Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Bobcat T870 Compact Track Loader Service Manual 6990269 – PDF DOWNLOAD
$35.95
Bobcat T870 Compact Track Loader Service Manual 6990269 – PDF DOWNLOAD
S/N AN8L11001 & Above
S/N ATF811001 & Above
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Bobcat T870 Compact Track Loader Service Manual 6990269 – PDF DOWNLOAD
FILE DETAILS:
Bobcat T870 Compact Track Loader Service Manual 6990269 – PDF DOWNLOAD
Language : English
Pages : 1092
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T870 Compact Track Loader Service Manual 6990269 – PDF DOWNLOAD
S/N AN8L11001 & Above
S/N ATF811001 & 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.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Bobcat T870 Compact Track Loader Service Manual 6990269 – 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 Description............................................................................. 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 Loader Service Tool Harness - 6689747................................................... 44 Computer Service Tool Harness - 6689746................................................. 45 Remote Start Procedure.................................................................. 46 DIAGMASTER (SERVICE TOOL) KIT - 7024161..................................................... 49 Diagmaster (Service Tool)............................................................... 49 DST-i LED Table......................................................................... 50 DST-i Operation Status And Display Specification........................................ 50 Diagmaster (Service Tool) Procedure..................................................... 51 SERVICE SCHEDULE............................................................................ 55 Maintenance Intervals................................................................... 55 ENGINE AIR CLEANER.......................................................................... 57 Replacing Filter Elements............................................................... 57 ENGINE COOLING SYSTEM....................................................................... 59 Maintenance Platform.................................................................... 59 Cleaning................................................................................ 59 Checking And Adding Coolant............................................................. 61 Removing And Replacing Coolant.......................................................... 62 FUEL SYSTEM................................................................................. 63 Fuel Specifications..................................................................... 63 Biodiesel Blend Fuel.................................................................... 63 Filling The Fuel Tank................................................................... 64 Fuel Filter............................................................................. 65 Removing Air From The Fuel System....................................................... 66 ENGINE LUBRICATION SYSTEM................................................................... 67 Checking And Adding Engine Oil.......................................................... 67 Engine Oil Chart........................................................................ 67 Removing And Replacing Oil And Filter................................................... 68 HYDRAULIC / HYDROSTATIC SYSTEM.............................................................. 69 Checking And Adding Fluid............................................................... 69 Hydraulic / Hydrostatic Fluid Chart..................................................... 69 Removing And Replacing Hydraulic Fluid.................................................. 70 Removing And Replacing Hydraulic / Hydrostatic Filter................................... 72 Removing And Replacing Hydraulic Charge Filter.......................................... 73 Replacing Reservoir 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 PIVOT PINS.................................................................................. 85 Inspection And Maintenance.............................................................. 85 LOADER STORAGE AND RETURN TO SERVICE........................................................ 87 Storage................................................................................. 87 Return To Service....................................................................... 87 STOPPING THE ENGINE AND LEAVING THE LOADER.................................................. 89 Procedure............................................................................... 89 EMERGENCY EXIT.............................................................................. 91 Rear Window Identification.............................................................. 91 Rear Window Removal (Latches)........................................................... 91 Rear Window Removal (Rubber Cord)....................................................... 92 External Access (Rear Window With Latches).............................................. 92 External Access (Rear Window With Rubber Cord).......................................... 93 Front Door.............................................................................. 93 SEAT BELT................................................................................... 95 Inspection And Maintenance.............................................................. 95 HYDRAULIC SYSTEM................................................................................ 97 HYDRAULIC / HYDROSTATIC SCHEMATICS.......................................................... 103 HYDRAULIC SYSTEM INFORMATION................................................................ 111 Glossary Of Hydraulic / Hydrostatic Symbols............................................. 111 Troubleshooting......................................................................... 115 CYLINDER (LIFT)............................................................................. 117 Testing................................................................................. 117 Removal And Installation................................................................ 118 Parts Identification (Earlier Models)................................................... 122 Parts Identification (Later Models)..................................................... 123 Disassembly............................................................................. 124 Assembly................................................................................ 126 CYLINDER (TILT)............................................................................. 129 Testing................................................................................. 129 Removal And Installation................................................................ 130 Base End Pivot Pin Removal And Installation............................................. 132 Parts Identification (Earlier Models)................................................... 133 Parts Identification (Later Models)..................................................... 134 Disassembly............................................................................. 135 Assembly................................................................................ 137 CYLINDER (BOB-TACH)......................................................................... 141 Testing................................................................................. 141 Removal And Installation................................................................ 142 Parts Identification.................................................................... 143 Disassembly............................................................................. 144 Assembly................................................................................ 146 MAIN RELIEF VALVES.......................................................................... 149 Description............................................................................. 149 Testing................................................................................. 149 Main Relief Valve Adjustment............................................................ 152 Main Relief Valve Removal And Installation.............................................. 152 Auxiliary Relief Valve Adjustment....................................................... 153 Auxiliary Relief Valve Removal And Installation......................................... 154 HYDRAULIC CONTROL VALVE (SJC)............................................................... 155 Description............................................................................. 155 Removal And Installation................................................................ 156 Actuator Removal And Installation (In Loader)........................................... 160 Actuator Removal And Installation (Out Of Loader)....................................... 161 Identification Chart.................................................................... 164 Mount Bracket Removal And Installation.................................................. 165 Lift Load Check Valve Removal And Installation.......................................... 165 Load Check Valve Removal And Installation (Tilt And Auxiliary).......................... 166 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).......................... 167 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)........... 167 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)........... 168 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............ 168 Port Relief Valve Removal And Installation.............................................. 169 Plug Removal And Installation........................................................... 171 End Cap Block Removal And Installation.................................................. 172 Lift Spool Removal And Installation..................................................... 172 Lift Spool Disassembly And Assembly..................................................... 174 Tilt Spool Removal And Installation..................................................... 175 Auxiliary Spool Removal And Installation................................................ 177 Auxiliary Solenoid Removal And Installation............................................. 178 Solenoid Removal And Installation....................................................... 179 Lock Valve Removal And Installation..................................................... 180 Lift Arm Bypass Orifice Removal And Installation........................................ 182 Main Relief Valve Removal And Installation.............................................. 182 Auxiliary Relief Valve Removal And Installation......................................... 183 Check Valve Removal And Installation.................................................... 183 HYDRAULIC CONTROL VALVE (SCPA).............................................................. 185 Description............................................................................. 185 Removal And Installation................................................................ 186 Mount Bracket Removal And Installation.................................................. 190 Identification Chart.................................................................... 191 Lift Load Check Valve Removal And Installation.......................................... 192 Load Check Valve Removal And Installation (Tilt And Auxiliary).......................... 193 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).......................... 194 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)........... 194 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)........... 195 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............ 195 Port Relief Valve Removal And Installation.............................................. 196 Plug Removal And Installation........................................................... 198 Rubber Boot Removal And Installation.................................................... 199 End Cap Block Removal And Installation.................................................. 199 Lift Spool And Detent Removal And Installation.......................................... 200 Tilt Spool Removal And Installation..................................................... 208 Auxiliary Spool Removal And Installation................................................ 210 Auxiliary Solenoid Removal And Installation............................................. 211 Solenoid Removal And Installation....................................................... 211 Lock Valve Removal And Installation..................................................... 213 Lift Arm Bypass Orifice Removal And Installation........................................ 215 Main Relief Valve Removal And Installation.............................................. 215 Auxiliary Relief Valve Removal And Installation......................................... 216 Check Valve Removal And Installation.................................................... 216 LIFT ARM BYPASS CONTROL VALVE............................................................... 219 Description............................................................................. 219 Testing................................................................................. 219 Removal And Installation................................................................ 220 Bracket Removal And Installation........................................................ 221 Disassembly And Assembly................................................................ 221 HYDRAULIC PUMP.............................................................................. 223 Description............................................................................. 223 Pump Test At Quick Couplers............................................................. 223 Direct Pump Test (Standard Section)..................................................... 224 Direct Pump Test (Charge Section)....................................................... 225 Removal And Installation................................................................ 227 Hydraulic Pump Startup.................................................................. 229 Parts Identification.................................................................... 230 Disassembly And Assembly................................................................ 231 HYDRAULIC PUMP (HIGH-FLOW).................................................................. 233 Description............................................................................. 233 Pump Test At Quick Couplers............................................................. 233 Direct Pump Test (Standard Section)..................................................... 234 Direct Pump Test (Charge Section)....................................................... 235 Direct Pump Test (High-Flow Section).................................................... 237 High-Flow Relief Valve Adjustment....................................................... 239 High-Flow Relief Valve Removal And Installation......................................... 240 Solenoid Removal And Installation....................................................... 241 Removal And Installation................................................................ 242 Hydraulic Pump Startup.................................................................. 245 Parts Identification.................................................................... 246 Disassembly And Assembly................................................................ 247 HYDRAULIC / HYDROSTATIC FILTERS............................................................. 249 Description............................................................................. 249 Housing Removal And Installation........................................................ 249 HYDRAULIC FLUID RESERVOIR................................................................... 251 Description............................................................................. 251 Removal And Installation................................................................ 251 Hydraulic Fluid Screen.................................................................. 252 OIL COOLER.................................................................................. 253 Description............................................................................. 253 Removal And Installation................................................................ 253 BUCKET POSITION VALVE....................................................................... 255 Description............................................................................. 255 Solenoid Removal And Installation....................................................... 255 Solenoid Testing........................................................................ 257 Removal And Installation................................................................ 257 Disassembly And Assembly................................................................ 259 REAR AUXILIARY DIVERTER VALVE............................................................... 261 Description............................................................................. 261 Solenoid Testing........................................................................ 261 Removal And Installation................................................................ 261 Disassembly And Assembly................................................................ 263 BOB-TACH (POWER) BLOCK (EARLIER MODELS)..................................................... 269 Description............................................................................. 269 Removal And Installation................................................................ 269 Disassembly And Assembly................................................................ 271 BOB-TACH (POWER) BLOCK (LATER MODELS)....................................................... 281 Description............................................................................. 281 Testing Relief Valve.................................................................... 282 Removal And Installation................................................................ 284 Disassembly And Assembly................................................................ 286 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK..................................................... 291 Description............................................................................. 291 Removal And Installation................................................................ 292 Disassembly And Assembly (FFI/FI)....................................................... 292 Disassembly And Assembly (FFH/FH)....................................................... 294 HYDROSTATIC SYSTEM.............................................................................. 297 HYDROSTATIC SYSTEM INFORMATION.............................................................. 299 Description............................................................................. 299 Troubleshooting......................................................................... 300 HYDROSTATIC DRIVE MOTOR..................................................................... 301 Description............................................................................. 301 Removing And Replacing Oil.............................................................. 301 Removal And Installation................................................................ 302 Parts Identification.................................................................... 304 Disassembly And Assembly................................................................ 306 HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N AN8L11001 - AN8L11599)............................. 319 Description............................................................................. 319 Removing And Replacing Oil.............................................................. 319 Removal And Installation................................................................ 320 Parts Identification.................................................................... 322 Disassembly And Assembly................................................................ 324 HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N AN8L11600 & ABOVE AND S/N ATF811001 & ABOVE)....... 337 Description............................................................................. 337 Removing And Replacing Oil.............................................................. 337 Removal And Installation................................................................ 338 Parts Identification.................................................................... 340 Disassembly And Assembly................................................................ 342 CHARGE PRESSURE............................................................................. 355 Description............................................................................. 355 Testing................................................................................. 355 Sender Removal And Installation......................................................... 357 Adjusting............................................................................... 358 HYDROSTATIC PUMP (SJC AND SCPA)............................................................. 359 Description............................................................................. 359 Hydraulic Controller Removal And Installation........................................... 360 Removal And Installation................................................................ 362 Hydrostatic Pump Startup................................................................ 363 Parts Identification.................................................................... 364 High Pressure Relief And Bypass Valve................................................... 365 Charge Relief Valve..................................................................... 366 Disassembly............................................................................. 367 Inspection.............................................................................. 375 Assembly................................................................................ 378 Mechanical Neutral Adjustment........................................................... 387 Hydraulic Controller Neutral Adjustment................................................. 390 DRIVE BELT.................................................................................. 393 Belt Adjustment......................................................................... 393 Stop Adjustment......................................................................... 393 Belt Replacement........................................................................ 393 Tensioner Pulley Removal And Installation............................................... 395 Tensioner Pulley Disassembly And Assembly............................................... 396 TWO-SPEED / BRAKE VALVE (S/N AN8L11001 - AN8L11599)......................................... 397 Description............................................................................. 397 Valve Block Removal And Installation.................................................... 398 Valve Block Disassembly And Assembly.................................................... 400 TWO-SPEED / BRAKE VALVE (S/N AN8L11600 & ABOVE AND S/N ATF811001 & ABOVE)................... 403 Description............................................................................. 403 Valve Block Removal And Installation.................................................... 404 Valve Block Disassembly And Assembly.................................................... 406 DRAIN MANIFOLD.............................................................................. 409 Description............................................................................. 409 Drain Manifold Removal And Installation................................................. 409 DRIVE SYSTEM.................................................................................... 411 BRAKE....................................................................................... 413 Description............................................................................. 413 Block Removal And Installation.......................................................... 413 Block Disassembly And Assembly.......................................................... 414 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION).......................................... 415 Description............................................................................. 415 Checking Tension........................................................................ 416 Adjusting Tension....................................................................... 417 Track Removal And Installation.......................................................... 418 Idler (Front) Removal And Installation.................................................. 420 Track Tensioner Disassembly And Assembly................................................ 423 Idler (Rear) Removal And Installation................................................... 425 Roller Removal And Installation......................................................... 425 Leaf Spring Removal And Installation.................................................... 426 Sprocket Removal And Installation (Single Speed)........................................ 427 Sprocket Removal And Installation (Two-Speed)........................................... 427 Track Housing Removal And Installation.................................................. 428 TRACK MAINTENANCE........................................................................... 429 Track Damage Identification............................................................. 429 MAINFRAME....................................................................................... 441 SEAT BAR.................................................................................... 445 Description............................................................................. 445 Removal And Installation................................................................ 445 Disassembly And Assembly................................................................ 446 Compression Spring Disassembly And Assembly............................................. 447 OPERATOR CAB................................................................................ 449 Gas Spring Removal And Installation..................................................... 449 Gas Spring Bracket Disassembly And Assembly............................................. 450 Removal And Installation................................................................ 450 OPERATOR SEAT (SUSPENSION).................................................................. 453 Removal And Installation................................................................ 453 Slide Rail Removal And Installation..................................................... 453 Seat Belt Removal And Installation...................................................... 454 Lower Cushion Removal................................................................... 454 Lower Cushion Installation.............................................................. 455 Back Cushion Removal And Installation................................................... 455 Shock Removal And Installation.......................................................... 456 3-Point Seat Belt Removal And Installation.............................................. 456 BOB-TACH (HAND LEVER)....................................................................... 459 Description............................................................................. 459 Removal And Installation................................................................ 459 Lever And Wedge Disassembly And Assembly................................................ 461 Pivot Pin Bushing And Seal Removal And Installation..................................... 463 BOB-TACH (POWER)............................................................................ 465 Description............................................................................. 465 Removal And Installation................................................................ 465 Lever And Wedge Disassembly And Assembly................................................ 468 Pivot Pin Bushing And Seal Removal And Installation..................................... 470 LIFT ARMS................................................................................... 471 Stabilizer Bar Removal And Installation................................................. 471 Link Removal And Installation........................................................... 472 Removal And Installation................................................................ 473 REAR GRILLE................................................................................. 477 Removing................................................................................ 477 Installing.............................................................................. 477 Shield Removal And Installation......................................................... 478 REAR DOOR (TAILGATE)........................................................................ 479 Removal And Installation................................................................ 479 Striker Removal And Installation........................................................ 480 Striker Disassembly And Assembly........................................................ 480 Striker (Adjusting)..................................................................... 480 Latch Removal And Installation (Earlier Models)......................................... 481 Latch Removal And Installation (Later Models)........................................... 482 FUEL TANK................................................................................... 483 Removal And Installation................................................................ 483 Fuel Level Sender Removal And Installation.............................................. 484 Fuel Fill Screen Removal And Installation............................................... 485 FUEL TANK (AUXILIARY)....................................................................... 487 Removal And Installation................................................................ 487 CONTROL PEDALS AND LINKAGES (SCPA).......................................................... 489 Description............................................................................. 489 Pedal Removal And Installation.......................................................... 489 Linkage Removal And Installation........................................................ 490 Pedal (Adjusting)....................................................................... 491 Floor Pan Removal And Installation...................................................... 492 CONTROL PANEL (SJC)......................................................................... 493 Description............................................................................. 493 Removal And Installation................................................................ 493 CONTROL PANEL (SCPA)........................................................................ 495 Description............................................................................. 495 Removal And Installation................................................................ 495 CONTROL HANDLE / LEVER (SJC)................................................................ 497 Description............................................................................. 497 Joystick Testing........................................................................ 497 Joystick Removal And Installation....................................................... 497 CONTROL HANDLE / LEVER (SCPA)............................................................... 499 Description............................................................................. 499 Steering Handle Testing................................................................. 499 Steering Handle Removal And Installation................................................ 499 ACCESS PANEL (INSIDE) (SJC)................................................................. 501 Removal And Installation (Left)......................................................... 501 Removal And Installation (Right)........................................................ 501 ACCESS PANEL (INSIDE) (SCPA)................................................................ 503 Removal And Installation (Left)......................................................... 503 Removal And Installation (Right)........................................................ 503 WINDOW (REAR)............................................................................... 505 Rear Window Identification.............................................................. 505 Removal (Rubber Cord)................................................................... 505 Installation (Rubber Cord).............................................................. 506 Removal And Installation (Latches)...................................................... 508 Disassembly And Assembly (Latches)...................................................... 508 WINDOW (TOP)................................................................................ 509 Removal And Installation................................................................ 509 WINDOW (SIDE)............................................................................... 511 Removal And Installation................................................................ 511 CAB DOOR.................................................................................... 513 Description............................................................................. 513 Removal And Installation................................................................ 513 Disassembly And Assembly................................................................ 514 Aligning................................................................................ 515 Adjusting............................................................................... 516 Checking Operation...................................................................... 516 ARMREST..................................................................................... 517 Description............................................................................. 517 Removal And Installation................................................................ 518 Disassembly And Assembly................................................................ 519 LEFT SIDE LOWER PANEL....................................................................... 521 Removal And Installation................................................................ 521 Disassembly And Assembly................................................................ 523 RIGHT SIDE LOWER PANEL...................................................................... 525 Removal And Installation................................................................ 525 Disassembly And Assembly................................................................ 526 HEADLINER................................................................................... 529 Removal And Installation................................................................ 529 ELECTRICAL SYSTEM AND ANALYSIS.................................................................. 531 ELECTRICAL SCHEMATICS....................................................................... 535 ELECTRICAL SYSTEM INFORMATION............................................................... 685 Glossary Of Electrical Symbols.......................................................... 685 Deluxe Cab Harness Connectors (Earlier Models).......................................... 688 Deluxe Cab Harness Connectors (Later Models)............................................ 689 Mainframe Harness Connectors............................................................ 690 Engine Harness Connectors............................................................... 691 Description............................................................................. 692 Troubleshooting......................................................................... 693 Fuse And Relay Location / Identification................................................ 694 Solenoid Testing........................................................................ 697 BATTERY..................................................................................... 699 Removal And Installation................................................................ 699 Servicing............................................................................... 700 Using A Booster Battery (Jump Starting)................................................. 700 ALTERNATOR.................................................................................. 703 Belt Adjustment......................................................................... 703 Belt Replacement........................................................................ 703 Charging System Inspection.............................................................. 704 Alternator Voltage Testing.............................................................. 705 Low Voltage Testing..................................................................... 705 High Voltage Testing.................................................................... 706 Removal And Installation................................................................ 707 Parts Identification.................................................................... 709 STARTER..................................................................................... 711 Testing................................................................................. 711 Removal And Installation................................................................ 711 Parts Identification.................................................................... 712 INSTRUMENT PANELS........................................................................... 713 Left Panel.............................................................................. 713 Display Screen.......................................................................... 715 Right Panel (Standard Key Panel)........................................................ 715 Right Panel (Keyless Start Panel)....................................................... 716 Right Panel (Deluxe Instrumentation Panel).............................................. 717 Left Switch Panel....................................................................... 719 Right Switch Panel...................................................................... 719 Left Side Lower Panel................................................................... 720 Right Side Lower Panel.................................................................. 720 Left Panel Removal And Installation..................................................... 721 Right Panel Removal And Installation.................................................... 721 Key Switch Disassembly And Assembly..................................................... 722 Alarm Disassembly And Assembly.......................................................... 722 Left Switch Panel Removal And Installation.............................................. 723 Right Switch Panel Removal And Installation............................................. 723 LIGHTS...................................................................................... 725 Front Removal And Installation.......................................................... 725 Rear Removal And Installation........................................................... 726 Cab Light Removal And Installation (Earlier Models)..................................... 726 Cab Light Removal And Installation (Later Models)....................................... 727 BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY).................................................. 729 Description............................................................................. 729 Connector Identification................................................................ 730 Removal And Installation................................................................ 736 BOBCAT CONTROLLER (ACS)..................................................................... 737 Description............................................................................. 737 Connector And Wire Identification....................................................... 738 Removal And Installation................................................................ 739 BOBCAT CONTROLLER (SJC) (DRIVE)............................................................. 741 Description............................................................................. 741 Connector Identification................................................................ 742 Removal And Installation................................................................ 744 BOBCAT CONTROLLER (SCPA) (DRIVE)............................................................ 745 Description............................................................................. 745 Connector Identification................................................................ 746 Removal And Installation................................................................ 748 ENGINE CONTROL UNIT (ECU)................................................................... 749 Description............................................................................. 749 Cleaning................................................................................ 750 Removal And Installation................................................................ 751 ECU Replacement......................................................................... 752 DIAGNOSTIC SERVICE CODES.................................................................... 753 Viewing Service Codes................................................................... 753 Service Codes List...................................................................... 754 DIAGMASTER DIAGNOSTIC TROUBLE CODES (DTC)................................................... 761 Viewing Trouble Codes................................................................... 761 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..................................................... 763 Description............................................................................. 763 Inspecting The BICS™ (Engine STOPPED - Key ON).......................................... 764 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON).... 764 Inspecting The Seat Bar Sensor (Engine RUNNING)......................................... 764 Inspecting The Traction Lock (Engine RUNNING)........................................... 764 Inspecting The Lift Arm Bypass Control.................................................. 764 Inspecting Deactivation Of Lift And Tilt Functions (SJC)................................ 764 Troubleshooting......................................................................... 765 SEAT BAR SENSOR............................................................................. 767 Description............................................................................. 767 Troubleshooting......................................................................... 767 Testing................................................................................. 768 Removal And Installation................................................................ 769 Bobcat Interlock Control System (BICS™) Circuit Test.................................... 772 TRACTION LOCK............................................................................... 773 Description............................................................................. 773 Troubleshooting......................................................................... 774 Inspecting.............................................................................. 775 ELECTRICAL / HYDRAULIC CONTROLS (SJC)....................................................... 777 Identification Chart.................................................................... 777 Description............................................................................. 778 Identification Chart ACD Group 0........................................................ 779 Identification Chart ACD Group 1........................................................ 780 Identification Chart ACD Group 2........................................................ 781 Identification Chart ACD Group 3........................................................ 782 ELECTRICAL / HYDRAULIC CONTROLS (SCPA)...................................................... 783 Identification Chart.................................................................... 783 Description............................................................................. 784 Identification Chart ACD Group 0........................................................ 785 Identification Chart ACD Group 1........................................................ 786 Identification Chart ACD Group 2........................................................ 787 Identification Chart ACD Group 3........................................................ 788 SERVICE PC (LAPTOP COMPUTER)................................................................ 789 Connecting Remote Start Tool............................................................ 789 Connecting Remote Start Tool (Service Tool)............................................. 789 Connecting Diagmaster (Service Tool).................................................... 790 Connecting Remote Parked Regeneration Kit............................................... 790 CALIBRATION................................................................................. 791 Description............................................................................. 791 Actuator Testing........................................................................ 791 Lift And Tilt Calibration (SJC)......................................................... 794 Hydrostatic Pump Calibration (SJC)...................................................... 796 Hydrostatic Pump Calibration (SCPA)..................................................... 801 STEERING DRIFT COMPENSATION (OPERATOR MODE)................................................. 807 Description............................................................................. 807 Operation............................................................................... 807 STEERING DRIFT COMPENSATION (SERVICE MODE).................................................. 809 Description............................................................................. 809 Operation............................................................................... 809 CONTROL PANEL SETUP......................................................................... 811 Right Panel Setup (Deluxe Instrumentation Panel)........................................ 811 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)............................................... 815 Password Description.................................................................... 815 Changing The Owner Password............................................................. 815 Changing The User Passwords............................................................. 816 Password Lockout Feature................................................................ 816 PASSWORD SETUP (KEYLESS START PANEL)........................................................ 817 Password Description.................................................................... 817 Changing The Owner Password............................................................. 817 Password Lockout Feature................................................................ 817 MAINTENANCE CLOCK........................................................................... 819 Description............................................................................. 819 Setup................................................................................... 820 Reset................................................................................... 823 BACK-UP ALARM SYSTEM........................................................................ 825 Description............................................................................. 825 Inspecting.............................................................................. 825 Troubleshooting (Joystick).............................................................. 826 Alarm Removal And Installation.......................................................... 827 FRONT HORN.................................................................................. 829 Removal And Installation................................................................ 829 Troubleshooting......................................................................... 830 Troubleshooting (Joystick).............................................................. 831 ENGINE SERVICE.................................................................................. 833 ENGINE INFORMATION.......................................................................... 837 Description............................................................................. 837 Specifications.......................................................................... 838 Sensor Location......................................................................... 841 Torque Values........................................................................... 844 Troubleshooting......................................................................... 845 Engine Removal And Installation......................................................... 846 Engine Mount Replacement................................................................ 858 Compression - Testing................................................................... 860 Injector Signal - Testing............................................................... 863 ENGINE SPEED CONTROL (HAND)................................................................. 865 Removal And Installation................................................................ 865 ENGINE SPEED CONTROL (FOOT)................................................................. 867 Removal And Installation................................................................ 867 Disassembly And Assembly................................................................ 868 Foot Throttle Calibration............................................................... 870 DIESEL PARTICULATE FILTER (DPF) SYSTEM...................................................... 873 Description............................................................................. 873 Removal And Installation................................................................ 874 DPF Regeneration........................................................................ 877 DPF Regeneration Table.................................................................. 877 Operation (Standard Switch)............................................................. 878 Operation (Optional Inhibit Switch Kit)................................................. 879 Operation (Optional Remote Parked Regeneration Kit)..................................... 880 Remote Parked Regeneration (Level 3).................................................... 880 DPF Service Regeneration (Level 4)...................................................... 882 DPF Cleaning (Level 5).................................................................. 885 AIR CLEANER................................................................................. 887 Housing Removal And Installation........................................................ 887 ENGINE COOLING SYSTEM....................................................................... 889 Radiator Removal And Installation....................................................... 889 Hydraulic Fan Description............................................................... 891 Lower Fan Duct Removal And Installation................................................. 892 Hydraulic Fan Motor Assembly Removal And Installation (Earlier Models).................. 892 Fan Removal And Installation (Earlier Models)........................................... 893 Hydraulic Fan Motor Removal And Installation (Earlier Models)........................... 893 Hydraulic Fan Disassembly And Assembly (Earlier Models)................................. 894 Hydraulic Fan Motor Assembly Removal And Installation (Later Models).................... 896 Fan Removal And Installation (Later Models)............................................. 897 Hydraulic Fan Motor Removal And Installation (Later Models)............................. 898 Hydraulic Fan Disassembly And Assembly (Later Models)................................... 899 Blower Housing Removal And Installation................................................. 904 Water Pump Removal And Installation..................................................... 905 Water Pump Disassembly And Assembly..................................................... 905 Thermostat Housing Removal And Installation............................................. 906 Thermostat - Checking................................................................... 906 LUBRICATION SYSTEM.......................................................................... 907 Oil Pan Removal And Installation........................................................ 907 Oil Pump Removal And Installation....................................................... 908 Oil Pump Inspection..................................................................... 908 Oil Filter Cooler Removal And Installation.............................................. 910 Engine Oil Pressure - Testing........................................................... 911 Crankcase Ventilation Filter Removal And Installation................................... 912 FUEL SYSTEM................................................................................. 913 Supply Pump Removal..................................................................... 913 Supply Pump Installation................................................................ 916 Supply Pump Difference Learning......................................................... 918 Fuel Cooler Bypass Valve Removal And Installation....................................... 920 Fuel Recirculation Valve Removal And Installation....................................... 920 Fuel Rail Assembly Removal And Installation............................................. 921 Supply Pump - Timing.................................................................... 922 Fuel Injector Removal And Installation.................................................. 923 Injector Correction..................................................................... 927 Removing Air From The Fuel System....................................................... 928 CYLINDER HEAD............................................................................... 931 Intake Air Heater - Testing............................................................. 931 Intake Air Heater Removal And Installation.............................................. 931 Valve Clearance Adjustment.............................................................. 933 Valve Timing - Checking................................................................. 934 Cylinder Head Removal And Installation.................................................. 935 Cylinder Head Disassembly And Assembly.................................................. 937 Cylinder Head - Servicing............................................................... 937 Cylinder Head Top Clearance............................................................. 937 Valve Guide - Inspecting................................................................ 938 Reconditioning The Valve And Valve Seat................................................. 940 Valve Spring............................................................................ 942 Valve Tappets........................................................................... 943 Rocker Arm And Shaft - Inspecting....................................................... 944 Valve Bridge Arm And Shaft - Inspecting................................................. 945 Push Rod Alignment - Inspecting......................................................... 946 CRANKSHAFT AND PISTONS...................................................................... 947 Piston And Connecting Rod Removal And Installation...................................... 947 Piston And Connecting Rod - Servicing................................................... 949 Cylinder Bore - Testing................................................................. 953 Connecting Rod Alignment................................................................ 954 Crankshaft Gear Removal And Installation................................................ 954 Crankshaft And Bearings Removal......................................................... 955 Crankshaft And Bearings Installation.................................................... 957 Crankshaft And Bearings - Servicing..................................................... 959 CRANKSHAFT POSITION SENSOR.................................................................. 965 Description............................................................................. 965 Removal And Installation................................................................ 965 Adjusting............................................................................... 966 CAMSHAFT AND TIMING GEARS................................................................... 969 Timing Gearcase Cover Removal And Installation.......................................... 969 Timing Gears Backlash - Testing......................................................... 970 Idler Gear And Camshaft Removal And Installation........................................ 970 Camshaft - Servicing.................................................................... 971 Idler Gear And Shaft - Servicing........................................................ 973 TURBOCHARGER................................................................................ 977 Description............................................................................. 977 Removal And Installation................................................................ 978 Testing................................................................................. 980 EGR Cooler Testing...................................................................... 981 FLYWHEEL AND HOUSING........................................................................ 983 Flywheel Removal And Installation....................................................... 983 Ring Gear Removal And Installation...................................................... 983 Housing Removal And Installation........................................................ 984 EXHAUST GAS RECIRCULATION (EGR) SYSTEM...................................................... 985 Description............................................................................. 985 Testing................................................................................. 986 Removal And Installation................................................................ 988 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)................................................ 989 AIR CONDITIONING SYSTEM FLOW................................................................ 991 Description............................................................................. 991 A/C System Diagram...................................................................... 992 Components.............................................................................. 993 Safety Equipment........................................................................ 996 REGULAR MAINTENANCE......................................................................... 997 Filters................................................................................. 997 Compressor Drive Belt Adjustment........................................................ 998 Compressor Drive Belt Replacement....................................................... 998 Condenser............................................................................... 998 Air Conditioning Lubrication............................................................ 998 Air Conditioning Service Chart.......................................................... 999 Evaporator / Heater Coil................................................................1000 TROUBLESHOOTING.............................................................................1003 Blower Motor Does Not Operate...........................................................1003 Blower Motor Operates Normally, But Air Flow Is Insufficient............................1003 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal..............1003 The Compressor Does Not Operate At All, Or Operates Improperly..........................1003 Gauge Pressure Related Troubleshooting..................................................1004 Troubleshooting Tree....................................................................1006 Temperature / Pressure Chart............................................................1009 Poor A/C Performance....................................................................1010 HVAC Repair And Leaks...................................................................1011 Electrical System.......................................................................1012 Engine Coolant Bypassing The Heater Valve...............................................1018 Heater Valve Not Opening Or Closing.....................................................1019 SYSTEM CHARGING AND RECLAMATION.............................................................1021 Refrigerant Identification..............................................................1021 Reclamation And Charging With Recovery / Charging Unit..................................1022 COMPRESSOR..................................................................................1025 Removal And Installation................................................................1025 Oil.....................................................................................1027 Oil Check...............................................................................1028 CONDENSER...................................................................................1029 Removal And Installation................................................................1029 RECEIVER / DRIER (EARLIER MODELS)...........................................................1031 Receiver / Drier Removal And Installation...............................................1031 Pressure Relief Valve Removal And Installation..........................................1032 Pressure Switch Removal And Installation................................................1033 Schrader® Valve Removal And Installation................................................1034 RECEIVER / DRIER (LATER MODELS).............................................................1035 Receiver / Drier Removal And Installation...............................................1035 Pressure Switch Removal And Installation................................................1037 Schrader® Valve Removal And Installation................................................1038 EVAPORATOR / HEATER UNIT....................................................................1039 Removal And Installation................................................................1039 THERMOSTAT..................................................................................1041 Description.............................................................................1041 Removal And Installation................................................................1042 EXPANSION VALVE.............................................................................1043 Removal And Installation................................................................1043 EVAPORATOR COIL.............................................................................1045 Removal And Installation................................................................1045 HEATER COIL.................................................................................1047 Removal And Installation................................................................1047 BLOWER FAN..................................................................................1049 Removal And Installation................................................................1049 Disassembly And Assembly................................................................1049 HEATER VALVE................................................................................1053 Removal And Installation................................................................1053 EVAPORATOR / HEATER COVER...................................................................1055 Removal.................................................................................1055 Installation............................................................................1055 SPECIFICATIONS..................................................................................1057 (T870) LOADER SPECIFICATIONS................................................................1059 Machine Dimensions......................................................................1059 Performance.............................................................................1060 Engine..................................................................................1060 Drive System............................................................................1061 Controls................................................................................1061 Hydraulic System........................................................................1062 Electrical System.......................................................................1063 Capacities..............................................................................1063 Tracks..................................................................................1063 Ground Pressure.........................................................................1063 TECHNICAL SERVICE GUIDE SPECIFICATIONS......................................................1065 Engine..................................................................................1065 Engine Torques..........................................................................1065 Cooling System..........................................................................1065 Loader Torques..........................................................................1066 Hydraulic / Hydrostatic System..........................................................1066 Fuel Consumption........................................................................1066 TORQUE SPECIFICATIONS FOR BOLTS.............................................................1067 Torque For General SAE Bolts............................................................1067 Torque For General Metric Bolts.........................................................1068 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................1069 Straight Thread O-ring Fitting..........................................................1069 Flare Fitting...........................................................................1070 Tubelines And Hoses.....................................................................1070 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS................................................1071 Specifications..........................................................................1071 CONVERSIONS.................................................................................1073 Decimal And Millimeter Equivalent Chart.................................................1073 U.S. To Metric Conversion Chart.........................................................1073 SERVICE TOOLS REQUIRED......................................................................1075 Remote Start Tools......................................................................1075 Hydraulic Tools.........................................................................1076 Mainframe And Drive Tools...............................................................1078 Electrical Tools........................................................................1080 Engine Tools............................................................................1081 HVAC Tools..............................................................................1086 ALPHABETICAL INDEX..............................................................................1087
Contact us: [email protected]
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
S.V
