solenoid Removal And Installation.................................................. 292
Solenoid Removal And Installation............................................................ 292
Lock Valve Removal And Installation.......................................................... 294
Lift Arm Bypass Orifice Removal And Installation............................................. 296
Main Relief Valve Removal And Installation................................................... 296
Auxiliary Relief Valve Removal And Installation.............................................. 297
Check Valve Removal And Installation......................................................... 297
LIFT ARM BYPASS CONTROL VALVE.................................................................... 299
Description.................................................................................. 299
Testing...................................................................................... 299
Removal And Installation..................................................................... 300
Bracket Removal And Installation............................................................. 301
Disassembly And Assembly..................................................................... 301
HYDRAULIC PUMP................................................................................... 303
Description.................................................................................. 303
Pump Test At Quick Couplers.................................................................. 303
Direct Pump Test (Standard Section).......................................................... 304
Direct Pump Test (Charge Section)............................................................ 306
Removal And Installation..................................................................... 308
Hydraulic Pump Startup....................................................................... 311
Parts Identification......................................................................... 312
Disassembly And Assembly..................................................................... 313
HYDRAULIC PUMP (HIGH FLOW)....................................................................... 315
Description.................................................................................. 315
Pump Test At Quick Couplers.................................................................. 315
Direct Pump Test (Standard Section).......................................................... 316
Direct Pump Test (Charge Section)............................................................ 317
Direct Pump Test (High Flow Section)......................................................... 319
High Flow Relief Valve Adjustment............................................................ 321
High Flow Relief Valve Removal And Installation.............................................. 322
Solenoid Removal And Installation............................................................ 323
Removal And Installation..................................................................... 324
Hydraulic Pump Startup....................................................................... 327
Parts Identification......................................................................... 328
Disassembly And Assembly..................................................................... 329
HYDRAULIC / HYDROSTATIC FILTERS (EARLIER MODELS)................................................. 331
Description.................................................................................. 331
Housing Removal And Installation............................................................. 331
HYDRAULIC / HYDROSTATIC FILTERS (LATER MODELS)................................................... 333
Description.................................................................................. 333
Housing Removal And Installation............................................................. 333
HYDRAULIC FLUID RESERVOIR (EARLIER MODELS)....................................................... 335
Description.................................................................................. 335
Removal And Installation..................................................................... 335
Hydraulic Fluid Screen....................................................................... 336
HYDRAULIC FLUID RESERVOIR (LATER MODELS)......................................................... 337
Description.................................................................................. 337
Removal And Installation..................................................................... 337
Hydraulic Fluid Screen....................................................................... 338
OIL COOLER (EARLIER MODELS)...................................................................... 339
Description.................................................................................. 339
Removal And Installation..................................................................... 339
OIL COOLER (LATER MODELS)........................................................................ 341
Removal And Installation..................................................................... 341
BUCKET POSITION VALVE............................................................................ 343
Description.................................................................................. 343
Solenoid Removal And Installation............................................................ 343
Solenoid Testing............................................................................. 344
Removal And Installation..................................................................... 345
Disassembly And Assembly..................................................................... 347
REAR AUXILIARY DIVERTER VALVE.................................................................... 349
Description.................................................................................. 349
Solenoid Testing............................................................................. 349
Removal And Installation..................................................................... 350
Disassembly And Assembly..................................................................... 351
BOB-TACH (POWER) BLOCK (EARLIER MODELS).......................................................... 357
Description.................................................................................. 357
Removal And Installation..................................................................... 357
Disassembly And Assembly..................................................................... 359
BOB-TACH (POWER) BLOCK (LATER MODELS)............................................................ 369
Description.................................................................................. 369
Testing Relief Valve......................................................................... 370
Removal And Installation..................................................................... 371
Disassembly And Assembly..................................................................... 373
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK.......................................................... 379
Description.................................................................................. 379
Removal And Installation..................................................................... 380
Disassembly And Assembly (FFI/FI)............................................................ 380
Disassembly And Assembly (FFH/FH)............................................................ 382
AUTOMATIC RIDE CONTROL........................................................................... 385
Description.................................................................................. 385
Removal And Installation..................................................................... 386
Checking The Pressure In The Accumulator..................................................... 389
Adding Nitrogen To The Accumulator........................................................... 391
HYDROSTATIC SYSTEM................................................................................... 393
HYDROSTATIC SYSTEM INFORMATION................................................................... 395
Description.................................................................................. 395
Troubleshooting.............................................................................. 396
HYDROSTATIC DRIVE MOTOR.......................................................................... 397
Description.................................................................................. 397
Removing And Replacing Oil................................................................... 397
Removal And Installation..................................................................... 398
Parts Identification......................................................................... 400
Disassembly And Assembly..................................................................... 402
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3PG11001 - A3PG12799 AND S/N A3PH11001 - A3PH12325).... 415
Description.................................................................................. 415
Removing And Replacing Oil................................................................... 415
Removal And Installation..................................................................... 416
Parts Identification......................................................................... 418
Disassembly And Assembly..................................................................... 420
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3PG12800 & ABOVE AND S/N A3PH12326 & ABOVE)............ 433
Description.................................................................................. 433
Removing And Replacing Oil................................................................... 433
Removal And Installation..................................................................... 434
Parts Identification......................................................................... 436
Disassembly And Assembly..................................................................... 438
CHARGE PRESSURE (EARLIER MODELS)................................................................. 451
Description.................................................................................. 451
Testing...................................................................................... 451
Sender Removal And Installation.............................................................. 453
Adjusting.................................................................................... 454
CHARGE PRESSURE (LATER MODELS)................................................................... 455
Description.................................................................................. 455
Testing...................................................................................... 455
Sender Removal And Installation.............................................................. 457
Adjusting.................................................................................... 458
HYDROSTATIC PUMP (SJC AND SCPA).................................................................. 459
Description.................................................................................. 459
Hydraulic Controller Removal And Installation................................................ 460
Removal And Installation..................................................................... 462
Hydrostatic Pump Startup..................................................................... 463
Parts Identification......................................................................... 464
High Pressure Relief And Bypass Valve........................................................ 465
Charge Relief Valve.......................................................................... 466
Disassembly.................................................................................. 467
Inspection................................................................................... 476
Assembly..................................................................................... 479
Mechanical Neutral Adjustment................................................................ 489
Hydraulic Controller Neutral Adjustment...................................................... 492
DRIVE BELT....................................................................................... 495
Belt Adjustment.............................................................................. 495
Stop Adjustment.............................................................................. 495
Belt Replacement............................................................................. 495
Tensioner Pulley Removal And Installation.................................................... 498
Tensioner Pulley Disassembly And Assembly.................................................... 498
TWO-SPEED / BRAKE VALVE (S/N A3PG11001 - A3PG12799 AND S/N A3PH11001 - A3PH12325)................ 501
Description.................................................................................. 501
Valve Block Removal And Installation......................................................... 502
Valve Block Disassembly And Assembly......................................................... 504
TWO-SPEED / BRAKE VALVE (S/N A3PG12800 & ABOVE AND S/N A3PH12326 & ABOVE)........................ 507
Description.................................................................................. 507
Valve Block Removal And Installation......................................................... 508
Valve Block Disassembly And Assembly......................................................... 510
DRAIN MANIFOLD................................................................................... 513
Description.................................................................................. 513
Drain Manifold Removal And Installation...................................................... 513
DRIVE SYSTEM......................................................................................... 515
BRAKE............................................................................................ 517
Description.................................................................................. 517
Block Removal And Installation............................................................... 517
Block Disassembly And Assembly............................................................... 519
TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION)............................................... 521
Description.................................................................................. 521
Checking Tension............................................................................. 523
Adjusting Tension (Earlier Models With Two Track Tension Fittings)........................... 524
Adjusting Tension (Later Models With One Track Tension Fitting).............................. 525
Track Removal And Installation............................................................... 527
Idler (Front) Removal And Installation....................................................... 529
Track Tensioner Disassembly And Assembly..................................................... 532
Idler (Rear) Removal And Installation........................................................ 534
Roller Removal And Installation.............................................................. 534
Leaf Spring Removal And Installation......................................................... 535
Sprocket Removal And Installation (Single Speed)............................................. 536
Sprocket Removal And Installation (Two-Speed)................................................ 536
Track Housing Removal And Installation....................................................... 537
TRACK MAINTENANCE................................................................................ 539
Track Damage Identification.................................................................. 539
MAINFRAME............................................................................................ 551
SEAT BAR......................................................................................... 555
Description.................................................................................. 555
Removal And Installation..................................................................... 555
Disassembly And Assembly..................................................................... 556
Compression Spring Disassembly And Assembly.................................................. 557
OPERATOR CAB..................................................................................... 559
Gas Spring Removal And Installation.......................................................... 559
Gas Spring Bracket Disassembly And Assembly.................................................. 560
Removal And Installation..................................................................... 560
OPERATOR SEAT (SUSPENSION)....................................................................... 563
Removal And Installation..................................................................... 563
Slide Rail Removal And Installation.......................................................... 563
Seat Belt Removal And Installation........................................................... 564
Lower Cushion Removal........................................................................ 564
Lower Cushion Installation................................................................... 565
Back Cushion Removal And Installation........................................................ 565
Shock Removal And Installation............................................................... 566
3-Point Seat Belt Removal And Installation................................................... 566
BOB-TACH (HAND LEVER)............................................................................ 569
Description.................................................................................. 569
Removal And Installation..................................................................... 569
Lever And Wedge Disassembly And Assembly..................................................... 571
Pivot Pin Bushing And Seal Removal And Installation.......................................... 573
BOB-TACH (POWER)................................................................................. 575
Description.................................................................................. 575
Removal And Installation..................................................................... 575
Lever And Wedge Disassembly And Assembly..................................................... 578
Pivot Pin Bushing And Seal Removal And Installation.......................................... 580
LIFT ARMS........................................................................................ 581
Stabilizer Bar Removal And Installation...................................................... 581
Link Removal And Installation................................................................ 582
Removal And Installation..................................................................... 583
REAR GRILLE...................................................................................... 587
Removing..................................................................................... 587
Installing................................................................................... 587
Shield Removal And Installation.............................................................. 588
REAR DOOR (TAILGATE)............................................................................. 589
Removal And Installation..................................................................... 589
Striker Removal And Installation............................................................. 590
Striker Disassembly And Assembly............................................................. 590
Striker (Adjusting).......................................................................... 590
Latch Removal And Installation (Earlier Models).............................................. 591
Latch Removal And Installation (Later Models)................................................ 592
FUEL TANK........................................................................................ 593
Removal And Installation..................................................................... 593
Fuel Level Sender Removal And Installation................................................... 594
Fuel Fill Screen Removal And Installation.................................................... 595
FUEL TANK (AUXILIARY)............................................................................ 597
Removal And Installation..................................................................... 597
CONTROL PEDALS AND LINKAGES (SCPA)............................................................... 599
Description.................................................................................. 599
Pedal Removal And Installation............................................................... 599
Linkage Removal And Installation............................................................. 600
Pedal (Adjusting)............................................................................ 601
Floor Pan Removal And Installation........................................................... 602
CONTROL PANEL (SJC).............................................................................. 603
Description.................................................................................. 603
Removal And Installation..................................................................... 603
CONTROL PANEL (SCPA)............................................................................. 605
Description.................................................................................. 605
Removal And Installation..................................................................... 605
CONTROL HANDLE / LEVER (SJC)..................................................................... 607
Description.................................................................................. 607
Joystick Testing............................................................................. 607
Joystick Removal And Installation............................................................ 608
CONTROL HANDLE / LEVER (SCPA).................................................................... 609
Description.................................................................................. 609
Steering Handle Testing...................................................................... 609
Steering Handle Removal And Installation..................................................... 610
ACCESS PANEL (INSIDE)............................................................................ 611
Removal And Installation (Left).............................................................. 611
Removal And Installation (Right)............................................................. 611
ACCESS PANEL (INSIDE) (SJC)...................................................................... 613
Removal And Installation (Left).............................................................. 613
Removal And Installation (Right)............................................................. 613
WINDOW (REAR).................................................................................... 615
Rear Window Identification................................................................... 615
Removal (Rubber Cord)........................................................................ 615
Installation (Rubber Cord)................................................................... 616
Removal And Installation (Latches)........................................................... 618
Disassembly And Assembly (Latches)........................................................... 618
WINDOW (TOP)..................................................................................... 619
Removal And Installation..................................................................... 619
WINDOW (SIDE).................................................................................... 621
Removal And Installation..................................................................... 621
CAB DOOR......................................................................................... 623
Description.................................................................................. 623
Removal And Installation..................................................................... 623
Disassembly And Assembly..................................................................... 624
Aligning..................................................................................... 625
Adjusting.................................................................................... 626
Checking Operation........................................................................... 626
ARMREST.......................................................................................... 627
Description.................................................................................. 627
Removal And Installation..................................................................... 628
Disassembly And Assembly..................................................................... 629
LEFT SIDE LOWER PANEL............................................................................ 633
Removal And Installation..................................................................... 633
Disassembly And Assembly..................................................................... 635
RIGHT SIDE LOWER PANEL........................................................................... 637
Removal And Installation..................................................................... 637
Disassembly And Assembly..................................................................... 638
HEADLINER........................................................................................ 641
Removal And Installation..................................................................... 641
ELECTRICAL SYSTEM AND ANALYSIS....................................................................... 643
ELECTRICAL SCHEMATICS............................................................................ 649
ELECTRICAL SYSTEM INFORMATION.................................................................... 811
Glossary Of Electrical Symbols............................................................... 811
Deluxe Cab Harness Connectors (Earlier Models)............................................... 814
Deluxe Cab Harness Connectors (Later Models)................................................. 815
Mainframe Harness Connectors (Earlier Models)................................................ 816
SJC Mainframe Harness Connectors (Later Models).............................................. 817
SCPA Mainframe Harness Connectors (Later Models)............................................. 818
Description.................................................................................. 819
Troubleshooting.............................................................................. 820
Fuse And Relay Location / Identification..................................................... 821
Solenoid Testing............................................................................. 825
BATTERY.......................................................................................... 827
Removal And Installation..................................................................... 827
Servicing.................................................................................... 828
Using A Booster Battery (Jump Starting)...................................................... 829
ALTERNATOR....................................................................................... 831
Belt Adjustment.............................................................................. 831
Belt Replacement............................................................................. 831
Charging System Inspection................................................................... 832
Alternator Voltage Testing................................................................... 833
Low Voltage Testing.......................................................................... 833
High Voltage Testing......................................................................... 834
Removal And Installation..................................................................... 835
Parts Identification......................................................................... 836
STARTER.......................................................................................... 837
Testing...................................................................................... 837
Removal And Installation..................................................................... 837
Parts Identification......................................................................... 838
INSTRUMENT PANELS................................................................................ 839
Left Panel (Earlier Models).................................................................. 839
Left Panel (Later Models).................................................................... 841
Display Screen............................................................................... 843
Right Panel (Standard Key Panel)............................................................. 844
Right Panel (Keyless Start Panel)............................................................ 845
Right Panel (Deluxe Instrumentation Panel)................................................... 846
Left Switch Panel............................................................................ 848
Right Switch Panel........................................................................... 848
Left Side Lower Panel........................................................................ 849
Right Side Lower Panel....................................................................... 849
Left Panel Removal And Installation.......................................................... 850
Right Panel Removal And Installation......................................................... 850
Key Switch Disassembly And Assembly.......................................................... 851
Alarm Disassembly And Assembly............................................................... 851
Left Switch Panel Removal And Installation................................................... 852
Right Switch Panel Removal And Installation.................................................. 852
LIGHTS........................................................................................... 853
Front Removal And Installation............................................................... 853
Rear Removal And Installation................................................................ 854
Cab Light Removal And Installation (Earlier Models).......................................... 854
Cab Light Removal And Installation (Later Models)............................................ 855
BOBCAT CONTOLERS (GATEWAY AND AUXILLIARY)........................................................ 857
Description.................................................................................. 857
Connector Identification..................................................................... 858
Removal And Installation (Earlier Models).................................................... 864
Removal And Installation (Later Models)...................................................... 865
BOBCAT CONTROLLER (ACS).......................................................................... 867
Description.................................................................................. 867
Connector And Wire Identification............................................................ 868
Removal And Installation..................................................................... 870
BOBCAT CONTROLLER (SJC) (DRIVE).................................................................. 871
Description.................................................................................. 871
Connector Identification (Earlier Models).................................................... 872
Removal And Installation (Earlier Models).................................................... 874
Connector Identification (Later Models)...................................................... 876
Removal And Installation (Later Models)...................................................... 879
BOBCAT CONTROLLER (SCPA) (DRIVE)................................................................. 881
Description.................................................................................. 881
Connector Identification (Earlier Models).................................................... 882
Removal And Installation (Earlier Models).................................................... 884
Connector Identification (Later Models)...................................................... 886
Removal And Installation (Later Models)...................................................... 889
SPEED SENSORS (SJC AND SCPA)..................................................................... 891
Description.................................................................................. 891
Testing...................................................................................... 891
Removal And Installation..................................................................... 892
DIAGNOSTIC SERVICE CODES......................................................................... 895
Viewing Service Codes........................................................................ 895
Service Codes List........................................................................... 896
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™).......................................................... 903
Description.................................................................................. 903
Inspecting The BICS™ (Engine STOPPED - Key ON)............................................... 904
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)......... 904
Inspecting The Seat Bar Sensor (Engine RUNNING).............................................. 904
Inspecting The Traction Lock And Parking Brake (Engine RUNNING).............................. 904
Inspecting The Lift Arm Bypass Control....................................................... 904
Inspecting Deactivation Of Lift And Tilt Functions (SJC)..................................... 904
Troubleshooting.............................................................................. 905
SEAT BAR SENSOR.................................................................................. 907
Description.................................................................................. 907
Troubleshooting.............................................................................. 907
Testing...................................................................................... 908
Removal And Installation..................................................................... 909
Bobcat Interlock Control System (BICS™) Circuit Test......................................... 912
TRACTION LOCK.................................................................................... 915
Description.................................................................................. 915
Troubleshooting.............................................................................. 916
Inspecting................................................................................... 917
ELECTRICAL / HYDRAULIC CONTROLS (SJC)............................................................ 919
Identification Chart......................................................................... 919
Description.................................................................................. 920
Identification Chart ACD Group 0............................................................. 921
Identification Chart ACD Group 1............................................................. 922
Identification Chart ACD Group 2............................................................. 923
Identification Chart ACD Group 3............................................................. 924
ELECTRICAL / HYDRAULIC CONTROLS (SCPA)........................................................... 925
Identification Chart......................................................................... 925
Description.................................................................................. 926
Identification Chart ACD Group 0............................................................. 927
Identification Chart ACD Group 1............................................................. 928
Identification Chart ACD Group 2............................................................. 929
Identification Chart ACD Group 3............................................................. 930
SERVICE PC (LAPTOP COMPUTER)..................................................................... 931
Connecting Remote Start Tool................................................................. 931
Connecting Remote Start Tool (Service Tool).................................................. 931
CALIBRATION...................................................................................... 933
Description.................................................................................. 933
Actuator Testing............................................................................. 933
Lift And Tilt Calibration (SJC).............................................................. 936
Hydrostatic Pump Calibration (SJC)........................................................... 937
Hydrostatic Pump Calibration (SCPA).......................................................... 943
STEERING DRIFT COMPENSATION (OPERATOR MODE)...................................................... 949
Description.................................................................................. 949
Operation.................................................................................... 949
STEERING DRIFT COMPENSATION (SERVICE MODE)....................................................... 951
Description.................................................................................. 951
Operation.................................................................................... 951
FLYWHEEL RPM SENSOR.............................................................................. 953
Description.................................................................................. 953
Removal...................................................................................... 953
Installation................................................................................. 954
CONTROL PANEL SETUP.............................................................................. 955
Right Panel Setup (Deluxe Instrumentation Panel)............................................. 955
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL).................................................... 959
Password Description......................................................................... 959
Changing The Owner Password.................................................................. 959
Changing The User Passwords.................................................................. 960
Password Lockout Feature..................................................................... 960
PASSWORD SETUP (KEYLESS START PANEL)............................................................. 961
Password Description......................................................................... 961
Changing The Owner Password.................................................................. 961
Password Lockout Feature..................................................................... 961
MAINTENANCE CLOCK................................................................................ 963
Description.................................................................................. 963
Setup........................................................................................ 964
Reset........................................................................................ 967
BACK-UP ALARM SYSTEM............................................................................. 969
Description.................................................................................. 969
Inspecting................................................................................... 969
Troubleshooting (Joystick)................................................................... 970
Alarm Removal And Installation............................................................... 971
FRONT HORN....................................................................................... 973
Removal And Installation..................................................................... 973
Troubleshooting.............................................................................. 974
Troubleshooting (Joystick)................................................................... 975
ENGINE SERVICE....................................................................................... 977
ENGINE INFORMATION............................................................................... 981
Description.................................................................................. 981
Specifications............................................................................... 982
Torque Values................................................................................ 985
Troubleshooting.............................................................................. 985
Engine Removal And Installation.............................................................. 987
Engine Mount Replacement..................................................................... 994
Compression - Checking....................................................................... 995
ENGINE SPEED CONTROL (HAND)...................................................................... 997
Removal And Installation..................................................................... 997
Disassembly And Assembly..................................................................... 997
Cable Removal And Installation............................................................... 998
ENGINE SPEED CONTROL (FOOT)...................................................................... 999
Removal And Installation (Earlier Models).................................................... 999
Disassembly And Assembly (Earlier Models)....................................................1000
Removal And Installation (Later Models)......................................................1002
Disassembly And Assembly (Later Models)......................................................1003
MUFFLER..........................................................................................1005
Removal And Installation.....................................................................1005
AIR CLEANER......................................................................................1007
Housing Removal And Installation (Earlier Models)............................................1007
Housing Removal And Installation (Later Models)..............................................1007
ENGINE COOLING SYSTEM (EARLIER MODELS)...........................................................1009
Radiator Removal And Installation............................................................1009
Hydraulic Fan Description....................................................................1011
Lower Fan Duct Removal And Installation......................................................1012
Hydraulic Fan Motor Assembly Removal And Installation........................................1012
Fan Removal And Installation.................................................................1013
Hydraulic Fan Motor Removal And Installation.................................................1013
Hydraulic Fan Disassembly And Assembly.......................................................1014
Blower Housing Removal And Installation......................................................1016
Water Pump Removal And Installation..........................................................1017
Water Pump Disassembly And Assembly..........................................................1017
Thermostat Housing Removal And Installation..................................................1018
Thermostat - Checking........................................................................1018
ENGINE COOLING SYSTEM (LATER MODELS).............................................................1019
Radiator / Oil Cooler Removal And Installation...............................................1019
Hydraulic Fan Description....................................................................1021
Hydraulic Reversing Fan Description..........................................................1021
Lower Fan Duct Removal And Installation......................................................1021
Hydraulic Fan Motor Assembly Removal And Installation........................................1022
Hydraulic Fan Motor Removal And Installation.................................................1024
Hydraulic Fan Motor Disassembly And Assembly.................................................1025
Blower Housing Removal And Installation......................................................1033
Water Pump Removal And Installation..........................................................1034
Water Pump Disassembly And Assembly..........................................................1034
Thermostat Housing Removal And Installation..................................................1035
Thermostat - Checking........................................................................1035
LUBRICATION SYSTEM...............................................................................1037
Oil Pan Removal And Installation.............................................................1037
Oil Pump Removal And Installation............................................................1038
Oil Pump Inspection..........................................................................1038
Oil Filter Cooler Removal And Installation...................................................1040
Engine Oil Pressure - Testing................................................................1041
FUEL SYSTEM......................................................................................1043
Fuel Shutoff Solenoid - Checking.............................................................1043
Fuel Shutoff Solenoid Removal And Installation...............................................1043
Fuel Injection Pump Assembly Removal.........................................................1044
Fuel Injection Pump Assembly Installation....................................................1048
Governor Housing Disassembly And Assembly....................................................1050
Governor Disassembly And Assembly............................................................1052
Fuel Camshaft Removal And Installation.......................................................1054
Fuel Injection Pump Removal..................................................................1056
Fuel Injection Pump Installation.............................................................1059
Injection Pump - Timing......................................................................1062
Fuel Injector Removal And Installation.......................................................1066
Fuel Injector Nozzle Pressure - Checking.....................................................1067
Nozzle Spraying Condition....................................................................1068
Valve Seat Tightness.........................................................................1068
CYLINDER HEAD....................................................................................1069
Intake Air Heater - Testing..................................................................1069
Intake Air Heater Removal And Installation...................................................1069
Valve Clearance Adjustment...................................................................1070
Valve Timing - Checking......................................................................1072
Cylinder Head Removal And Installation.......................................................1073
Cylinder Head Disassembly And Assembly.......................................................1075
Cylinder Head - Servicing....................................................................1076
Cylinder Head Top Clearance..................................................................1076
Valve Guide - Checking.......................................................................1077
Reconditioning The Valve And Valve Seat......................................................1079
Valve Spring.................................................................................1081
Valve Tappets................................................................................1082
Rocker Arm And Shaft - Checking..............................................................1083
Push Rod Alignment - Checking................................................................1083
CRANKSHAFT AND PISTONS...........................................................................1085
Piston And Connecting Rod Removal And Installation...........................................1085
Piston And Connecting Rod - Servicing........................................................1087
Cylinder Bore - Checking.....................................................................1091
Connecting Rod Alignment.....................................................................1092
Crankshaft Gear Removal And Installation.....................................................1092
Crankshaft And Bearings Removal..............................................................1093
Crankshaft And Bearings Installation.........................................................1095
Crankshaft And Bearings - Servicing..........................................................1097
CAMSHAFT AND TIMING GEARS........................................................................1103
Timing Gearcase Cover Removal And Installation...............................................1103
Timing Gears Backlash - Checking.............................................................1104
Idler Gear And Camshaft Removal And Installation.............................................1104
Camshaft - Servicing.........................................................................1105
Idler Gear And Shaft - Servicing.............................................................1107
TURBOCHARGER.....................................................................................1109
Description..................................................................................1109
Testing......................................................................................1109
Removal And Installation.....................................................................1110
FLYWHEEL AND HOUSING.............................................................................1113
Flywheel Removal And Installation............................................................1113
Ring Gear Removal And Installation...........................................................1113
Housing Removal And Installation.............................................................1114
EXHAUST GAS RECIRCULATION (EGR) SYSTEM...........................................................1115
Description..................................................................................1115
Testing......................................................................................1116
Removal And Installation.....................................................................1119
HEATING, VENTILATION AND AIR CONDITIONING (HVAC).....................................................1121
AIR CONDITIONING SYSTEM FLOW.....................................................................1123
Description..................................................................................1123
AC System Diagram............................................................................1124
Components...................................................................................1125
Safety Equipment.............................................................................1129
REGULAR MAINTENANCE..............................................................................1131
Filters......................................................................................1131
Compressor Drive Belt Adjustment.............................................................1132
Compressor Drive Belt Replacement............................................................1132
Condenser....................................................................................1132
Air Conditioning Lubrication.................................................................1132
Air Conditioning Service Chart...............................................................1133
Evaporator / Heater Coil.....................................................................1134
TROUBLESHOOTING..................................................................................1137
Blower Motor Does Not Operate................................................................1137
Blower Motor Operates Normally, But Air Flow Is Insufficient.................................1137
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...................1137
The Compressor Does Not Operate At All, Or Operates Improperly...............................1137
Gauge Pressure Related Troubleshooting.......................................................1138
Troubleshooting Tree.........................................................................1140
Temperature / Pressure Chart.................................................................1143
Poor A/C Performance.........................................................................1144
HVAC Repair And Leaks........................................................................1145
Electrical System............................................................................1146
Engine Coolant Bypassing The Heater Valve....................................................1152
Heater Valve Not Opening Or Closing..........................................................1153
SYSTEM CHARGING AND RECLAMATION..................................................................1155
Refrigerant Identification...................................................................1155
Reclamation And Charging With Recovery / Charging Unit.......................................1156
COMPRESSOR.......................................................................................1159
Removal And Installation.....................................................................1159
Oil..........................................................................................1161
Oil Check....................................................................................1162
CONDENSER (EARLIER MODELS).......................................................................1163
Removal And Installation.....................................................................1163
CONDENSER (LATER MODELS).........................................................................1165
Removal And Installation.....................................................................1165
RECEIVER / DRIER (EARLIER MODELS)................................................................1167
Receiver / Drier Removal And Installation....................................................1167
Pressure Relief Valve Removal And Installation...............................................1168
Pressure Switch Removal And Installation.....................................................1169
Schrader® Valve Removal And Installation.....................................................1170
RECEIVER / DRIER (LATER MODELS)..................................................................1171
Receiver / Drier Removal And Installation....................................................1171
Pressure Switch Removal And Installation.....................................................1173
Schrader® Valve Removal And Installation.....................................................1174
EVAPORATOR / HEATER UNIT.........................................................................1175
Removal And Installation.....................................................................1175
THERMOSTAT.......................................................................................1177
Description..................................................................................1177
Removal And Installation.....................................................................1178
EXPANSION VALVE..................................................................................1179
Removal And Installation.....................................................................1179
EVAPORATOR COIL..................................................................................1181
Removal And Installation.....................................................................1181
HEATER COIL......................................................................................1183
Removal And Installation.....................................................................1183
BLOWER FAN.......................................................................................1185
Removal And Installation.....................................................................1185
Disassembly And Assembly.....................................................................1185
HEATER VALVE.....................................................................................1189
Removal And Installation.....................................................................1189
EVAPORATOR / HEATER COVER........................................................................1191
Removal......................................................................................1191
Installation.................................................................................1191
SPECIFICATIONS.......................................................................................1193
(T870) LOADER SPECIFICATIONS.....................................................................1195
Machine Dimensions...........................................................................1195
Performance..................................................................................1196
Engine.......................................................................................1196
Drive System.................................................................................1196
Controls.....................................................................................1197
Hydraulic System.............................................................................1197
Electrical System............................................................................1198
Capacities...................................................................................1198
Tracks.......................................................................................1198
Ground Pressure..............................................................................1198
TORQUE SPECIFICATIONS FOR BOLTS..................................................................1199
Torque For General SAE Bolts.................................................................1199
Torque For General Metric Bolts..............................................................1200
HYDRAULIC CONNECTION SPECIFICATIONS..............................................................1201
Straight Thread O-ring Fitting...............................................................1201
Flare Fitting................................................................................1202
Tubelines And Hoses..........................................................................1202
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS.....................................................1203
Specifications...............................................................................1203
CONVERSIONS......................................................................................1205
Decimal And Millimeter Equivalent Chart......................................................1205
U.S. To Metric Conversion Chart..............................................................1205
SERVICE TOOLS REQUIRED...........................................................................1207
Remote Start Tools...........................................................................1207
Hydraulic Tools..............................................................................1208
Mainframe And Drive Tools....................................................................1210
Electrical Tools.............................................................................1212
Engine Tools.................................................................................1213
HVAC Tools...................................................................................1218
ALPHABETICAL INDEX...................................................................................1219

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Bobcat T870 Compact Track Loader Service Manual 6987487 – PDF DOWNLOAD

Bobcat T870 Compact Track Loader Service Manual 6987487 – PDF DOWNLOAD

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Bobcat T870 Compact Track Loader Service Manual 6987487 – PDF DOWNLOAD

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