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Bobcat T870 Compact Track Loader Service Manual 7248302 – PDF DOWNLOAD
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Bobcat T870 Compact Track Loader Service Manual 7248302 – PDF DOWNLOAD
S/N ASWT11001 & Above
S/N B3BZ11001 & Above
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Description
Bobcat T870 Compact Track Loader Service Manual 7248302 – PDF DOWNLOAD
FILE DETAILS:
Bobcat T870 Compact Track Loader Service Manual 7248302 – PDF DOWNLOAD
Language : English
Pages : 1052
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T870 Compact Track Loader Service Manual 7248302 – PDF DOWNLOAD
S/N ASWT11001 & Above
S/N B3BZ11001 & 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 7248302 – 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............................................................. 21 Procedure............................................................................... 21 LIFT ARM SUPPORT DEVICE..................................................................... 23 Description............................................................................. 23 Installing.............................................................................. 24 Removing................................................................................ 25 OPERATOR CAB................................................................................ 27 Description............................................................................. 27 Raising................................................................................. 27 Lowering................................................................................ 28 Cab Door Sensor......................................................................... 29 Special Applications Kit................................................................ 30 Special Applications Kit Inspection And Maintenance..................................... 30 Forestry Door And Window Kit............................................................ 31 Forestry Door And Window Kit Inspection And Maintenance................................. 31 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 ENGINE AIR CLEANER.......................................................................... 53 Replacing Filter Elements............................................................... 53 ENGINE COOLING SYSTEM....................................................................... 55 Maintenance Platform.................................................................... 55 Cleaning................................................................................ 55 Checking And Adding Coolant............................................................. 58 Removing And Replacing Coolant.......................................................... 59 FUEL SYSTEM................................................................................. 61 Fuel Specifications..................................................................... 61 Biodiesel Blend Fuel.................................................................... 61 Filling The Fuel Tank................................................................... 62 Fuel Filter............................................................................. 63 Removing Air From The Fuel System....................................................... 64 ENGINE LUBRICATION SYSTEM................................................................... 65 Checking And Adding Engine Oil.......................................................... 65 Engine Oil Chart........................................................................ 65 Removing And Replacing Oil And Filter................................................... 66 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........................................................ 74 BOB-TACH (HAND LEVER)....................................................................... 75 Inspection And Maintenance.............................................................. 75 BOB-TACH (POWER)............................................................................ 77 Inspection And Maintenance.............................................................. 77 LUBRICATING THE LOADER...................................................................... 79 Lubrication Locations................................................................... 79 PIVOT PINS.................................................................................. 83 Inspection And Maintenance.............................................................. 83 LOADER STORAGE AND RETURN TO SERVICE........................................................ 85 Storage................................................................................. 85 Return To Service....................................................................... 85 STOPPING THE ENGINE AND LEAVING THE LOADER.................................................. 87 Procedure............................................................................... 87 EMERGENCY EXIT.............................................................................. 89 Rear Window Identification.............................................................. 89 Rear Window Removal (Latches)........................................................... 89 Rear Window Removal (Rubber Cord)....................................................... 90 External Access (Rear Window With Latches).............................................. 90 External Access (Rear Window With Rubber Cord).......................................... 91 Front Door.............................................................................. 91 SEAT BELT................................................................................... 93 Inspection And Maintenance.............................................................. 93 HYDRAULIC SYSTEM................................................................................ 95 HYDRAULIC / HYDROSTATIC SCHEMATICS.......................................................... 101 HYDRAULIC SYSTEM INFORMATION................................................................ 107 Glossary Of Hydraulic / Hydrostatic Symbols............................................. 107 Troubleshooting......................................................................... 111 CYLINDER (LIFT)............................................................................. 113 Testing................................................................................. 113 Removal And Installation................................................................ 114 Parts Identification.................................................................... 118 Disassembly............................................................................. 119 Assembly................................................................................ 121 CYLINDER (TILT)............................................................................. 125 Testing................................................................................. 125 Removal And Installation................................................................ 126 Base End Pivot Pin Removal And Installation............................................. 128 Parts Identification.................................................................... 129 Disassembly............................................................................. 130 Assembly................................................................................ 132 CYLINDER (BOB-TACH)......................................................................... 135 Testing................................................................................. 135 Removal And Installation................................................................ 136 Parts Identification.................................................................... 137 Disassembly............................................................................. 138 Assembly................................................................................ 140 MAIN RELIEF VALVES.......................................................................... 143 Description............................................................................. 143 Testing................................................................................. 143 Main Relief Valve Adjustment............................................................ 146 Main Relief Valve Removal And Installation.............................................. 146 Auxiliary Relief Valve Adjustment....................................................... 147 Auxiliary Relief Valve Removal And Installation......................................... 148 HYDRAULIC CONTROL VALVE (SJC)............................................................... 149 Description............................................................................. 149 Removal And Installation................................................................ 150 Actuator Removal And Installation (In Loader)........................................... 154 Actuator Removal And Installation (Out Of Loader)....................................... 155 Identification Chart.................................................................... 158 Mount Bracket Removal And Installation.................................................. 159 Lift Load Check Valve Removal And Installation.......................................... 159 Load Check Valve Removal And Installation (Tilt And Auxiliary).......................... 160 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).......................... 161 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)........... 161 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)........... 162 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............ 162 Port Relief Valve Removal And Installation.............................................. 163 Plug Removal And Installation........................................................... 165 End Cap Block Removal And Installation.................................................. 166 Lift Spool Removal And Installation..................................................... 166 Lift Spool Disassembly And Assembly..................................................... 168 Tilt Spool Removal And Installation..................................................... 169 Auxiliary Spool Removal And Installation................................................ 171 Auxiliary Solenoid Removal And Installation............................................. 172 Solenoid Removal And Installation....................................................... 173 Lock Valve Removal And Installation..................................................... 174 Lift Arm Bypass Orifice Removal And Installation........................................ 176 Main Relief Valve Removal And Installation.............................................. 176 Auxiliary Relief Valve Removal And Installation......................................... 177 Check Valve Removal And Installation.................................................... 177 HYDRAULIC CONTROL VALVE (SCPA).............................................................. 179 Description............................................................................. 179 Removal And Installation................................................................ 180 Mount Bracket Removal And Installation.................................................. 184 Identification Chart.................................................................... 185 Lift Load Check Valve Removal And Installation.......................................... 186 Load Check Valve Removal And Installation (Tilt And Auxiliary).......................... 187 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).......................... 188 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)........... 188 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)........... 189 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............ 189 Port Relief Valve Removal And Installation.............................................. 190 Plug Removal And Installation........................................................... 192 Rubber Boot Removal And Installation.................................................... 193 End Cap Block Removal And Installation.................................................. 193 Lift Spool And Detent Removal And Installation.......................................... 194 Tilt Spool Removal And Installation..................................................... 202 Auxiliary Spool Removal And Installation................................................ 204 Auxiliary Solenoid Removal And Installation............................................. 205 Solenoid Removal And Installation....................................................... 205 Lock Valve Removal And Installation..................................................... 207 Lift Arm Bypass Orifice Removal And Installation........................................ 209 Main Relief Valve Removal And Installation.............................................. 209 Auxiliary Relief Valve Removal And Installation......................................... 210 Check Valve Removal And Installation.................................................... 210 LIFT ARM BYPASS CONTROL VALVE............................................................... 213 Description............................................................................. 213 Testing................................................................................. 213 Removal And Installation................................................................ 214 Bracket Removal And Installation........................................................ 215 Disassembly And Assembly................................................................ 215 HYDRAULIC PUMP.............................................................................. 217 Description............................................................................. 217 Pump Test At Quick Couplers............................................................. 217 Direct Pump Test (Standard Section)..................................................... 218 Direct Pump Test (Charge Section)....................................................... 220 Removal And Installation................................................................ 222 Hydraulic Pump Startup.................................................................. 225 Parts Identification.................................................................... 226 Disassembly And Assembly................................................................ 227 HYDRAULIC PUMP (HIGH FLOW).................................................................. 229 Description............................................................................. 229 Pump Test At Quick Couplers............................................................. 229 Direct Pump Test (Standard Section)..................................................... 230 Direct Pump Test (Charge Section)....................................................... 231 Direct Pump Test (High Flow Section).................................................... 233 High Flow Relief Valve Adjustment....................................................... 235 High Flow Relief Valve Removal And Installation......................................... 236 Solenoid Removal And Installation....................................................... 237 Removal And Installation................................................................ 238 Hydraulic Pump Startup.................................................................. 240 Parts Identification.................................................................... 241 Disassembly And Assembly................................................................ 242 HYDRAULIC / HYDROSTATIC FILTERS............................................................. 243 Description............................................................................. 243 Housing Removal And Installation........................................................ 243 HYDRAULIC FLUID RESERVOIR................................................................... 245 Description............................................................................. 245 Removal And Installation................................................................ 245 Hydraulic Fluid Screen.................................................................. 246 OIL COOLER.................................................................................. 247 Removal And Installation................................................................ 247 BUCKET POSITION VALVE....................................................................... 249 Description............................................................................. 249 Solenoid Removal And Installation....................................................... 249 Solenoid Testing........................................................................ 251 Removal And Installation................................................................ 251 Disassembly And Assembly................................................................ 253 REAR AUXILIARY DIVERTER VALVE............................................................... 255 Description............................................................................. 255 Solenoid Testing........................................................................ 255 Removal And Installation................................................................ 256 Disassembly And Assembly................................................................ 257 BOB-TACH (POWER) BLOCK...................................................................... 263 Description............................................................................. 263 Testing Relief Valve.................................................................... 264 Removal And Installation................................................................ 266 Disassembly And Assembly................................................................ 268 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK..................................................... 273 Description............................................................................. 273 Removal And Installation................................................................ 273 Disassembly And Assembly................................................................ 274 AUTOMATIC RIDE CONTROL...................................................................... 277 Description............................................................................. 277 Removal And Installation................................................................ 278 Checking The Pressure In The Accumulator................................................ 281 Adding Nitrogen To The Accumulator...................................................... 283 HYDROSTATIC SYSTEM.............................................................................. 285 HYDROSTATIC SYSTEM INFORMATION.............................................................. 287 Description............................................................................. 287 Troubleshooting......................................................................... 288 HYDROSTATIC DRIVE MOTOR..................................................................... 289 Description............................................................................. 289 Removing And Replacing Oil.............................................................. 289 Removal And Installation................................................................ 290 Parts Identification.................................................................... 292 Disassembly And Assembly................................................................ 294 HYDROSTATIC DRIVE MOTOR (TWO-SPEED)......................................................... 307 Description............................................................................. 307 Removing And Replacing Oil.............................................................. 307 Removal And Installation................................................................ 308 Parts Identification.................................................................... 310 Disassembly And Assembly................................................................ 312 CHARGE PRESSURE............................................................................. 325 Description............................................................................. 325 Testing................................................................................. 325 Sender Removal And Installation......................................................... 327 Adjusting............................................................................... 328 HYDROSTATIC PUMP (SJC AND SCPA)............................................................. 329 Description............................................................................. 329 Hydraulic Controller Removal And Installation........................................... 330 Removal And Installation................................................................ 332 Hydrostatic Pump Startup................................................................ 333 Parts Identification.................................................................... 334 High Pressure Relief And Bypass Valve................................................... 335 Charge Relief Valve..................................................................... 336 Disassembly............................................................................. 337 Inspection.............................................................................. 346 Assembly................................................................................ 349 Mechanical Neutral Adjustment........................................................... 359 Hydraulic Controller Neutral Adjustment................................................. 362 DRIVE BELT.................................................................................. 365 Belt Adjustment......................................................................... 365 Stop Adjustment......................................................................... 365 Belt Replacement........................................................................ 366 Tensioner Pulley Removal And Installation............................................... 368 TWO-SPEED / BRAKE VALVE..................................................................... 371 Description............................................................................. 371 Valve Block Removal And Installation.................................................... 372 Valve Block Disassembly And Assembly.................................................... 374 DRAIN MANIFOLD.............................................................................. 377 Description............................................................................. 377 Drain Manifold Removal And Installation................................................. 377 DRIVE SYSTEM.................................................................................... 379 BRAKE....................................................................................... 381 Description............................................................................. 381 Block Removal And Installation.......................................................... 381 Block Disassembly And Assembly.......................................................... 382 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION).......................................... 383 Description............................................................................. 383 Checking Tension........................................................................ 384 Adjusting Tension (Earlier Models With Two Track Tension Fittings)...................... 386 Adjusting Tension (Later Models With One Track Tension Fitting)......................... 387 Track Removal And Installation.......................................................... 388 Idler (Front) Removal And Installation.................................................. 390 Track Tensioner Disassembly And Assembly................................................ 393 Idler (Rear) Removal And Installation................................................... 395 Roller Removal And Installation......................................................... 395 Leaf Spring Removal And Installation.................................................... 396 Sprocket Removal And Installation (Single Speed)........................................ 397 Sprocket Removal And Installation (Two-Speed)........................................... 397 Track Housing Removal And Installation.................................................. 398 TRACK MAINTENANCE........................................................................... 399 Track Damage Identification............................................................. 399 MAINFRAME....................................................................................... 411 SEAT BAR.................................................................................... 415 Description............................................................................. 415 Removal And Installation................................................................ 415 Disassembly And Assembly................................................................ 416 Compression Spring Disassembly And Assembly............................................. 417 OPERATOR CAB................................................................................ 419 Gas Spring Removal And Installation..................................................... 419 Gas Spring Bracket Disassembly And Assembly............................................. 420 Removal And Installation................................................................ 420 OPERATOR SEAT (SUSPENSION).................................................................. 423 Removal And Installation................................................................ 423 Slide Rail Removal And Installation..................................................... 423 Seat Belt Removal And Installation...................................................... 424 Lower Cushion Removal................................................................... 424 Lower Cushion Installation.............................................................. 425 Back Cushion Removal And Installation................................................... 425 Shock Removal And Installation.......................................................... 426 3-Point Seat Belt Removal And Installation.............................................. 426 BOB-TACH (HAND LEVER)....................................................................... 429 Description............................................................................. 429 Removal And Installation................................................................ 429 Lever And Wedge Disassembly And Assembly................................................ 431 Pivot Pin Bushing And Seal Removal And Installation..................................... 433 BOB-TACH (POWER)............................................................................ 435 Description............................................................................. 435 Removal And Installation................................................................ 435 Lever And Wedge Disassembly And Assembly................................................ 438 Pivot Pin Bushing And Seal Removal And Installation..................................... 440 LIFT ARMS................................................................................... 441 Stabilizer Bar Removal And Installation................................................. 441 Link Removal And Installation........................................................... 442 Removal And Installation................................................................ 443 REAR GRILLE................................................................................. 447 Removing................................................................................ 447 Installing.............................................................................. 447 Shield Removal And Installation......................................................... 448 REAR DOOR (TAILGATE)........................................................................ 449 Removal And Installation................................................................ 449 Striker Removal And Installation........................................................ 450 Striker Disassembly And Assembly........................................................ 450 Striker (Adjusting)..................................................................... 450 Latch Removal And Installation.......................................................... 451 Tailgate Fan Removal And Installation................................................... 452 FUEL TANK................................................................................... 453 Removal And Installation................................................................ 453 Fuel Level Sender Removal And Installation.............................................. 454 Fuel Fill Screen Removal And Installation............................................... 455 FUEL TANK (AUXILIARY)....................................................................... 457 Removal And Installation................................................................ 457 CONTROL PEDALS AND LINKAGES (SCPA).......................................................... 459 Description............................................................................. 459 Pedal Removal And Installation.......................................................... 459 Linkage Removal And Installation........................................................ 460 Pedal (Adjusting)....................................................................... 461 Floor Pan Removal And Installation...................................................... 462 CONTROL PANEL (SJC)......................................................................... 463 Description............................................................................. 463 Removal And Installation................................................................ 463 CONTROL PANEL (SCPA)........................................................................ 465 Description............................................................................. 465 Removal And Installation................................................................ 465 CONTROL HANDLE / LEVER (SJC)................................................................ 467 Description............................................................................. 467 Joystick Testing........................................................................ 467 Joystick Removal And Installation....................................................... 468 CONTROL HANDLE / LEVER (SCPA)............................................................... 469 Description............................................................................. 469 Steering Handle Testing................................................................. 469 Steering Handle Removal And Installation................................................ 470 ACCESS PANEL (INSIDE) (SJC)................................................................. 471 Removal And Installation (Left)......................................................... 471 Removal And Installation (Right)........................................................ 471 ACCESS PANEL (INSIDE) (SCPA)................................................................ 473 Removal And Installation (Left)......................................................... 473 Removal And Installation (Right)........................................................ 473 WINDOW (REAR)............................................................................... 475 Rear Window Identification.............................................................. 475 Removal (Rubber Cord)................................................................... 475 Installation (Rubber Cord).............................................................. 476 Removal And Installation (Latches)...................................................... 478 Disassembly And Assembly (Latches)...................................................... 478 WINDOW (TOP)................................................................................ 479 Removal And Installation................................................................ 479 WINDOW (SIDE)............................................................................... 481 Removal And Installation................................................................ 481 CAB DOOR.................................................................................... 483 Description............................................................................. 483 Removal And Installation................................................................ 483 Disassembly And Assembly................................................................ 484 Aligning................................................................................ 485 Adjusting............................................................................... 486 Checking Operation...................................................................... 486 ARMREST..................................................................................... 487 Description............................................................................. 487 Removal And Installation................................................................ 488 Disassembly And Assembly................................................................ 489 LEFT SIDE LOWER PANEL....................................................................... 491 Removal And Installation................................................................ 491 Disassembly And Assembly................................................................ 493 RIGHT SIDE LOWER PANEL...................................................................... 495 Removal And Installation................................................................ 495 Disassembly And Assembly................................................................ 496 HEADLINER................................................................................... 499 Removal And Installation................................................................ 499 FAN DUCT PANELS............................................................................. 501 Removal And Installation................................................................ 501 ELECTRICAL SYSTEM AND ANALYSIS.................................................................. 503 ELECTRICAL SCHEMATICS....................................................................... 507 ELECTRICAL SYSTEM INFORMATION............................................................... 619 Glossary Of Electrical Symbols.......................................................... 619 Deluxe Cab Harness Connectors........................................................... 622 SCPA Mainframe Harness Connectors....................................................... 623 SJC Mainframe Harness Connectors........................................................ 624 Engine Harness Connectors............................................................... 625 Description............................................................................. 626 Troubleshooting......................................................................... 627 Fuse And Relay Location / Identification................................................ 628 Solenoid Testing........................................................................ 633 BATTERY..................................................................................... 635 Removal And Installation................................................................ 635 Servicing............................................................................... 636 Using A Booster Battery (Jump Starting)................................................. 637 ALTERNATOR.................................................................................. 639 Belt Adjustment......................................................................... 639 Belt Replacement........................................................................ 639 Charging System Inspection.............................................................. 640 Alternator Voltage Testing.............................................................. 641 Low Voltage Testing..................................................................... 641 High Voltage Testing.................................................................... 642 Removal And Installation................................................................ 643 STARTER..................................................................................... 647 Testing................................................................................. 647 Removal And Installation................................................................ 647 Parts Identification.................................................................... 648 INSTRUMENT PANELS........................................................................... 649 Left Panel.............................................................................. 649 Display Screen.......................................................................... 651 Right Panel (Standard Key Panel)........................................................ 652 Right Panel (Keyless Start Panel)....................................................... 653 Right Panel (Deluxe Instrumentation Panel).............................................. 654 Left Switch Panel....................................................................... 656 Right Switch Panel...................................................................... 656 Left Side Lower Panel................................................................... 657 Right Side Lower Panel.................................................................. 657 Radio................................................................................... 658 Left Panel Removal And Installation..................................................... 660 Right Panel Removal And Installation.................................................... 660 Key Switch Disassembly And Assembly..................................................... 661 Alarm Disassembly And Assembly.......................................................... 661 Left Switch Panel Removal And Installation.............................................. 662 Right Switch Panel Removal And Installation............................................. 662 LIGHTS...................................................................................... 663 Front Removal And Installation.......................................................... 663 Rear Removal And Installation........................................................... 664 Cab Light Removal And Installation...................................................... 664 BOBCAT CONTOLERS (GATEWAY AND AUXILLIARY)................................................... 665 Description............................................................................. 665 Connector Identification................................................................ 666 Removal And Installation................................................................ 672 BOBCAT CONTROLLER (ACS)..................................................................... 673 Description............................................................................. 673 Connector And Wire Identification....................................................... 674 Removal And Installation................................................................ 676 BOBCAT CONTROLLER (SJC) (DRIVE)............................................................. 677 Description............................................................................. 677 Connector Identification (Earlier Models)............................................... 678 Removal And Installation (Earlier Models)............................................... 680 Connector Identification (Later Models)................................................. 682 Removal And Installation (Later Models)................................................. 685 BOBCAT CONTROLLER (SCPA) (DRIVE)............................................................ 687 Description............................................................................. 687 Connector Identification (Earlier Models)............................................... 688 Removal And Installation (Earlier Models)............................................... 690 Connector Identification (Later Models)................................................. 692 Removal And Installation (Later Models)................................................. 695 DOSING CONTROL UNIT (DCU)................................................................... 697 Description............................................................................. 697 Removal And installation................................................................ 697 ENGINE CONTROL UNIT (ECU)................................................................... 699 Description............................................................................. 699 Cleaning................................................................................ 700 Removal And Installation................................................................ 701 DIAGNOSTIC SERVICE CODES.................................................................... 703 Viewing Service Codes................................................................... 703 Service Codes List...................................................................... 704 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..................................................... 719 Description............................................................................. 719 Inspecting The BICS™ (Engine STOPPED - Key ON).......................................... 720 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON).... 720 Inspecting The Seat Bar Sensor (Engine RUNNING)......................................... 720 Inspecting The Traction Lock (Engine RUNNING)........................................... 720 Inspecting The Lift Arm Bypass Control.................................................. 720 Inspecting Deactivation Of Lift And Tilt Functions (SJC)................................ 720 Troubleshooting......................................................................... 721 SEAT BAR SENSOR............................................................................. 723 Description............................................................................. 723 Troubleshooting......................................................................... 723 Testing................................................................................. 724 Removal And Installation................................................................ 725 Bobcat Interlock Control System (BICS™) Circuit Test.................................... 728 TRACTION LOCK............................................................................... 731 Description............................................................................. 731 Troubleshooting......................................................................... 732 Inspecting.............................................................................. 733 ELECTRICAL / HYDRAULIC CONTROLS (SJC)....................................................... 735 Identification Chart.................................................................... 735 Description............................................................................. 736 Identification Chart ACD Group 0........................................................ 737 Identification Chart ACD Group 1........................................................ 738 Identification Chart ACD Group 2........................................................ 739 Identification Chart ACD Group 3........................................................ 740 ELECTRICAL / HYDRAULIC CONTROLS (SCPA)...................................................... 741 Identification Chart.................................................................... 741 Description............................................................................. 742 Identification Chart ACD Group 0........................................................ 743 Identification Chart ACD Group 1........................................................ 744 Identification Chart ACD Group 2........................................................ 745 Identification Chart ACD Group 3........................................................ 746 SERVICE PC (LAPTOP COMPUTER)................................................................ 747 Connecting Remote Start Tool............................................................ 747 Connecting Remote Start Tool (Service Tool)............................................. 747 CALIBRATION................................................................................. 749 Description............................................................................. 749 Actuator Testing........................................................................ 749 Lift And Tilt Calibration (SJC)......................................................... 752 Hydrostatic Pump Calibration (SJC)...................................................... 754 Hydrostatic Pump Calibration (SCPA)..................................................... 759 STEERING DRIFT COMPENSATION (OPERATOR MODE)................................................. 765 Description............................................................................. 765 Operation............................................................................... 765 STEERING DRIFT COMPENSATION (SERVICE MODE).................................................. 767 Description............................................................................. 767 Operation............................................................................... 767 CONTROL PANEL SETUP......................................................................... 769 Right Panel Setup (Deluxe Instrumentation Panel)........................................ 769 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)............................................... 773 Password Description.................................................................... 773 Changing The Owner Password............................................................. 773 Changing The User Passwords............................................................. 774 Password Lockout Feature................................................................ 774 PASSWORD SETUP (KEYLESS START PANEL)........................................................ 775 Password Description.................................................................... 775 Changing The Owner Password............................................................. 775 Password Lockout Feature................................................................ 775 MAINTENANCE CLOCK........................................................................... 777 Description............................................................................. 777 Setup................................................................................... 778 Reset................................................................................... 781 BACK-UP ALARM SYSTEM........................................................................ 783 Description............................................................................. 783 Inspecting.............................................................................. 783 Troubleshooting (Joystick).............................................................. 784 Alarm Removal And Installation.......................................................... 785 FRONT HORN.................................................................................. 787 Removal And Installation................................................................ 787 Troubleshooting......................................................................... 788 Troubleshooting (Joystick).............................................................. 789 ENGINE COMPARTMENT TEMPERATURE SENSOR....................................................... 791 Removal And Installation................................................................ 791 ENGINE SERVICE.................................................................................. 793 ENGINE INFORMATION.......................................................................... 797 Description............................................................................. 797 Specifications.......................................................................... 798 Sensor Location......................................................................... 800 Torque Values........................................................................... 807 Troubleshooting......................................................................... 809 Engine Removal And Installation......................................................... 811 Engine Mount Replacement................................................................ 822 Compression - Testing................................................................... 824 Injector Signal - Testing............................................................... 826 Injector Signal - Testing (In-Line)..................................................... 828 ENGINE SPEED CONTROL (HAND)................................................................. 831 Removal And Installation................................................................ 831 ENGINE SPEED CONTROL (FOOT)................................................................. 833 Removal And Installation................................................................ 833 Disassembly And Assembly................................................................ 834 Foot Throttle Calibration............................................................... 836 SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM.................................................. 839 Description............................................................................. 839 Diesel Exhaust Fluid (DEF) / AdBlue® Level.............................................. 840 DeSOX Process........................................................................... 841 SCR System Codes........................................................................ 843 Diesel Exhaust Fluid (DEF) / AdBlue® Unsatisfactory Quality............................. 844 SCR System Component Tampering.......................................................... 844 EGR Impeded............................................................................. 845 Diesel Exhaust Fluid (DEF) / AdBlue® Dosing Interruption................................ 845 SCR Removal And Installation............................................................ 846 Dosing Module Removal And Installation.................................................. 848 Dosing Control Unit (DCU) Removal And Installation...................................... 849 Supply Module Removal And Installation.................................................. 851 Supply Module Filter Removal And Installation........................................... 852 Diesel Exhaust Fluid (DEF) / AdBlue® Tank Removal And Installation (Earlier Models)..... 854 Diesel Exhaust Fluid (DEF) / AdBlue® Tank Removal And Installation (Later Models)....... 857 Diesel Exhaust Fluid (DEF) / AdBlue® Sensor Removal And Installation (Later Models)..... 859 Diesel Exhaust Fluid (DEF) / AdBlue® Coolant Valve Removal And Installation............. 861 DIESEL OXIDATION CATALYST (DOC)............................................................. 863 Removal And Installation................................................................ 863 AIR CLEANER................................................................................. 865 Housing Removal And Installation........................................................ 865 ENGINE COOLING SYSTEM....................................................................... 867 Radiator / Oil Cooler Removal And Installation.......................................... 867 Hydraulic Fan Description............................................................... 870 Hydraulic Reversing Fan Description..................................................... 870 Lower Fan Duct Removal And Installation................................................. 870 Hydraulic Fan Motor Assembly Removal And Installation................................... 871 Hydraulic Fan Motor Removal And Installation............................................ 873 Hydraulic Fan Motor Disassembly And Assembly............................................ 874 Blower Housing Removal And Installation................................................. 882 Water Pump Removal And Installation..................................................... 883 Thermostat Housing Removal And Installation............................................. 883 Thermostat - Testing.................................................................... 884 LUBRICATION SYSTEM.......................................................................... 885 Description............................................................................. 885 Oil Pan Removal And Installation........................................................ 886 Oil Pump Removal And Installation....................................................... 887 Oil Pump Relief Valve Description....................................................... 888 Oil Suction Pipe Removal And Installation............................................... 888 Oil Cooler Removal And Installation..................................................... 889 Oil Filter Head Removal And Installation................................................ 889 Oil Cooler Bypass Description........................................................... 890 FUEL SYSTEM................................................................................. 891 Description............................................................................. 891 High Pressure Pump Removal And Installation............................................. 892 High Pressure Pump Drive Gear Removal And Installation.................................. 894 Fuel Temperature Sensor Removal And Installation........................................ 894 Fuel Cooler Removal And Installation.................................................... 894 Fuel Cooler Bypass Valve Removal And Installation....................................... 895 Fuel Recirculation Valve Removal And Installation....................................... 896 Fuel Rail Assembly Removal And Installation............................................. 897 Fuel Injector Removal And Installation.................................................. 898 Injector Coding......................................................................... 900 Removing Air From The Fuel System....................................................... 902 CYLINDER HEAD............................................................................... 905 Intake Air Heater Removal And Installation.............................................. 905 Intake Air Heater Tube Removal And Installation......................................... 906 Valve Clearance Adjustment.............................................................. 907 Cylinder Head Removal And Installation.................................................. 909 Cylinder Head Disassembly And Assembly.................................................. 912 Cylinder Head Inspection................................................................ 913 Cylinder Head Top Clearance............................................................. 914 Valve Step Height....................................................................... 915 Valve Stem Height....................................................................... 915 Valve Guide............................................................................. 916 Valve................................................................................... 916 Valve Spring............................................................................ 917 Rocker Arm Shaft Disassembly And Assembly............................................... 918 Rocker Arm Shaft Inspection............................................................. 919 Push Rod Inspection..................................................................... 919 CRANKSHAFT AND PISTONS...................................................................... 921 Piston And Connecting Rod Removal And Installation...................................... 921 Piston And Connecting Rod Inspection.................................................... 922 Timing Wheel Removal And Installation................................................... 924 Crankshaft Removal And Installation..................................................... 926 Cylinder Block Inspection............................................................... 928 Crankshaft Inspection................................................................... 930 Connecting Rod Inspection............................................................... 930 Engine Component Class.................................................................. 931 CAMSHAFT.................................................................................... 933 Removal And Installation................................................................ 933 Inspecting.............................................................................. 934 GEARCASE.................................................................................... 937 Gear Backlash........................................................................... 937 Gear End Play........................................................................... 937 Gear Timing............................................................................. 938 Idle Gear Removal And Installation...................................................... 939 Idle Gear Inspection.................................................................... 939 TURBOCHARGER................................................................................ 941 Description............................................................................. 941 Removal And Installation................................................................ 941 Testing................................................................................. 943 FLYWHEEL AND HOUSING........................................................................ 945 Flywheel Removal And Installation....................................................... 945 Ring Gear Removal And Installation...................................................... 945 Housing Removal And Installation........................................................ 946 EXHAUST GAS RECIRCULATION (EGR) SYSTEM...................................................... 947 Description............................................................................. 947 Removal And Installation................................................................ 948 DIESEL EXHAUST FLUID (DEF) / ADBLUE® SYSTEM................................................. 951 Description............................................................................. 951 Filling The DEF / AdBlue® Tank.......................................................... 951 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)................................................ 953 AIR CONDITIONING SYSTEM FLOW................................................................ 955 Description............................................................................. 955 AC System Diagram....................................................................... 956 Components.............................................................................. 957 Safety Equipment........................................................................ 960 REGULAR MAINTENANCE......................................................................... 961 Filters................................................................................. 961 Compressor Drive Belt Adjustment........................................................ 962 Compressor Drive Belt Replacement....................................................... 962 Air Conditioning Condenser.............................................................. 963 Air Conditioning Lubrication............................................................ 963 Air Conditioning Service Chart.......................................................... 964 Evaporator / Heater Coil................................................................ 965 TROUBLESHOOTING............................................................................. 967 Blower Motor Does Not Operate........................................................... 967 Blower Motor Operates Normally, But Air Flow Is Insufficient............................ 967 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal.............. 967 The Compressor Does Not Operate At All, Or Operates Improperly.......................... 967 Gauge Pressure Related Troubleshooting.................................................. 968 Troubleshooting Tree.................................................................... 970 Temperature / Pressure Chart............................................................ 973 Poor A/C Performance.................................................................... 974 HVAC Repair And Leaks................................................................... 975 Electrical System....................................................................... 976 Engine Coolant Bypassing The Heater Valve............................................... 982 Heater Valve Not Opening Or Closing..................................................... 983 SYSTEM CHARGING AND RECLAMATION............................................................. 985 Refrigerant Identification.............................................................. 985 Reclamation And Charging With Recovery / Charging Unit.................................. 986 COMPRESSOR.................................................................................. 989 Removal And Installation................................................................ 989 Oil..................................................................................... 991 Oil Check............................................................................... 992 CONDENSER................................................................................... 993 Removal And Installation................................................................ 993 RECEIVER / DRIER............................................................................ 995 Receiver / Drier Removal And Installation............................................... 995 Pressure Switch Removal And Installation................................................ 997 Schrader® Valve Removal And Installation................................................ 998 EVAPORATOR / HEATER UNIT.................................................................... 999 Removal And Installation................................................................ 999 THERMOSTAT..................................................................................1001 Description.............................................................................1001 Removal And Installation................................................................1002 EXPANSION VALVE.............................................................................1003 Removal And Installation................................................................1003 EVAPORATOR COIL.............................................................................1005 Removal And Installation................................................................1005 HEATER COIL.................................................................................1007 Removal And Installation................................................................1007 BLOWER FAN..................................................................................1009 Removal And Installation................................................................1009 Disassembly And Assembly................................................................1009 HEATER VALVE................................................................................1013 Removal And Installation................................................................1013 EVAPORATOR / HEATER COVER...................................................................1015 Removal.................................................................................1015 Installation............................................................................1015 SPECIFICATIONS..................................................................................1017 (T870) LOADER SPECIFICATIONS................................................................1019 Machine Dimensions......................................................................1019 Performance.............................................................................1020 Engine..................................................................................1020 Drive System............................................................................1021 Controls................................................................................1021 Hydraulic System........................................................................1022 Electrical System.......................................................................1023 Capacities..............................................................................1023 Tracks..................................................................................1024 Ground Pressure.........................................................................1024 Fuel Consumption........................................................................1024 Environmental...........................................................................1024 Temperature Range.......................................................................1024 TECHNICAL SERVICE GUIDE SPECIFICATIONS......................................................1025 Engine..................................................................................1025 Engine Torques..........................................................................1025 Cooling System..........................................................................1025 Loader Torques..........................................................................1026 Hydraulic / Hydrostatic System..........................................................1026 Fuel Consumption........................................................................1026 TORQUE SPECIFICATIONS FOR BOLTS.............................................................1027 Torque For General SAE Bolts............................................................1027 Torque For General Metric Bolts.........................................................1028 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................1029 Straight Thread O-ring Fitting..........................................................1029 Flare Fitting...........................................................................1030 Tubelines And Hoses.....................................................................1030 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS................................................1031 Specifications..........................................................................1031 CONVERSIONS.................................................................................1033 Decimal And Millimeter Equivalent Chart.................................................1033 U.S. To Metric Conversion Chart.........................................................1033 SERVICE TOOLS REQUIRED......................................................................1035 Remote Start Tools......................................................................1035 Hydraulic Tools.........................................................................1036 Mainframe And Drive Tools...............................................................1038 Electrical Tools........................................................................1040 Engine Tools............................................................................1041 HVAC Tools..............................................................................1046 ALPHABETICAL INDEX..............................................................................1047
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