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Bobcat T870 Compact Track Loader Service Manual SN B47H11001 & Above – PDF DOWNLOAD
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Bobcat T870 Compact Track Loader Service Manual SN B47H11001 & Above – PDF DOWNLOAD
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Description
Bobcat T870 Compact Track Loader Service Manual SN B47H11001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat T870 Compact Track Loader Service Manual SN B47H11001 & Above – PDF DOWNLOAD
Language : English
Pages : 928
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T870 Compact Track Loader Service Manual SN B47H11001 & Above – PDF DOWNLOAD
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 SN B47H11001 & Above – PDF DOWNLOAD
MAINTENANCE SAFETY.............................................................................. 3 CONTENTS........................................................................................ 5 FOREWORD........................................................................................ 7 FOREWORD.................................................................................... 9 SAFETY INSTRUCTIONS......................................................................... 11 FIRE PREVENTION............................................................................. 13 Maintenance............................................................................. 13 Operation............................................................................... 13 Electrical.............................................................................. 13 Hydraulic System........................................................................ 13 Fueling................................................................................. 13 Starting................................................................................ 13 Spark Arrester Exhaust System........................................................... 13 Welding And Grinding.................................................................... 14 Fire Extinguishers...................................................................... 14 SERIAL NUMBER LOCATIONS..................................................................... 15 Loader Serial Number.................................................................... 15 Engine Serial Number.................................................................... 15 DELIVERY REPORT............................................................................. 16 LOADER IDENTIFICATION....................................................................... 17 SAFETY AND MAINTENANCE.......................................................................... 19 LIFTING AND BLOCKING THE LOADER............................................................. 23 Procedure............................................................................... 23 LIFT ARM SUPPORT DEVICE..................................................................... 25 Installing.............................................................................. 25 Removing................................................................................ 26 OPERATOR CAB................................................................................ 27 Description............................................................................. 27 Raising................................................................................. 28 Lowering................................................................................ 29 Cab Door Sensor......................................................................... 30 Special Applications Kit................................................................ 31 Special Applications Kit Inspection And Maintenance..................................... 31 Forestry Door And Window Kit............................................................ 32 Forestry Door And Window Kit Inspection And Maintenance................................. 32 TRANSPORTING THE LOADER ON A TRAILER........................................................ 33 Loading And Unloading................................................................... 33 Fastening............................................................................... 33 TOWING THE LOADER........................................................................... 35 Procedure............................................................................... 35 REMOTE START TOOL KIT - MEL1563............................................................. 37 Remote Start Tool - MEL1563............................................................. 37 Service Tool Harness Communicator - MEL1566............................................. 39 Remote Start Procedure.................................................................. 39 REMOTE START TOOL (SERVICE TOOL) KIT - 7217666.............................................. 43 Description............................................................................. 43 Remote Start Tool (Service Tool) - 7022042.............................................. 44 Loader Service Tool Harness - 6689747................................................... 45 Computer Service Tool Harness - 6689746................................................. 46 Remote Start Procedure.................................................................. 47 SERVICE SCHEDULE............................................................................ 51 Maintenance Intervals................................................................... 51 AIR CLEANER SERVICE......................................................................... 53 Replacing Filter Elements............................................................... 53 ENGINE COOLING SYSTEM....................................................................... 55 Maintenance Platform.................................................................... 55 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 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 SPARK ARRESTER MUFFLER...................................................................... 83 Cleaning Procedure...................................................................... 83 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................................................................................ 98 HYDRAULIC / HYDROSTATIC SCHEMATICS..........................................................103 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................................................................................139 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..................................................183 Identification Chart....................................................................184 Lift Load Check Valve Removal And Installation..........................................185 Load Check Valve Removal And Installation (Tilt And Auxiliary)..........................186 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................187 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...........187 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...........188 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............188 Port Relief Valve Removal And Installation..............................................189 Plug Removal And Installation...........................................................191 Rubber Boot Removal And Installation....................................................192 End Cap Block Removal And Installation..................................................192 Lift Spool And Detent Removal And Installation..........................................193 Tilt Spool Removal And Installation.....................................................201 Auxiliary Spool Removal And Installation................................................203 Auxiliary Solenoid Removal And Installation.............................................204 Solenoid Removal And Installation.......................................................204 Lock Valve Removal And Installation.....................................................206 Lift Arm Bypass Orifice Removal And Installation........................................208 Main Relief Valve Removal And Installation..............................................208 Auxiliary Relief Valve Removal And Installation.........................................209 Check Valve Removal And Installation....................................................209 LIFT ARM BYPASS CONTROL VALVE...............................................................211 Description.............................................................................211 Testing.................................................................................211 Removal And Installation................................................................212 Bracket Removal And Installation........................................................213 Disassembly And Assembly................................................................214 HYDRAULIC PUMP..............................................................................215 Description.............................................................................215 Pump Test At Quick Couplers.............................................................215 Direct Pump Test (Standard Section).....................................................216 Direct Pump Test (Charge Section).......................................................218 Removal And Installation................................................................220 Hydraulic Pump Startup..................................................................222 Parts Identification....................................................................223 Disassembly And Assembly................................................................224 HYDRAULIC PUMP (HIGH FLOW)..................................................................225 Description.............................................................................225 Pump Test At Quick Couplers.............................................................225 Direct Pump Test (Standard Section).....................................................226 Direct Pump Test (Charge Section).......................................................227 Direct Pump Test (High Flow Section)....................................................229 High Flow Relief Valve Adjustment.......................................................231 High Flow Relief Valve Removal And Installation.........................................233 Solenoid Removal And Installation.......................................................235 Removal And Installation................................................................236 Hydraulic Pump Startup..................................................................238 Parts Identification....................................................................239 Disassembly And Assembly................................................................240 HYDRAULIC / HYDROSTATIC FILTERS.............................................................241 Description.............................................................................241 Housing Removal And Installation........................................................241 HYDRAULIC FLUID RESERVOIR...................................................................243 Description.............................................................................243 Removal And Installation................................................................243 Hydraulic Fluid Screen..................................................................244 OIL COOLER..................................................................................245 Removal And Installation................................................................245 BUCKET POSITION VALVE.......................................................................247 Description.............................................................................247 Solenoid Removal And Installation.......................................................247 Solenoid Testing........................................................................248 Removal And Installation................................................................249 Disassembly And Assembly................................................................251 REAR AUXILIARY DIVERTER VALVE...............................................................253 Description.............................................................................253 Solenoid Testing........................................................................253 Removal And Installation................................................................254 Disassembly And Assembly................................................................255 BOB-TACH (POWER) BLOCK......................................................................261 Description.............................................................................261 Testing Relief Valve....................................................................262 Removal And Installation................................................................264 Disassembly And Assembly................................................................266 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK.....................................................271 Description.............................................................................271 Removal And Installation................................................................271 Disassembly And Assembly................................................................272 AUTOMATIC RIDE CONTROL......................................................................275 Description.............................................................................275 Removal And Installation................................................................276 Checking The Pressure In The Accumulator................................................279 Adding Nitrogen To The Accumulator......................................................281 HYDRAULIC PRESSURE REDUCING VALVE...........................................................283 Description.............................................................................283 Removal And Installation................................................................284 Disassembly And Assembly................................................................285 HYDROSTATIC SYSTEM..............................................................................287 HYDROSTATIC SYSTEM INFORMATION..............................................................289 Description.............................................................................289 Troubleshooting.........................................................................290 HYDROSTATIC DRIVE MOTOR.....................................................................291 Description.............................................................................291 Removing And Replacing Fluid............................................................291 Removal And Installation................................................................292 Parts Identification....................................................................295 Disassembly And Assembly................................................................297 CHARGE PRESSURE.............................................................................311 Description.............................................................................311 Testing.................................................................................311 Sender Removal And Installation.........................................................313 Adjusting...............................................................................314 HYDROSTATIC PUMP (SJC AND SCPA).............................................................315 Description.............................................................................315 Hydraulic Controller Removal And Installation...........................................316 Removal And Installation................................................................318 Hydrostatic Pump Startup................................................................319 Parts Identification....................................................................320 High Pressure Relief And Bypass Valve...................................................321 Charge Relief Valve.....................................................................322 Disassembly.............................................................................323 Inspection..............................................................................332 Assembly................................................................................335 Mechanical Neutral Adjustment...........................................................343 Hydraulic Controller Neutral Adjustment.................................................346 DRIVE BELT..................................................................................349 Belt Adjustment.........................................................................349 Stop Adjustment.........................................................................349 Belt Replacement........................................................................349 Tensioner Pulley Removal And Installation...............................................352 Tensioner Pulley Disassembly And Assembly...............................................352 TWO-SPEED / BRAKE VALVE.....................................................................355 Description.............................................................................355 Valve Block Removal And Installation....................................................356 Valve Block Disassembly And Assembly....................................................358 DRAIN MANIFOLD..............................................................................361 Description.............................................................................361 Drain Manifold Removal And Installation.................................................361 DRIVE SYSTEM....................................................................................363 TRACK UNDERCARRIAGE COMPONENTS..............................................................365 Description.............................................................................365 Track Tension Description...............................................................366 Adjusting The Hydraulic Pressure Reducing Valve.........................................366 Hydraulic Tensioner Valve Service Position..............................................367 Track Removal And Installation..........................................................368 Idler (Front) Removal And Installation..................................................370 Track Tensioner Removal And Installation................................................371 Track Tensioner Parts Identification....................................................373 Track Tensioner Disassembly And Assembly................................................374 Idler (Rear) Removal And Installation...................................................377 Roller Removal And Installation.........................................................377 Sprocket Removal And Installation.......................................................378 Track Housing Removal And Installation..................................................379 Torsion Axle Removal And Installation...................................................382 TRACK MAINTENANCE...........................................................................383 Track Damage Identification.............................................................383 MAINFRAME.......................................................................................395 SEAT BAR....................................................................................399 Description.............................................................................399 Removal And Installation................................................................399 Disassembly And Assembly................................................................400 Compression Spring Disassembly And Assembly.............................................401 OPERATOR CAB................................................................................403 Gas Spring Removal And Installation.....................................................403 Gas Spring Bracket Disassembly And Assembly.............................................404 Removal And Installation................................................................405 OPERATOR SEAT (SUSPENSION)..................................................................407 Removal And Installation................................................................407 Slide Rail Removal And Installation.....................................................407 Seat Belt Removal And Installation......................................................408 Lower Cushion Removal...................................................................408 Lower Cushion Installation..............................................................409 Back Cushion Removal And Installation...................................................409 Shock Removal And Installation..........................................................410 3-Point Seat Belt Removal And Installation..............................................410 BOB-TACH (HAND LEVER).......................................................................413 Description.............................................................................413 Removal And Installation................................................................413 Lever And Wedge Disassembly And Assembly................................................415 Pivot Pin Bushing And Seal Removal And Installation.....................................417 BOB-TACH (POWER)............................................................................419 Description.............................................................................419 Removal And Installation................................................................419 Lever And Wedge Disassembly And Assembly................................................422 Pivot Pin Bushing And Seal Removal And Installation.....................................424 LIFT ARMS...................................................................................425 Stabilizer Bar Removal And Installation.................................................425 Link Removal And Installation...........................................................426 Removal And Installation................................................................427 REAR GRILLE.................................................................................431 Removing................................................................................431 Installing..............................................................................431 Shield Removal And Installation.........................................................432 REAR DOOR (TAILGATE)........................................................................433 Removal And Installation................................................................433 Striker Removal And Installation........................................................434 Striker Disassembly And Assembly........................................................434 Striker (Adjusting).....................................................................434 Latch Removal And Installation..........................................................435 FUEL TANK...................................................................................437 Removal And Installation................................................................437 Fuel Level Sender Removal And Installation..............................................438 Fuel Fill Screen Removal And Installation...............................................439 CONTROL PEDALS AND LINKAGES (SCPA)..........................................................441 Description.............................................................................441 Pedal Removal And Installation..........................................................441 Linkage Removal And Installation........................................................442 Pedal (Adjusting).......................................................................443 Floor Pan Removal And Installation......................................................444 CONTROL PANEL (SJC).........................................................................445 Description.............................................................................445 Removal And Installation................................................................445 CONTROL PANEL (SCPA)........................................................................447 Description.............................................................................447 Removal And Installation................................................................447 CONTROL HANDLE / LEVER (SJC)................................................................449 Description.............................................................................449 Joystick Testing........................................................................449 Joystick Removal And Installation.......................................................450 CONTROL HANDLE / LEVER (SCPA)...............................................................451 Description.............................................................................451 Steering Handle Testing.................................................................451 Steering Handle Removal And Installation................................................452 ACCESS PANEL (INSIDE).......................................................................453 Removal And Installation (Left).........................................................453 Removal And Installation (Right)........................................................453 ACCESS PANEL (INSIDE) (SJC).................................................................455 Removal And Installation (Left).........................................................455 Removal And Installation (Right)........................................................455 WINDOW (REAR)...............................................................................457 Rear Window Identification..............................................................457 Removal (Rubber Cord)...................................................................457 Installation (Rubber Cord)..............................................................458 Removal And Installation (Latches)......................................................460 Disassembly And Assembly (Latches)......................................................460 WINDOW (TOP)................................................................................461 Removal And Installation................................................................461 WINDOW (SIDE)...............................................................................463 Removal And Installation................................................................463 CAB DOOR....................................................................................465 Description.............................................................................465 Removal And Installation................................................................465 Disassembly And Assembly................................................................466 Aligning................................................................................467 Adjusting...............................................................................468 Checking Operation......................................................................468 ARMREST.....................................................................................469 Description.............................................................................469 Removal And Installation................................................................470 Disassembly And Assembly................................................................471 LEFT SIDE LOWER PANEL.......................................................................473 Removal And Installation................................................................473 Disassembly And Assembly................................................................476 RIGHT SIDE LOWER PANEL......................................................................477 Removal And Installation................................................................477 Disassembly And Assembly................................................................479 HEADLINER...................................................................................481 Removal And Installation................................................................481 ELECTRICAL SYSTEM AND ANALYSIS..................................................................483 ELECTRICAL SCHEMATICS.......................................................................487 ELECTRICAL SYSTEM INFORMATION...............................................................549 Glossary Of Electrical Symbols..........................................................549 Deluxe Cab Harness Connectors...........................................................552 SJC Mainframe Harness Connectors........................................................553 SCPA Mainframe Harness Connectors.......................................................554 Description.............................................................................555 Troubleshooting.........................................................................556 Solenoid Testing........................................................................560 BATTERY.....................................................................................561 Battery Maintenance.....................................................................561 Maintaining Battery Charge Level........................................................561 Battery Service During Machine Storage..................................................561 Battery Testing.........................................................................562 Battery Charging........................................................................562 Removal And Installation................................................................563 Using A Booster Battery (Jump Starting).................................................564 ALTERNATOR..................................................................................565 Belt Adjustment.........................................................................565 Belt Replacement........................................................................565 Charging System Inspection..............................................................566 Alternator Voltage Testing..............................................................567 Low Voltage Testing.....................................................................567 High Voltage Testing....................................................................568 Removal And Installation................................................................569 Parts Identification....................................................................570 STARTER.....................................................................................571 Testing.................................................................................571 Removal And Installation................................................................571 Parts Identification....................................................................572 INSTRUMENT PANELS...........................................................................573 Left Panel..............................................................................573 Display Screen..........................................................................575 Right Panel (Standard Key Panel)........................................................575 Right Panel (Keyless Start Panel).......................................................576 Right Panel (Deluxe Instrumentation Panel)..............................................577 Left Switch Panel.......................................................................579 Right Switch Panel......................................................................579 Left Side Lower Panel...................................................................580 Right Side Lower Panel..................................................................580 Left Panel Removal And Installation.....................................................581 Right Panel Removal And Installation....................................................581 Key Switch Disassembly And Assembly.....................................................582 Alarm Disassembly And Assembly..........................................................582 Left Switch Panel Removal And Installation..............................................583 Right Switch Panel Removal And Installation.............................................583 LIGHTS......................................................................................585 Front Removal And Installation..........................................................585 Rear Removal And Installation...........................................................586 Cab Light Removal And Installation......................................................586 BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)..................................................587 Description.............................................................................587 Connector Identification................................................................588 Removal And Installation................................................................594 BOBCAT CONTROLLER (ACS).....................................................................595 Description.............................................................................595 Connector And Wire Identification.......................................................595 Removal And Installation................................................................597 BOBCAT CONTROLLER (SJC) (DRIVE).............................................................599 Description.............................................................................599 Connector Identification................................................................600 Removal And Installation................................................................603 BOBCAT CONTROLLER (SCPA) (DRIVE)............................................................605 Description.............................................................................605 Connector Identification................................................................606 Removal And Installation................................................................609 DIAGNOSTIC SERVICE CODES....................................................................611 Viewing Service Codes...................................................................611 Service Codes List......................................................................612 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™).....................................................619 Description.............................................................................619 Inspecting The BICS™ (Engine STOPPED - Key ON)..........................................620 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....620 Inspecting The Seat Bar Sensor (Engine RUNNING).........................................620 Inspecting The Traction Lock And Parking Brake (Engine RUNNING).........................620 Inspecting The Lift Arm Bypass Control..................................................620 Inspecting Deactivation Of Lift And Tilt Functions (SJC)................................620 Troubleshooting.........................................................................621 SEAT BAR SENSOR.............................................................................623 Description.............................................................................623 Troubleshooting.........................................................................623 Testing.................................................................................624 Removal And Installation................................................................625 Bobcat Interlock Control System (BICS™) Circuit Test....................................628 TRACTION LOCK...............................................................................631 Description.............................................................................631 Troubleshooting.........................................................................632 Inspecting..............................................................................633 ELECTRICAL / HYDRAULIC CONTROLS (SJC).......................................................635 Identification Chart....................................................................635 Description.............................................................................636 Identification Chart ACD Group 0........................................................637 Identification Chart ACD Group 1........................................................638 Identification Chart ACD Group 2........................................................639 Identification Chart ACD Group 3........................................................640 ELECTRICAL / HYDRAULIC CONTROLS (SCPA)......................................................641 Identification Chart....................................................................641 Description.............................................................................642 Identification Chart ACD Group 0........................................................643 Identification Chart ACD Group 1........................................................644 Identification Chart ACD Group 2........................................................645 Identification Chart ACD Group 3........................................................646 SERVICE PC (LAPTOP COMPUTER)................................................................647 Connecting Remote Start Tool............................................................647 Connecting Remote Start Tool (Service Tool).............................................647 CALIBRATION.................................................................................649 Description.............................................................................649 Actuator Testing........................................................................649 Lift And Tilt Calibration (SJC).........................................................652 Hydrostatic Pump Calibration (SJC)......................................................653 Hydrostatic Pump Calibration (SCPA).....................................................659 STEERING DRIFT COMPENSATION (OPERATOR MODE).................................................665 Description.............................................................................665 Operation...............................................................................665 STEERING DRIFT COMPENSATION (SERVICE MODE)..................................................667 Description.............................................................................667 Operation...............................................................................667 FLYWHEEL RPM SENSOR.........................................................................669 Description.............................................................................669 Removal.................................................................................669 Installation............................................................................670 CONTROL PANEL SETUP.........................................................................671 Right Panel Setup (Deluxe Instrumentation Panel)........................................671 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...............................................675 Password Description....................................................................675 Changing The Owner Password.............................................................675 Changing The User Passwords.............................................................676 Password Lockout Feature................................................................676 PASSWORD SETUP (KEYLESS START PANEL)........................................................677 Password Description....................................................................677 Changing The Owner Password.............................................................677 Password Lockout Feature................................................................677 MAINTENANCE CLOCK...........................................................................679 Description.............................................................................679 Setup...................................................................................680 Reset...................................................................................683 BACK-UP ALARM SYSTEM........................................................................685 Description.............................................................................685 Inspecting..............................................................................685 Troubleshooting (Joystick)..............................................................686 Alarm Removal And Installation..........................................................687 FRONT HORN..................................................................................689 Removal And Installation................................................................689 Troubleshooting.........................................................................690 Troubleshooting (Joystick)..............................................................691 BOBCAT MACHINE IQ WIRELESS COMMUNICATIONS...................................................693 Description.............................................................................693 Removal And Installation................................................................693 Procedure...............................................................................694 ENGINE SERVICE..................................................................................695 ENGINE INFORMATION..........................................................................699 Description.............................................................................699 Specifications..........................................................................700 Torque Values...........................................................................703 Troubleshooting.........................................................................703 Engine Removal And Installation.........................................................705 Engine Mount Replacement................................................................712 Compression - Checking..................................................................713 ENGINE SPEED CONTROL (HAND).................................................................715 Removal And Installation................................................................715 Disassembly And Assembly................................................................715 Cable Removal And Installation..........................................................716 ENGINE SPEED CONTROL (FOOT) (EARLIER MODELS)................................................717 Removal And Installation................................................................717 Disassembly And Assembly................................................................718 ENGINE SPEED CONTROL (FOOT) (LATER MODELS)..................................................721 Removal And Installation................................................................721 Disassembly And Assembly................................................................722 MUFFLER.....................................................................................723 Removal And Installation................................................................723 AIR CLEANER.................................................................................725 Housing Removal And Installation........................................................725 ENGINE COOLING SYSTEM.......................................................................727 Radiator / Oil Cooler Removal And Installation..........................................727 Hydraulic Fan Description...............................................................729 Hydraulic Reversing Fan Description.....................................................729 Lower Fan Duct Removal And Installation.................................................730 Hydraulic Fan Motor Assembly Removal And Installation...................................731 Hydraulic Fan Motor Removal And Installation............................................733 Hydraulic Fan Motor Disassembly And Assembly............................................734 Blower Housing Removal And Installation.................................................742 Water Pump Removal And Installation.....................................................743 Water Pump Disassembly And Assembly.....................................................743 Thermostat Housing Removal And Installation.............................................744 Thermostat - Checking...................................................................744 LUBRICATION SYSTEM..........................................................................745 Oil Pan Removal And Installation........................................................745 Oil Pump Removal And Installation.......................................................746 Oil Pump Inspection.....................................................................746 Oil Filter Cooler Removal And Installation..............................................748 Engine Oil Pressure - Testing...........................................................749 FUEL SYSTEM.................................................................................751 Fuel Shutoff Solenoid - Checking........................................................751 Fuel Shutoff Solenoid Removal And Installation..........................................751 Fuel Injection Pump Assembly Removal....................................................752 Fuel Injection Pump Assembly Installation...............................................756 Governor Housing Disassembly And Assembly...............................................758 Governor Disassembly And Assembly.......................................................760 Fuel Camshaft Removal And Installation..................................................762 Fuel Injection Pump Removal.............................................................764 Fuel Injection Pump Installation........................................................767 Injection Pump - Timing.................................................................770 Fuel Injector Removal And Installation..................................................774 Fuel Injector Nozzle Pressure - Checking................................................775 Nozzle Spraying Condition...............................................................776 Valve Seat Tightness....................................................................776 CYLINDER HEAD...............................................................................777 Intake Air Heater - Testing.............................................................777 Intake Air Heater Removal And Installation..............................................777 Valve Clearance Adjustment..............................................................778 Valve Timing - Checking.................................................................780 Cylinder Head Removal And Installation..................................................781 Cylinder Head Disassembly And Assembly..................................................783 Cylinder Head - Servicing...............................................................784 Cylinder Head Top Clearance.............................................................784 Valve Guide - Checking..................................................................785 Reconditioning The Valve And Valve Seat.................................................787 Valve Spring............................................................................789 Valve Tappets...........................................................................790 Rocker Arm And Shaft - Checking.........................................................791 Push Rod Alignment - Checking...........................................................791 CRANKSHAFT AND PISTONS......................................................................793 Piston And Connecting Rod Removal And Installation......................................793 Piston And Connecting Rod - Servicing...................................................795 Cylinder Bore - Checking................................................................799 Connecting Rod Alignment................................................................800 Crankshaft Gear Removal And Installation................................................800 Crankshaft And Bearings Removal.........................................................801 Crankshaft And Bearings Installation....................................................803 Crankshaft And Bearings - Servicing.....................................................805 CAMSHAFT AND TIMING GEARS...................................................................811 Timing Gearcase Cover Removal And Installation..........................................811 Timing Gears Backlash - Checking........................................................812 Idler Gear And Camshaft Removal And Installation........................................812 Camshaft - Servicing....................................................................813 Idler Gear And Shaft - Servicing........................................................815 TURBOCHARGER................................................................................817 Description.............................................................................817 Testing.................................................................................817 Removal And Installation................................................................818 FLYWHEEL AND HOUSING........................................................................821 Flywheel Removal And Installation.......................................................821 Ring Gear Removal And Installation......................................................821 Housing Removal And Installation........................................................822 EXHAUST GAS RECIRCULATION (EGR) SYSTEM......................................................823 Description.............................................................................823 Testing.................................................................................824 Removal And Installation................................................................827 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)................................................829 AIR CONDITIONING SYSTEM FLOW................................................................831 Description.............................................................................831 A/C System Diagram......................................................................832 Components..............................................................................833 Safety Equipment........................................................................836 REGULAR MAINTENANCE.........................................................................837 Filters.................................................................................837 Compressor Drive Belt Adjustment........................................................838 Compressor Drive Belt Replacement.......................................................838 Air Conditioning Condenser..............................................................839 Air Conditioning Lubrication............................................................839 Air Conditioning Service Chart..........................................................840 Evaporator / Heater Coil................................................................841 TROUBLESHOOTING.............................................................................843 Blower Motor Does Not Operate...........................................................843 Blower Motor Operates Normally, But Air Flow Is Insufficient............................843 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal..............843 The Compressor Does Not Operate At All, Or Operates Improperly..........................843 Gauge Pressure Related Troubleshooting..................................................844 Troubleshooting Tree....................................................................846 Temperature / Pressure Chart............................................................849 Poor A/C Performance....................................................................850 HVAC Repair And Leaks...................................................................851 Electrical System.......................................................................852 Engine Coolant Bypassing The Heater Valve...............................................858 Heater Valve Not Opening Or Closing.....................................................859 SYSTEM CHARGING AND RECLAMATION.............................................................861 Refrigerant Identification..............................................................861 Reclamation And Charging With Recovery / Charging Unit..................................862 COMPRESSOR..................................................................................865 Removal And Installation................................................................865 Oil.....................................................................................867 Oil Check...............................................................................868 CONDENSER...................................................................................869 Removal And Installation................................................................869 RECEIVER / DRIER............................................................................871 Receiver / Drier Removal And Installation...............................................871 Pressure Switch Removal And Installation................................................873 Schrader® Valve Removal And Installation................................................874 EVAPORATOR / HEATER UNIT....................................................................875 Removal And Installation................................................................875 THERMOSTAT..................................................................................877 Description.............................................................................877 Removal And Installation................................................................878 EXPANSION VALVE.............................................................................879 Removal And Installation................................................................879 EVAPORATOR COIL.............................................................................881 Removal And Installation................................................................881 HEATER COIL.................................................................................883 Removal And Installation................................................................883 BLOWER FAN..................................................................................885 Removal And Installation................................................................885 Disassembly And Assembly................................................................885 HEATER VALVE................................................................................889 Removal And Installation................................................................889 EVAPORATOR / HEATER COVER...................................................................891 Removal.................................................................................891 Installation............................................................................891 SPECIFICATIONS..................................................................................893 (T870) LOADER SPECIFICATIONS................................................................895 Machine Dimensions......................................................................895 Performance.............................................................................896 Engine..................................................................................896 Drive System............................................................................897 Controls................................................................................898 Hydraulic System........................................................................898 Electrical System.......................................................................899 Capacities..............................................................................899 Tracks..................................................................................899 Ground Pressure.........................................................................899 TORQUE SPECIFICATIONS FOR BOLTS.............................................................901 Torque For General SAE Bolts............................................................901 Torque For General Metric Bolts.........................................................902 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................903 Straight Thread O-ring Fitting..........................................................903 Flare Fitting...........................................................................904 Tubelines And Hoses.....................................................................904 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS................................................905 Specifications..........................................................................905 CONVERSIONS.................................................................................907 Decimal And Millimeter Equivalent Chart.................................................907 U.S. To Metric Conversion Chart.........................................................907 SERVICE TOOLS REQUIRED......................................................................909 Remote Start Tools......................................................................909 Hydraulic Tools.........................................................................910 Mainframe And Drive Tools...............................................................913 Electrical Tools........................................................................916 Engine Tools............................................................................917 HVAC Tools..............................................................................922 ALPHABETICAL INDEX..............................................................................923
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V
