Service Manual

T870 Compact Track Loader

S/N A3PG11001 & Above

S/N A3PH11001 & Above

Dealer Copy -- Not for Resale

EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)

6987487 (4-11) Printed in U.S.A. © Bobcat Company 2011

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 MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807

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

CORRECT CORRECT CORRECT

P-90216 NA1711 NA1715

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.

WRONG WRONG WRONG

Dealer Copy -- Not for Resale

NA1714 NA1710 NA1712
Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG

NA1722 NA1725 B-6589

Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW40-0609

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 CONTENTS

SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

MAINFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

ELECTRICAL SYSTEM & ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . 80-01

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

Dealer Copy -- Not for Resale

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 FOREWORD

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Spark Arrestor Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Loader Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Dealer Copy -- Not for Resale

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

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 SAFETY &
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.
SYSTEM
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including side screens) is in function correctly.
good condition and is not
modified.

2. Check that ROPS mounting 10. Enclosure door latches must DRIVE
hardware is tightened and is open and close freely.
Bobcat approved.

3. The seat belt must be 11. Bob-Tach wedges and

correctly installed, functional linkages must function
and in good condition. correctly and be in good

Dealer Copy -- Not for Resale

condition.

4. The seat bar must be 12. Safety treads must be in good

correctly adjusted, clean and condition.
lubricated.

5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps.
HVAC

6. Machine signs (decals) must 14. Check hydraulic fluid level,

be legible and in the correct engine oil level and fuel
location. supply.

7. Steering levers, hand controls 15. Inspect for fuel, oil or

and foot pedals must return to hydraulic fluid leaks.
neutral (as applicable).

8. Check for correct function of 16. Lubricate the loader.

the work lights.

FW SSL-1008 SM

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17. Check the condition of the 23. Operate the machine and
battery and cables. check all functions.

18. Inspect the air cleaner for 24. Check for correct function of
damage or leaks. Check the the Bobcat Interlock Control
condition of the element. System (BICS™) before the
machine is returned to the
customer.
19. Check the electrical charging 25. Check for proper function of
system. front horn and back-up alarm
(if equipped).

20. Check tires for wear and 26. Check function or condition of
pressure. Check tracks for all equipped options and
wear and tension. Use only accessories (examples: fire

Dealer Copy -- Not for Resale

approved tires or tracks. extinguisher, rotating beacon,
lift kits, etc.).
21. Inspect for loose or broken 27. Recommend to the owner
parts or connections. that all necessary corrections
be made before the machine
is returned to service.

22. Check for any field

modification not completed.

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

FW SSL-1008 SM

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FW SSL-1008 SM

11 of 822 1-9 T870 Service Manual

SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• 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
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions • An Operator’s Handbook fastened to the operator
can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903

Dealer Copy -- Not for Resale

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.
IMPORTANT
• The AEM Safety Manual delivered with the machine
This notice identifies procedures which must be gives general safety information.
followed to avoid damage to the machine.
I-2019-0284 • The Service Manual and Parts Manual are available
from your dealer for use by mechanics to do shop-
type service and repair work.

• The Skid-Steer Loader Operator Training Course is

DANGER available through your local dealer or at

www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
The signal word DANGER on the machine and in the of correct operation of the Skid-Steer Loader. The
manuals indicates a hazardous situation which, if not course is available in English and Spanish versions.
avoided, will result in death or serious injury.
D-1002-1107 • Service Safety Training Courses are available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com. They provide information for
safe and correct service procedures.

WARNING • The Skid-Steer Loader Safety Video is available from

your Bobcat dealer or at www.training.bobcat.com
The signal word WARNING on the machine and in the or www.bobcat.com.
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107

SI SSL-1008 SM

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SAFETY INSTRUCTIONS (CONT’D)

The dealer and owner / operator review the

recommended uses of the product when delivered. If the
owner / operator will be using the machine for a different
application(s) he or she must ask the dealer for
recommendations on the new use.

Cutting or drilling concrete containing sand or rock

containing quartz may result in exposure to silica dust.
Do not exceed Permissible Exposure Limits (PEL) to
silica dust as determined by OSHA or other job site Rules
and Regulations. Use a respirator, water spray or other
means to control dust. Silica dust can cause lung disease
and is known to the state of California to cause cancer.

Call Before You Dig

Dial 811 (USA Only)

Dealer Copy -- Not for Resale

1-888-258-0808 (USA & Canada)
When you call, you will be directed to a location in your
state / province, or city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.).

SI SSL-1008 SM

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FIRE PREVENTION Hydraulic System

Check hydraulic tubes, hoses and fittings for damage

and leakage. Never use open flame or bare skin to check
for leaks. Hydraulic tubes and hoses must be properly
routed and have adequate support and secure clamps.
Tighten or replace any parts that show leakage.

Maintenance Always clean fluid spills. Do not use gasoline or diesel

fuel for cleaning parts. Use commercial nonflammable
The machine and some attachments have components
solvents.
that are at high temperatures under normal operating
conditions. The primary source of high temperatures is
Fueling
the engine and exhaust system. The electrical system, if
damaged or incorrectly maintained, can be a source of
arcs or sparks.

Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard. Stop the engine and let it cool before adding fuel. No
smoking! Do not refuel a machine near open flames or
The operator’s area, engine compartment and engine sparks. Fill the fuel tank outdoors.

Dealer Copy -- Not for Resale

cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Starting

All fuels, most lubricants and some coolants mixtures are Do not use ether or starting fluids on any engine that has
flammable. Flammable fluids that are leaking or spilled glow plugs or air intake heater. These starting aids can
onto hot surfaces or onto electrical components can cause explosion and injure you or bystanders.
cause a fire.
Use the procedure in the Operation & Maintenance
Operation Manual for connecting the battery and for jump starting.

Do not use the machine where exhaust, arcs, sparks or

hot components can contact flammable material, Spark Arrestor Exhaust System
explosive dust or gases. The spark arrestor exhaust system is designed to control
the emission of hot particles from the engine and exhaust
Electrical system, but the muffler and the exhaust gases are still
hot.

Check the spark arrestor exhaust system regularly to

make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
cleaning the spark arrestor muffler (if equipped).
Check all electrical wiring and connections for damage.
Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or
frayed.

Battery gas can explode and cause serious injury. Use

the procedure in the Operation & Maintenance Manual
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.

SI SSL-1008 SM

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FIRE PREVENTION (CONT’D)

Welding And Grinding

Always clean the machine and attachment, disconnect

the battery, and disconnect the wiring from the Bobcat
controllers before welding. Cover rubber hoses, battery
and all other flammable parts. Keep a fire extinguisher
near the machine when welding.

Have good ventilation when grinding or welding painted

parts. Wear dust mask when grinding painted parts.
Toxic dust or gas can be produced.

Dust generated from repairing nonmetallic parts such as

hoods, fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away
from open flames or sparks.

Fire Extinguishers

Dealer Copy -- Not for Resale

Know where fire extinguishers and first aid kits are
located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.

SI SSL-1008 SM

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SERIAL NUMBER LOCATIONS Engine Serial Number

Always use the serial number of the loader when Figure 3

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.

Loader Serial Number

Figure 1

P-90641A
1

The engine serial number (Item 1) [Figure 3] is located

on the side of the engine above the oil filter.

Dealer Copy -- Not for Resale

P-90642

The loader serial number plate (Item 1) [Figure 1] is

located on the outside of the loader frame.

Figure 2

Module 2 - Production
Sequence (Series)

Module 1 - Model / Engine

Combination P-90175

Explanation of loader Serial Number [Figure 2]:

1. The four digit Model / Engine Combination Module

number identifies the model number and engine
combination.

2. The five digit Production Sequence Number identifies

the order which the loader is produced.

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DELIVERY REPORT

Figure 4

B-16315

The delivery report [Figure 4] must be completed by the

dealer and signed by the owner or operator when the
Bobcat loader is delivered. An explanation of the form
must be given to the owner.

Dealer Copy -- Not for Resale

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LOADER IDENTIFICATION

FRONT OPERATION &

LIGHTS MAINTENANCE
MANUAL AND
OPERATOR’S
GRAB HANDBOOK
HANDLES
OPERATOR SEAT
with SEAT BELT
AND SEAT BAR

TILT
CYLINDERS

FRONT AUXILIARY
QUICK COUPLERS

[1] BUCKET

Dealer Copy -- Not for Resale

STEP
BUCKET
STEPS

[2] OPERATOR CAB

LIFT (ROPS AND FOPS)
CYLINDER LIFT ARM
SUPPORT DEVICE

REAR
GRILLE

LIFT ARM

BACK-UP
ALARM

REAR
LIGHT
REAR
NA1838
DOOR TAIL LIGHT TRACKS NA1839

[1] BUCKETS - Several different buckets and other attachments are available for the Bobcat loader.
[2] ROPS, FOPS - Roll Over Protective Structure, per ISO 3471, and Falling Object Protective Structure per ISO
3449, Level I. Level II is available.

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 SAFETY & MAINTENANCE

LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Cab Door Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Special Applications Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
Special Applications Kit Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
Forestry Door And Window Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-5
Forestry Door And Window Kit Inspection And Maintenance . . . . . . . . . . . . . . . . . . 10-30-5

TRANSPORTING THE LOADER ON A TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Dealer Copy -- Not for Resale

Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

REMOTE START TOOL KIT-MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Service Tool Harness Communicator - MEL1566 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-3
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-3

REMOTE START TOOL (SERVICE TOOL) KIT - 7003031 . . . . . . . . . . . . . . . . . . . . . . 10-61-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1
Remote Start Tool (Service Tool) - 7003030 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-2
Loader Service Tool Harness - 6689747 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-3
Computer Service Tool Harness - 6689746 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-4
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-5

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Maintenance Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-3
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-3

19 of 822 10-01 T870 Service Manual

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-1

Checking And Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-1
Engine Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-1
Removing And Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-2

HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . 10-120-4
Removing And Replacing Hydraulic Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-5
Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-6

BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Dealer Copy -- Not for Resale

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-131-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-131-1

LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

SPARK ARRESTER MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

LOADER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

STOPPING THE ENGINE AND LEAVING THE LOADER . . . . . . . . . . . . . . . . . . . . . . 10-180-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

External Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

20 of 822 10-02 T870 Service Manual

LIFTING AND BLOCKING THE LOADER Figure 10-10-2

Procedure

Figure 10-10-1

P-85425
P-85423

Lift the rear of the loader and install jackstands in the

B-7023A notched area of the frame [Figure 10-10-2].

Figure 10-10-3

WARNING

Dealer Copy -- Not for Resale

AVOID INJURY OR DEATH
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0807 P-85424

Read the Removal & Installation, Disassembly & Lift the front of the loader and install jackstands under the
Assembly, etc. completely to become familiar with the struts [Figure 10-10-3].
procedure before beginning [Figure 10-10-1].
NOTE: Make sure the jackstands do not touch the
Always park the loader on a level surface. tracks. Make sure the tracks clear the floor or
any obstacles.

NOTE: The lift arms are raised for photo clarity.

WARNING
MACHINE FALLING OR MOVING CAN CAUSE
SERIOUS INJURY OR DEATH
Put jackstands under the front and rear of the
machine before running engine for service.
W-2718-0208

21 of 822 10-10-1 T870 Service Manual

 Dealer Copy -- Not for Resale

22 of 822 10-10-2 T870 Service Manual

LIFT ARM SUPPORT DEVICE Figure 10-20-1

Installing

1
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.

Service lift arm support device if damaged or if parts P-85463A P-90672

are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
causing injury or death. Put jackstands under the rear corners of the loader frame
W-2572-0407 (Inset) [Figure 10-20-1].

Remove the lift arm support device (Item 1) [Figure 10-

20-1] from the storage position.

DANGER

Dealer Copy -- Not for Resale

The operator must stay in the operator seat with the seat
belt fastened and the seat bar lowered until the lift arm
support device is installed.

Start the engine and raise the lift arms all the way up.

Figure 10-20-2

P-90328

AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409

Remove attachment from the loader. (See Removal And P-90677

Installation on Page 50-40-1.) OR (See Removal And
Installation on Page 50-41-1.)
Have a second person install the lift arm support device
over the rod of one of the lift cylinders [Figure 10-20-2].

The lift arm support device must be tight against the

cylinder rod.

23 of 822 10-20-1 T870 Service Manual

LIFT ARM SUPPORT DEVICE (CONT’D) Removing

Installing (Cont’d) The operator must be in the operator’s seat, with the seat
belt fastened and seat bar lowered, until the lift arm
Figure 10-20-3 support device is removed and the lift arms are lowered
all the way.

Start the engine and raise the lift arms all the way up.

Have a second person remove the lift arm support

device.

Lower the lift arms all the way and stop the engine.
P-90640B
Return the lift arm support device to the storage position
and secure with clamping knobs.

Remove the jackstands.

P-90640A

Lower the lift arms slowly until the lift arm support device
is held between the lift arms and the lift cylinder [Figure

Dealer Copy -- Not for Resale

10-20-3]. The tabs of the lift arm support device must go
past the end of the cylinder (Inset) [Figure 10-20-3].

24 of 822 10-20-2 T870 Service Manual

OPERATOR CAB Raising

Description Always stop the engine before raising or lowering the

operator cab.
The Bobcat loader has an operator cab (ROPS and
FOPS) as standard equipment to protect the operator Stop the loader on a level surface. Lower the lift arms. If
from rollover and falling objects. The seat belt must be the lift arms must be up while raising the operator cab,
worn for rollover protection. install the lift arm support device. (See LIFTING AND
BLOCKING THE LOADER on Page 10-10-1.)
Check the ROPS / FOPS cab, mounting and hardware
for damage. Never modify the ROPS / FOPS cab. Figure 10-30-1
Replace the cab and hardware if damaged. See your
Bobcat dealer for parts.

ROPS / FOPS - Roll Over Protective Structure per ISO

3471, and Falling Object Protective Structure per ISO
3449, Level I. Level II is available.

Level I

Protection from falling bricks, small concrete blocks,

and hand tools encountered in operations such as
highway maintenance, landscaping, and other
construction sites. P-85463A

Dealer Copy -- Not for Resale

Level II
Install jackstands under the rear of the loader frame
[Figure 10-30-1].
Protection from falling trees, rocks: for machines
involved in site clearing, overhead demolition or
Figure 10-30-2
forestry.
Hardware Installed Hardware Removed

WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to
the cab can cause loss of operator protection from
rollover and falling objects, and result in injury or
death.
W-2069-0200

P100235A P100236A

Remove the nuts and washers [Figure 10-30-2] (both

sides) at the front corners of the operator cab.

25 of 822 10-30-1 T870 Service Manual

OPERATOR CAB (CONT’D) NOTE: The weight of the operator cab increases
when equipped with options and accessories
Raising (Cont’d) such as cab door, heater, air conditioning,
etc. In these cases, the operator cab may need
Figure 10-30-3 to be raised slightly from the latch to be able
to release the latch.

Support the operator cab and release the latching

mechanism (Inset) [Figure 10-30-4]. Remove your hand
from the latch mechanism when the operator cab is past
the latch stop. Use both hands to lower the operator cab
all the way down.

WARNING
P-90564A
PINCH POINT CAN CAUSE INJURY
Remove your hand from the latching mechanism
Lift on the grab handles and bottom of the operator cab when the cab is past the latch stop.
W-2469-0803
[Figure 10-30-3] slowly until the operator cab is all the
way up and the latching mechanism engages.
Figure 10-30-5

Dealer Copy -- Not for Resale

Lowering
Hardware Removed Hardware Installed
Always stop the engine before raising or lowering the
operator cab.

NOTE: Always use the grab handles to lower the

operator cab.

Figure 10-30-4

P100235A P100235A

Install the washers and nuts (both sides) [Figure 10-30-

5].

Tighten the nuts to 54 - 61 N•m (40 - 45 ft-lb) torque.

N-20120 P-90565A

Pull down on the bottom of the operator cab until it stops

at the latching mechanism [Figure 10-30-4].

26 of 822 10-30-2 T870 Service Manual

OPERATOR CAB (CONT’D) Figure 10-30-7

Cab Door Sensor

This machine may be equipped with a Cab Door Sensor.

Figure 10-30-6

P-76461Q

S3999A
The LIFT AND TILT VALVE light (Item 3) [Figure 10-30-
6] will be ON when the door is open, the key switch is
turned to RUN or the RUN button is pressed, the seat bar
is lowered and the PRESS TO OPERATE LOADER
1
button is pressed.
2
[DOOR] will appear in the data display [Figure 10-30-7].
P-68116A P-68115A

Dealer Copy -- Not for Resale

The cab door has a sensor (Item 1) [Figure 10-30-6]
installed which deactivates the lift and tilt valves when the
door is open.

A decal is located on the latch mechanism (Item 2)

[Figure 10-30-6].

The LIFT AND TILT VALVE light (Item 3) [Figure 10-30-

6] will be OFF when the door is closed, the key switch is
turned to RUN or the RUN button is pressed, the seat bar
is lowered and the PRESS TO OPERATE LOADER
button is pressed.

27 of 822 10-30-3 T870 Service Manual

OPERATOR CAB (CONT’D) Special Applications Kit Inspection And Maintenance

Special Applications Kit • Inspect for cracks or damage. Replace if required.

• Pre-rinse with water to remove gritty materials.
• Wash with a mild household detergent and warm
water.

WARNING • Use a sponge or soft cloth. Rinse well with water and
dry with a clean soft cloth or rubber squeegee.
• Do not use abrasive or highly alkaline cleaners.
AVOID INJURY OR DEATH • Do not clean with metal blades or scrapers.
Some attachment applications can cause flying
debris or objects to enter front, top or rear cab
openings. Install the Special Applications Kit to
provide added operator protection in these
applications.
W-2737-0508

Figure 10-30-8

Dealer Copy -- Not for Resale

NA1026

Available for special applications to restrict material from

entering cab openings. Kit includes 12,7 mm (0.5 in) thick
polycarbonate front door and polycarbonate rear window
[Figure 10-30-8].

Polycarbonate top window (standard item) must be

installed for special applications to restrict material from
entering cab openings.

See your Bobcat dealer for availability.

28 of 822 10-30-4 T870 Service Manual

OPERATOR CAB (CONT’D) Forestry Door And Window Kit Inspection And
Maintenance
Forestry Door And Window Kit
• Inspect for cracks or damage. Replace if required.
Figure 10-30-9 • Order part number 7171104 if door frame is damaged
and needs to be replaced.
• Order kit part number 7193293 if door polycarbonate
is damaged and needs to be replaced.
• Pre-rinse with water to remove gritty materials.
• Wash with a mild household detergent and warm
water.
• Use a sponge or soft cloth. Rinse well with water and
dry with a clean soft cloth or rubber squeegee.
• Do not use abrasive or highly alkaline cleaners.
• Do not clean with metal blades or scrapers.

Forestry Door Emergency Exit

Figure 1
NA1819

Must be used as part of the Forestry Applications Kit to

prevent flying debris and objects from entering the

Dealer Copy -- Not for Resale

loader. Kit includes 19,1 mm (0.75 in) thick laminated
1
polycarbonate front door, polycarbonate side windows
and polycarbonate rear window [Figure 10-30-9].

Polycarbonate top window (standard item) must be

installed as part of the Forestry Applications Kit to restrict
material from entering cab openings.

P-96030

• Inspect both emergency exit levers (Item 1)

[Figure 1], linkages and hardware for loose or
damaged parts.
• Repair or replace if necessary.

29 of 822 10-30-5 T870 Service Manual

 Dealer Copy -- Not for Resale

30 of 822 10-30-6 T870 Service Manual

TRANSPORTING THE LOADER ON A TRAILER Fastening

Loading And Unloading Figure 10-40-2

Rear Tie Down Front Tie Down

WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury. P-85615A P-85616A
W-2058-0807

Be sure the transport and towing vehicles are of

adequate size and capacity for weight of loader. (See
Performance on Page SPEC-10-2.)

Figure 10-40-1

Dealer Copy -- Not for Resale

P-90729C

Alternate Rear Tie Down Alternate Front Tie Down

1
P-90728C

P-85466
P-85717A P-85599A
A loader with an empty bucket or no attachment must be
loaded backward onto the transport vehicle [Figure 10-
40-1]. Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving
The rear of the trailer must be blocked or supported (Item during sudden stops or when going up or down slopes
1) [Figure 10-40-1] when loading or unloading the loader [Figure 10-40-2].
to prevent the front end of the trailer from raising up.
1. Lower the bucket or attachment to the floor.

2. Stop the engine.

3. Engage the parking brake.

4. Install chains at the front and rear loader tie down

positions [Figure 10-40-2]. (Lift arms shown raised
for clarity.)

5. Fasten each end of the chain to the transport vehicle.

6. Use chain binders to tighten the chains.

31 of 822 10-40-1 T870 Service Manual

 Dealer Copy -- Not for Resale

32 of 822 10-40-2 T870 Service Manual

TOWING THE LOADER

Procedure

Because of the design of the loader, there is not a

recommended towing procedure.

• The loader can be lifted onto a transport vehicle.

• The loader can be skidded a short distance to move

for service (EXAMPLE: Move onto a transport
vehicle.) without damage to the hydrostatic system.
(The tracks will not turn.) There might be slight wear
to the tracks when the loader is skidded.

The towing chain (or cable) must be rated at 1.5 times

the weight of the loader. (See Performance on Page
SPEC-10-2.)

Dealer Copy -- Not for Resale

33 of 822 10-50-1 T870 Service Manual

 Dealer Copy -- Not for Resale

34 of 822 10-50-2 T870 Service Manual

REMOTE START TOOL KIT-MEL1563 Figure 10-60-2

Remote Start Tool - MEL1563

Tools that will be needed to complete the following steps

are:
2
MEL1563 - Remote Start Tool 3
MEL1566 - Service Tool Harness Communicator 1
(Computer Interface)

Figure 10-60-1

1
P16117

The traction lock switch (Item 1) [Figure 10-60-2] is used

to turn traction lock ON or OFF. Push the switch to the
override position. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the brakes are
released.

Dealer Copy -- Not for Resale

The maximum flow / variable flow switch (Item 2) [Figure
10-60-2] is used to activate the auxiliary hydraulics.
P16114 Pressing the switch will activate variable flow. The switch
will illuminate to indicate the flow rate is active. Pressing
the switch again will turn the flow OFF. The switch is used
The remote start tool (Item 1) [Figure 10-60-1] is when checking pressures and flow rate.
required when the service technician is checking the
hydraulic / hydrostatic system, adjusting the steering NOTE: With the engine running; pushing and holding
linkage, and electrical diagnostics. the pressure release switch (Item 3) [Figure
10-60-2] will cause the engine to stop.

35 of 822 10-60-1 T870 Service Manual

REMOTE START TOOL-MEL1563 (CONT'D) Figure 10-60-5

Remote Start Tool - MEL1563 (Cont’d) 1

Figure 10-60-3

3
1 2

P-90972

Loaders equipped with an attachment harness (Item 1)

P16114 must remove the tie strap (Item 2) and disconnect the
attachment harness from the loader harness (Item 3)
[Figure 10-60-5].
The service tool harness control (Item 1) is used to
connect the remote start tool (Item 2) [Figure 10-60-3] to Connect the service tool harness to the ACD connector

Dealer Copy -- Not for Resale

the electrical system on the loader. and the loader harness connector.

Figure 10-60-4 NOTE: To monitor, diagnose or load new software

the Service PC must be connected to the
Remote Start Tool.

P-90973

Remove the cap (Item 1) [Figure 10-60-4] from the

loader harness connector.

Connect the service tool harness control to the loader

harness connector.

36 of 822 10-60-2 T870 Service Manual

REMOTE START TOOL-MEL1563 (CONT'D) Remote Start Procedure

Service Tool Harness Communicator - MEL1566 The tool listed will be needed to do the following
procedure:
Figure 10-60-6
MEL1563: Remote Start Tool Kit
2
Figure 10-60-7

1
1

P16119

The service tool harness communicator (Item 1) is P16115

required to connect remote start tool to the Service PC

Dealer Copy -- Not for Resale

(Item 2) [Figure 10-60-6].
The remote start tool (Item 1) [Figure 10-60-7] is
required when the operator cab is in the raised position
for service and the service technician needs to turn the
key switch on or start the engine. Example: trouble
shooting procedures.

Lift and block the loader.

Raise the lift arms (if required by the procedure) and

install an approved lift arm support device.

Raise the operator cab (if required by the procedure).

Open the rear door of the loader.

37 of 822 10-60-3 T870 Service Manual

REMOTE START TOOL KIT-MEL1563 (CONT’D) Figure 10-60-10

Remote Start Procedure (Cont'd)

Figure 10-60-8

P-90974

Figure 10-60-11
P-90973

Figure 10-60-9

Dealer Copy -- Not for Resale

1
2

1
2
P-90975

Connect the remote start tool to the engine harness

P-90972
connector (Item 1) [Figure 10-60-10].

OR
Remove the cap (Item 1) [Figure 10-60-8].
Connect the remote start tool to the engine harness
OR connector (Item 1) and to the attachment control harness
(Item 2) [Figure 10-60-11] (If equipped).
Remove the tie strap (Item 2) and disconnect the
attachment control harness (Item 1) [Figure 10-60-9] (If NOTE: The key switch on the right-hand side
equipped). operator panel must be in the off position or
the Remote Start Tool Kit will not operate.

38 of 822 10-60-4 T870 Service Manual

REMOTE START TOOL KIT-MEL1563 (CONT'D) Figure 10-60-13

Remote Start Procedure (Cont'd)

WARNING
2
3 1
UNAUTHORIZED AND UNEXPECTED ENGINE
STARTUP CAN CAUSE SERIOUS INJURY OR DEATH
With the 7-pin connector plugged into the machine
and Remote Start Tool Key Switch in the OFF
position, the engine can be started from the operator
panel inside the cab.
P16118
• Place the key switch of the Remote Start Tool in
the RUN position to disconnect the operator
panel from the start circuit. The traction lock switch (Item 1) [Figure 10-60-13] is
• Remove the operator panel key (key switch), lock used to turn traction lock ON or OFF. Push the switch to
the keypad with a unique password (keyless) or the override position. The switch will illuminate to indicate
otherwise disable the starter before working in traction lock OVERRIDE, in this position the brakes are
the engine area. released.
W-2457-1110

Dealer Copy -- Not for Resale

The maximum flow / variable flow switch (Item 2) [Figure
Figure 10-60-12 10-60-13] is used to activate the auxiliary hydraulics.
Pressing the switch will activate variable flow. The switch
will illuminate to indicate the flow rate is active. Pressing
the switch again will turn the flow OFF. The switch is used
when checking pressures and flow rate.

NOTE: With the engine running; pushing and holding

the pressure release switch (Item 3) [Figure
1 10-60-13] will cause the engine to stop.

WARNING
AVOID INJURY OR DEATH
P16116
• Use traction lock override switch for service
work with seat bar raised.
The remote start tool (Item 1) [Figure 10-60-12] has • Traction lock is engaged when light is OFF.
three rocker switches. • Lift and block the loader. Check that wheels are
clear.
• Traction lock is disengaged when light is ON.
• See Service Manual for more instruction.
W-2785-0209

39 of 822 10-60-5 T870 Service Manual

REMOTE START TOOL KIT-MEL1563 (CONT'D)

Remote Start Procedure (Cont'd)

Figure 10-60-14

P-85311B

Push the couplers on the front auxiliary block toward the

block and hold for five seconds to release the front

Dealer Copy -- Not for Resale

auxiliary pressure [Figure 10-60-14].

40 of 822 10-60-6 T870 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT -
7003031

Description

The Remote Start Tool (Service Tool) Kit is a replacement

tool for MEL 1563 Remote Start Tool and MEL1400B
BOSS® Diagnostic Tool.

The Remote Start Tool (Service Tool) Kit, P/N 7003031,

can be used to service newer loaders using the supplied
harness P/N 6689747.

A computer can be connected to the Remote Start Tool

(Service Tool) for diagnostics and software updates using
the computer harness P/N 6689746 in conjunction with
the loader harness.

Dealer Copy -- Not for Resale

41 of 822 10-61-1 T870 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-2
7003031 (CONT'D)
2
Remote Start Tool (Service Tool) - 7003030

Tools that will be needed to complete the following steps

5 3
are:

Order from Bobcat Parts P/N: 7003031 - Remote Start 6 4

Tool (Service Tool) Kit

Kit Includes:
1
7003030 - Remote Start Tool (Service Tool)
6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness
P-76439
6689745 - BOSS® Service Tool Harness

Figure 10-61-1 The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
61-2] has five buttons.

The STOP button (Item 2) [Figure 10-61-2] is used to

stop the Remote Start Tool (Service Tool) from
communicating and stop the loader engine.

Dealer Copy -- Not for Resale

The RUN button (Item 3) [Figure 10-61-2] is used to turn
the Remote Start Tool (Service Tool) on and activates the
loader ignition power. The button will illuminate to
indicate the service tool is active.
1
The START button (Item 4) [Figure 10-61-2] is used to
start the loader engine.

P-76678 The traction lock button (Item 5) [Figure 10-61-2] is used

to turn traction lock ON or OFF. Push the button and the
button will illuminate indicating the traction lock is
The remote start tool (Item 1) [Figure 10-61-1] is disabled in which the wheels or tracks are able to turn.
required when the service technician is checking the
hydraulic / hydrostatic system, adjusting the steering The auxiliary button (Item 6) [Figure 10-61-2] is used to
linkage, and electrical diagnostics. activate the auxiliary hydraulics. The button will illuminate
to indicate the auxiliary hydraulics are active. Pressing
the button a second time will turn the flow OFF. The
button is used when checking pressures and flow rate.

42 of 822 10-61-2 T870 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-5
7003031 (CONT'D)

Loader Service Tool Harness - 6689747

1
Figure 10-61-3

2 3

P-90972
2

Loaders with an attachment control harness (7 pin or 14

pin), the attachment harness (Item 1) must remove the tie
P-76678 strap (Item 2) and disconnect the attachment harness
from the loader harness (Item 3) [Figure 10-61-5].

The loader service tool harness (Item 1) [Figure 10-61-3] When the remote start procedure is completed, replace

Dealer Copy -- Not for Resale

is used to connect the remote start tool (service tool) the loader connector cap (Item 1) [Figure 10-61-4] or
(Item 2) [Figure 10-61-3] to the electrical system on the reconnect the attachment control harness to the loader
loader. harness [Figure 10-61-5].

Figure 10-61-4

P-90973

Loaders without an attachment control harness, remove

the loader harness cap (Item 1) [Figure 10-61-4] and
connect the Loader Service Tool Harness from the
Remote Start Tool (Service Tool).

43 of 822 10-61-3 T870 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Computer Service Tool Harness - 6689746
7003031 (CONT'D)
Figure 10-61-7
Loader Service Tool Harness - 6689747 (Cont’d)

Figure 10-61-6

3 2
1 P-76450

P-90976 The computer service tool harness (Item 1) [Figure 10-

61-7] is required to connect remote start tool (service
tool) to the Service PC (Item 2) [Figure 10-61-7].
NOTE: The Remote Start Tool (Service Tool)
connection harness has two connectors (Item

Dealer Copy -- Not for Resale

1) and (Item 3). The main connector (Item 1)
[Figure 10-61-6] is always used for connection
to the loader harness.

The second connector (Item 3) [Figure 10-61-

6] is used for attachment ACD upgrades or
attachment operational diagnostics only. This
connector has a cap attached to it to prevent
damage or corrosion when not in use.

Connect the Remote Start Tool (Service Tool) connector

(Item 1) to the loader harness connector (Item 2) and the
other Remote Start Tool (Service Tool) connector to the
ACD harness connector (Item 3) [Figure 10-61-6].

NOTE: The key switch must be in the off position or

the Remote Start Tool (Service Tool) will not
operate.

WARNING
AVOID INJURY OR DEATH
• Lift and block the machine.
• Check that wheels or tracks are clear.
• Cab ignition must be in the “STOP” position to
start the engine with the Service Tool (if
applicable).
• See machine Service Manual for more
instructions.
W-2792-0409

44 of 822 10-61-4 T870 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-9
7003031 (CONT'D)

Remote Start Procedure

WARNING
1
UNAUTHORIZED AND UNEXPECTED ENGINE
STARTUP CAN CAUSE SERIOUS INJURY OR DEATH
With the 7-pin connector plugged into the machine
and Remote Start Tool Key Switch in the OFF
position, the engine can be started from the operator
panel inside the cab.
P-90973
• Place the key switch of the Remote Start Tool in
the RUN position to disconnect the operator
panel from the start circuit. Loaders without an attachment control harness, remove
• Remove the operator panel key (key switch), lock the loader harness cap (Item 1) [Figure 10-61-9] and
the keypad with a unique password (keyless) or connect the Loader Service Tool Harness from the
otherwise disable the starter before working in Remote Start Tool (Service Tool).
the engine area.
W-2457-1110
NOTE: When using a Remote Start Tool (Service tool)

Dealer Copy -- Not for Resale

harness on loaders not equipped with an
The tool listed will be needed to do the following attachment control device, the Remote Start
procedure: Tool (Service Tool) harness attachment
control device connector must be capped.
7003031: Remote Start Tool (Service Tool) Kit
Figure 10-61-8 Figure 10-61-10

1
2

P-76450 P-90974

The Remote Start Tool (Service Tool) (Item 1) [Figure 10-

61-8] is required when the operator cab is in the raised Loaders with an attachment control harness (7 pin or 14
position for service and the service technician needs to pin), the attachment harness (Item 1) must be
turn on the loader or start the engine. Example: adjusting disconnected from the loader harness (Item 2) [Figure
the steering linkage. 10-61-10].

Lift and block the loader. When the remote start procedure is completed, replace
Raise the lift arms (if required by the procedure) and the loader connector cap (Item 1) [Figure 10-61-10] or
install an approved lift arm support device. reconnect the attachment control harness to the loader
harness.
Raise the operator cab (if required by the procedure).

Open the rear door of the loader.

45 of 822 10-61-5 T870 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-12
7003031 (CONT'D)
2
Remote Start Procedure (Cont'd)

Figure 10-61-11
5 3

6 4

2 1

P-76439
3
1
The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
61-12] has five buttons.
P-90976
The STOP button (Item 2) [Figure 10-61-12] is used to
stop the Remote Start Tool (Service Tool) from
NOTE: The Remote Start Tool (Service Tool) communicating and stop the loader engine.
connection harness has two connectors (Item

Dealer Copy -- Not for Resale

1) and (Item 3). The main connector (Item 1) The RUN button (Item 3) [Figure 10-61-12] is used to
[Figure 10-61-11] is always used for turn the Remote Start Tool (Service Tool) on and
connection to the loader harness. activates the loader ignition power. The button will
illuminate to indicate the service tool is active.
The second connector (Item 3) [Figure 10-61-
11] is used for attachment ACD upgrades or The START button (Item 4) [Figure 10-61-12] is used to
attachment operational diagnostics only. This start the loader engine.
connector has a cap attached to it to prevent
damage or corrosion when not in use. The traction lock button (Item 5) [Figure 10-61-12] is
used to turn traction lock ON or OFF. Push the button and
Connect the Remote Start Tool (Service Tool) connector the button will illuminate indicating the traction lock is
(Item 1) to the loader harness connector (Item 2) and the disabled in which the wheels or tracks are able to turn.
other Remote Start Tool (Service Tool) connector to the
ACD harness connector (Item 3) [Figure 10-61-11]. The auxiliary button (Item 6) [Figure 10-61-12] is used to
activate the auxiliary hydraulics. The button will illuminate
NOTE: The key switch must be in the off position or to indicate the auxiliary hydraulics are active. Pressing
the Remote Start Tool (Service Tool) will not the button a second time will turn the flow OFF. The
operate. button is used when checking pressures and flow rate.

WARNING
AVOID INJURY OR DEATH
• Lift and block the machine.
• Check that wheels or tracks are clear.
• Cab ignition must be in the “STOP” position to
start the engine with the Service Tool (if
applicable).
• See machine Service Manual for more
instructions.
W-2792-0409

46 of 822 10-61-6 T870 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-14
7003031 (CONT'D)

Remote Start Procedure (Cont'd)

Figure 10-61-13

1 2

P-85311B

Push the couplers on the front auxiliary block toward the

block and hold for five seconds to release the front
P-76441 auxiliary pressure [Figure 10-61-14].

The gear icon with the left facing arrows (Item 1) [Figure
10-61-13] will illuminate and blink when the RUN key is

Dealer Copy -- Not for Resale

pressed and the loader is communicating with the service
tool.

The computer icon with the right facing arrows (Item 2)

[Figure 10-61-13] will illuminate and blink when the
Remote Start Tool (Service Tool) is transmitting data to
and from the computer.

NOTE: To relieve the pressure at the rear or

secondary front auxiliary, (if equipped) press
the RUN button on the remote start tool. Then
press the auxiliary (AUX) hydraulics button on
the remote start tool and move the AUXILIARY
Hydraulic Switch to the right and left several
times.

47 of 822 10-61-7 T870 Service Manual

 Dealer Copy -- Not for Resale

48 of 822 10-61-8 T870 Service Manual

SERVICE SCHEDULE

Chart

Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat loader.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903

SERVICE SCHEDULE HOURS

[5] [5] [5]
ITEM SERVICE REQUIRED
8-10 50 100 250 500 1000
Engine Oil Check the oil level and add as needed. Do not overfill.
Check display panel. Service only when required. Check for leaks and
Engine Air Filter and Air System
damaged components.
Clean debris from oil cooler, radiator and grille. Check coolant level COLD and
Engine Cooling System
add premixed coolant as needed.
Fuel Filter Remove the trapped water.
Lift Arms, Lift Links, Cylinders,
Lubricate with multipurpose lithium based grease.
Bob-Tach, Pivot Pins, Wedges
Check the condition of seat belt. Clean or replace seat belt retractors as
Seat Bar, Control Interlocks, Seat
needed. Check the seat bar and control interlocks for correct operation. Clean
Belt, Seat Belt Retractors
dirt and debris from moving parts.

Dealer Copy -- Not for Resale

Bobcat Interlock Control Systems Check for correct function. Lift and Tilt functions MUST NOT operate with seat
(BICS™) bar raised. See details in this Manual.
Front Horn / Back-up Alarm Check for proper function.
Check for damaged signs (decals) and safety treads. Replace any signs or
Safety Signs and Safety Treads
safety treads that are damaged or worn.
Operator Cab Check the fastening bolts, washers and nuts. Check the condition of the cab.
Indicators and Lights Check for correct operation of all indicators and lights.
Heater and Air Conditioning
Clean or replace filters as needed.
Filters (If Equipped)
Hydraulic Fluid Check fluid level and add as needed.
Hydraulic Hoses and Tubelines Check for damage and leaks. Repair or replace as needed.
Tracks Check for damaged and worn tracks and correct tension. [1]
Track Sprocket Nuts Check torque. Tighten as needed. See procedure in this manual.
Parking Brake, Foot Pedals and
Check for correct operation. Repair or adjust as needed.
Steering Handles or Joysticks
Spark Arrester Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Fuel Filter Replace filter element.
Engine / Hydrostatic Drive Belt Check for wear or damage. Check idler arm stop. [2]
Drive Belts (Alternator, air
Check condition. Replace as needed.
conditioning, water pump)
Bobcat Interlock Control System
Check the function of the lift arm bypass control.
(BICS™)
Engine Oil and Filter Replace oil and filter. [2] [3]
Hydraulic Charge Filter,
Replace the charge filter and the reservoir breather.
Hydraulic Reservoir Breather
Hydrostatic Drive Motors Replace oil with high performance synthetic oil P/N 7003026.
Hydraulic / Hydrostatic Filter Replace the hydraulic / hydrostatic filter.
Hydraulic Reservoir Replace the fluid.
Engine Valves Adjust the engine valves. [4]
Coolant Replace the coolant Every 2 years

[1] Check every 8 - 10 hours for the first 24 hours, then at 50 hour intervals.
[2] Perform at first 50 hours, then as scheduled.
[3] Change oil and filter every 100 hours when operating under severe conditions.
[4] Perform at first 500 hours, then as scheduled.
[5] Or every 12 months.

49 of 822 10-70-1 T870 Service Manual

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50 of 822 10-70-2 T870 Service Manual

AIR CLEANER SERVICE Figure 10-80-3

Replacing Filter Elements

Figure 10-80-1

1 1

P-90647
P-76460G

Pull the outer filter element (Item 1) [Figure 10-80-3] out

It is important to change the air filter element only when and discard.
necessary. The service indicator (Item 1) will FLASH.
Press the information button (Item 3) until the display NOTE: Make sure the filter housing is free of dirt and
screen (Item 2) shows the service codes. Service code debris. Verify that sealing surfaces are clean.
[M0117] (Air Filter Plugged) will show in the display DO NOT use compressed air.

Dealer Copy -- Not for Resale

screen (Item 2) [Figure 10-80-1] when air filter change is
necessary. Install new filter element. Push all the way in until it
contacts the base of the housing.
Replace the inner filter every third time the outer filter is
replaced or as indicated. Install the cover and secure the latches [Figure 10-80-2].

Outer Filter NOTE: Ensure the intake hose is connected to the

fitting on the fan housing (Inset) [Figure 10-
Remove the rear grille. (See Removing on Page 50-60- 80-5].
1.)
NOTE: Ensure the coolant tank is secured into the
NOTE: The coolant tank can be raised to facilitate coolant tank bracket.
access to the air cleaner.
Install the rear grille. (See Removing on Page 50-60-1.)
Figure 10-80-2

2
1

P100229

Open the latches (Item 2) and remove the cover (Item 1)

[Figure 10-80-2].

51 of 822 10-80-1 T870 Service Manual

AIR CLEANER SERVICE (CONT’D) Figure 10-80-5

Replacing Filter Elements (Cont’d)

Inner Filter

Only replace the inner filter element under the following

conditions:

• Replace the inner filter element every third time the

outer filter is replaced. 2

• After the outer element has been replaced, start the

engine and run at full rpm. If service code [M0117]
(Air Filter Plugged) is still displayed in the data 1
display, replace the inner filter element. P100229

Remove the rear grille. (See Removing on Page 50-60-

1.) Install the cover (Item 1) and secure the latches (Item 2)
[Figure 10-80-5].
Remove the cover [Figure 10-80-2] and the outer filter
element [Figure 10-80-3]. NOTE: Ensure the intake hose is connected to the
fitting on the fan housing (Inset) [Figure 10-
Figure 10-80-4 80-5].

Dealer Copy -- Not for Resale

NOTE: Ensure the coolant tank is secured into the
coolant tank bracket.

Install the rear grille.

P-90646

Remove the inner filter element (Item 1) [Figure 10-80-

4].

NOTE: Make sure the filter housing is free of dirt and

debris. Verify that sealing surfaces are clean.
DO NOT use compressed air.

Install new inner filter element. Push all the way in until it
contacts the base of the housing.

Install the outer filter element [Figure 10-80-3].

52 of 822 10-80-2 T870 Service Manual

ENGINE COOLING SYSTEM Cleaning

Check the cooling system every day to prevent over- Remove the rear grille. (See Removing on Page 50-60-
heating, loss of performance or engine damage. 1.)

Maintenance Platform Loaders With Air Conditioning

Figure 10-90-2
Figure 10-90-1

2 2

3
1

P100329
P100039A
Use low air pressure or water pressure to clean the top of

Dealer Copy -- Not for Resale

A maintenance platform (Item 1) [Figure 10-90-1] is the air conditioning condenser (Item 1) [Figure 10-90-2].
available from your Bobcat dealer to facilitate access The area between the air conditioning condenser and the
when cleaning the engine cooling system. oil cooler will require occasional cleaning. Remove the
bolts (Item 2) and the brackets (Item 3) [Figure 10-90-2].

WARNING Figure 10-90-3

AVOID INJURY OR DEATH 1

Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907
2

P100331

NOTE: Be careful when raising and lowering the air

conditioning condenser so that the air
conditioning condenser does not fall on the
oil cooler and damage the fins.
Raise the air conditioning condenser (Item 1) and use
low air pressure or water pressure to clean the top of the
oil cooler (Item 2) [Figure 10-90-3].
Lower the air conditioning condenser (Item 1) [Figure
10-90-3]. Install the brackets (Item 3) [Figure 10-90-2]
and the bolts (Item 2) [Figure 10-90-2].

53 of 822 10-90-1 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) All Loaders

Cleaning (Cont’d) Unhook the two rubber straps (Item 2) [Figure 10-90-4].

Loaders Without Air Conditioning Figure 10-90-5

Figure 10-90-4

1
1

2
3

2
P100327

P100779
Raise the oil cooler (Item 1) until the bar (Item 2) drops
into place to support the oil cooler. Use low air pressure

Dealer Copy -- Not for Resale

Use low air pressure or water pressure to clean the top of or water pressure to clean the top of the radiator (Item 3)
the oil cooler (Item 1) [Figure 10-90-4]. [Figure 10-90-5].

Raise the bar (Item 2) [Figure 10-90-5] slightly and lower

the oil cooler. Fasten the two rubber straps [Figure 10-
90-4].

Check the cooling system for leaks.

Install the rear grille.

54 of 822 10-90-2 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Removing And Replacing Coolant

Checking Level For the service interval for replacing the engine
coolant (See SERVICE SCHEDULE on Page 10-70-1.)
Remove the rear grille. (See Removing on Page 50-60-
1.) Open the rear door and remove the rear grille.

Figure 10-90-6 Remove the coolant fill cap (Item 1) [Figure 10-90-6].

Figure 10-90-7

P100330

Dealer Copy -- Not for Resale

Check coolant level using the level markers (Item 2)
P-90657A
[Figure 10-90-6] on the tank. Coolant must be between
top and bottom level markers when the engine is cold.
Attach a hose to the coolant drain petcock (Item 1)
NOTE: The loader is factory filled with propylene [Figure 10-90-7] located to the left of the oil filter
glycol coolant (purple color). DO NOT mix assembly. Open the petcock and drain the coolant into a
propylene glycol with ethylene glycol. container. Close the petcock and remove the hose.
Recycle or dispose of coolant in an environmentally safe
Use a refractometer to check the condition of propylene manner.
glycol in your cooling system.
Close the rear door.
Install the rear grille.
Mix new coolant in a separate container. (See Capacities
on Page SPEC-10-4.)

The correct mixture of coolant to provide a -37°C (-34°F)

IMPORTANT freeze protection is 5 L propylene glycol mixed with 4,4 L
of water OR 1 U.S. gal propylene glycol mixed with 3.5 qt
of water.
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Add premixed coolant, 47% water and 53% propylene
glycol to the coolant tank until the coolant level reaches
Too much antifreeze reduces cooling system
the lower marker on the tank [Figure 10-90-6].
efficiency and may cause serious premature engine
damage.
Install the coolant fill cap.
Too little antifreeze reduces the additives which
NOTE: When installing the coolant fill cap, the cap
protect the internal engine components; reduces the
must be tightened until it clicks.
boiling point and freeze protection of the system.
Run the engine until it is at operating temperature. Stop
Always add a premixed solution. Adding full strength
the engine. Check the coolant level when cool. Add
concentrated coolant can cause serious premature
coolant as needed.
engine damage.
I-2124-0497 Install the rear grille.

55 of 822 10-90-3 T870 Service Manual

 Dealer Copy -- Not for Resale

56 of 822 10-90-4 T870 Service Manual

FUEL SYSTEM Biodiesel Blend Fuel

Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
The following is one suggested blending guideline which
should prevent fuel gelling during cold temperatures: • Biodiesel blend fuel is an excellent medium for
microbial growth and contamination which can cause
TEMPERATURE NO. 2 NO. 1 corrosion and plugging of fuel system components.

-9°C (+15°F) 100% 0% • Use of biodiesel blend fuel may result in premature
Down to -29°C (-20°F) 50% 50% failure of fuel system components, such as plugged
Below -29°C (-20°F) 0% 100% fuel filters and deteriorated fuel lines.

• Shorter maintenance intervals may be required, such

At a minimum, low sulfur diesel fuel must be used in this
as cleaning the fuel system and replacing fuel filters
machine. Low sulfur is defined as 500 mg/kg (500 ppm)
and fuel lines.
sulfur maximum.
• Using biodiesel blended fuels containing more than
The following fuels may also be used in this machine:
five percent biodiesel can affect engine life and cause
deterioration of hoses, tubelines, injectors, injector
• Ultra low sulfur diesel fuel. Ultra low sulfur is defined
pump and seals.

Dealer Copy -- Not for Resale

as 15 mg/kg (15 ppm) sulfur maximum.
Apply the following guidelines if biodiesel blend fuel is
• Biodiesel blend fuel - Must contain no more than five
used:
percent biodiesel mixed with low sulfur or ultra low
sulfur petroleum based diesel. This is commonly
• Ensure the fuel tank is as full as possible at all times
marketed as B5 blended diesel fuel. B5 blended
to prevent moisture from collecting in the fuel tank.
diesel fuel must meet ASTM D975 (US Standard) or
EN590 (EU Standard) specifications.
• Ensure that the fuel tank cap is securely tightened.

• Biodiesel blend fuel can damage painted surfaces,

remove all spilled fuel from painted surfaces
immediately.

• Drain all water from the fuel filter daily before

operating the machine.

• Do not exceed engine oil change interval. Extended

oil change intervals can cause engine damage.

• Before vehicle storage; drain the fuel tank, refill with

100% petroleum diesel fuel, add fuel stabilizer and
run the engine for at least 30 minutes.

NOTE: Biodiesel blend fuel does not have long term

stability and should not be stored for more
than three months.

57 of 822 10-100-1 T870 Service Manual

FUEL SYSTEM (CONT’D) Figure 10-100-2

Filling The Fuel Tank WRONG

WARNING
AVOID INJURY OR DEATH
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807

Open the rear door. NA1726

Figure 10-100-1
Use a clean, approved safety container to add fuel of the
correct specification. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING [Figure 10-100-2].

1 Install and tighten the fuel cap (Item 1) [Figure 10-100-

Dealer Copy -- Not for Resale

1].

Close the rear door.

WARNING
P100035 AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Remove the fill cap (Item 1) [Figure 10-100-1]. Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

58 of 822 10-100-2 T870 Service Manual

FUEL SYSTEM (CONT’D) Removing Air From The Fuel System

Fuel Filter After replacing the filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel
For the service interval for removing water from, or system before starting the engine.
replacing the fuel filter (See SERVICE SCHEDULE on
Page 10-70-1.)

Removing Water
WARNING
Figure 10-100-3
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807

2
Figure 10-100-4
1

Dealer Copy -- Not for Resale

1
P-90653A

Loosen the drain (Item 1) [Figure 10-100-3] at the

bottom of the filter element to remove water from the
filter.

Replacing Element
2
Remove the filter element (Item 2) [Figure 10-100-3].

Clean the area around the filter housing. Put clean oil on
the seal of the new filter element. Install the fuel filter, and P100780
hand tighten.
Open the vent (Item 1) [Figure 10-100-4] on the fuel filter
Remove air from the fuel system. (See Removing Air
housing.
From The Fuel System on Page 10-100-3.)
Squeeze the hand pump (priming bulb) (Item 2) [Figure
10-100-4] until fuel flows from the vent with no air
WARNING bubbles.

Close the vent (Item 1) [Figure 10-100-4].

AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

59 of 822 10-100-3 T870 Service Manual

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60 of 822 10-100-4 T870 Service Manual

ENGINE LUBRICATION SYSTEM Engine Oil Chart

Checking And Adding Engine Oil Figure 10-110-2

ENGINE OIL
Check the engine oil level every day before starting the RECOMMENDED SAE VISCOSITY NUMBER
engine for the work shift. (LUBRICATION OILS FOR DIESEL ENGINE
CRANKCASE)
Figure 10-110-1

P-90654A

Dealer Copy -- Not for Resale

TEMPERATURE RANGE ANTICIPATED BEFORE
Park the machine on level ground. Open the rear door NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
and remove the dipstick (Item 1) [Figure 10-110-1]. CLASSIFICATION CI-4 OR BETTER)
[1] Synthetic Oil - Use recommendation from Synthetic
Keep the oil level between the marks on the dipstick. Do Oil Manufacturer.
not overfill.
Use good quality engine oil that meets API Service
Remove the oil fill cap (Item 2) [Figure 10-110-1] to add Classification of CI-4 or better [Figure 10-110-2].
engine oil.

WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

61 of 822 10-110-1 T870 Service Manual

ENGINE LUBRICATION SYSTEM (CONT’D) Install and tighten the oil drain cap [Figure 10-110-4].

Removing And Replacing Oil And Filter Install the cover and the cover mounting bolts [Figure
10-110-3]. Tighten all bolts.
For the service interval for replacing the engine oil and
filter (See SERVICE SCHEDULE on Page 10-70-1.) Figure 10-110-5

Run the engine until it is at operating temperature. Stop

the engine.

Figure 10-110-3 2

3
1

P-90654A

2
Open the rear door, remove the oil filter (Item 2) [Figure

Dealer Copy -- Not for Resale

10-110-5] and clean the filter housing surface.
3 P-90497A
P-90499A
Use genuine Bobcat filter only.

The oil drain hose is located behind a cover under the Put clean oil on the new filter gasket, install the filter and
right rear corner of the loader (Inset) [Figure 10-110-3]. hand tighten.
Remove two cover mounting bolts (Item 1) [Figure 10-
110-3]. Remove the oil fill cap (Item 3) [Figure 10-110-5].

Loosen one cover mounting bolt (Item 2), slide the cover Put oil in the engine and replace the fill cap. For the
(Item 3) [Figure 10-110-3] to the rear of the loader and correct quantity (See Capacities on Page SPEC-10-4.)
remove. Do not overfill.

Figure 10-110-4 Start the engine and let it run for several minutes. Stop
the engine and check for leaks at the filter.

Remove the dipstick (Item 1) [Figure 10-110-5] and

check the oil level.

Add oil as needed if it is not at the top mark on the

dipstick. Install the dipstick and close the rear door.

WARNING
1
AVOID INJURY OR DEATH
P-90498A Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
Remove the oil drain cap (Item 1) [Figure 10-110-4] from
explosion or fire.
the oil drain hose and drain the oil into a container. W-2103-0508
Recycle or dispose of used oil in an environmentally safe
manner.

62 of 822 10-110-2 T870 Service Manual

HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart

Checking And Adding Fluid Figure 10-120-3

Check the hydraulic / hydrostatic fluid level every day HYDRAULIC / HYDROSTATIC FLUID
before starting the work shift. RECOMMENDED ISO VISCOSITY GRADE (VG)
AND VISCOSITY INDEX (VI)
Park the loader on a level surface, lower the lift arms and
place the attachment flat on the ground or tilt the Bob-
Tach fully back if no attachment is installed.

Stop the engine.

Figure 10-120-1

TEMPERATURE RANGE ANTICIPATED

DURING MACHINE USE
1 [1] VG 100; Minimum VI 130
[2] VG 46; Minimum VI 150
[3] BOBCAT All-Season Fluid
[4] BOBCAT Synthetic Fluid
[5] BOBCAT Biodegradable Hydraulic / Hydrostatic

Dealer Copy -- Not for Resale

Fluid (Unlike biodegradable fluids that are vegetable
based, Bobcat biodegradable fluid is formulated to
prevent oxidation and thermal breakdown at operating
P-90661 temperatures.)

Check the fluid level in the sight gauge (Item 1) [Figure Use only recommended fluid in the hydraulic system
10-120-1]. Keep the fluid level within the operating range. [Figure 10-120-3]. (See Hydraulic System on Page
SPEC-10-3.)
Remove the rear grille. (See Removing on Page 50-60-
1.)

Figure 10-120-2
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
1
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

P100055

Remove the fill cap (Item 1) [Figure 10-120-2].

Add fluid as needed to bring the level within the operating

range in the sight gauge (Item 1) [Figure 10-120-1].

Install the fill cap (Item 1) [Figure 10-120-2] and install

the rear grille.

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HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-5

Removing And Replacing Hydraulic Fluid

For the correct service interval (See SERVICE

SCHEDULE on Page 10-70-1.)

Replace the fluid if it becomes contaminated or after 1

major repair.

Always replace the hydraulic / hydrostatic filter and the 2

hydraulic charge filter whenever the hydraulic fluid is
replaced. (See Removing And Replacing Hydraulic /
Hydrostatic Filter on Page 10-120-4.) and (See
Removing And Replacing Hydraulic Charge Filter on
Page 10-120-5.) P100327

Remove the rear grille. (See Removing on Page 50-60-

1.) Raise the oil cooler (Item 1) until the bar (Item 2) [Figure
10-120-5] drops into place to support the oil cooler. This
Figure 10-120-4 will aid in draining the hydraulic fluid.

Figure 10-120-6

Dealer Copy -- Not for Resale

1

P100055

P100033

Remove the right side access cover bolts (Item 1)

[Figure 10-120-6] and remove the cover. (Lift arms
shown raised for visual clarity.)

P100779

Remove the hydraulic fill cap (Item 1) and unhook the

two rubber straps (Item 2) [Figure 10-120-4].

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HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-8

Removing And Replacing Hydraulic Fluid (Cont’d)

Figure 10-120-7

1
1
2

P-90506

Remove and clean the hydraulic fill screen (Item 1)

P100784 [Figure 10-120-8]. Use low air pressure to dry the
screen.

Remove the clamp (Item 1). Pinch off the hose (Item 2) Install hydraulic fill screen and add the correct fluid to the
[Figure 10-120-7] near the fitting and disconnect hose reservoir until the fluid level is within the operating range

Dealer Copy -- Not for Resale

from the fitting. Route the hose out the side of the loader of the sight gauge. (See Capacities on Page SPEC-10-
and drain the fluid into a container. 4.) and (See Checking And Adding Fluid on Page 10-
120-1.)
Connect the hose to the fitting when the fluid stops
draining. Install the hydraulic fill cap.

Recycle or dispose of used fluid in an environmentally Install the rear grille. (See Removing on Page 50-60-1.)
safe manner.
Start the engine and operate the loader hydraulic
controls.

WARNING Stop the engine and check for leaks.

Check the fluid level in the reservoir and add as needed.

AVOID INJURY OR DEATH
(See Checking And Adding Fluid on Page 10-120-1.)
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

Install the side access cover and bolts [Figure 10-120-6].

Raise the bar supporting the oil cooler and lower the oil
cooler. Fasten the two rubber straps [Figure 10-120-4].

65 of 822 10-120-3 T870 Service Manual

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Install new O-ring and lubricate with clean oil.

Removing And Replacing Hydraulic / Hydrostatic Install new filter element ensuring that element is fully
Filter seated in the housing.

For the correct service interval. (See SERVICE Install the filter cap and tighten to 25 N•m (18 ft-lb)
SCHEDULE on Page 10-70-1.) torque.

Remove the rear grille. (See Removing on Page 50-60-

1.)

The filter housing is located behind the hydraulic fluid

WARNING
reservoir.
AVOID INJURY OR DEATH
Clean the top of the filter housing. Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Figure 10-120-9 Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

Install the rear grille.

Start the engine and operate the loader hydraulic

controls.

Dealer Copy -- Not for Resale

1
WARNING
AVOID INJURY OR DEATH
P100047 Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Remove the filter cap (Item 1) [Figure 10-120-9].
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
Figure 10-120-10
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807

1
Stop the engine and check for leaks at the filter.

Check the fluid level in the reservoir and add as needed.

(See Checking And Adding Fluid on Page 10-120-1.)

2 P100044 P100046

Remove the filter element (Item 1) [Figure 10-120-10]

and discard.

Remove the O-ring (Item 2) [Figure 10-120-10] and

discard.

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HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-13

Removing And Replacing Hydraulic Charge Filter

The hydraulic charge filter is located under the operator

cab. For the correct service interval (See SERVICE
SCHEDULE on Page 10-70-1.)

Raise the operator cab. (See Raising on Page 10-30-1.)

1
Figure 10-120-11

1
P100785A

2 Remove and discard the filter element (Item 1) [Figure

10-120-13].

Clean the surface of the filter housing and the filter base
1 where they contact the filter element seal.

Dealer Copy -- Not for Resale

Put clean oil on the seal of the new filter element. Install
P100275 the element on the filter base. Install and tighten the filter
housing to 47 - 54 N•m (35 - 40 ft-lb) torque.

Unhook the four rubber straps (Item 1) and remove the

lower fan duct (Item 2) [Figure 10-120-11].

Figure 10-120-12
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
1
Install the lower fan duct [Figure 10-120-11].

NOTE: Failure to install the lower fan duct correctly

may result in decreased cooling.

Lower the operator cab. (See Lowering on Page 10-30-

P100785 2.)

Start the engine and operate the loader hydraulic

Place a suitable container below the filter housing and controls.
remove the filter housing (Item 1) [Figure 10-120-12]
using a socket wrench.

Recycle or dispose of used fluid in an environmentally

safe manner.

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HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Breather Cap

Removing And Replacing Hydraulic Charge Filter See the SERVICE SCHEDULE for the correct
(Cont’d) replacement interval. (See SERVICE SCHEDULE on
Page 10-70-1.)

Remove the rear grille. (See Removing on Page 50-60-

WARNING 1.)

Figure 10-120-14
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid 1
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807

Stop the engine and check for leaks at the filter.

Check the fluid level in the reservoir and add as needed.

(See Checking And Adding Fluid on Page 10-120-1.)

Dealer Copy -- Not for Resale

P100055

Remove the breather cap (Item 1) [Figure 10-120-14]

and discard.

Install new breather cap.

Install the rear grille. (See Removing on Page 50-60-1.)

68 of 822 10-120-6 T870 Service Manual

BOB-TACH (HAND LEVER) The spring loaded wedges (Item 1) must contact the
lower edge of the holes in the attachment (Item 2)
Inspection And Maintenance [Figure 10-130-2].

Figure 10-130-1 If the wedges do not contact the lower edge of the holes
[Figure 10-130-2], the attachment will be loose and can
come off the Bob-Tach.

Figure 10-130-3

P-85513A

Move the Bob-Tach levers down to engage the wedges

[Figure 10-130-1].

Dealer Copy -- Not for Resale

The levers and wedges must move freely.

WARNING
AVOID INJURY OR DEATH
The Bob-Tach wedges must extend through the
holes in the attachment mounting frame. Levers
must be fully down and locked. Failure to secure
wedges can allow attachment to come off.
W-2715-0208

Figure 10-130-2

B-17460
1

Inspect the mounting frame on the attachment and Bob-

Tach, linkages and wedges for excessive wear or
2 damage [Figure 10-130-3]. Replace any parts that are
damaged, bent or missing. Keep all fasteners tight.

Look for cracked welds. Contact your Bobcat dealer for

Wedge must contact repair or replacement parts.
lower edge of hole in the
attachment mounting Lubricate the wedges. (See SERVICE SCHEDULE on
frame. Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-140-1.)
P-31233A P-31233

The wedges (Item 1) [Figure 10-130-2] must extend

through the holes in the attachment mounting frame.

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70 of 822 10-130-2 T870 Service Manual

BOB-TACH (POWER) The wedges (Item 1) [Figure 10-131-2] must extend
through the holes in the attachment mounting frame.
This machine may be equipped with a Power Bob-Tach.
The spring loaded wedges (Item 1) must contact the
Inspection And Maintenance lower edge of the holes in the attachment mounting
frame (Item 2) [Figure 10-131-2].
Figure 10-131-1
If the wedges do not contact the lower edge of the holes
[Figure 10-131-2], the attachment will be loose and can
come off the Bob-Tach.
1
Figure 10-131-3

P-85320A

Push and hold the BOB-TACH “WEDGES UP” switch

Dealer Copy -- Not for Resale

(Item 1) until wedges are fully raised. Push and hold the
BOB-TACH “WEDGES DOWN” switch (Item 2) [Figure
10-131-1] until the wedges are fully down.

The levers and wedges must move freely.

WARNING
AVOID INJURY OR DEATH
The Bob-Tach wedges must extend through the
holes in the attachment mounting frame. Levers
must be fully down and locked. Failure to secure
wedges can allow attachment to come off.
W-2715-0208

Figure 10-131-2

B-17460
1

Inspect the mounting frame on the attachment and Bob-

Tach, linkages and wedges for excessive wear or
2 damage [Figure 10-131-3]. Replace any parts that are
damaged, bent or missing. Keep all fasteners tight.

Look for cracked welds. Contact your Bobcat dealer for

Wedge must contact repair or replacement parts.
lower edge of hole in the
attachment mounting Lubricate the wedges. (See SERVICE SCHEDULE on
frame. Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-140-1.)
P-31233A P-31233

71 of 822 10-131-1 T870 Service Manual

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72 of 822 10-131-2 T870 Service Manual

LUBRICATING THE LOADER Figure 10-140-2

Lubrication Locations
Lubricate the loader as specified for the best
performance of the loader. (See SERVICE SCHEDULE
on Page 10-70-1.)

Record the operating hours each time you lubricate the

Bobcat loader.
2
Always use a good quality lithium based multipurpose
grease when you lubricate the loader. Apply the lubricant
until extra grease shows.

Remove attachment from the loader.

P-90572A

Tilt the Bob-Tach forward until it contacts the ground.

2. Base End Lift Cylinder (Both Sides) (2) [Figure 10-
Stop the engine. 140-2].

Lubricate the following: Figure 10-140-3

Figure 10-140-1

Dealer Copy -- Not for Resale

3
1

P100713A

P100730
3. Lift Arm Pivot Pin (Both Sides) (2) [Figure 10-140-3].

1. Rod End Lift Cylinder (Both Sides) (2) [Figure 10-

140-1].

73 of 822 10-140-1 T870 Service Manual

LUBRICATING THE LOADER (CONT’D) Figure 10-140-6

Lubrication Locations (Cont’d)

Figure 10-140-4

P-85720

6. Rod End Tilt Cylinder (Both Sides) (2) [Figure 10-

P-90542A
140-6].

Figure 10-140-7
4. Lift Arm Link Pivot (Both Sides) (2) [Figure 10-140-4].

Dealer Copy -- Not for Resale

Figure 10-140-5

5
7

P-85719

P-85484
7. Bob-Tach Pivot Pin (Both Sides) (2) [Figure 10-140-
7].

5. Base End Tilt Cylinder (Both Sides) (2) [Figure 10-

140-5].

74 of 822 10-140-2 T870 Service Manual

LUBRICATING THE LOADER (CONT’D) Figure 10-140-10

Lubrication Locations (Cont’d)

Figure 10-140-8

10

P-90544A

10. Front Control Link (Both Sides) (2) [Figure 10-140-

P-85487
10].

8. Bob-Tach Wedge (Both Sides) (2) [Figure 10-140-8].

Dealer Copy -- Not for Resale

Figure 10-140-9

P-90570A

9. Rear Control Link (Both Sides) (2) [Figure 10-140-9].

75 of 822 10-140-3 T870 Service Manual

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76 of 822 10-140-4 T870 Service Manual

SPARK ARRESTER MUFFLER

Cleaning Procedure
WARNING
See the SERVICE SCHEDULE for service interval for
cleaning the spark arrester muffler. (See SERVICE
When the engine is running during service, the
SCHEDULE on Page 10-70-1.)
driving and steering controls must be in neutral and
the parking brake engaged. Failure to do so can
Do not operate the loader with a defective exhaust
cause injury or death.
system. W-2006-1209

Start the engine and run for about 10 seconds while a

IMPORTANT second person, wearing safety glasses, holds a piece of
wood over the outlet of the muffler.

This machine is factory equipped with a U.S.D.A. This will force contaminants out through the cleanout
Forestry Service approved spark arrester exhaust hole.
system.
Stop the engine.
The spark arrester muffler, if equipped, must be
cleaned to keep it in working condition. The spark Install and tighten the plug. Close the rear door.
arrester muffler must be serviced by dumping the
spark chamber every 100 hours of operation.
WARNING

Dealer Copy -- Not for Resale

On some models, the turbocharger functions as the
spark arrester and must operate correctly for proper
spark arrester function. AVOID INJURY OR DEATH
When an engine is running in an enclosed area, fresh
If this machine is operated on flammable forest, air must be added to avoid concentration of exhaust
brush, or grass covered land, it must be equipped fumes. If the engine is stationary, vent the exhaust
with a spark arrester attached to the exhaust system outside. Exhaust fumes contain odorless, invisible
and maintained in working order. Failure to do so will gases which can kill without warning.
be in violation of California State Law, Section 4442. W-2050-0807
PRC. Refer to local laws and regulations for spark
arrester requirements.
I-2284-0111

Stop the engine and open the rear door. WARNING

Figure 10-150-1 Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285

WARNING
1
Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact
flammable material. Failure to obey warnings can
P-90662A
cause injury or death.
W-2068-1285
Remove the plug (Item 1) [Figure 10-150-1] from the
bottom of the muffler.

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78 of 822 10-150-2 T870 Service Manual

PIVOT PINS

Inspection And Maintenance

Figure 10-160-1

P-90667

All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure

Dealer Copy -- Not for Resale

10-160-1].

Check that the lock nuts are tightened to 48 - 54 N•m (35

- 40 ft-lb) torque.

79 of 822 10-160-1 T870 Service Manual

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80 of 822 10-160-2 T870 Service Manual

LOADER STORAGE AND RETURN TO SERVICE Return To Service

Storage After the Bobcat loader has been in storage, it is

necessary to follow a list of items to return the loader to
Sometimes it may be necessary to store your Bobcat service.
loader for an extend period of time. Below is a list of
items to perform before storage. • Check the engine and hydraulic oil levels; check
coolant level.
• Thoroughly clean the loader including the engine
compartment. • Install a fully charged battery.

• Lubricate the loader. • Remove grease from exposed cylinder rods.

• Replace worn or damaged parts. • Check all belt tensions.

• Park the loader in a dry protected shelter. • Be sure all shields and guards are in place.

• Lower the lift arms all the way and put the bucket flat • Lubricate the loader.
on the ground.
• Check track condition and remove blocks from under
• Put blocks under the frame to remove weight from the frame.
tracks.
• Remove cover from exhaust pipe opening.
• Put grease on any exposed cylinder rods.

Dealer Copy -- Not for Resale

• Start the engine and let run for a few minutes while
• Put fuel stabilizer in the fuel tank and run the engine observing the instrument panels and systems for
a few minutes to circulate the stabilizer to the pump correct operation.
and fuel injectors.
• Operate machine, check for correct function.
If biodiesel blend fuel has been used, perform the
following: • Stop the engine and check for leaks. Repair as
needed.
Drain the fuel tank, refill with 100% petroleum diesel
fuel, add fuel stabilizer and run the engine for at least
30 minutes.

• Drain and flush the cooling system. Refill with

premixed coolant.

• Replace all fluids and filters (engine, hydraulic /

hydrostatic).

• Replace air cleaner, heater and air conditioning filters.

• Put all controls in neutral position.

• Remove the battery. Be sure the electrolyte level is

correct then charge the battery. Store it in a cool dry
place above freezing temperatures and charge it
periodically during storage.

• Cover the exhaust pipe opening.

• Tag the machine to indicate that it is in storage

condition.

81 of 822 10-170-1 T870 Service Manual

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82 of 822 10-170-2 T870 Service Manual

STOPPING THE ENGINE AND LEAVING THE Remove the key from the switch (Standard Key Panel) to
LOADER prevent operation of the loader by unauthorized
personnel.
Procedure
NOTE: Activating the Password Lockout Feature on
Stop the loader on level ground. machines with the Keyless Start Panel or the
Deluxe Instrumentation Panel allows
Fully lower the lift arms and put the attachment flat on the operation of the loader without using a
ground. password. (See Password Lockout Feature on
Page 60-190-2.) or (See Password Lockout
Figure 10-180-1 Feature on Page 60-191-1.)

Figure 10-180-3

Dealer Copy -- Not for Resale

P-85737A P-85735A
P-90525A

Exit the loader using grab handles, safety tread and

Push the engine speed control fully down [Figure 10- steps (maintaining a 3-point contact) [Figure 10-180-3].
180-1] to decrease the engine speed.

Engage the parking brake.

Figure 10-180-2
WARNING
AVOID INJURY OR DEATH
1 Before you leave the operator’s seat:
• Lower the lift arms and put the attachment flat on
the ground.
• Stop the engine.
2 • Engage the parking brake.
• Raise the seat bar.
• Move all controls to the NEUTRAL / LOCKED
position to make sure the lift, tilt and traction
drive functions are deactivated.
P-90688A P-90214A
The seat bar system must deactivate these functions
when the seat bar is up. See your Bobcat dealer for
Turn the key switch to the STOP position (Item 1) or service if controls do not deactivate.
press the STOP button (Item 2) [Figure 10-180-2]. W-2463-1110

NOTE: If the loader lights are ON, they will remain ON

for approximately 90 seconds after turning
the loader OFF.

Raise the seat bar and make sure the lift and tilt functions
are deactivated.

Unbuckle the seat belt.

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84 of 822 10-180-2 T870 Service Manual

EMERGENCY EXIT Figure 10-190-3

The front opening on the operator cab and rear window

provide exits.

External Access

Figure 10-190-1

P-90676

Exit through the rear of the operator cab [Figure 10-190-

3].

Front Door
P-90669A
This machine may be equipped with a front door.

Dealer Copy -- Not for Resale

The rear window can be removed from outside the loader NOTE: Use this procedure to remove the front door
using a T40 TORX® driver. Turn both screws (Item 1) only under emergency conditions. Damage to
[Figure 10-190-1] in until the latches disengage from the machine may occur.
window frame. Pull the top of the window away from the
cab and lift up to remove. Figure 10-190-4

Rear Window

NOTE: Use this procedure to remove the rear window

only under emergency conditions. Damage to
machine may occur.
1
Figure 10-190-2

P-90725

Turn both latches (Item 1) [Figure 10-190-4] down until

they disengage from the door frame.

Push the door out of the operator cab door frame.

P-85309A Exit through the opening.

Turn both latches (Item 1) [Figure 10-190-2] in until they

disengage from the window frame.

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

85 of 822 10-190-1 T870 Service Manual

EMERGENCY EXIT (CONT’D) Figure 10-190-7

Front Door (Cont’d)

Front Door Reassembly

2
Reassemble the front door using the following
instructions if the door was opened using the emergency
exit procedure.

Figure 10-190-5
1
1

P-90685

Orient the latches as shown (Item 1) and install the door

hinges (Item 2) [Figure 10-190-7] on the door. (Bottom
hinge shown)
2
Figure 10-190-8

Dealer Copy -- Not for Resale

P-85781A 1

Disconnect electrical connector (Item 2) and washer fluid

hose (Item 1) [Figure 10-190-5]. 2

Figure 10-190-6

2
3
P-90686A

Install cast washers (Item 2) on door hinges taking care

to match rectangular surfaces. Hold cast washer firmly
1 against door and rotate latch (Item 1) [Figure 10-190-8]
up to lock cast washer into place. (Bottom hinge shown)
(Plastic cap shown removed for clarity)

P-85588A P-85589A Install door on loader.

Install the gas spring socket on the ball stud fitting. Install
Rotate and pull the clip (Item 1) out of the gas spring the clip into the hole in the gas spring socket. Rotate the
socket. Pull the gas spring socket (Item 3) straight off the clip to lock into place [Figure 10-190-6].
ball stud fitting (Item 2) [Figure 10-190-6].
Connect electrical connector (Item 2) and washer fluid
Remove the door hinges from the loader. hose (Item 1) [Figure 10-190-5].

86 of 822 10-190-2 T870 Service Manual

SEAT BELT Figure 10-200-1

Inspection And Maintenance 1

WARNING 3

Failure to properly inspect and maintain the seat belt

can cause lack of operator restraint resulting in
serious injury or death.
W-2466-0703

2 4
Check the seat belt daily for correct function.

Inspect the seat belt system thoroughly at least once

each year or more often if the machine is exposed to
severe environmental conditions or applications.

Any seat belt system that shows cuts, fraying, extreme or

unusual wear, significant discolorations due to ultraviolet
UV exposure, dusty / dirty conditions, abrasion to the
seat belt webbing, or damage to the buckle, latch plate,

Dealer Copy -- Not for Resale

retractor (if equipped), hardware or any other obvious
problem should be replaced immediately. B-22283

The items below are referenced in [Figure 10-200-1].

1. Check the webbing. If the system is equipped with a

retractor, pull the webbing completely out and inspect
the full length of the webbing. Look for cuts, wear,
fraying, dirt and stiffness.

2. Check the buckle and latch for correct operation.

Make sure latch plate is not excessively worn,
deformed or buckle is not damaged or casing broken.

3. Check the retractor web storage device (if equipped)

by extending webbing to determine if it looks correct
and that it spools out and retracts webbing correctly.

4. Check webbing in areas exposed to ultraviolet (UV)

rays from the sun or extreme dust or dirt. If the original
color of the webbing in these areas is extremely faded
and / or the webbing is packed with dirt, the webbing
strength may have deteriorated.

See your Bobcat dealer for seat belt system replacement

parts for your machine.

87 of 822 10-200-1 T870 Service Manual

 Dealer Copy -- Not for Resale

88 of 822 10-200-2 T870 Service Manual

 HYDRAULIC SYSTEM

HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5

CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-9

CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-2
Base End Pivot Pin Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-8

Dealer Copy -- Not for Resale

CYLINDER (BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-5

MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-2
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4

89 of 822 20-01 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
Actuator Removal And Installation (Out Of Loader) . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-7
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-10
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-11
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-11
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . 20-40-12
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-40-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-40-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-40-14
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-40-14
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17
Lift Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-19
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-21
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-23
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-24

Dealer Copy -- Not for Resale

Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-25
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-26
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-28

90 of 822 20-02 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-2
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-5
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-6
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-7
Load Check Valve Removal And Installation (Tilt & Auxiliary) . . . . . . . . . . . . . . . . . 20-41-8
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . . 20-41-9
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . . 20-41-9
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-41-10
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-41-10
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-11
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-12
Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-13
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-14
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-25
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-27
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-30
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-31

Dealer Copy -- Not for Resale

Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-33
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-33
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-34

LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-2
Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3

HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-6
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-7
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-8
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-9

91 of 822 20-03 T870 Service Manual

HYDRAULIC PUMP (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-2
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-3
Direct Pump Test (High Flow Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-5
High Flow Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-7
High Flow Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-8
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-9
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-10
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-12
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-13
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-14

HYDRAULIC / HYDROSTATIC FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Dealer Copy -- Not for Resale

Hydraulic Fluid Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-2

OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4

REAR AUXILIARY DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-3

BOB-TACH (POWER) BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-3

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

92 of 822 20-04 T870 Service Manual

 Printable Version Click Here

HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH NO OPTIONS
T870 (S/N A3PG11001 AND ABOVE)
(S/N A3PH11001 AND ABOVE)
(PRINTED SEPTEMBER 2010)
V-1396legend
LEGEND
1 RESERVOIR: 19 PULL BUTTON ACTIVATED 36 VARIABLE CAPACITY DISPLACEMENT
Capacity at sight gauge . . 10.3 Qts. (9,75 L) DIRECTIONAL CONTROL VALVE - LIFT BIDIRECTIONAL HYDROSTATIC PUMP
System Capacity . . . . . . . . 9.5 Gal. (36 L) ARM BY-PASS
37 CHECK VALVE – COLD WEATHER BY-PASS
2 SIGHT GAUGE 20 LIFT CYLINDER SPOOL - MADE TO With 50 PSI (3,45 bar) Spring
3 RESTRICT FLOW DURING BOOM 38
DIFFERENTIAL PRESSURE SWITCH: SERVO PISTON – Swash Plate
DOWN BUT NOT DURING BOOM UP
15 PSI (1,07 bar)
21 ANTICAVITATION VALVE 39 RELIEF/REPLENISHING VALVE - HIGH
Normally Closed
4 FILTER - HYDRAULIC (CANISTER) PRESSURE: 5294 PSI (365 bar)
22 PROPORTIONAL RELIEF VALVE –
5 SPRING LOADED FILTER BY-PASS (Fan Speed Regulator): 40 RELIEF VALVE - CHARGE INLET:
1566 - 1784 PSI (108 - 123 bar) 430 - 530 PSI (29,6 – 36,5 bar) at High Engine Idle
VALVE: 25 PSI (1,7 bar)
With 140 degrees F. (60 degrees C.) Fluid
6 DIAGNOSTIC COUPLER 23 SPRING LOADED FILTER BY-PASS
VALVE: 75 - 83 PSI (5,2 - 5,7 bar) 41 SOLENOID ACTIVATED DIRECTIONAL
7 RELIEF VALVE - MAIN:
24 FIXED CAPACITY DISPLACEMENT CONTROL VALVE – FORWARD/REVERSE
3450 - 3550 PSI (238 - 245 bar) Dealer Copy -- Not for Resale
at Front Quick Couplers HYDRAULIC MOTOR
42 FILTER (Screen)
8 RELIEF/ANTICAVITATION VALVE - 25 FILTER - HYDRAULIC (CANISTER)
PORT 4500 PSI (310 bar) 43 Not Used For This Model
26 SENSOR – CHARGE PRESSURE –
9 RELIEF/ANTICAVITATION VALVE - Fan Filter
PORT 4000 PSI (276 bar) 27 FRONT AUXILIARY MANUAL PRESSURE 44 Not Used For This Model
(AUXILIARY RELIEF IS OPTIONAL) BLEED-OFF VALVE
10 SOLENOID ACTIVATED DIRECTIONAL 28 SENSOR – HYD. TEMPERATURE 45 Not Used For This Model
CONTROL VALVE - AUXILIARY
11 LOAD CHECK VALVE 29 RESTRICTION - 0.067 inch (1,7 mm) 46 SOLENOID ACTIVATED DIRECECTIONAL
CHECK VALVE - With 200 PSI (13,8 bar) CONTROL VALVE – BRAKE
ANTICAVITATION VALVE 30
12 Spring 47 FILTER - BRAKE
13 PILOTED ACTIVATED DIRECTIONAL 31 DRIVE MOTOR SHUTTLE VALVE
CONTROL VALVE - TILT CONTROL 48 HYDRAULIC PUMP . . . . . . . Gear Type
32 Not Used For This Model 23.8 GPM (90,1 L/min.) at High Engine Idle
14 PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL 33 Not Used For This Model 49 CHARGE PUMP -
15 SOLENOID ACTIVATED DIRECTIONAL 13.5 GPM (51,1 L/min) at High Engine Idle
CONTROL VALVE - BICS CONTROL
16 FILTER - BICS CONTROL VALVE 34 FIXED CAPACITY DISPLACEMENT
(SCREEN) BIDIRECTIONAL HYDROSTATIC
17 CHECK VALVE - With 14.5 PSI (1,0 bar) MOTOR
Spring 35 HYDRAULIC BRAKE – SPRING APPLIED –
18 RESTRICTION . . . . . . . 0.079 in. (2,0 mm) PRESSURE RELEASE (SAPR)
NOTE: Unless otherwise specified
springs have NO significant
pressure value.

Printed in U.S.A. V-1396legend (9-9-10)

93 of 822
 27
DRIVE MOTOR Male

30 L
INTEGRATED
29 Male
31 COUPLER BLOCK
27

Female

HYDRAULIC CONTROL VALVE

34

9
10
Z

A B 10
35
Auxiliary Spool

6 TILT CYLINDERS
9 11
HYDROSTATIC PUMP BOBCAT INTERLOCK CONTROL
36 R SYSTEM (BICS)
T 8

X 42 41 Tilt Spool

13
38
12
X

11
39
39
14 LIFT CYLINDERS
SAPR BRAKE VALVE
M
M 42
47 A B
47
M
Dealer Copy
Lift Spool -- Not for Resale
3 40
8
2 G
A B 20
45 M
46 16 16
1 M 42 11 17 ?

15 18
2
39
39 ? 7 6
X

38
1 19
X ? OIL COOLER
42 41
RESERVOIR
T 2 (VENTED)
36
R
FILTER 1
48 37
CANISTER

3
VARIABLE SPEED HYDRAULIC
FAN MOTOR W/ INTEGRATED FILTER
49
26
5
4
25 23

WORKING

CHARGE
PRESSURE
DRAIN /
35 21 RETURN
24
B A 22
P DR
Z

34 DRAIN/RETURN MANIFOLD

HYDRAULIC/HYDROSTATIC SCHEMATIC
28 WITH NO OPTIONS
T870 (S/N A3PG11001 & ABOVE)
31 (S/N A3PH11001 & ABOVE)
29
30
(PRINTED SEPTEMBER 2010)
L
DRIVE MOTOR
94 of 822 7194197
Printed In U.S.A. Printable Version Click Here
 Printable Version Click Here

HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH ALL OPTIONS
T870 (S/N A3PG11001 AND ABOVE)
(S/N A3PH11001 AND ABOVE)
(PRINTED SEPTEMBER 2010)
V-1397legend
LEGEND
1 RESERVOIR: 20 LIFT CYLINDER SPOOL - MADE TO 39 RELIEF/REPLENISHING VALVE - HIGH 58 CHECK VALVE - With 80 PSI (5,5 bar) Spring
Capacity at sight gauge . . 10.3 Qts. (9,75 L) RESTRICT FLOW DURING BOOM PRESSURE: 5294 PSI (365 bar)
System Capacity . . . . . . . . 9.5 Gal. (36 L) 59 RELIEF VALVE - 2000 PSI (137 bar)
DOWN BUT NOT DURING BOOM UP 40 RELIEF VALVE - CHARGE INLET:
2 SIGHT GAUGE 21 ANTICAVITATION VALVE 430 - 530 PSI (29,6 – 36,5 bar) at CHECK VALVE - With 300 PSI (20,7 bar)
High Engine Idle With 140 degrees F. 60
3 Spring And With 0.016 inch (0,40 mm) Orifice
DIFFERENTIAL PRESSURE SWITCH: 22 PROPORTIONAL RELIEF VALVE – (60 degrees C.) Fluid
15 PSI (1,07 bar) (Fan Speed Regulator): 61 RESTRICTION - 0.025 inch (0,6 mm)
41 SOLENOID ACTIVATED DIRECTIONAL
Normally Closed 1566 - 1784 PSI (108 - 123 bar)
4 CONTROL VALVE – FORWARD/REVERSE 62 FILTER – BOB-TACH VALVE
FILTER - HYDRAULIC (CANISTER)
23 SPRING LOADED FILTER BY-PASS
42 FILTER (Screen) 63 PILOT ACTIVATED DIRECTIONAL
5 SPRING LOADED FILTER BY-PASS VALVE: 75 - 83 PSI (5,2 - 5,7 bar)
CONTROL VALVE - REAR AUXILIARY
VALVE: 25 PSI (1,7 bar) 24 FIXED CAPACITY DISPLACEMENT 43 Not Used For This Model 64 RELIEF VALVE: 3300 PSI (228 bar)
6 DIAGNOSTIC COUPLER HYDRAULIC MOTOR
25 FILTER - HYDRAULIC (CANISTER) 65 SOLENOID ACTIVATED DIRECTIONAL
7 RELIEF VALVE - MAIN: 44 Not Used For This Model
CONTROL VALVE - TWO COIL
3450 - 3550 PSI (238 - 245 bar) 26 SENSOR – CHARGE PRESSURE – Dealer Copy -- Not for Resale
at Front Quick Couplers 66 RESTRICTOR - 0.031 inch (0,8 mm)
Fan Filter 45 Not Used For This Model
8 RELIEF/ANTICAVITATION VALVE - 27 FRONT AUXILIARY MANUAL PRESSURE 67 LOAD SHUTTLE VALVE - BLEED OFF
PORT 4500 PSI (310 bar) 46 SOLENOID ACTIVATED DIRECECTIONAL
BLEED-OFF VALVE
CONTROL VALVE – BRAKE 68 SOLENOID ACTIVATED DIRECTIONAL
9 RELIEF/ANTICAVITATION VALVE - 28 SENSOR – HYD. TEMPERATURE CONTROL VALVE - BASE
PORT 4000 PSI (276 bar) 47 FILTER - BRAKE
(AUXILIARY RELIEF IS OPTIONAL) 29 RESTRICTION - 0.067 inch (1,7 mm) 69 SOLENOID ACTIVATED DIRECTIONAL
48 HYDRAULIC PUMP . . . . . . . Gear Type CONTROL VALVE - ROD
10 SOLENOID ACTIVATED DIRECTIONAL 30 CHECK VALVE - With 200 PSI (13,8 bar)
CONTROL VALVE - AUXILIARY Spring 23.8 GPM (90,1 L/min.) at High Engine Idle 70 SOLENOID ACTIVATED DIRECTIONAL
11 LOAD CHECK VALVE 31 DRIVE MOTOR SHUTTLE VALVE 49 CHARGE PUMP - CONTROL VALVE - BUCKET POSITION
VALVE (ON/OFF)
12 ANTICAVITATION VALVE 32 Not Used For This Model 13.5 GPM (51,1 L/min) at High Engine Idle
71 FLOW DIVIDER ADJUSTMENT VALVE
13 33 Not Used For This Model 50 HIGH FLOW HYDRAULIC PUMP Gear Type 72
PILOTED ACTIVATED DIRECTIONAL PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL 13.6 GPM (51,5 L/min.) at High Engine Idle CONTROL VALVE - FLOW CONTROL
14 PILOTED ACTIVATED DIRECTIONAL SPOOL
51 RELIEF VALVE - 3500 PSI (241 bar)
CONTROL VALVE - LIFT CONTROL 73 CHECK VALVE - BUCKET POSITION
34 FIXED CAPACITY DISPLACEMENT
15 SOLENOID ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC 52 DUMP VALVE – ON / OFF VALVE
CONTROL VALVE - BICS CONTROL MOTOR 74 PILOTED ACTIVATED DIRECTIONAL
53 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - UNLOADING
16 FILTER - BICS CONTROL VALVE 35 HYDRAULIC BRAKE – SPRING APPLIED – CONTROL VALVE - HYDRAULIC SPOOL
(SCREEN) PRESSURE RELEASE (SAPR) POWERED BOB-TACH
17 CHECK VALVE - With 14.5 PSI (1,0 bar) 54 FILTER - BOB-TACH VALVE 75 RIDE CONTROL VALVE
36 VARIABLE CAPACITY DISPLACEMENT
Spring
BIDIRECTIONAL HYDROSTATIC PUMP 55 RESTRICTION - 0.089 inch (2,26 mm) 76 HIGH PRESSURE CHAMBER
18 RESTRICTION . . . . . . . 0.079 in. (2,0 mm)
37 CHECK VALVE – COLD WEATHER BY-PASS LOW PRESSURE CHAMBER
56 SOLENOID ACTIVATED DIRECTIONAL 77
19 PULL BUTTON ACTIVATED With 50 PSI (3,45 bar) Spring
DIRECTIONAL CONTROL VALVE - LIFT CONTROL VALVE (TWO COIL) NOTE: Unless otherwise specified
ARM BY-PASS 38 SERVO PISTON – Swash Plate 57 RELIEF VALVE - 1200 PSI (83 bar) springs have NO significant
Printed in U.S.A. pressure value. V-1397legend (9-9-10)
95 of 822
 27
DRIVE MOTOR Male

30 L
INTEGRATED
29 Male
31 COUPLER BLOCK
27
RIDE CONTROL
Female (OPTION)

76 77

HYDRAULIC CONTROL VALVE

LIFT CYLINDERS
34

9 75
REAR AUXILIARY VALVE 10
(OPTION)
Z FEMALE MALE
REAR QUICK
A B
COUPLERS 10
35
Auxiliary Spool
? ?

67

69 6
68 9 11
HYDROSTATIC PUMP 65 BOBCAT INTERLOCK CONTROL
? ?
R SYSTEM (BICS) BUCKET POSITIONING
36 VALVE (OPTIONAL)
T 8 E1 E2 A1 A2

66 E3
X 42 41 Tilt Spool 70

13 B
38 71
64 12
X 72
11 ?
39 63 73
39
SAPR BRAKE VALVE 14 D2

P - in P - out T
M
M 42
47 A B
47
M
Dealer Copy
Lift Spool -- Not for Resale
3 40
C2
POWER BOBTACH CYLINDER 8 74
2 G (OPTIONAL)
C1 D1
A B 20
45 M
46 62 62 16
1 M 42 11 16 17 ?

58 15 18
57 2
39
39 ? 60 7 6
X

56
38 TILT CYLINDERS
1 19
X ? OIL COOLER
42 41
59 55 RESERVOIR
T D 61 2 (VENTED)
36 54
R
FILTER 1
48 37 POWER BOBTACH 53 CANISTER
VALVE (OPTIONAL)
3
VARIABLE SPEED HYDRAULIC
FAN MOTOR W/ INTEGRATED FILTER
49
26
5
52 4
25 23
50
51 ?

WORKING

CHARGE
PRESSURE
DRAIN /
35 21 RETURN
24
B A 22
P DR
Z

34 DRAIN/RETURN MANIFOLD

HYDRAULIC/HYDROSTATIC SCHEMATIC
28 WITH ALL OPTIONS
T870 (S/N A3PG11001 & ABOVE)
31 (S/N A3PH11001 & ABOVE)
29
30
(PRINTED SEPTEMBER 2010)
L
DRIVE MOTOR
96 of 822 7194197
Printed In U.S.A.
Printable Version Click Here
HYDRAULIC SYSTEM INFORMATION

Glossary Of Hydraulic / Hydrostatic Symbols

SYMBOL DESCRIPTION SYMBOL DESCRIPTION

FLOW LINES and CONNECTIONS BASIC and MISCELLANEOUS SYMBOLS

WORKING CIRCUITS - Continuous, RESTRICTION - Line with Fixed

Solid Line - Working (Main) Line, Restriction - Affected by Viscosity
Return Line (line conducting fluid (property of resistance to flowing
from working devices to the reservoir) fluid).
and Feed line (main line conductor).
VARIABLE ADJUSTMENT
RESTRICTION - Regulated or
Variable Restriction.
PILOT PRESSURE - Dashed Line -
Pilot Line (Line which conducts TEMPERATURE CONTROL -
control fluid). (Indication of temperature).

DRAIN CIRCUITS - Dotted Line -

TEMPERATURE INDICATOR -
Drain Line (drain or bleed line - line
(temperature measurement -
conducting fluid from a component
thermometer).
housing to the reservoir.

Dealer Copy -- Not for Resale

FILTER (strainer or screen) - For fluid
conditioning.
COMPONENTS - Long Chain Line -
Enclosure outline for several
components assembled in one unit. VENTED AND FILTERED
RESERVOIR (reservoir open to
atmosphere).
MECHANICAL CONNECTIONS -
Double Line (Shaft, Lever, Piston
Rod). PRESSURIZED, VENTED AND
FiLTERED RESERVOIR (Reservoir
uses a pressured cap).
CONNECTED JUNCTION OF OIL
LINES (Flow Line Connection). OIL COOLER (heat exchanger) - The
arrows in the diamond indicate the
extraction of heat (heat dissipation).

OIL LINES CROSSING (NOT PRESSURE SENSOR - Varies

Connected). electric signal with pressure.

DIFFERENTIAL PRESSURE
COUPLER - Quick - Acting Coupling SWITCH - Switch activates when
(uncoupled, closed by non-return pressure difference reaches specified
valve). level.

PRESSURE SWITCH - Switch

activates when pressure reaches
specified level.

MUFFLER (silencer) - Reduces

noise.

97 of 822 20-10-1 T870 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT’D)

Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

SYMBOL DESCRIPTION SYMBOL DESCRIPTION

CYLINDER: Equipment to convert hydraulic energy into CONTROL MECHANISMS

linear energy and in which the fluid pressure operates
alternately in both directions (forward and backward CONTROL VALVE WITH DETENT
strokes). (Holds Valve in Position) - device for
maintaining a given position
DOUBLE ACTING HYDRAULIC (mechanical).
CYLINDER, UNEQUAL
DISPLACEMENT - With single piston CONTROL VALVE ACTIVATED BY A
rod. PULL BUTTON (manual).

DOUBLE ACTING HYDRAULIC

CYLINDER, UNEQUAL CONTROL VALVE ACTIVATED BY A
DISPLACEMENT and CUSHION ON PUSH-PULL BUTTON (manual).
ONE END - With single piston rod.

CONTROL VALVE ACTIVATED BY A

LEVER (manual).
PUMP: To convert mechanical energy into hydraulic

Dealer Copy -- Not for Resale

energy.
CONTROL VALVE ACTIVATED BY A
PEDAL (manual).
FIXED CAPACITY DISPLACEMENT
HYDRAULIC PUMP - With one
direction of flow.
CONTROL VALVE WITH SPRING
RETURN (mechanical).
VARIABLE CAPACITY
DISPLACEMENT BIDIRECTIONAL
HYDRAULIC PUMP - With two CONTROL VALVE ACTIVATED BY
directions of flow (bidirectional). AN ELECTRIC SOLENOID
(electrical).

MOTOR: To convert hydraulic energy into rotary CONTROL VALVE ACTIVATED BY A

mechanical energy. PROPORTIONAL ELECTRICAL
SOLENOID (electrical).

FIXED CAPACITY DISPLACEMENT CONTROL VALVE ACTIVATED BY

BIDIRECTIONAL HYDRAULIC DUAL ELECTRICAL SOLENOID
MOTOR - With two directions of flow (electrical).
(bidirectional.
CONTROL VALVE ACTIVATED BY
PILOT PRESSURE (indirect control,
pilot actuated by application of
pressure).

98 of 822 20-10-2 T870 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT’D)

Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

SYMBOL DESCRIPTION SYMBOL DESCRIPTION

NON-RETURN VALVE, SHUTTLE VALVE: Valve which DIRECTIONAL CONTROL VALVE: Valve providing for
allows free flow in one direction only. the opening (fully or restricted) or the closing of one or
more flow paths (represented by several squares).

NON-RETURN VALVE (Check Valve) TWO PORTS and CLOSED FLOW

OUT IN - Used as Replenishing Valve, Lock PATHS
Check Valve or Anticavitation Valve -
Opens if the Inlet pressure is higher
than the Outlet pressure. Often SOLENOID ACTIVATED
contains internal spring which has NO DIRECTIONAL CONTROL VALVE
significant pressure value. (Two Position) - controlled by an
electric solenoid (with return spring).
SPRING LOADED VALVE (bypass
OUT IN Valve) - Opens if the Inlet pressure is PILOT ACTIVATED DIRECTIONAL
greater than the Outlet pressure plus CONTROL VALVE (Two Position) -
the spring pressure. controlled by pressure (with return
spring).
PILOT CONTROLLED NON-

Dealer Copy -- Not for Resale

RETURN VALVE- It is possible to MANUALLY ACTIVATED
open the valve by pilot pressure. DIRECTION CONTROL VALVE
T
OUT IN
(Variable Position) Joystick
P
Controlled, variable pressure to shift
the pilot activated directional control
SHUTTLE VALVE - The Inlet port
valve spool.
IN IN connected to the higher pressure is
OUT
automatically connected to the Outlet MANUALLY ACTIVATED FLOW
port while the other Inlet port is CONTROL VALVE (Two Position)
closed. allows for changing pilot flow to
ST

O
IS
D

FRON T

BACK
control switching joystick functions for
STD / ISO Control (Excavators Only).

STEERING CONTROL VALVE

(Variable Position) - Used for
controlling the hydraulic flow for the
steering cylinders in relationship to
the amount the steering wheel is
rotated.

99 of 822 20-10-3 T870 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT’D)

Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

SYMBOL DESCRIPTION SYMBOL DESCRIPTION

PRESSURE CONTROL VALVE: Valve ensuring the MISCELLANEOUS

control of pressure.
ACCUMULATOR - Supplies
RELIEF VALVE - When the Inlet temporary reserve pressure to the
pressure overcomes the opposing hydraulic system when the engine
IN OUT
force of the spring, the valve opens has been stopped.
permitting flow from the Outlet port.

RELIEF / REPLENISHING VALVE or

RELIEF / ANTICAVITATION VALVE -
When the Inlet pressure overcomes
IN OUT
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port - Allows free flow in the
opposite direction.

DUAL PRESSURE RELIEF VALVE -

Dealer Copy -- Not for Resale

When the Inlet pressure overcomes
IN OUT
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port. Pilot pressure provides a
second pressure value.

LOCK VALVE - hydraulic pressure is

applied to open the valve to allow the
hydraulic cylinder to move.

FLOW CONTROL VALVE: Valve controlling the flow in

one or both directions.

ONE WAY RESTRICTOR VALVE

(Non-Return Valve with Restriction) -
Unit allowing free flow in one direction
but restricted flow in the other
direction.

TOW VALVE - Normally in closed

position.

LOAD SENSE BLEED VALVE -

Regulates small amount of fluid flow
(leakage).

100 of 822 20-10-4 T870 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT'D)

Troubleshooting
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are
Check for correct function after adjustments, repairs
most common. Many of the recommended procedures
or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel
adjustments can cause injury or death.
only. W-2004-1285

If a service code appears in the left instrument panel.

(See DIAGNOSTIC SERVICE CODES on Page 60-90-
1.)

PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine rpm 1, 3, 4, 5, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position 4
The lift arms come down with the pedal in neutral position 4, 9, 10, 11
Lift Arm Bypass Control valve stuck 12

Dealer Copy -- Not for Resale

Lift Arm Bypass Control valve stem bent or broken 13

KEY TO CORRECT CAUSE

1. The fluid level is not correct.

2. The pedal linkage is disconnected.
3. The hydraulic pump has damage.
4. The pedal linkage is not adjusted correctly.
5. Relief valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold. Wrong viscosity fluid. (See HYDRAULIC / HYDROSTATIC FLUID
SPECIFICATIONS on Page SPEC-40-1.)
8. Exceeding the loaders rated operating capacity.
9. Internal leak in the lift cylinder(s).
10. External leak from the cylinder(s).
11. Damaged lift spool.
12. Rotate shaft.
13. Replace Lift Arm Bypass Control valve assembly.

101 of 822 20-10-5 T870 Service Manual

 Dealer Copy -- Not for Resale

102 of 822 20-10-6 T870 Service Manual

CYLINDER (LIFT) Figure 20-20-2

Testing

Figure 20-20-1

1
P100297

1 Install a cap (Item 1) [Figure 20-20-2] on the hose and

P100296 tighten.

Engage the parking brake. Lower the seat bar. Start the
Lower the lift arms. Stop the engine. Raise the seat bar. engine and press the PTOL button.

Dealer Copy -- Not for Resale

Operate the controls that lower the lift arms.

WARNING If there is any leakage from the fitting on the cylinder

(Item 2) [Figure 20-20-2], remove the lift cylinder for
repair. Repeat the procedure to check the other lift
Hydraulic fluid escaping under pressure can have cylinder.
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290

Check only one cylinder at a time. Disconnect the hose

(Item 1) [Figure 20-20-1] which goes to the base end of
the lift cylinder.

103 of 822 20-20-1 T870 Service Manual

CYLINDER (LIFT) (CONT'D)

Removal And Installation

WARNING
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
NOTE: Remove only one cylinder at a time.
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.

WARNING W-2103-0508

Figure 20-20-4
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286

2
1

IMPORTANT 2

Dealer Copy -- Not for Resale

When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
P100298
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 Cap and plug both fittings on the cylinder (Item 1)
[Figure 20-20-4].
Figure 20-20-3
NOTE: Do not cap or plug the two hydraulic hoses
(Item 2) [Figure 20-20-4].

Place the hoses (Item 2) [Figure 20-20-4] in a suitable

container to collect the hydraulic oil as the lift arms are
raised.

Recycle or dispose of used fluid in an environmentally

safe manner.
1

WARNING
P100296 AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
Mark and disconnect the two hydraulic hoses (Item 1) death. Fluid leaks under pressure may not be visible.
[Figure 20-20-3]. Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807

104 of 822 20-20-2 T870 Service Manual

CYLINDER (LIFT) (CONT'D)

Removal And Installation (Cont’d)

Figure 20-20-5

P100226

Remove the retaining bolt and nut (Item 1) [Figure 20-

20-5] from the pin on the rod end of the lift cylinder.

Dealer Copy -- Not for Resale

Installation: Tighten the retainer bolt and nut to 48 - 54
N•m (35 - 40 ft-lb) torque.

Figure 20-20-6

P100227

With a slide hammer, remove the pin (Item 1) [Figure 20-

20-6] from the rod end of the lift cylinder.

105 of 822 20-20-3 T870 Service Manual

CYLINDER (LIFT) (CONT'D) Figure 20-20-7

Removal And Installation (Cont’d)

DANGER
1

P-90605
P-90328

AVOID DEATH Install a sling in the middle of the Bob-Tach as shown in

• Disconnecting or loosening any hydraulic (Item 1) [Figure 20-20-7].
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. Using a chain hoist raise the lift arms and install an
• Keep out of this area when lift arms are raised approved lift arm support device on the cylinder that is
unless supported by an approved lift arm connected to the lift arm.
support. Replace if damaged.

Dealer Copy -- Not for Resale

D-1009-0409 Figure 20-20-8

WARNING 2
1

Never work on a machine with the lift arms up unless

the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598

P100299

Install a bolt (Item 1) [Figure 20-20-8] through the eyelet

of the cylinder and install a strap (Item 2) [Figure 20-20-
8] to secure the cylinder.

106 of 822 20-20-4 T870 Service Manual

CYLINDER (LIFT) (CONT'D) Figure 20-20-11

Removal And Installation (Cont’d)

Open the rear door.

NOTE: When removing the left side lift cylinder the

battery will need to be removed to gain access
to the lower retaining bolt and nut. 1

Remove the battery (If required). (See Removal And

Installation on Page 60-20-1.)

Figure 20-20-9

P100233

1
With a slide hammer, remove the pin (Item 1) [Figure 20-
20-11] from the base end of the lift cylinder.

Figure 20-20-12

Dealer Copy -- Not for Resale

1

P-90834

Remove the retaining bolt and nut (Item 1) [Figure 20-

20-9] from the pin on the base end of the lift cylinder.

Installation: Tighten the retainer bolt and nut to 48 - 54 1

N•m (35 - 40 ft-lb) torque.

Figure 20-20-10 P100299

Using a chain hoist remove the lift cylinder (Item 1)

[Figure 20-20-12] from the loader.

P100234

Remove the grease fitting (Item 1) [Figure 20-20-10]

from the base end of the lift cylinder.

Installation: Tighten the grease fitting to 20 N•m (15 ft-

lb) torque.

107 of 822 20-20-5 T870 Service Manual

CYLINDER (LIFT) (CONT'D)

Parts Identification

1. Lift Cylinder
2. Hydraulic Tubeline
3. Cylinder Case Tube
4. Plug
5. Clamp 1
6. Nut
7. Back-up Ring
8. O-ring
9. Piston Assembly 4
10. Spacer
11. O-ring
12. Back-up Ring
13. O-ring 3
14. Head
15. Seal 4
16. Seal 5
17. Shaft
18. Grease Fitting

Dealer Copy -- Not for Resale

7
2 8
9
10
11
12
13
14

15
16

17

18

NA1413S

108 of 822 20-20-6 T870 Service Manual

CYLINDER (LIFT) (CONT'D) Figure 20-20-15

Disassembly
2
Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook 1

Spanner Wrench

Hold the hydraulic cylinder over a drain pan and move

the rod in and out slowly to remove the fluid from the
cylinder.

Put the base end of the cylinder in a vise. 3

Figure 20-20-13 P-48038

1 Remove the back-up ring (Item 1) and O-ring (Item 2)

[Figure 20-20-15] from the piston.

NOTE: If the fiber surface (Item 3) [Figure 20-20-15]

on the piston, becomes damaged, the
complete piston must be replaced.

Dealer Copy -- Not for Resale

Figure 20-20-16

1
P-48033

Use a spanner wrench to loosen the head (Item 1)

[Figure 20-20-13] from the cylinder case.

Figure 20-20-14

4
3 P101716
2

1 Remove the two O-rings (Item 1) and the back-up ring

(Item 2) [Figure 20-20-16] from the cylinder head.

P-48036

Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-14].

109 of 822 20-20-7 T870 Service Manual

CYLINDER (LIFT) (CONT'D)

Disassembly (Cont'd)

Figure 20-20-17

P-48040

Remove the wiper seal (Item 1) [Figure 20-20-17] from

the cylinder head.

Dealer Copy -- Not for Resale

Figure 20-20-18

P-48042

Remove the rod seal (Item 1) [Figure 20-20-18] from the

cylinder head.

110 of 822 20-20-8 T870 Service Manual

CYLINDER (LIFT) (CONT'D) Figure 20-20-20

Assembly

Use the following tools to assemble the cylinder: 1

MEL1396 - Seal Installation Tool 2

MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench

Figure 20-20-19

P-48038

Install the O-ring (Item 1) and back-up ring (Item 2)

[Figure 20-20-20] on the cylinder piston.

Figure 20-20-21

Dealer Copy -- Not for Resale

P7424 1

Wash the cylinder parts in solvent and air dry them.

Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts.

Always install new O-rings and seals during assembly.

Lubricate all O-rings and seals with hydraulic oil during P-48043 P7427
installation.

Install the new seal on the tool and slowly stretch it until it Install the rod seal on the rod seal tool (MEL1033)
fits the piston [Figure 20-20-19]. [Figure 20-20-21].

Allow the seal to stretch for 30 seconds before installing it NOTE: During installation the spring side of the seal
on the piston. (Item 1) [Figure 20-20-21] must be installed
toward the inside of the cylinder.

Rotate the handles to collapse the rod seal [Figure 20-

20-21].

111 of 822 20-20-9 T870 Service Manual

CYLINDER (LIFT) (CONT'D) Figure 20-20-24

Assembly (Cont'd)

Figure 20-20-22 1
2 3

P-48036

NOTE: Clean and dry the threads before installing the

P7425 nut. Install the new nut from the kit.

Install the head (Item 1), spacer (Item 2) piston (Item 3),
Install the rod seal in the head [Figure 20-20-22]. and nut (Item 4) [Figure 20-20-24].

Dealer Copy -- Not for Resale

Figure 20-20-23 Tighten the nut (Item 4) [Figure 20-20-24] to 1491 N•m
(1100 ft-lb) torque.

Figure 20-20-25
2

1
1

P-48041 P-48042

Install the wiper seal, with the wiper side of the seal (Item
P-48035
1) toward the outside of the head (Item 2) [Figure 20-20-
23].
Put the base end of the hydraulic cylinder in a vise.

Using a spanner wrench, tighten the head (Item 1)

[Figure 20-20-25] until the head is flush with the end of
the cylinder tube assembly.

112 of 822 20-20-10 T870 Service Manual

CYLINDER (TILT) Figure 20-21-2

Testing

Figure 20-21-1

1
2

P100721

Install a cap (Item 1) [Figure 20-21-2] in the hydraulic

P-85553 hose and tighten.

Engage the parking brake. Lower the seat bar. Start the
Remove the attachment. Tilt the Bob-Tach fully back. engine and press the PTOL button.
Stop the engine. Raise the seat bar.

Dealer Copy -- Not for Resale

Operate the controls that tilts the Bob-Tach forward.

If there is any leakage from the fitting on the cylinder

WARNING (Item 2) [Figure 20-21-2]. Remove the cylinder for repair.

Repeat procedure to test the other cylinder.

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

Disconnect the hose (Item 1) [Figure 20-21-1] which

goes to the rod end of the cylinder.

113 of 822 20-21-1 T870 Service Manual

CYLINDER (TILT) (CONT'D) Figure 20-21-5

Removal And Installation

Figure 20-21-3

2
1

1
P-85562

Disconnect the two hydraulic hoses (Items 1 and 2)

P-85554 [Figure 20-21-5] from the cylinder.

Cap the hoses and plug the fittings on the cylinder.

Remove the attachment from the Bob-Tach. Roll the Bob-
Tach forward Figure 20-21-6

Dealer Copy -- Not for Resale

Stop the engine. Raise the seat bar.

Remove the retainer bolt and nut (Item 1) [Figure 20-21-

3] from the rod end pivot pin.
1
Installation: Tighten the retainer nut to 48 - 54 N•m (35 -
40 ft-lb) torque.

Figure 20-21-4

P-85648

Remove the base end pivot bolt and washer (Item 3)

[Figure 20-21-5].

Remove the retainer nut and washer (Item 1) [Figure 20-

21-6] from the base end pivot pin.

Installation: Tighten the retainer nut to 257,6 N•m (190

P-85649 ft-lb) torque.

Remove the rod end pivot pin (Item 1) [Figure 20-21-4].

114 of 822 20-21-2 T870 Service Manual

CYLINDER (TILT) (CONT'D)

Removal And Installation (Cont'd)

Figure 20-21-7

P-85564

Slide the cylinder from the base pin and remove the
cylinder from the loader [Figure 20-21-7].

Dealer Copy -- Not for Resale

115 of 822 20-21-3 T870 Service Manual

CYLINDER (TILT) (CONT'D) Figure 20-21-10

Base End Pivot Pin Removal And Installation

Figure 20-21-8

P-85567

1
Inspect pivot pin and replace as needed [Figure 20-21-
P-85565 10].

Figure 20-21-9

Dealer Copy -- Not for Resale

1

P-85566

Remove the cylinder from the cylinder base pin (Item 1)

[Figure 20-21-8]. (See Removal And Installation on
Page 20-21-2.)

Remove the cylinder base pin from the lift arms as shown
in [Figure 20-21-9].

116 of 822 20-21-4 T870 Service Manual

CYLINDER (TILT) (CONT'D)

Parts Identification

1. Tube
2. Piston
3. Head
4. Rod
5. Bushing
6. Nut
7. O-ring
8. Seal
9. O-ring 17
10. Washer
11. O-ring
12. Seal 12
13. Seal
14. Plug
15. O-ring 9
16. Tubeline 1
17. Grease Fitting 15
18. Seal 10
16 14

Dealer Copy -- Not for Resale

11

15 6
3
14

2 13

4
8

18
18

17

TS-1688a PE3951S
TS-1060a

117 of 822 20-21-5 T870 Service Manual

CYLINDER (TILT) (CONT'D) Figure 20-21-12

Disassembly

Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook

Spanner Wrench
1
Hold the hydraulic cylinder over a drain pan and move
the rod in and out slowly to remove the fluid from the
cylinder.

Put the base end of the cylinder in a vise.

Figure 20-21-11 P-85647

1
Use a spanner wrench to loosen the head (Item 1)
[Figure 20-21-12] from the cylinder case.
2
Figure 20-21-13

Dealer Copy -- Not for Resale

3

1 2

P-85651

Remove the seals (Item 1) [Figure 20-21-11] on both

sides of the pivot bushing.

Remove and replace bushing (Item 2) with a driver tool P-48071

and hammer [Figure 20-21-11].

Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-21-13].

118 of 822 20-21-6 T870 Service Manual

CYLINDER (TILT) (CONT'D) Figure 20-21-16

Disassembly (Cont'd)

Figure 20-21-14
1
2

P-48040

Remove the wiper seal (Item 1) [Figure 20-21-16] from

P-48073 the cylinder head.

Figure 20-21-17
Remove the seal (Item 1), and O-ring (Item 2) [Figure
20-21-14] from the piston.

Dealer Copy -- Not for Resale

Figure 20-21-15

1 1

P-48042

Remove the rod seal (Item 1) [Figure 20-21-17] from the

P101716 cylinder head.

Remove the two O-rings (Item 1) [Figure 20-21-15] from

the cylinder head.

119 of 822 20-21-7 T870 Service Manual

CYLINDER (TILT) (CONT'D) Figure 20-21-19

Assembly
1
Use the following tools to assemble the cylinder:

MEL1396 - Seal Installation Tool 2

MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench

Figure 20-21-18

P-48073

Install the O-ring (Item 1) and seal (Item 2) [Figure 20-

21-19] on the cylinder piston.

Figure 20-21-20

Dealer Copy -- Not for Resale

P7424 1

Wash the cylinder parts in solvent and air dry them.

Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts.

Always install new O-rings and seals during assembly.

Lubricate all O-rings and seals with hydraulic oil during P-48043 P7427
installation.

Install the new seal on the tool and slowly stretch it until it Install the rod seal on the rod seal tool [Figure 20-21-20].
fits the piston [Figure 20-21-18].
NOTE: During installation the spring side of the seal
Allow the seal to stretch for 30 seconds before installing it (Item 1) [Figure 20-21-20] must be installed
on the piston. toward the inside of the cylinder.

Rotate the handles to collapse the rod seal [Figure 20-

21-20].

120 of 822 20-21-8 T870 Service Manual

CYLINDER (TILT) (CONT'D) Figure 20-21-23

Assembly (Cont'd)

Figure 20-21-21 1
2

P-48071

NOTE: Clean and dry the threads before installing the

P7425 nut. Install the new nut from the kit.

Install the head (Item 1), piston (Item 2) and nut (Item 3)
Install the rod seal in the head [Figure 20-21-21]. [Figure 20-21-23].

Dealer Copy -- Not for Resale

Figure 20-21-22 Tighten the nut (Item 3) [Figure 20-21-23] to 1152 N•m
(850 ft-lb) torque.

Put the base end of the hydraulic cylinder in a vise.

2
Figure 20-21-24

P-48041 P-48042

Install the wiper seal, with the wiper side of the seal (Item
1) toward the outside of the head (Item 2) [Figure 20-21-
22].
P-85647

Using a spanner wrench, tighten the head (Item 1)

[Figure 20-21-24] until the head is flush with the end of
the cylinder tube assembly.

121 of 822 20-21-9 T870 Service Manual

CYLINDER (TILT) (CONT'D)

Assembly (Cont'd)

Figure 20-21-25

P-85650

Install the bushing (Item 1) and seals (Item 2) [Figure 20-

21-25] using a driver tool and hammer.

Dealer Copy -- Not for Resale

122 of 822 20-21-10 T870 Service Manual

CYLINDER (BOB-TACH) Figure 20-22-2

Testing

WARNING 1
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention P-85570
from a physician familiar with this injury.
W-2072-0807
Disconnect the hose (Item 1) [Figure 20-22-2] from the
cylinder base end port.

WARNING Figure 20-22-3

Dealer Copy -- Not for Resale

AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
1
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

Figure 20-22-1

P-85568

Install a plug in the hose (Item 1) [Figure 20-22-3] and

tighten.

Engage the parking brake. Lower the seat bar. Start the
engine.

Push and hold the BOB-TACH “WEDGES UP” Switch

(Front Accessory Panel).
P-85570

If there is any leakage from the base end cylinder port

Tilt the Bob-Tach forward, so it is parallel to the floor (Item 2) [Figure 20-22-3], remove the cylinder for repair.
[Figure 20-22-1].

Push and hold BOB-TACH “WEDGES UP” switch until

levers are in the unlocked position (Wedges fully raised).

123 of 822 20-22-1 T870 Service Manual

CYLINDER (BOB-TACH) (CONT’D)

Removal And Installation

Figure 20-22-4

P-85570

Disconnect the hoses from the rod and base end cylinder
fitting (Item 1) [Figure 20-22-4].

Dealer Copy -- Not for Resale

Install plugs in the hoses and cap on fittings.

Installation: Tighten the hoses to 29,8 - 32,5 N•m (22 -

24 ft-lb) torque.

Figure 20-22-5

1
1

P-85569

Remove the bolts and washers (Item 1) [Figure 20-22-

5].

Remove the cylinder from the lever pivots.

Installation: Tighten the bolts to 48 - 54 N•m (35 - 40 ft-

lb) torque.

124 of 822 20-22-2 T870 Service Manual

CYLINDER (BOB-TACH) (CONT’D)

Parts Identification

1. Tube 8. Ring
2. Nut 9. O-ring
3. Piston 10. Head
4. O-ring 11. Seal
5. Ring 12. Seal
6. Spacer 13. Rod
7. O-ring

Dealer Copy -- Not for Resale

2
3

4
5
6

7
8
9
10

11
12

13

PE3954S

125 of 822 20-22-3 T870 Service Manual

CYLINDER (BOB-TACH) (CONT’D) Figure 20-22-8

Disassembly 3 2 1
Figure 20-22-6

P16295

Piston: Remove the O-ring (Item 1), and seal (Item 2)

P-85647 from the piston (Item 3) [Figure 20-22-8].

Figure 20-22-9
Use the following tools to disassemble the cylinder:

Dealer Copy -- Not for Resale

MEL1074 - O-ring Seal Hook
Spanner Wrench 4

Hold the hydraulic cylinder over a drain pan and move

2
the rod in and out slowly to remove the fluid from the
1
cylinder.

Put the base end of the cylinder in a vise.

5
Use a spanner wrench to loosen the head [Figure 20-22- 3
6].

Figure 20-22-7 N-20611

2
4 3 1 Remove the wiper seal (Item 1), and rod seal (Item 2),
the back-up washer (Item 3), the thin O-ring (Item 4), and
the thick O-ring (Item 5) [Figure 20-22-9] from the head.

P16294

Remove the head and rod assembly from the cylinder

[Figure 20-22-7]. Put the rod end in a vise.

Remove the nut (Item 1), piston (Item 2), spacer (Item 3),
and head (Item 4) [Figure 20-22-7] from the rod.

126 of 822 20-22-4 T870 Service Manual

CYLINDER (BOB-TACH) (CONT’D) Figure 20-22-11

Assembly
3 1
2
Figure 20-22-10

P16295

Piston: Install the O-ring (Item 1) and seal (Item 2) on the

P7424 piston (Item 3) [Figure 20-22-11].

NOTE: The piston center hole (Item 4) [Figure 20-22-

Use the following tools to assembly the cylinder: 11] has a bevel on one end. The bevel goes
toward the rod.

Dealer Copy -- Not for Resale

MEL1396 - Seal Installation Tool
MEL1033 - Rod Seal Installation Tool Figure 20-22-12
Piston Ring Compressor
Spanner Wrench

Wash the cylinder parts in solvent and air dry them.

Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts.

Always install new O-rings and seals during assembly.

Lubricate all O-rings and seals with hydraulic oil during

installation.

Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-22-10]. N-20612

Allow the seal to stretch for 30 seconds before installing it

on the piston. Install the rod seal on the rod seal tool [Figure 20-22-12].

NOTE: During installation the spring side of the seal

must be toward the inside of the cylinder.

127 of 822 20-22-5 T870 Service Manual

CYLINDER (BOB-TACH) (CONT’D) Figure 20-22-15

Assembly (Cont’d)

Figure 20-22-13

2
3

P7422

Install the thin O-ring (Item 1) [Figure 20-22-15].

N-20613
Install the back-up washer (Item 2) and thick O-ring (Item
3) [Figure 20-22-15] into the groove on the head.
Rotate the handles to collapse the rod seal [Figure 20-
22-13]. NOTE: Clean and dry the threads before installing the

Dealer Copy -- Not for Resale

nut. Install the new nut from the seal kit.
Figure 20-22-14
Figure 20-22-16

3
2 4
1

P7425
P16294

Install the rod seal in the head [Figure 20-22-14].

Install the head (Item 1), and spacer (Item 2) [Figure 20-
Install the wiper seal with the wiper toward the outside of 22-16].
the head.
Install the piston (Item 3) [Figure 20-22-16].

Grease the piston where the nut contacts the piston. do

not get grease on the threads. Install the new nut (Item 4)
[Figure 20-22-16].

Tighten the nut to 122 N•m (90 ft-lb) torque.

128 of 822 20-22-6 T870 Service Manual

CYLINDER (BOB-TACH) (CONT'D)

Assembly (Cont'd)

Figure 20-22-17

P-85647

Put the base end of the hydraulic cylinder in a vise.

Dealer Copy -- Not for Resale

Tighten the head using a spanner wrench [Figure 20-22-
17].

129 of 822 20-22-7 T870 Service Manual

 Dealer Copy -- Not for Resale

130 of 822 20-22-8 T870 Service Manual

MAIN RELIEF VALVE

Description

The main relief valve limits the hydraulic system pressure

by opening at a certain pressure and allowing the
hydraulic oil to flow back to the hydraulic reservoir. (See
Hydraulic System on Page SPEC-10-3.)

The main relief valve is adjustable and is located on the

hydraulic control valve near the bottom, facing the front of
the loader.

Dealer Copy -- Not for Resale

131 of 822 20-30-1 T870 Service Manual

MAIN RELIEF VALVE (CONT’D) Figure 20-30-1

Testing
1
2

IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284

P-85571
WARNING
Connect the IN port (Item 1) [Figure 20-30-1] of the
When the engine is running during service, the hydraulic tester to the bottom (female) quick coupler on
driving and steering controls must be in neutral and the loader.
the parking brake engaged. Failure to do so can
cause injury or death. Connect the OUT port (Item 2) [Figure 20-30-1] of the
W-2006-1209 hydraulic tester to the top (male) quick coupler on the

Dealer Copy -- Not for Resale

loader.

Figure 20-30-2
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
2
1
The tools listed will be needed to do the following
procedure:

TWX-RFIK200-S-6 Flow Meter 200 L/min (54 U.S. gpm)

MEL10006 - Hydraulic Test Kit
P-76460C
NOTE: This procedure is for loaders equipped with
SJC or SCPA controls. The main relief valve is
located in the same place on all of the loaders. Start the engine and run at low idle.

Lift and block the loader. (See Procedure on Page 10-10- • Press the AUXILIARY HYDRAULICS Button (Item 1)
1.) [Figure 20-30-2] once to engage the auxiliary
hydraulics.

NOTE: The light (Item 2) [Figure 20-30-2] will be on.

132 of 822 20-30-2 T870 Service Manual

MAIN RELIEF VALVE (CONT’D) Watch the flow meter on the hydraulic tester to make
sure the flow is correct. Increase the engine speed to full
Testing (Cont’d) rpm.

Figure 20-30-3 Refer to (See Hydraulic System on Page SPEC-10-3.) for

both flow and pressure specifications of the hydraulic
system.

Test the free flow specification.

With the engine at high idle and hydraulic oil at 60°C

Right (140°F) turn the restrictor control on the tester until the
Steering flow through the tester drops to zero. Test the relief
1 Lever pressure.
Control
If the relief pressure is not correct, stop the engine and
adjust the main relief valve.

P-26697

• Push the front switch (Item 1) [Figure 20-30-3] to give

the front quick couplers a constant flow of fluid.

Dealer Copy -- Not for Resale

• To release from continuous operation, press the front
switch (Item 1) [Figure 20-30-3] a second time.

133 of 822 20-30-3 T870 Service Manual

MAIN RELIEF VALVE (CONT’D) Removal And Installation

Adjusting

NOTE: This procedure is for loaders equipped with

SJC or SCPA controls. The main relief valve is IMPORTANT
located in the same place on all of the loaders.
When repairing hydrostatic and hydraulic systems,
Figure 20-30-4 clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

1 Raise the operator cab. (See Raising on Page 10-30-1.)

2

Clean the area around the control valve.

NOTE: This procedure is for loaders equipped with

SJC or SCPA controls. The main relief valve is
located in the same place on all of the loaders.

Figure 20-30-5
P-85573

Dealer Copy -- Not for Resale

If the pressure is not correct, adjust the main relief valve.
Loosen the lock nut (Item 1) [Figure 20-30-4].
1
Turn the adjusting screw (Item 2) [Figure 20-30-4] in or
out until the pressure is correct. Turning screw in will
increase pressure.

NOTE: If the correct pressure can not be reached,

replace the main relief valve. Test the
pressure setting of the new relief valve.

P-85573

NOTE: The right side motor cover if removed may

provide better access to the main relief valve
on some machines.

The main relief valve (Item 1) [Figure 20-30-5] is located

at the lower front of the control valve below the lift and tilt
spool connections.

Loosen and remove the main relief valve (Item 1) [Figure

20-30-5].

134 of 822 20-30-4 T870 Service Manual

MAIN RELIEF VALVE (CONT’D)

Removal And Installation (Cont’d)

Figure 20-30-6

1
1

P-37689

Remove the O-rings (Item 1) and back-up washers (Item

2) [Figure 20-30-6] from the main relief valve.

Dealer Copy -- Not for Resale

Clean the main relief valve in clean solvent. Use air
pressure to dry the valve.

Install new O-rings (Item 1) and back-up washers (Item

2) [Figure 20-30-6]. Install the main relief valve and
tighten.

Installation: Tighten the main relief valve to 51 - 62 N•m

(38 - 45 ft-lb) torque.

Test the pressure again. (See Testing on Page 20-30-2.)

135 of 822 20-30-5 T870 Service Manual

 Dealer Copy -- Not for Resale

136 of 822 20-30-6 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) Removal And Installation

Description

Figure 20-40-1
DANGER

P-90328

AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
P-90337
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
The hydraulic control valve is located inside the main support. Replace if damaged.
frame on the right hand side, below the operator’s cab. D-1009-0409

Dealer Copy -- Not for Resale

The hydraulic control valve is the hydraulic component
that uses spools to direct the flow of hydraulic fluid to the
lift, tilt and auxiliary functions.
WARNING
The lift and tilt functions in the hydraulic control valve are
operated using electronic control handles / levers that Never work on a machine with the lift arms up unless
send an electronic signal to the electronic actuators to the lift arms are secured by an approved lift arm
move the lift and tilt spools in the control valve. support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
The auxiliary function is operated by pilot pressure. to fall and cause injury or death.
There is one solenoid located by each side of the spool. W-2059-0598
Only one solenoid at a time is activated by the switch on
the right side control handles / levers. The activated
solenoid sends pilot pressure oil to one side of the spool
and forces the spool to shift.

The hydraulic control valve also contains a main relief IMPORTANT

valve which is adjustable.
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

137 of 822 20-40-1 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-3

Removal And Installation (Cont’d)

3
Raise the lift arms and install an approved lift arm support
device. (See LIFT ARM SUPPORT DEVICE on Page 10- 1
20-1.)

Raise the operator cab. (See Raising on Page 10-30-1.)

Drain the hydraulic reservoir. (See Removing And 2

Replacing Hydraulic Fluid on Page 10-120-2.)

Remove the control panel. (See Removal And Installation 1

on Page 50-100-1.)
P-90269
NOTE: Mark all tubelines, hoses, and electrical
connections for correct installation.
Disconnect the wire harness connectors (Item 1) [Figure
NOTE: Cap and plug all hydraulic connection points 20-40-3] from the control valve.
when tubelines or hoses are removed.
Disconnect the hose (Item 2) [Figure 20-40-3] that
Clean area around control valve. routes from the control valve to the drain manifold.

Dealer Copy -- Not for Resale

Open rear door. Disconnect the hose (Item 3) [Figure 20-40-3] that
routes from the control valve to the inlet fitting of the
Figure 20-40-2 hydraulic pump.

Figure 20-40-4

1
2
1

P-90267

P-90270
The fixed end main valve hose assembly is connected to
a fixed end fitting on the control valve. The hose is routed
to the junction block at the rear of the loader where it Disconnect the hose (Item 1) [Figure 20-40-4] that
feeds the base end of both lift cylinders. The hose can routes from the control valve to the brake valve.
only be removed by first removing it from the fitting (Item
1)[Figure 20-40-2]. Disconnect the hose (Item 2) [Figure 20-40-4] that
routes from the control valve to the fan motor.

138 of 822 20-40-2 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-7

Removal And Installation (Cont'd)

Figure 20-40-5

P-90273

Remove the tubeline clamp (Item 1) [Figure 20-40-7].

P-90271
Figure 20-40-8

Disconnect the hose (Item 1) [Figure 20-40-5] that

routes from the top of the control valve to the hydraulic

Dealer Copy -- Not for Resale

filter.

Figure 20-40-6 1 1

2 2
1
1
P-90274

Disconnect the three tubelines (Item 1) [Figure 20-40-8]

that route from the control valve to the junction block at
the rear of the loader.
P-90272

Remove the tubeline clamp (Item 1) [Figure 20-40-6].

Disconnect the two tubelines (Item 2) [Figure 20-40-6]

that route from the control valve to the front auxiliary
hydraulics.

139 of 822 20-40-3 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-11

Removal And Installation (Cont'd)

Figure 20-40-9

1 1

P-90278

Support the control valve and remove the two bolts and
P-90275 nuts (Item 1) [Figure 20-40-11].

Remove the control valve from the loader.

Disconnect the hose (Item 1) [Figure 20-40-9] that
routes from the control valve to the junction block at the

Dealer Copy -- Not for Resale

rear of the machine.

Disconnect the lift arm bypass drain hose (Item 2)

[Figure 20-40-9] from the control valve.

Figure 20-40-10

P-90276

Disconnect the hose (Item 1) [Figure 20-40-10] that

routes from the bottom of the control valve to the outlet
fitting of the hydraulic pump.

140 of 822 20-40-4 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-13

Actuator Removal And Installation (In Loader)

WARNING 1

Never work on a machine with the lift arms up unless

the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598

P-54587
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Remove the two screws (Item 1) [Figure 20-40-13] from
Stop the engine. Raise the seat bar. the actuator retainer.

Mark the actuator wiring harness connectors for proper Installation: Tighten the bolts to 10,2 - 11,3 N•m (90 -
installation. 100 in-lb) torque.

Dealer Copy -- Not for Resale

Figure 20-40-12 Figure 20-40-14

1
2

P-90330 P-54566

Unplug the actuator connectors (Item 1) [Figure 20-40- Pull the actuator (Item 1) [Figure 20-40-14] away from
12] from the loader harness. the control valve.

Use a punch to remove the actuator pin (Item 2) [Figure

20-40-14] from the actuator and spool.

Remove the actuator from the hydraulic control valve.

NOTE: The calibration procedure must be followed

when replacing a lift or tilt actuator. (See Lift
And Tilt Calibration (SJC) on Page 60-150-4.)

141 of 822 20-40-5 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D)

Actuator Removal And Installation (In Loader)

(Cont’d)

Figure 20-40-15

1
2

P-54568

Inspect the O-ring (Item 1) [Figure 20-40-15] on the face

Dealer Copy -- Not for Resale

of the actuator, and replace as needed.

Inspect the linkage pin (Item 2) [Figure 20-40-15] and

replace as needed.

142 of 822 20-40-6 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-18

Actuator Removal And Installation (Out Of Loader)

Remove the control valve from the loader.

Figure 20-40-16

P-54339

1 Using a punch and a hammer, remove the actuator

linkage pin (Item 1) [Figure 20-40-18] from the actuator
and the tilt spool.
P-54337
Remove the actuator and linkage pin from the valve.

Dealer Copy -- Not for Resale

Remove the two mount bolts (Item 1) [Figure 20-40-16] Figure 20-40-19
from the tilt actuator.

Installation: Tighten the mounting bolts to 10,2 - 11,3

N•m (90 - 100 in-lb) torque.

Figure 20-40-17

P-54340

1
Inspect the O-ring (Item 1) [Figure 20-40-19] on the face
of the actuator, and replace as needed.

P-54338 Inspect the linkage pin (Item 2) [Figure 20-40-19] and

replace as needed.

Slide the actuator mount bracket (Item 1) [Figure 20-40-

17] away from the control valve.

Pull the actuator away from the control valve [Figure 20-
40-17].

143 of 822 20-40-7 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-22

Actuator Removal And Installation (Out of Loader)

(Cont’d)

Figure 20-40-20

1
1

P-54343

Using a punch and a hammer, remove the actuator

1 linkage pin (Item 1) [Figure 20-40-22] from the actuator
P-54341 and the tilt spool.

Remove the actuator and linkage pin from the valve.

Remove the two mount bolts (Item 1) [Figure 20-40-20]

Dealer Copy -- Not for Resale

from the lift actuator. Figure 20-40-23

Installation: Tighten the mounting bolts to 10,2 - 11,3

N•m (90 - 100 in-lb) torque.

Figure 20-40-21

P-54340

1 Inspect the O-ring (Item 1) [Figure 20-40-23] on the face

of the actuator, and replace as needed.
P-54342
Inspect the linkage pin (Item 2) [Figure 20-40-23] and
replace as needed.
Slide the actuator mount bracket (Item 1) [Figure 20-40-
21] away from the control valve.

Pull the actuator away from the control valve [Figure 20-
40-21].

144 of 822 20-40-8 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D)

Actuator Removal And Installation (Out Of Loader)

(Cont’d)

Figure 20-40-24

4 3

1
3

P-90329

NOTE: The two longer bolts (Item 1) are used to

Dealer Copy -- Not for Resale

mount the lift actuator and end cap (Item 2)
[Figure 20-40-24] to the control valve.
The two shorter mount bolts (Item 3) are used
to mount the tilt actuator to the end cap (Item
4) [Figure 20-40-24].

Installation: Tighten the mounting bolts to 10,2 - 11,3

N•m (90 - 100 in-lb) torque (Item 1) [Figure 20-40-24]

145 of 822 20-40-9 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D)

Identification Chart

Figure 20-40-25

C2 C3
J4 J2
B3 E3
E3
F2
G1 G2
D5
A3 D3
B2
A2
D4 F4 E2
C4
D1

D2
A1
H3
F3 E1
H2 B1
F1 MR J3

Dealer Copy -- Not for Resale

H1 J1 C1

P-90307

ITEM S850 LOADER ITEM S850 LOADER

A1 Lift Cylinder Base End E1 Lift Spool Detent
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool / Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End F3 Lift Spool Lock Solenoid
C1 Load Check F4 Tilt Spool Lock Solenoid
C2 Load Check Valve Tilt Function G1 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function G2 Auxiliary Solenoid Stem
C4 Check Valve H1 BICS™ Solenoid
D1 Anti-Cavitation Valve H2 BICS™ Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief / Anti-Cavitation Valve – 27579,0 H3 BICS™ Lock Valve (Lift)
kPa (275,8 bar) (4000 psi) J1 Inlet Fluid Flow (From Pump)
Lift (Base End) J2 Outlet Fluid Flow (Return to Tank)
D3 Port Relief / Anti-Cavitation Valve – 27579,0 J3 Lift Arm Bypass Orifice
kPa (275,8 bar) (4000 psi)
J4 Drain (Case)
Tilt (Base End)
MR Main Relief Valve – 24131,7 kPa (241,3 bar)
D4 Port Relief / Anti-Cavitation Valve – 27579,0
(3500 psi)
kPa (275,8 bar) (4000 psi)
Tilt (Rod End)
D5 Port Relief / Anti-Cavitation Valve (Auxiliary)
27579,0 kPa (275,8 bar) (4000 psi) (Optional)

146 of 822 20-40-10 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Lift Load Check Valve Removal And Installation

Mount Bracket Removal And Installation Figure 20-40-28

Figure 20-40-26

1
1

P-90308

P-90280
Remove the charge tubeline (Item 1) [Figure 20-40-28]
from the BICS™ valve fitting on the top of the lift load
Support the mounting bracket (Item 1) [Figure 20-40-26]. check valve.

Dealer Copy -- Not for Resale

Figure 20-40-27 Figure 20-40-29

2
1

P100202 P-90310

Remove the two control valve mount bolts (Item 1) Remove the lift load check valve (Item 1) [Figure 20-40-
[Figure 20-40-27]. 29] and fitting from the top of the control valve.

Remove the two frame bolts (Item 2) [Figure 20-40-27] Installation: Lubricate the O-ring and threads and
tighten to 75 - 88 N•m (55 - 65 ft-lb) torque.
Installation: Torque the two frame bolts (Item 2) [Figure
20-40-27] to 406 - 447 N•m (300 - 330 ft lb).

Remove the control valve bracket from the loader.

147 of 822 20-40-11 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Load Check Valve Removal And Installation (Tilt And
Auxiliary)
Lift Load Check Valve Removal And Installation
(Cont’d) Figure 20-40-31

Figure 20-40-30

2
1

P-90311
3
P-90309
At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-40-31].
Remove and install new O-rings (Item 1) and back-up

Dealer Copy -- Not for Resale

ring (Item 2) [Figure 20-40-30]. At the front side of the control valve locate the auxiliary
section load check valve (Item 2) [Figure 20-40-31].
Inspect the free movement load check valve and spring
(Item 3) [Figure 20-40-30]. NOTE: The tilt and auxiliary load check valves are
interchangeable.

Figure 20-40-32
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all 1
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 2
damage the system.
I-2003-0888 3
4

P-90312

Remove the spring (Item 1) and poppet (Item 2) [Figure

20-40-32].

Inspect the orifice (Item 3) [Figure 20-40-32] in the

poppet to be sure it is not plugged.

Installation: Install a new O-ring (Item 4) [Figure 20-40-

32] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 52 - 61 N•m (38 - 45 ft-lb)
torque.

148 of 822 20-40-12 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Port Relief / Anti-Cavitation Valve Removal And
Installation (Lift, Base End)
Anti-Cavitation Valve Removal And Installation (Lift,
Rod End) Figure 20-40-35

Figure 20-40-33

P-90314

P-90314
Loosen the lift circuit port relief / anti cavitation valve
(Item 1) [Figure 20-40-35].
At the back side of the control valve, remove the lift

Dealer Copy -- Not for Resale

section anti-cavitation valve (Item 1) [Figure 20-40-33]. Figure 20-40-36

Figure 20-40-34

3
4 1

P-90315

P-90312
Replace the O-ring (Item 1) [Figure 20-40-36] before
installation.
Remove the spring (Item 1) and poppet (Item 2) [Figure
20-40-34]. Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

Inspect the orifice (Item 3) [Figure 20-40-34] in the

poppet to be sure it is not plugged.

Installation: Install a new O-ring (Item 4) [Figure 20-40-

34] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 52 - 61 N•m (38 - 45 ft-lb)
torque.

149 of 822 20-40-13 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Port Relief / Anti-Cavitation Valve Removal And
Installation (Tilt, Rod End)
Port Relief / Anti-Cavitation Valve Removal And
Installation (Tilt, Base End) Figure 20-40-39

Figure 20-40-37

P-90314

P-90314
Remove the tilt port relief / anti cavitation valve (Item 1)
[Figure 20-40-39] from the rod end of the tilt section.
Remove the tilt port relief / anti cavitation valve (Item 1)

Dealer Copy -- Not for Resale

[Figure 20-40-37] from the base end of the tilt section. Figure 20-40-40

Figure 20-40-38

1
1

P-90319

P-90316
Replace the O-ring (Item 1) [Figure 20-40-40] before
installation.
Replace the O-ring (Item 1) [Figure 20-40-38] before
installation. Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

150 of 822 20-40-14 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-43

Port Relief Valve Removal And Installation

1
Figure 20-40-41

P-90318A

The control valve may be equipped with an optional

P-90314 auxiliary port relief valve (Item 1) [Figure 20-40-43].

Remove the auxiliary port relief valve.

Remove the port relief plug (Item 1) [Figure 20-40-41]
from the auxiliary circuit of the control valve. Figure 20-40-44

Dealer Copy -- Not for Resale

Figure 20-40-42

P-51640

P-90318
Installation: Always use new O-rings (Item 1) [Figure
20-40-44]. Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Always use new O-rings (Item 1) [Figure
20-40-42]. Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

151 of 822 20-40-15 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-47

Plug Removal And Installation

Figure 20-40-45

1
P-51461

At the bottom side of the control valve remove the plug

P-68016 (Item 1) [Figure 20-40-47].

Figure 20-40-48
At the top side of the control valve, remove the plug (Item
1) [Figure 20-40-45].

Dealer Copy -- Not for Resale

Figure 20-40-46

P-51462

1 Installation: Always use new O-rings (Item 1) [Figure

P-51460A 20-40-48]. Tighten to 81,3 N•m (60 ft-lb) torque.

Installation: Always use new O-rings (Item 1) [Figure

20-40-46]. Tighten to 81,3 N•m (60 ft-lb) torque.

152 of 822 20-40-16 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Lift Spool Removal And Installation

End Cap Block Removal And Installation The tool listed will be needed to do the following
procedure:
Remove the lift and tilt actuators from the control valve.
(See Actuator Removal And Installation (In Loader) on MEL 1285 - Spring Tool
Page 20-40-5.)
Remove the end cap block from the control valve.
Figure 20-40-49
Figure 20-40-51

1 2

P-90338

Dealer Copy -- Not for Resale

P-68042

Disconnect the tube line (Item 1) [Figure 20-40-49] from

the end cap block. Remove the O-ring (Item 1) [Figure 20-40-51].

Remove the two end cap block mount screws (Item 2) Installation: Replace the O-ring, and lubricate lightly
[Figure 20-40-49]. with oil before installation of the end cap block.

Installation: Tighten the screws to 10,2 - 11,3 N•m (90 - Figure 20-40-52
100 in-lb) torque.

Figure 20-40-50

P-68047
1

P-90339 Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-52] from the lift spool.

Remove the end cap block (Item 1) [Figure 20-40-50]

from the control valve.

153 of 822 20-40-17 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-55

Lift Spool Removal And Installation (Cont'd)

Figure 20-40-53

1 P-68045

Remove the lift spool assembly and seal (Item 1) [Figure

P-68043 20-40-55] from the control valve.

Figure 20-40-56
Remove the two screws (Item 1) [Figure 20-40-53] from
the lift spool end cap.

Dealer Copy -- Not for Resale

Installation: Lubricate the screws and tighten to 10,2 -
11,3 N•m (90 - 100 in-lb) torque.

Figure 20-40-54

P-68046

1
Remove the lift spool seal (Item 1) [Figure 20-40-56]
from the linkage end of the valve.

P-68044

Remove the lift spool end cap (Item 1) [Figure 20-40-54]

from the control valve.

154 of 822 20-40-18 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-59

Lift Spool Disassembly And Assembly

Figure 20-40-57 1

N-190146

Remove the bolt (Item 1) [Figure 20-40-59] holding the

P-51772 centering spring to the spool.

Installation: Tighten the bolt to 10,2 - 11,3 N•m (90 - 100

Clamp the linkage end of the spool in a vise [Figure 20- in-lb) torque.
40-57].

Dealer Copy -- Not for Resale

Remove spring tool from the spring assembly.
NOTE: Protect spool before clamping in vise.
Figure 20-40-60
Figure 20-40-58

1 1
4

P-51776
P-51773

Inspect the adapter (Item 1), collar (Item 2), spring (Item
Install the spring tool (Item 1) [Figure 20-40-58] over the 3) and washer (Item 4) [Figure 20-40-60].
centering spring.

155 of 822 20-40-19 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) NOTE: Inspect the O-ring for damage. The lift spool
will have an internal leak if there is damage to
Lift Spool Disassembly And Assembly (Cont,d) this O-ring. Always replace the O-ring and
plastic plug. Inspect the lift spool before the
Figure 20-40-61 control valve is replaced.

Figure 20-40-63

N-18920

Removal of the plastic plug:

P-74184

Make a center point in the plug using a 1/16 in (1,6 mm)

Dealer Copy -- Not for Resale

drill. Install the plastic plug and O-ring in the spool [Figure 20-
40-63].
Drill a hole all the way through the plug using a 2,8 mm
(7/64 in) tap drill. Figure 20-40-64

Turn a 6-32 tap (Item 1) [Figure 20-40-61] into the plug.

Pull the tap and plug out of the spool. Be careful, do not
break the tap. 2
1

Clean all the debris from inside the spool bore.

NOTE: DO NOT USE Loctite® ON THE STUD

THREADS.

Figure 20-40-62 1

2 P-68046 P-51775

1
Remove the spool seal(s) (Item 1) and the back-up
washer (Item 2) [Figure 20-40-64].

Assembly: Always use a new spool seal.

P-74183

Install the O-ring (Item 1) over the nipple on the plastic

plug (Item 2) [Figure 20-40-62].

156 of 822 20-40-20 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-67

Tilt Spool Removal And Installation

Remove the end cap block. (See End Cap Block

Removal And Installation on Page 20-40-17.)

Figure 20-40-65 2

P-90342

2 Remove the spool centering block (Item 1) [Figure 20-

40-67] from the control valve.
1
Installation: Replace the O-ring (Item 2) [Figure 20-40-
P-68049 67] and lubricate lightly with oil / grease before
installation of the end cap block.

Dealer Copy -- Not for Resale

Remove the spacer (Item 1) and O-ring (Item 2) [Figure Figure 20-40-68
20-40-65] from the tilt spool.

Figure 20-40-66

1
1

1
P-68052
2

P-90321 Remove the tilt spool, centering spring, back-up washer

and spool seal (Item 1) [Figure 20-40-68].

Disconnect the two tubelines (Item 1) [Figure 20-40-66]. Assembly: Always use a new spool seal.

Remove the three screws (Item 2) [Figure 20-40-66]

from the spool centering block.

Installation: Tighten the bolt to 10,2 - 11,3 N•m (90 - 100

in-lb) torque.

157 of 822 20-40-21 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-71

Tilt Spool Disassembly And Assembly

Figure 20-40-69 2 1
3

4
1

N-18944A

Inspect the adapter (Item 1), collar (Item 2), spring (Item
N-18942 3) and washer (Item 4) [Figure 20-40-71].

Figure 20-40-72
Put the linkage end of the spool in the vice [Figure 20-
40-69].
2

Dealer Copy -- Not for Resale

Install the spring tool (Item 1) [Figure 20-40-69] over the 1
centering spring.

Figure 20-40-70

1 1

P-51545 N-18943

Remove the spool seal(s) (Item 1) and the back-up

washer (Item 2) [Figure 20-40-72].

Assembly: Always use a new spool seal.

N-19014

Remove the bolt (Item 1) [Figure 20-40-70] holding the

centering spring to the spool.

Installation: Tighten the bolt to 10,2 - 11,3 N•m (90 - 100

in-lb) torque.

Remove spring tool from the spring assembly.

158 of 822 20-40-22 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-75

Auxiliary Spool Removal And Installation

Figure 20-40-73

1 2

1
2

1 P-68054

2
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
P-90321 20-40-75] from the auxiliary spool.

Figure 20-40-76
Disconnect the two tubelines (Item 1) [Figure 20-40-73]
from the spool centering block.

Dealer Copy -- Not for Resale

Remove the three screws (Item 2) [Figure 20-40-73]
from the spool centering block.

Installation: Tighten the bolts to 10,2 - 11,3 N•m (90 -

100 in-lb) torque.

Remove the spool centering block from the control valve. 2

1
Figure 20-40-74

P-68076

Remove the spring (Item 1) and center spring retainer

(Item 2) [Figure 20-40-76] from the auxiliary spool.

2 NOTE: If the centering spring retainer (Item 2) [Figure

20-40-76] must be replaced, replace the
retainer on the opposite end also.

P-68053

Remove the spring (Item 1) and center spring retainer

(Item 2) [Figure 20-40-74] from the auxiliary spool.

NOTE: If the centering spring retainer (Item 2) [Figure

20-40-74] must be replaced, replace the
retainer on the opposite end also.

159 of 822 20-40-23 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Auxiliary Solenoid Removal And Installation

Auxiliary Spool Removal And Installation (Cont,d) Figure 20-40-79

Figure 20-40-77

1
2
1

2
P-90337

P-68077
Remove the screws (Item 1) [Figure 20-40-79] from both
solenoids.
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-40-77] from the auxiliary spool. Remove the solenoids (Item 2) [Figure 20-40-79].

Dealer Copy -- Not for Resale

Figure 20-40-78 Installation: Tighten the screws to 2,44 - 2,98 N•m (21.6
- 26.4 in-lb) torque.

Figure 20-40-80

P-68078

Remove the auxiliary spool (Item 1) [Figure 20-40-78].

P-85556

Inspect and remove the O-rings (Item 1) [Figure 20-40-

80] from the solenoid stem.

Use an ohmmeter to measure the solenoid coil

resistance.

The correct resistance for the coil is 4.1 - 6.1 ohm.

160 of 822 20-40-24 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-83

Solenoid Removal And Installation

Figure 20-40-81
1

P-90346

Remove the solenoid stem (Item 1) [Figure 20-40-83].

P-90337
Installation: Lubricate the O-rings and tighten the stem
to 27 - 33 N•m (20 - 24 ft-lb) torque.
Remove the nut (Item 1) [Figure 20-40-81] from the
solenoid stem. Figure 20-40-84

Dealer Copy -- Not for Resale

Installation: Tighten the nut to 6 N•m (53 in-lb) torque.

Remove the solenoid coil (Item 2) [Figure 20-40-81].

3
Figure 20-40-82 2

N-18694

Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-40-84] from the stem.

N-18693A Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear and replace any showing

Remove the O-rings (Item 1) [Figure 20-40-82] from excessive wear.
both ends of the solenoid coil.
NOTE: The screen (Item 3) [Figure 20-40-84] may be
Use an ohmmeter to measure the solenoid coil cleaned with solvent. If it is torn or worn the
resistance. solenoid stem needs to be replaced.

The correct resistance for the coil is 9.5 - 10.08 ohm. Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.

Install new O-rings (Item 1) [Figure 20-40-82] and

[Figure 20-40-84] and new back-up rings (Item 2)
[Figure 20-40-84] on the solenoid stem.

161 of 822 20-40-25 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-87

Lock Valve Removal And Installation

Figure 20-40-85

1
2
P-51792

Remove the tilt lock valve (Item 1) [Figure 20-40-87]

P-90310 from the back of the control valve.

Installation: Lightly lubricate the lock valve O-rings and

Locate the two BICS™ lock valves, (Item 1) is for the tilt tighten to 27 - 33 N•m (20 - 24 ft-lb) torque.
circuit and (Item 2) [Figure 20-40-85] is for the lift circuit.

Dealer Copy -- Not for Resale

Figure 20-40-88
Figure 20-40-86

1
1
1
1

1
2
2
2
P-51564
P-90321

Remove the O-rings (Item 1) and back-up rings (Item 2)

Remove the lift lock valve (Item 1) [Figure 20-40-86] [Figure 20-40-88] from the valve, and replace with new.
from the back of the control valve.

Installation: Lightly lubricate the lock valve O-rings and

tighten to 27 - 33 N•m (20 - 24 ft-lb) torque.

162 of 822 20-40-26 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Main Relief Valve Removal And Installation

Lift Arm Bypass Orifice Removal And Installation Figure 20-40-91

Figure 20-40-89

1
P-51794

P-90308
Remove the main relief valve (Item 1) [Figure 20-40-91].

Remove the fitting (Item 1) [Figure 20-40-89] from the Figure 20-40-92
valve.

Dealer Copy -- Not for Resale

Figure 20-40-90

1 1

P-90344

P-51437 Remove the O-rings from the main relief valve (Item 1)
[Figure 20-40-92].

Inspect the lift arm bypass orifice (Item 1) [Figure 20-40- Installation: Always use new O-rings. Tighten to 52 - 61
90]. N•m (38 - 45 ft-lb) torque.

NOTE: This orifice is not removable from the valve

casting.

163 of 822 20-40-27 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-95

Check Valve Removal And Installation

Figure 20-40-93

1
P-68869

Installation: Lubricate the O-ring (Item 1) [Figure 20-40-

P-90308 95] and tighten the fitting to 27 - 33 N•m (20 - 24 ft-lb)
torque.

Remove the tubeline (Item 1) [Figure 20-40-93]. Figure 20-40-96

Dealer Copy -- Not for Resale

Figure 20-40-94

P-90326

P-90310
Inspect the screen (Item 1) [Figure 20-40-96].

Remove the check valve fitting (Item 1) [Figure 20-40-

94] from the hydraulic control valve.

164 of 822 20-40-28 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA)

Description

Figure 20-41-1

P100246

The hydraulic control valve is located inside the main

frame on the right hand side, below the operators cab.

Dealer Copy -- Not for Resale

The hydraulic control valve is the hydraulic component
that uses spools to direct the flow of hydraulic fluid to the
lift, tilt and auxiliary functions.

The lift and tilt functions in the hydraulic control valve are
operated by linkage connected to the foot pedals.

The auxiliary function is operated by pilot pressure.

There is one solenoid located by each side of the spool.
Only one solenoid at a time is activated by the switch on
the right side control handle / lever. The activated
solenoid sends pilot pressure oil to one side of the spool
and forces the spool to shift.

The hydraulic control valve also contains a main relief

valve which is adjustable.

165 of 822 20-41-1 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)
Removal And Installation
Remove the control panel. (See Removal And Installation
on Page 50-100-1.)

DANGER Remove the control linkage. (See Linkage Removal And

Installation on Page 50-90-2.)

NOTE: Mark all tubelines, hoses, and electrical

connections for correct installation.

NOTE: Cap and plug all hydraulic connection points

when tubelines or hoses are removed.

Clean area around control valve.

P-90328

AVOID DEATH Open rear door.

• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure Figure 20-41-2
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm 3
support. Replace if damaged.

Dealer Copy -- Not for Resale

D-1009-0409
1

WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm 2
P-90187
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598 Remove the two bolts (Item 1), move the hose clamp
(Item 2) to the middle of the hose, and the place the fuel
inlet assembly (Item 3) [Figure 20-41-2] off to the side.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Raise the lift arms and install an approved lift arm support
device. (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)

Raise the operator cab. (See Raising on Page 10-30-1.)

166 of 822 20-41-2 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-5

Removal And Installation (Cont’d)

Figure 20-41-3
2
1

P-90270

Disconnect the hose (Item 1) [Figure 20-41-5] that

P-90267 routes from the control valve to the brake valve.

Disconnect the hose (Item 2) [Figure 20-41-5] that

The fixed end main valve hose assembly is connected to routes from the control valve to the fan motor.
a fixed end fitting on the control valve. The hose is routed

Dealer Copy -- Not for Resale

to the junction block at the rear of the loader where it Figure 20-41-6
feeds the base end of both lift cylinders. The hose can
only be removed by first removing it from the fitting (Item
1)[Figure 20-41-3].

Figure 20-41-4
1
3

2
P-90271

1 Disconnect the hose (Item 1) [Figure 20-41-6] that

routes from the top of the control valve to the hydraulic
P-90269 filter.

Disconnect the wire harness connectors (Item 1) [Figure

20-41-4] from the control valve.

Disconnect the hose (Item 2) [Figure 20-41-4] that

routes from the control valve to the drain manifold.

Disconnect the hose (Item 3) [Figure 20-41-4] that

routes from the control valve to the inlet fitting of the
hydraulic pump.

167 of 822 20-41-3 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-9

Removal And Installation (Cont’d)

Figure 20-41-7

1 1

2 2

1
1

P-90274

Disconnect the three tubelines (Item 1) [Figure 20-41-9]

P-90272 that route from the control valve to the junction block at
the rear of the loader.

Remove the tubeline clamp (Item 1) [Figure 20-41-7]. Figure 20-41-10

Dealer Copy -- Not for Resale

Disconnect the two tubelines (Item 2) [Figure 20-41-7]
that route from the control valve to the front auxiliary
hydraulics. 1
Figure 20-41-8

P-90275

1 Disconnect the hose (Item 1) [Figure 20-41-10] that

routes from the control valve to the junction block at the
rear of the machine.
P-90273
Disconnect the lift arm bypass drain hose (Item 2)
[Figure 20-41-10] from the control valve.
Remove the tubeline clamp (Item 1) [Figure 20-41-8].

168 of 822 20-41-4 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Mount Bracket Removal And Installation

Removal And Installation (Cont’d) Figure 20-41-13

Figure 20-41-11

P-90280

P-90276
Support the mounting bracket (Item 1) [Figure 20-41-13].

Disconnect the hose (Item 1) [Figure 20-41-11] that Figure 20-41-14

routes from the bottom of the control valve to the outlet

Dealer Copy -- Not for Resale

fitting of the hydraulic pump.

Figure 20-41-12
2

1 1

P100202

Remove the two control valve mount bolts (Item 1)

P-90278 [Figure 20-41-14].

Remove the two frame bolts (Item 2) [Figure 20-41-14]

Support the control valve and remove the two bolts (Item
1) [Figure 20-41-12]. Installation: Torque the two frame bolts (Item 2) [Figure
20-41-14] to 406 - 447 N•m (300 - 330 ft-lb).
Remove the control valve from the loader.
Remove the control valve bracket from the loader.

169 of 822 20-41-5 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D)

Identification Chart

Figure 20-41-15

C2 C3
J4 J2
B3 E3
E3
F2
G1 G2
D5
A3 D3
B2
A2
D4 F4 E2
C4
D1

D2
A1
H3
F3 E1
H2 B1
F1 MR J3

Dealer Copy -- Not for Resale

H1 J1 C1
P-90307

ITEM T870 LOADER ITEM T870 LOADER

A1 Lift Cylinder Base End E1 Lift Spool Detent
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool / Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End F3 Lift Spool Lock Solenoid
C1 Load Check F4 Tilt Spool Lock Solenoid
C2 Load Check Valve Tilt Function G1 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function G2 Auxiliary Solenoid Stem
C4 Check Valve H1 BICS™ Solenoid
D1 Anti-Cavitation Valve H2 BICS™ Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief / Anti-Cavitation Valve – 27579,0 H3 BICS™ Lock Valve (Lift)
kPa (275,8 bar) (4000 psi) J1 Inlet Fluid Flow (From Pump)
Lift (Base End) J2 Outlet Fluid Flow (Return to Tank)
D3 Port Relief / Anti-Cavitation Valve – 27579,0 J3 Lift Arm Bypass Orifice
kPa (275,8 bar) (4000 psi)
J4 Drain (Case)
Tilt (Base End)
MR Main Relief Valve – 24131,7 kPa (241,3 bar)
D4 Port Relief / Anti-Cavitation Valve – 27579,0
(3500 psi)
kPa (275,8 bar) (4000 psi)
Tilt (Rod End)
D5 Port Relief / Anti-Cavitation Valve (Auxiliary)
27579,0 kPa (275,8 bar) (4000 psi) (Optional)

170 of 822 20-41-6 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-18

Lift Load Check Valve Removal And Installation

1
Figure 20-41-16

1 3
P-90309

Remove and install new O-rings (Item 1) and back-up

P-90308 ring (Item 2) [Figure 20-41-18].

Check the free movement load check valve and spring

Remove the charge tubeline (Item 1) [Figure 20-41-16] (Item 3) [Figure 20-41-18].
from the BICS™ valve fitting on the top of the lift load

Dealer Copy -- Not for Resale

check valve.

Figure 20-41-17

P-90310

Remove the lift load check valve (Item 1) [Figure 20-41-

17] and fitting from the top of the control valve.

Installation: Lubricate the O-ring and threads and

tighten to 68 - 94 N•m (50- 70 ft-lb) torque.

171 of 822 20-41-7 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-20

Load Check Valve Removal And Installation (Tilt &

Auxiliary)

Figure 20-41-19 1

3
2 4

P-90312

Remove the spring (Item 1) and poppet (Item 2) [Figure

20-41-20].
P-90311
Check the orifice (Item 3) [Figure 20-41-20] in the
poppet to be sure it is not plugged.
At the front side of the control valve locate the tilt section

Dealer Copy -- Not for Resale

load check valve (Item 1) [Figure 20-41-19]. Installation: Install a new O-ring (Item 4) [Figure 20-41-
20] on the plug and lightly lubricate with oil before
At the front side of the control valve locate the auxiliary installing. Tighten the plug to 52 - 61 N•m (38 - 45 ft-lb)
section load check valve (Item 2) [Figure 20-41-19]. torque.

NOTE: The tilt and auxiliary load check valves are

interchangeable.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

172 of 822 20-41-8 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Port Relief / Anti-Cavitation Valve Removal And
Installation (Lift, Base End)
Anti-Cavitation Valve Removal And Installation (Lift,
Rod End) Figure 20-41-23

Figure 20-41-21

P-90314

P-90314
Loosen the lift circuit port relief / anti cavitation valve
(Item 1) [Figure 20-41-23].
At the back side of the control valve, remove the lift

Dealer Copy -- Not for Resale

section anti-cavitation valve (Item 1) [Figure 20-41-21]. Figure 20-41-24

Figure 20-41-22

3
4 1

P-90315

P-90312
Replace the O-ring (Item 1) [Figure 20-41-24] before
installation.
Remove the spring (Item 1) and poppet (Item 2) [Figure
20-41-22]. Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

Check the orifice (Item 3) [Figure 20-41-22] in the

poppet to be sure it is not plugged.

Installation: Install a new O-ring (Item 4) [Figure 20-41-

22] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 52 - 61 N•m (38 - 45 ft-lb)
torque.

173 of 822 20-41-9 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Port Relief / Anti-Cavitation Valve Removal And
Installation (Tilt, Rod End)
Port Relief / Anti-Cavitation Valve Removal And
Installation (Tilt, Base End) Figure 20-41-27

Figure 20-41-25

P-90314

P-90314
Remove the tilt port relief / anti cavitation valve (Item 1)
[Figure 20-41-27] from the rod end of the tilt section.
Remove the tilt port relief / anti cavitation valve (Item 1)

Dealer Copy -- Not for Resale

[Figure 20-41-25] from the base end of the tilt section. Figure 20-41-28

Figure 20-41-26

1
1

P-90319

P-90316
Replace the O-ring (Item 1) [Figure 20-41-28] before
installation.
Replace the O-ring (Item 1) [Figure 20-41-26] before
installation. Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

174 of 822 20-41-10 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-31

Port Relief Valve Removal And Installation

1
Figure 20-41-29

P-90318A

The control valve may be equipped with an optional

P-90314 auxiliary port relief valve (Item 1) [Figure 20-41-31].

Remove the auxiliary port relief valve.

Remove the port relief plug (Item 1) [Figure 20-41-29]
from the auxiliary circuit of the control valve. Figure 20-41-32

Dealer Copy -- Not for Resale

Figure 20-41-30

P-51640
2
P-90318
Installation: Always use new O-rings (Item 1) [Figure
20-41-32]. Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Always use new O-rings (Item 1) [Figure
20-41-30]. Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

175 of 822 20-41-11 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-35

Plug Removal And Installation

Figure 20-41-33

1
P-51461

At the bottom side of the control valve remove the plug

P-68016 (Item 1) [Figure 20-41-35].

Figure 20-41-36
At the top side of the control valve, remove the plug (Item
1) [Figure 20-41-33].

Dealer Copy -- Not for Resale

Figure 20-41-34

P-51462

1 Installation: Always use new O-rings (Item 1) [Figure

P-51460A 20-41-36]. Tighten to 54 N•m (40 ft-lb) torque.

Installation: Always use new O-rings (Item 1) [Figure

20-41-34]. Tighten to 54 N•m (40 ft-lb) torque.

176 of 822 20-41-12 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D)

Rubber Boot Removal And Installation

Figure 20-41-37

P-51506

Remove the three screws (Item 1) [Figure 20-41-37] on

the rubber boot retainer plate.

Dealer Copy -- Not for Resale

Installation: Tighten the screws to 10,7 - 11,9 N•m (95 -
105 in-lb) torque.

Figure 20-41-38

1
2

P-51701

Remove the rubber boots (Item 1) from the retainer plate

(Item 2) [Figure 20-41-38].

177 of 822 20-41-13 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-41

End Cap Block Removal And Installation

Figure 20-41-39

1 1
2

1 1

1 P-51699A

Figure 20-41-42
P-51697

Remove the lift spool lock solenoid (Item 1) and the tilt 1
spool lock solenoid (Item 2) [Figure 20-41-39] from the

Dealer Copy -- Not for Resale

end cap / spool lock block.

Figure 20-41-40 4

1
P-51701

Remove the four end cap / spool lock block mount

1 screws (Item 1) [Figure 20-41-41] and [Figure 20-41-
42].

Installation: Tighten the screws to 10,7 - 11,9 N•m (95 -

P-90320 105 in-lb) torque.

Remove the rubber boots and retainer plate (Item 2)

Disconnect the tube line (Item 1) [Figure 20-41-40] from [Figure 20-41-42] from the lift and tilt spools.
the end cap / spool lock block.
Remove the end cap / spool lock block (Item 4) [Figure
20-41-42] from the control valve.

178 of 822 20-41-14 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-45

Lift Spool And Detent Removal And Installation

The tool listed will be needed to do the following

procedure: 1

MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool

Remove the end cap / spool lock block from the control
valve.

Figure 20-41-43

P-90321

Remove the end cap (Item 1) [Figure 20-41-45].

Figure 20-41-46
1

Dealer Copy -- Not for Resale

P-51511A

1
Remove the O-ring (Item 1) [Figure 20-41-43].
2
Installation: Replace the O-ring, and lubricate the O-ring
lightly with grease or oil before installation of the end cap
/ spool lock block. P-51514

Figure 20-41-44
Use a screwdriver to remove the snap ring (Item 1)
[Figure 20-41-46].

Remove the washer (Item 2) [Figure 20-41-46].

P-51512

Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-41-44] from the lift spool.

179 of 822 20-41-15 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Put a rag around the detent assembly [Figure 20-41-48].
This will prevent the detent balls and spring from being
Lift Spool And Detent Removal And Installation lost when the detent sleeve is removed.
(Cont'd)
Figure 20-41-49
Figure 20-41-47

2 1
1 3

1 2 P-51517
2
P-51515

Remove the detent sleeve (Item 1), detent balls (Item 2)

Remove the screws (Item 1) [Figure 20-41-47] from the and spring (Item 3) [Figure 20-41-49].

Dealer Copy -- Not for Resale

detent bonnet.

Remove the detent bonnet (Item 2) [Figure 20-41-47].

Installation: Lubricate the screws and tighten to 10,7 -

11,9 N•m (95 - 105 in-lb) torque.

IMPORTANT
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284

Figure 20-41-48

P-51516

180 of 822 20-41-16 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-52

Lift Spool And Detent Removal And Installation

(Cont'd)

Figure 20-41-50

P-8988

1 Clamp the linkage end of the spool in a vise [Figure 20-

41-52].
P-51518
NOTE: Protect spool before clamping in vise.

Remove the lift spool assembly and seal (Item 1) [Figure Figure 20-41-53

Dealer Copy -- Not for Resale

20-41-50] from the control valve.
2
Figure 20-41-51

1
3

1
N-18915

P-51519 Install the spring tool (Item 1) [Figure 20-41-53] over the
centering spring.

Remove the lift spool seal (Item 1) [Figure 20-41-51] NOTE: Be careful when removing the detent adapter
from the linkage end of the valve. (Item 2) [Figure 20-41-53] from the centering
spring, as it is under spring pressure.

181 of 822 20-41-17 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-56

Lift Spool And Detent Removal And Installation

1
(Cont'd)

Figure 20-41-54

N-19009

1 Remove spring tool (Item 1) [Figure 20-41-56] from the

2 spring assembly.
N-18916
Figure 20-41-57

Put a rag around the detent assembly [Figure 20-41-54].

1

Dealer Copy -- Not for Resale

This will prevent the detent balls and spring from being 2
lost when the detent adapter is removed.
3
Remove the detent adapter with an Alan wrench.

Remove the back-up washer (Item 1) and spool seal 4

(Item 2) [Figure 20-41-54].

Figure 20-41-55

N-18919A

Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-41-57].

N-19004

Remove the detent adapter (Item 1) [Figure 20-41-55]

from the spring assembly.

182 of 822 20-41-18 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-60

Lift Spool And Detent Removal And Installation

(Cont'd)

Figure 20-41-58 2
1

N-18961

Install the O-ring (Item 1) over the nipple on the plastic

plug (Item 2) [Figure 20-41-60].
N-18918
NOTE: Check the O-ring for damage. The lift spool
will have an internal leak if there is damage to
Remove the stud from the end of the spool [Figure 20-
this O-ring. Always replace the O-ring and
41-58].

Dealer Copy -- Not for Resale

plastic plug. Recheck the lift spool before the
control valve is replaced.
Figure 20-41-59
Figure 20-41-61

N-18920

Removal of the plastic plug: N-18963

Make a center point in the plastic plug using a 1/16 in

Install the plastic plug and O-ring in the spool [Figure 20-
(1,6 mm) drill.
41-61].
Drill a hole all the way through the plastic plug using a 7/
64 in (2,8 mm) tap drill

Turn a 6-32 tap (Item 1) [Figure 20-41-59] into the plastic

plug. Pull the tap and plastic plug out of the spool. Be
careful, do not break the tap.

Clean all the debris from inside the spool bore.

NOTE: DO NOT USE Loctite® ON THE STUD

THREADS.

183 of 822 20-41-19 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-64

Lift Spool And Detent Removal And Installation

(Cont'd)

Figure 20-41-62 2

O-ring

1 3
2

Plastic N-18958
Plug
15,2 mm
(0.60 in) Apply grease on all the detent component surfaces
before assembly [Figure 20-41-64].
B-14712
Install the spring (Item 1) [Figure 20-41-64] and detent
balls (Item 2) [Figure 20-41-64] into the adapter (Item 3)
Install the stud and tighten until the other end of the stud [Figure 20-41-64] and compress with the detent pliers

Dealer Copy -- Not for Resale

is out about 15,2 mm (0.600 in) from the spool [Figure (Item 1) [Figure 20-41-65].
20-41-62].
Figure 20-41-65
Figure 20-41-63

N-18968
N-18967

Install the detent adapter to the collar [Figure 20-41-65].

Clamp the collar (Item 1) [Figure 20-41-63] in a vice.
NOTE: The collar and the detent adapter are held
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.

184 of 822 20-41-20 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-68

Lift Spool And Detent Removal And Installation

(Cont'd)

Figure 20-41-66

N-19005

Install the spring assembly to the lift spool hand tight

[Figure 20-41-68].
N-19004
Remove the spring tool.

Install the spring tool (Item 1) [Figure 20-41-66] over the Check the alignment of the detent adapter and the

Dealer Copy -- Not for Resale

washer, spring, collar and detent adapter. washer.

Figure 20-41-67 Tighten the adapter to 10,7 - 11,9 N•m (95 - 105 in-lb)
torque.

NOTE: The adapter must fit in the center of the

washer (Item 1) [Figure 20-41-68].
2
Figure 20-41-69

N-18917

Install the spool seal (Item 1) and back-up washer (Item

2) [Figure 20-41-67].

CD-15051

Install the detent balls and spring [Figure 20-41-69].

185 of 822 20-41-21 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-72

Lift Spool And Detent Removal And Installation

(Cont'd)

Figure 20-41-70

2
P-51515

Install the lift spool assembly in the spool bore [Figure

20-41-72].
N-19007
Install the detent bonnet (Item 1) [Figure 20-41-72].

Hold the detent balls in place with the detent pliers Install the mounting screws (Item 2) [Figure 20-41-72].

Dealer Copy -- Not for Resale

[Figure 20-41-70].
Installation: Lubricate the screws and tighten to 10,7 -
Figure 20-41-71 11,9 N•m (95 - 105 in-lb)) torque.

Figure 20-41-73

1
N-19008

P-51514
Install the detent sleeve (Item 1) [Figure 20-41-71] to the
detent adapter.
Install the washer (Item 1) and snap ring (Item 2) [Figure
20-41-73].

186 of 822 20-41-22 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-76

Lift Spool And Detent Removal And Installation

(Cont'd)

Figure 20-41-74

1 1

P-51512

Install the O-ring (Item 1) and bushing (Item 2) [Figure

20-41-76] on the lift spool.
P-90321
Figure 20-41-77

Install the end cap (Item 1) [Figure 20-41-74].

Dealer Copy -- Not for Resale

Figure 20-41-75

P-51511A

Install the O-ring (Item 1) [Figure 20-41-77] on the

P-51520 control valve.

Install the spool seal (Item 1) [Figure 20-41-75] on the

linkage end of the valve.

187 of 822 20-41-23 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-80

Lift Spool And Detent Removal And Installation

(Cont'd)

Figure 20-41-78

2
2

1
1

P-51697

3
Use an ohmmeter to measure the lock solenoid coils
resistance.
4
P-51701
The correct resistance for the coil is 16.02 - 19.58 ohm.

Install the end cap / spool lock block (Item 1) and the Installation: Install the lift spool (Item 1) and tilt spool

Dealer Copy -- Not for Resale

mount bolt (Item 2) [Figure 20-41-78]. (Item 2) lock solenoids and tighten to 52 - 61 N•m (38 -
45 ft-lb) torque [Figure 20-41-80].
Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-41-78].

Installation: Tighten the screws to 10,7 - 11,9 N•m (95 -

105 in-lb) torque.

Figure 20-41-79

P-90320

Connect the tubeline (Item 1) [Figure 20-41-79].

188 of 822 20-41-24 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-83

Tilt Spool Removal And Installation

Remove the lift and tilt end cap / spool lock block. (See
End Cap Block Removal And Installation on Page 20-41-
14.) 2

Figure 20-41-81

P-90323

1 2 Remove the spool centering block (Item 1) [Figure 20-

41-83] from the control valve.

Installation: Replace the O-ring (Item 2) [Figure 20-41-

83] and lubricate the O-ring lightly with grease or oil
P-51521 before installation of the end cap / spool lock block.

Dealer Copy -- Not for Resale

Figure 20-41-84
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-41-81] from the tilt spool.

Figure 20-41-82

P-51544

2 1
Remove the tilt spool, centering spring, back-up washer
P-90321 and spool seal [Figure 20-41-84].

Assembly: Always use a new spool seal.

Disconnect the two tubelines (Item 1) [Figure 20-41-82]
from the spool centering block.

Remove the three screws (Item 2) [Figure 20-41-82]

from the spool centering block.

Installation: Tighten the bolt to 10,7 - 11,9 N•m (95 - 105

in-lb) torque.

189 of 822 20-41-25 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-87

Tilt Spool Removal And Installation (Cont'd)

Figure 20-41-85 2 1
3

1 4

N-18944A

Inspect the adapter (Item 1), collar (Item 2), spring (Item
N-18942 3) and washer (Item 4) [Figure 20-41-87].

Figure 20-41-88
Put the linkage end of the spool in the vice [Figure 20-
41-85].
2

Dealer Copy -- Not for Resale

Install the spool tool (Item 1) [Figure 20-41-85] over the 1
centering spring.

Figure 20-41-86

1 1

P-51545 N-18943

Remove the spool seal(s) (Item 1) and the back-up

washer (Item 2) [Figure 20-41-88].

Assembly: Always use a new spool seal.

N-19014

Remove the bolt (Item 1) [Figure 20-41-86] holding the

centering spring to the spool.

Installation: Tighten the bolt to 10,7 - 11,9 N•m (95 - 105

in-lb) torque.

Remove spring tool from the spring assembly.

190 of 822 20-41-26 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-91

Auxiliary Spool Removal And Installation

Figure 20-41-89

2 3 1
2

P-51547

2 1
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
P-90321 20-41-91] from the auxiliary spool.

Figure 20-41-92
Remove the two tubelines (Item 1) [Figure 20-41-89]
from the spool centering block.

Dealer Copy -- Not for Resale

Remove the three screws (Item 2) [Figure 20-41-89]
from the spool centering block.

Installation: Tighten the bolt to 10,7 - 11,9 N•m (95 - 105

in-lb) torque. 2
1
Remove the spool centering block (Item 3) [Figure 20-
41-89] from the control valve.

Figure 20-41-90

P-51549A

Remove the spring (Item 1) and center spring retainer

(Item 2) [Figure 20-41-92] from the auxiliary spool.

2 NOTE: If the centering spring retainer (Item 2) [Figure

1 20-41-92] must be replaced, replace the
retainer on the opposite end also.

P-51546A

Remove the spring (Item 1) and center spring retainer

(Item 2) [Figure 20-41-90] from the auxiliary spool.

NOTE: If the centering spring retainer (Item 2) [Figure

20-41-90] must be replaced, replace the
retainer on the opposite end also.

191 of 822 20-41-27 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D)

Auxiliary Spool Removal And Installation (Cont’d)

Figure 20-41-93

1
2

P-51550

Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-41-93] from the auxiliary spool.

Dealer Copy -- Not for Resale

Figure 20-41-94

P-51551

Remove the spool (Item 1) [Figure 20-41-94].

192 of 822 20-41-28 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D)

Auxiliary Solenoid Removal And Installation

Figure 20-41-95

1
2

P-85528

Remove the screws (Item 1) [Figure 20-41-95] from both

solenoids.

Dealer Copy -- Not for Resale

Remove the solenoids (Item 2) [Figure 20-41-95] from
the control valve.

Installation: Tighten the screws to 2,44 - 2,98 N•m (21.6

- 26.4 in-lb) torque.

Figure 20-41-96

P-85556

Check and remove the O-rings (Item 1) [Figure 20-41-

96] from the solenoid stem.

Use an ohmmeter to measure the solenoid coil

resistance.

The correct resistance for the coil is 3.3 ohm.

193 of 822 20-41-29 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-99

Solenoid Removal And Installation

Figure 20-41-97
1

1
2

P-85528

Remove the solenoid stem (Item 1) [Figure 20-41-99].

P-90310
Installation: Lubricate the O-rings and tighten the stem
to 27 - 33 N•m (20 - 24 ft-lb) torque.
Remove the nut (Item 1) [Figure 20-41-97] from the
solenoid stem. Figure 20-41-100

Dealer Copy -- Not for Resale

Installation: Tighten the nut to 6 N•m (53 in-lb) torque.

Remove the solenoid coil (Item 2) [Figure 20-41-97].

3
Figure 20-41-98 2

N-18694

Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-41-100] from the stem.

N-18693A Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear and replace any showing

Remove the O-rings (Item 1) [Figure 20-41-98] from excessive wear.
both ends of the solenoid coil.
NOTE: The screen (Item 3) [Figure 20-41-100] may be
Use an ohmmeter to measure the solenoid coil cleaned with solvent. If it is torn or worn,
resistance. replace the solenoid valve

The correct resistance for the coil is 9.8 ohm. Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.

Install new O-rings (Item 1) [Figure 20-41-98] and

[Figure 20-41-100] and new back-up rings (Item 2)
[Figure 20-41-100] on the solenoid stem.

194 of 822 20-41-30 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-103

Lock Valve Removal And Installation

Figure 20-41-101
1
1
1

1
2
1 2
2 2
P-51564

Remove the O-rings (Item 1) and back-up rings (Item 2)

P-90310 [Figure 20-41-103] from the lift lock valve, and replace
with new.

Locate the two BICS™ lock valves, (Item 1) is for the tilt Figure 20-41-104
circuit and (Item 2) [Figure 20-41-101] is for the lift

Dealer Copy -- Not for Resale

circuit.

Figure 20-41-102

P-51705

Locate the tilt circuit lock valve (Item 1) [Figure 20-41-

P-90321 104].

Remove the lift lock valve (Item 1) [Figure 20-41-102]

from the back of the control valve.

Installation: Lightly lubricate the lock valve O-rings and

tighten to 27 - 33 N•m (20 - 24 ft-lb) torque.

195 of 822 20-41-31 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-107

Lock Valve Removal And Installation (Cont’d)

Figure 20-41-105
1
1
1
2

1
2
2
1
2
P-51564

Remove the O-rings (Item 1) and back-up rings (Item 2)

P-90325 [Figure 20-41-107] from the tilt lock valve, and replace
with new.

Remove the lift spool lock solenoid (Item 1) [Figure 20-

41-105].

Dealer Copy -- Not for Resale

Remove the tilt spool lock solenoid (Item 2) [Figure 20-
41-105].

Installation: Lubricate the O-rings and tighten the spool

lock solenoids to 52 - 61 N•m (38 - 45 ft-lb) torque.

Figure 20-41-106

P-90324

Remove the tilt lock valve (Item 1) [Figure 20-41-106]

from the front of the control valve.

Installation: Lightly lubricate the lock valve O-rings and

tighten to 27 - 33 N•m (20 - 24 ft-lb) torque.

196 of 822 20-41-32 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Main Relief Valve Removal And Installation

Lift Arm Bypass Orifice Removal And Installation Figure 20-41-110

Figure 20-41-108

1
P-51707

P-90308
Remove the main relief valve (Item 1) [Figure 20-41-
110].
Remove the fitting (Item 1) [Figure 20-41-108] from the
valve. Figure 20-41-111

Dealer Copy -- Not for Resale

Figure 20-41-109

P-51463

P-51437
Remove the O-rings from the main relief valve (Item 1)
[Figure 20-41-111].
Check the lift arm bypass orifice (Item 1) [Figure 20-41-
109]. Installation: Always use new O-rings. Tighten to 52 - 61
N•m (38 - 45 ft-lb) torque.
NOTE: This orifice is not removable from the valve
casting.

197 of 822 20-41-33 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT'D) Figure 20-41-114

Check Valve Removal And Installation

Figure 20-41-112

1
P-68869

Installation: Lubricate the O-ring (Item 1) [Figure 20-41-

P-90308 114] and tighten the fitting to 27 - 33 N•m (20 - 24 ft-lb)
torque.

Remove the tubeline (Item 1) [Figure 20-41-112]. Figure 20-41-115

Dealer Copy -- Not for Resale

Figure 20-41-113

P-90326

P-90310
Inspect the screen (Item 1) [Figure 20-41-115].

Remove the check valve fitting (Item 1) [Figure 20-41-

113] from the hydraulic control valve.

198 of 822 20-41-34 T870 Service Manual

LIFT ARM BYPASS CONTROL VALVE

Description

The lift arm bypass control valve is located on the right

side of the machine.

The lift arm bypass control valve is manually operated by

pulling on the valve (Item 1) [Figure 20-50-1] and turning
the knob clockwise a 1/4 turn. The valve releases the
hydraulic fluid from the base end of the lift cylinder(s)
which allows the lift arm to slowly come down to the
transport position.

Testing

Figure 20-50-1

Dealer Copy -- Not for Resale

P-85290B P-85290A

Raise the lift arms 2 m (6 ft) off the ground. Stop the
engine. Turn the Lift Arm Bypass Control Knob (Item 1)
[Figure 20-50-1] clockwise 1/4 turn. Then pull up and
hold the Lift Arm Bypass Control Knob until the lift arms
slowly lower.

The knob should return to its normal position.

199 of 822 20-50-1 T870 Service Manual

LIFT ARM BYPASS CONTROL VALVE (CONT’D) Figure 20-50-2

Removal And Installation

1
3
DANGER
2

P-85670
P-90328

AVOID DEATH Hold the lift arm bypass control knob (Item 1) [Figure 20-
• Disconnecting or loosening any hydraulic 50-2] and loosen the jam nut on the lift arm bypass valve
tubeline, hose, fitting, component or a part failure shaft.
can cause lift arms to drop.
• Keep out of this area when lift arms are raised Remove the lift arm bypass control knob (Item 1).
unless supported by an approved lift arm Remove the jam nut (Item 2) from the valve shaft [Figure
support. Replace if damaged.

Dealer Copy -- Not for Resale

20-50-2].
D-1009-0409
Remove the rubber washer (Item 3) [Figure 20-50-2].

Figure 20-50-3
WARNING 2
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598

Lower the lift arms.

1
Raise the operator cab. (See Raising on Page 10-30-1.)

P-85671

Disconnect and cap the hydraulic tubeline and hose

(Item 1) [Figure 20-50-3].

Remove the two mounting bolts and nuts (Item 2)

[Figure 20-50-3].

Installation: Tighten the mounting bolts to 21 - 23 N•m

(180 - 200 in-lb) torque.

Remove the lift arm bypass valve.

200 of 822 20-50-2 T870 Service Manual

LIFT ARM BYPASS CONTROL VALVE (CONT'D) Disassembly And Assembly

Bracket Removal And Installation Figure 20-50-5

Figure 20-50-4

1 2

P-85673

P-85672
Remove the lift arm bypass valve (Item 1) [Figure 20-50-
5] from the valve block. Inspect the bypass valve for
Remove the two bolts (Item 1) [Figure 20-50-4] to damage and replace if necessary.
replace the bypass valve mounting bracket if necessary.

Dealer Copy -- Not for Resale

Installation: Tighten the valve to 45 - 50 N•m (33 - 37 ft-
lb) torque.

Inspect the hydraulic fittings (Item 2) [Figure 20-50-5] on

the valve block for damage and replace if necessary.

201 of 822 20-50-3 T870 Service Manual

 Dealer Copy -- Not for Resale

202 of 822 20-50-4 T870 Service Manual

HYDRAULIC PUMP NOTE: When testing the hydraulic flow of a machine,
hoses must be at least 19,05 mm (3/4 in) in
Description diameter and connected directly to the
hydraulic tester without using any type of
The hydraulic pump is attached to the end of the “quick coupler” on the connection to the
hydrostatic pumps and is located on the right side of the tester. Also make sure your hydraulic tester is
loader between the hydraulic control valve and the capable of at least 189,3 L/min (50 U.S. gpm).
engine.
Install a hydraulic tester (Item 1) [Figure 20-60-1] onto
The hydraulic pump is a combination of gear pumps that the front auxiliary quick couplers.
provide hydraulic flow to several hydraulic systems.
This procedure will require one operator in the cab and
The hydraulic pump has a dedicated charge pump. This one operator running the tester.
supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump. Start the engine and run at low idle rpm. Press the
Auxiliary hydraulics button. Engage the front auxiliary
A seal kit is available to service the hydraulic pump. If with the trigger on the right handle or joystick. Make sure
any of the main components of the pump are damaged, the tester is connected correctly. If no flow is indicated on
the entire pump must be replaced. the tester, the hoses are connected wrong. With the
hoses connected correctly, increase the engine speed to
Pump Test At Quick Couplers full rpm*.

Warm the fluid to 60°C (140°F) by turning the restrictor

control clockwise on the tester so it reads about 6,9 MPa
WARNING

Dealer Copy -- Not for Resale

(68,9 bar) (1000 psi).

NOTE: DO NOT EXCEED 25,5 MPa (255,1 bar) (3700

Put jackstands under the front axles and rear corners
psi).
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
Turn the restrictor control (Item 2) [Figure 20-60-1] on
fall or move and cause injury or death.
W-2017-0286
the tester counterclockwise to obtain free flow, the flow
should be approximately 87 - 91 L/min (23 - 24 U.S.
gpm). Start turning the restrictor clockwise, causing more
The tools listed will be needed to do the following restriction on the flow. The L/min (U.S. gpm) should drop
procedure: off slightly until the pressure reaches approximately 21,4
MPa (213,7 bar) (3100 psi). At approximately 21,4 MPa
TWX-RFIK200-S-6 Flow Meter 200 L/min (54 U.S. gpm) (213,7 bar) (3100 psi) the flow should start decreasing
MEL10006 - Fitting Kit rapidly until the pressure reaches 23,8 - 24 MPa (237,9 -
241,3 bar) (3450 - 3500 psi). At 23,8 - 24 MPa (237,9 -
Lift and block the loader. (See Procedure on Page 10-10- 241,3 bar) (3450 - 3500 psi) the flow should be at 0 L/min
1.) (0 U.S. gpm). Turn the restrictor (Item 2) [Figure 20-60-
1] counterclockwise to free flow. Shut the auxiliary
Figure 20-60-1 hydraulics off.

1 If flow and pressure specifications are not obtained, go to

Direct Pump Testing. (See Direct Pump Test (Standard
Section) on Page 20-60-2.)

*Refer to (See Hydraulic System on Page SPEC-10-3.)

for system relief pressure and full rpm.

2 P-90171

203 of 822 20-60-1 T870 Service Manual

HYDRAULIC PUMP (CONT'D) Figure 20-60-2

Direct Pump Test (Standard Section)

The tools listed will be needed to do the following

procedure:

MEL1563 or 7003031 - Remote Start Tool 2

TWX-RFIK200-S-6 Flow Meter 200 L/min (54 U.S. gpm)
MEL10006 - Fitting Kit

WARNING 2
1
P-90178 P100014
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-60-2]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
control valve.

Lift and block the loader. (See Procedure on Page 10-10- Figure 20-60-3
1.)

Dealer Copy -- Not for Resale

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)

WARNING
1 2
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
P-90580
W-2059-0598

Raise the operator cab. Connect the INLET hose (Item 1) [Figure 20-60-3] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-2]
Connect the remote start tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT-MEL1563 on Page 10-60-1.) or (See 20-60-3] from the tester to the control valve fitting (Item
REMOTE START TOOL (SERVICE TOOL) KIT - 2) [Figure 20-60-2] on the control valve.
7003031 on Page 10-61-1.)

NOTE: The control panel is shown removed for photo

clarity.
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284

204 of 822 20-60-2 T870 Service Manual

HYDRAULIC PUMP (CONT'D)

Direct Pump Test (Standard Section) (Cont'd)

Start the engine and run at low idle rpm. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
rpm*.

Warm the fluid to 60°C (140°F) by turning the restrictor

control on the tester to about 6,9 MPa (68,9 bar) (1000
psi). DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (L/min [U.S.
gpm]) at full rpm*.

On the remote start tool engage the auxiliary hydraulics,

the light will come ON. Pull the trigger on the right handle
or joystick for fluid flow to the quick coupler (fluid
pressure will go over main relief). Record the highest
pressure (psi) and flow (L/min [U.S. gpm]). The high
pressure flow must be at least 80% of free flow.

%= HIGH PRESSURE FLOW (L/min [U.S. gpm]) X 100

Dealer Copy -- Not for Resale

FREE FLOW (L/min [U.S. gpm])

A low percentage may indicate a failed pump.

*Refer to (See Hydraulic System on Page SPEC-10-3.)

for system relief pressure and full rpm.

205 of 822 20-60-3 T870 Service Manual

HYDRAULIC PUMP (CONT'D) Figure 20-60-4

Direct Pump Test (Charge Section)

The tools listed will be needed to do the following

procedure:

MEL1563 or 7003031 - Remote Start Tool

TWX-RFIK200-S-6 Flow Meter 200 L/min (54 U.S. gpm)
MEL10006 - Fitting Kit

1
WARNING
P100729
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to Disconnect the inlet hose (Item 1) [Figure 20-60-4].
fall or move and cause injury or death.
W-2017-0286
Figure 20-60-5

Lift and block the loader. (See Procedure on Page 10-10-

1.)

Dealer Copy -- Not for Resale

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)

WARNING 1 2

Never work on a machine with the lift arms up unless

the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
P-90580
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598 Connect the INLET hose (Item 1) [Figure 20-60-5] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-4]
NOTE: The fluid from the charge pump must be of the pump. Connect the OUTLET hose (Item 2) [Figure
filtered after it passes through the Hydraulic 20-60-5] from the tester to the inlet fitting on the fan (Item
Tester, to prevent any contamination to the 1) [Figure 20-60-4].
Hydrostatic Pumps.

Raise the operator cab.

Open the rear door of the loader.

Connect the remote start tool. (See REMOTE START

TOOL KIT-MEL1563 on Page 10-60-1.) or (See
REMOTE START TOOL (SERVICE TOOL) KIT -
7003031 on Page 10-61-1.)

206 of 822 20-60-4 T870 Service Manual

HYDRAULIC PUMP (CONT'D)

Direct Pump Test (Charge Section) (Cont’d)

IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284

Start the engine and run at low idle rpm. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
rpm*.

Warm the fluid to 60°C (140°F) by turning the restrictor

control on the tester to about 4,1 MPa (41,4 bar) (600
psi). DO NOT exceed 8,3 MPa (82,7 bar) (1200 psi).
Open the restrictor control and record the free flow (L/min
[U.S. gpm]) at full rpm*.

Dealer Copy -- Not for Resale

Turn the restrictor down to system operating pressure
approximately 6,9 MPa (68,9 bar) (1000 psi). DO NOT
EXCEED 8,3 MPa (82,7 bar) (1200 psi). Refer to
Hydraulic Schematics for flow. The high pressure flow
must be at least 80% of free flow.
HIGH PRESSURE FLOW (L/min [U.S. gpm])
%= X 100
FREE FLOW (L/min [U.S. gpm])

A low percentage may indicate a failed pump.

*Refer to the Hydraulic Schematics for pump flow and

rpm.

207 of 822 20-60-5 T870 Service Manual

HYDRAULIC PUMP (CONT'D) Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10-
Removal And Installation 120-2.)

Open the rear door of the loader.

WARNING
Figure 20-60-6
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598 1

1
1
DANGER 1

P-90180

Disconnect and cap the four hoses (Item 1) [Figure 20-

Dealer Copy -- Not for Resale

60-6] from the hydraulic pump.

P-90328 Remove the Power Bob-Tach block if equipped. (See

Removal And Installation on Page 20-120-1.)
AVOID DEATH
• Disconnecting or loosening any hydraulic Figure 20-60-7
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised 2
unless supported by an approved lift arm
support. Replace if damaged. 1
D-1009-0409
2

IMPORTANT 1

When repairing hydrostatic and hydraulic systems, 3

clean the work area before disassembly and keep all
P-90509
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Disconnect and cap the outlet hoses (Item 1) [Figure 20-
I-2003-0888 60-7] from the hydraulic pump.

Lift and block the rear of the loader. (See Procedure on Remove the two mounting bolts (Item 2) [Figure 20-60-
Page 10-10-1.) 7] from the hydraulic pump.

Raise the lift arms and install an approved lift arm support Installation: Tighten the mounting bolts to 75 - 85 N•m
device. (See Installing on Page 10-20-1.) (55 - 60 ft-lb) torque.

Raise the operator cab. (See Raising on Page 10-30-1.) Remove the hydraulic pump (Item 3) [Figure 20-60-7]
from the loader.

208 of 822 20-60-6 T870 Service Manual

HYDRAULIC PUMP (CONT'D) Figure 20-60-10

Removal And Installation (Cont’d)

Figure 20-60-8 1

1
P100352

Attach a push button starter switch (MEL1712) (Item 1)

[Figure 20-60-9] to the starter terminal S (Item 1) and the
P-43940 P-43938A
positive battery cable (Item 2) [Figure 20-60-10].

Replace the O-ring (Item 1) [Figure 20-60-8] on the Crank the engine for 15 seconds, then stop for at least 30
hydraulic pump. seconds. Again, crank the engine for 15 seconds.
Remove the starter bypass tool.

Dealer Copy -- Not for Resale

Reverse the removal procedure to install the hydraulic
pump. Start the loader from the operators cab and run the
engine at low idle for 1 - 2 minutes without operating the
Hydraulic Pump Startup hydraulics.

NOTE: This procedure is necessary to prevent a dry After operating the engine at low idle, remove the lift arm
startup of the hydraulic pump. support device and fully raise and lower the loader lift
arms several times or until air is purged from the system.
Fill the system with hydraulic fluid. (See Removing And Avoid running over the relief valve setting at the end
Replacing Hydraulic Fluid on Page 10-120-2.) of cylinder stroke.

Figure 20-60-9 With the loader parked on a level surface and lift arms
down, check and fill the hydraulic reservoir as required.
Check for hydraulic leaks.

P100685

209 of 822 20-60-7 T870 Service Manual

HYDRAULIC PUMP (CONT'D)

Parts Identification

Figure 20-60-11

12
6
11
4

17

Dealer Copy -- Not for Resale

2 15
5

5 13 14
6
2
3
7
6

10
2
5

8 9
6
4 5
3
16 2

P-66540

210 of 822 20-60-8 T870 Service Manual

HYDRAULIC PUMP (CONT'D) Disassembly And Assembly

Parts Identification (Cont’d)

The items listed below refer to Page 20-60-8 [Figure 20-

60-11]. IMPORTANT
1. Auxiliary Pump End Section When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
2. Section Seal parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
3. Pre-Load Seal damage the system.
I-2003-0888
4. Load Seal
Mark the pump sections for correct assembly.
5. Wear Plate
To disassemble and assemble the hydraulic pump, follow
6. Alignment Pins the Parts Identification page (See Parts Identification on
Page 20-60-8.) for proper placement of components
7. Drive Gear (Auxiliary Pump) along with the information below.

8. Idler Gear (Auxiliary Pump) NOTE: A seal kit is available through Bobcat Service
Parts.
9. Auxiliary Pump Center Section

Dealer Copy -- Not for Resale

Assembly: Tighten the eight pump housing bolts (Item
10. Auxiliary Pump End Section 17) [Figure 20-60-11] to 50 N•m (37 ft-lb) torque.

11. Spline Shaft NOTE: Position the wear plate (Item 5) [Figure 20-60-
11] inlets and traps as shown with the bronze
12. Drive Gear (Charge Pump) side toward the gears on all wear plates.

13. Idler Gear (Charge Pump) NOTE: Inspect all gears, shafts and pump end
sections. If any of these components have
14. Charge Pump Center Section excessive wear or damage is visible, the
complete pump must be replaced.
15. Charge Pump End Section

16. Shaft Seal

17. Bolts (8)

211 of 822 20-60-9 T870 Service Manual

 Dealer Copy -- Not for Resale

212 of 822 20-60-10 T870 Service Manual

HYDRAULIC PUMP (HIGH FLOW) Install a hydraulic tester (Item 1) [Figure 20-61-1] onto
the front auxiliary quick couplers.
Description
This procedure will require one operator in the cab and
The hydraulic gear pump is attached to the end of the one operator running the tester.
hydrostatic pumps and is located on the right side of the
loader between the hydraulic control valve and the Start the engine and run at low idle rpm. Press the
engine. Auxiliary hydraulics button. Engage the front auxiliary
with the trigger on the right handle or joystick. Make sure
The hydraulic gear pump is a combination of gear pumps the tester is connected correctly. If no flow is indicated on
that provide hydraulic flow to several hydraulic systems. the tester, the hoses are connected wrong. With the
hoses connected correctly, increase the engine speed to
The hydraulic gear pump has a dedicated charge pump. full rpm*.
This supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump. Warm the fluid to 60°C (140°F) by turning the restrictor
control clockwise on the tester so it reads about 6,9 MPa
The high flow hydraulic pump has an additional pump (68,9 bar) (1000 psi).
section that provides an additional amount of flow that is
controlled by an external valve. The valve is switched NOTE: DO NOT EXCEED 25,5 MPa (255 bar) (3700
from a button on the panel in the cab. psi).

A seal kit is available to service the hydraulic pump. If Turn the restrictor control (Item 2) [Figure 20-61-1] on
any of the main components of the pump are damaged, the tester counterclockwise to obtain free flow, the flow
the entire pump must be replaced. should be approximately 140 - 148 L/min (37 - 38 U.S.

Dealer Copy -- Not for Resale

gpm). Start turning the restrictor clockwise, causing more
Pump Test At Quick Couplers restriction on the flow. The L/min (U.S. gpm) should drop
off slightly until the pressure reaches approximately 21,4
The tools listed will be needed to do the following MPa (213,7 bar) (3100 psi). At approximately 21,4 MPa
procedure: (213,7 bar) (3100 psi) the flow should start decreasing
rapidly until the pressure reaches 23,8 - 24,1 MPa (241,3
TWX-RFIK200-S-6 Flow Meter 200 L/min (54 U.S. gpm) bar) (3450 - 3500 psi). At 23,8 - 24,1 MPa (237,9 - 241,3
MEL10006 - Fitting Kit bar) (3450 - 3500 psi) the flow should be at 0 L/min (0
U.S. gpm). Turn the restrictor (Item 2) [Figure 20-61-1]
Figure 20-61-1 counterclockwise to free flow. Shut the auxiliary
hydraulics off.
1
If flow and pressure specifications are not obtained, go to
Direct Pump Testing. (See Direct Pump Test (Standard
Section) on Page 20-61-2.)

*Refer to (See Hydraulic System on Page SPEC-10-3.)

for system relief pressure and full rpm.

2 P-90171

NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 19,05 mm (3/4 in) in
diameter and connected directly to the
hydraulic tester without using any type of
“quick coupler” on the connection to the
tester. Also make sure your hydraulic tester is
capable of at least 189,3 L/min (50 U.S. gpm).

213 of 822 20-61-1 T870 Service Manual

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-2

Direct Pump Test (Standard Section)

The tools listed will be needed to do the following

procedure:

MEL1563 or 7003031 - Remote Start Tool

2
TWX-RFIK200-S-6 Flow Meter 200 L/min (54 U.S. gpm)
MEL10006 - Fitting Kit

WARNING 2 1
P-90178 P-90176
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-61-2]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
control valve.

Lift and block the loader. (See Procedure on Page 10-10- Figure 20-61-3
1.)

Dealer Copy -- Not for Resale

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)

1
WARNING 2

Never work on a machine with the lift arms up unless

the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
P-90177
W-2059-0598

Raise the operator cab. (See Raising on Page 10-30-1.) Connect the INLET hose (Item 1) [Figure 20-61-3] from
the tester to the OUTLET hose (Item 1) [Figure 20-61-2]
Connect the remote start tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT-MEL1563 on Page 10-60-1.) or (See 20-61-3] from the tester to the control valve fitting (Item
REMOTE START TOOL (SERVICE TOOL) KIT - 2) [Figure 20-61-2] on the control valve.
7003031 on Page 10-61-1.)

NOTE: The control panel is shown removed for photo

clarity.

214 of 822 20-61-2 T870 Service Manual

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Direct Pump Test (Charge Section)

Direct Pump Test (Standard Section) (Cont'd) The tools listed will be needed to do the following
procedure:
Start the engine and run at low idle rpm. Make sure the
tester is connected correctly. If no flow is indicated on the MEL1563 or 7003031 - Remote Start Tool
tester, the hoses are connected wrong. With the hoses TWX-RFIK200-S-6 Flow Meter 200 L/min (54 U.S. gpm)
connected correctly, increase the engine speed to full MEL10006 - Fitting Kit
rpm*.

Warm the fluid to 60°C (140°F) by turning the restrictor

control on the tester to about 6,9 MPa (68,9 bar) (1000
psi). DO NOT exceed system relief pressure. Open the
WARNING
restrictor control and record the free flow (L/min [U.S.
gpm]) at full rpm*. Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
On the remote start tool engage the auxiliary hydraulics, Failure to use jackstands can allow the machine to
the light will come ON. Pull the trigger on the right handle fall or move and cause injury or death.
or joystick for fluid flow to the quick coupler (fluid W-2017-0286
pressure will go over main relief). Record the highest
pressure (psi) and flow (L/min [U.S. gpm]). The high Lift and block the loader. (See Procedure on Page 10-10-
pressure flow must be at least 80% of free flow. 1.)

%= HIGH PRESSURE FLOW (L/min [U.S. gpm]) X 100 Raise the lift arms and install an approved lift arm support

Dealer Copy -- Not for Resale

FREE FLOW (L/min [U.S. gpm]) device. (See Installing on Page 10-20-1.)

A low percentage may indicate a failed pump.

*Refer to (See Hydraulic System on Page SPEC-10-3.)

WARNING
for system relief pressure and full rpm.
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598

NOTE: The fluid from the charge pump must be

filtered after it passes through the Hydraulic
Tester, to prevent any contamination to the
Hydrostatic Pumps.

Raise the operator cab. (See Raising on Page 10-30-1.)

Open the rear door of the loader.

Connect the remote start tool. (See REMOTE START

TOOL KIT-MEL1563 on Page 10-60-1.) or (See
REMOTE START TOOL (SERVICE TOOL) KIT -
7003031 on Page 10-61-1.)

215 of 822 20-61-3 T870 Service Manual

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Start the engine and run at low idle rpm. Make sure the
tester is connected correctly. If no flow is indicated on the
Direct Pump Test (Charge Section) (Cont’d) tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
Figure 20-61-4 rpm*.

Warm the fluid to 60°C (140°F) by turning the restrictor

control on the tester to about 4,14 MPa (41,4 bar) (600
psi). DO NOT exceed 8,27 MPa (82,7 bar) (1200 psi).
Open the restrictor control and record the free flow (L/min
[U.S. gpm]) at full rpm*.

Turn the restrictor down to system operating pressure

approximately 6,9 MPa (68,9 bar) (1000 psi). DO NOT
EXCEED 8,27 MPa (82,7 bar) (1200 psi). Refer to
1 Hydraulic Schematics for flow. The high pressure flow
must be at least 80% of free flow.
HIGH PRESSURE FLOW (L/min [U.S. gpm])
%= X 100
FREE FLOW (L/min [U.S. gpm])
P100729

A low percentage may indicate a failed pump.

Disconnect the inlet hose (Item 1) [Figure 20-61-4].
*Refer to the Hydraulic Schematics for pump flow and

Dealer Copy -- Not for Resale

Figure 20-61-5 rpm.

1
2

P-90177

Connect the INLET hose (Item 1) [Figure 20-61-5] from

the tester to the OUTLET hose (Item 1) [Figure 20-61-4]
of the pump. Connect the OUTLET hose (Item 2) [Figure
20-61-5] from the tester to the inlet fitting on the fan (Item
1) [Figure 20-61-4].

IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284

216 of 822 20-61-4 T870 Service Manual

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-6

Direct Pump Test (High Flow Section)

1
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286

P-90186

WARNING Install a jumper hose (Item 1) [Figure 20-61-6] onto the

front auxiliary quick couplers.
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
Raise the lift arms and install an approved lift arm support
support device. Failure to use an approved lift arm
device. (See Installing on Page 10-20-1.)
support device can allow the lift arms or attachment
to fall and cause injury or death.

Dealer Copy -- Not for Resale

W-2059-0598

IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284

The tools listed will be needed to do the following

procedure:

MEL1563 or 7003031 - Remote Start Tool

MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit

Lift and block the loader. (See Procedure on Page 10-10-

1.)

Raise the operator cab. (See Installing on Page 10-20-1.)

Open the rear door of the loader.

Connect the remote start tool. (See REMOTE START

TOOL KIT-MEL1563 on Page 10-60-1.) or (See
REMOTE START TOOL (SERVICE TOOL) KIT -
7003031 on Page 10-61-1.)

217 of 822 20-61-5 T870 Service Manual

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Warm the fluid to 60°C (140°F) by turning the restrictor
control on the tester to about 6,9 MPa (68,9 bar) (1000
Direct Pump Test (High Flow Section) (Cont'd) psi).

Figure 20-61-7 NOTE: DO NOT EXCEED 25,5 MPa (255,1 bar) (3700
psi).

1 Open the restrictor control and record the free flow (L/min
[U.S. gpm]) at full rpm. Increase the restriction and the
flow should drop to 0 L/min (0 U.S. gpm) between 24,1
MPa (241,3 bar) (3500 psi) and 25,5 MPa (255,1 bar)
(3700 psi).

If pressure readings are not obtained go to the High Flow

2 Valve, relief valve adjustment procedure.(See High Flow
Relief Valve Removal And Installation on Page 20-61-8.)

Record the highest pressure (psi) and flow (L/min [U.S.

gpm]). The high pressure flow must be at least 80% of
P100413 free flow.
HIGH PRESSURE FLOW (L/min [U.S. gpm])
%= X 100
FREE FLOW (L/min [U.S. gpm])
Disconnect the high flow pump OUTLET hose (Item 1)
from the high flow check valve INLET fitting (Item 2)

Dealer Copy -- Not for Resale

[Figure 20-61-7]. A low percentage may indicate a failed pump.

Figure 20-61-8 *Refer to Hydraulic Schematics Legend for system relief

pressure and full rpm.

1
2

P-90177

Connect the INLET hose (Item 1) [Figure 20-61-8] from

the tester, to the high flow pump OUTLET hose (Item 1)
[Figure 20-61-7]. Connect the OUTLET hose (Item 2)
[Figure 20-61-8] from the tester, to the high flow check
valve INLET fitting (Item 2) [Figure 20-61-7].

Lower the cab.

Start the engine and run at low idle rpm. Press the front
auxiliary button. Press the High Flow button. Push the
button (on the right control lever) for fluid flow to the quick
coupler. Make sure the tester is connected correctly. If no
flow is indicated on the tester, the hoses are connected
wrong. With the hoses connected correctly, increase the
engine speed to full rpm*.

218 of 822 20-61-6 T870 Service Manual

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-10

High Flow Relief Valve Adjustment

If the pump is unable to reach 24,1 MPa (241,3 bar)

(3500 psi) stop the engine. The relief screw (Item 1)
P-45443
[Figure 20-61-11] will need to be turned clockwise a 1/4
turn and retested with the procedure above. (A 90° turn
equals approximately 1,38 MPa (13,8 bar) (200 psi).
1
NOTE: If the relief screw has been turned 90° and the 2
pressure remains the same, go to the high
flow relief valve removal and installation
section. (See High Flow Relief Valve Removal
And Installation on Page 20-61-8.) If relief
valve has been checked and is OK, go to the P-64022
high flow pump disassembly and assembly
section. (See Disassembly And Assembly on
Page 20-61-14.) Locate the high flow relief valve (Item 1) [Figure 20-61-
10] along the right side of the engine.
Remove the track from the right side of the loader. (See
Track Removal And Installation on Page 40-20-4.) Remove the plug (Item 2) [Figure 20-61-10] located on
the bottom of the high flow relief valve.
Figure 20-61-9

Dealer Copy -- Not for Resale

Figure 20-61-11

1 1

1
1

P-90352 1
P-45445

Remove the mounting bolts (Item 1) [Figure 20-61-9]

from the access cover and remove the cover from the NOTE: [Figure 20-61-11] shows adjusting the relief
loader. screw on a wheeled machine for photo clarity.

If the pump reaches 25,5 kPa (255,1 bar) (3700 psi) and
there is flow stop the engine. The relief screw must be
turned counterclockwise 1/4 turn and retested with the
procedure above.

219 of 822 20-61-7 T870 Service Manual

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-13

High Flow Relief Valve Removal And Installation

WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to 1
fall or move and cause injury or death.
W-2017-0286

Remove the track from the right side of the loader. (See P-64022
Track Removal And Installation on Page 40-20-4.)

Figure 20-61-12 Locate the high flow relief valve through rear door along
the right side of the engine.

Remove the relief valve (Item 1) [Figure 20-61-13] from

the pump.

Dealer Copy -- Not for Resale

Installation: Tighten the relief valve to 41 - 47 N•m (30 -
1 35 ft-lb) torque.
1
Figure 20-61-14
1
1
1 1

P-90352

3
Remove the mounting bolts (Item 1) [Figure 20-61-12]
from the access cover and remove the cover from the 2
loader.

P-45459

Inspect the relief valve and replace the two O-rings (Item
1) and washer (Item 2) [Figure 20-61-14].

If the relief valve is bad, it must be replaced as a

complete unit.

Remove the plug (Item 3) and inspect the O-ring [Figure

20-61-14] damage and replace as needed.

220 of 822 20-61-8 T870 Service Manual

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-17

Solenoid Removal And Installation 2

Figure 20-61-15

P-45461

NOTE: Mark the pump housing (Item 1) [Figure 20-61-

P-43958 17] for proper installation of the solenoid
valve cartridge.

At the right side access hole, disconnect the electrical Remove the valve cartridge (Item 2) [Figure 20-61-17].
connector (Item 1) [Figure 20-61-15] from the high flow

Dealer Copy -- Not for Resale

pump solenoid. Installation: Tighten the solenoid valve to 47 - 54 N•m
(35 - 40 ft-lb).
Figure 20-61-16
Figure 20-61-18

P-45460
P-45462

Remove the solenoid nut (Item 1) [Figure 20-61-16].

Inspect the O-ring (Item 1) [Figure 20-61-18] and
Remove the solenoid (Item 2) [Figure 20-61-16]. replace as needed.

Installation: Tighten the solenoid nut to 5 - 8 N•m (48 - Inspect the O-ring and back-up washer (Item 2) [Figure
72 in-lb) 20-61-18] and replace as needed.

221 of 822 20-61-9 T870 Service Manual

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10-
Removal And Installation 120-2.)

Open the rear door of the loader.

WARNING Figure 20-61-19

Never work on a machine with the lift arms up unless 1

the lift arms are secured by an approved lift arm
1
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598

DANGER 1
1
P-90184

Dealer Copy -- Not for Resale

Disconnect and cap the inlet hoses (Item 1) [Figure 20-
61-19] from the front of the hydraulic pump.

Figure 20-61-20
P-90328

AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
1

IMPORTANT P-90185

When repairing hydrostatic and hydraulic systems,

Disconnect and cap the hoses (Item 1) [Figure 20-61-20]
clean the work area before disassembly and keep all
from the back of the hydraulic pump.
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
Remove the Power Bob-Tach block if equipped. (See
damage the system.
I-2003-0888
Removal And Installation on Page 20-120-1.)

Lift and block the rear of the loader. (See Procedure on

Page 10-10-1.)

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)

Raise the operator cab. (See Raising on Page 10-30-1.)

222 of 822 20-61-10 T870 Service Manual

HYDRAULIC PUMP (HIGH FLOW) (CONT'D)

Removal And Installation (Cont’d)

Figure 20-61-21

1
2

3
P-90509A

Disconnect and cap the outlet hoses (Item 1) [Figure 20-

61-19] from the hydraulic pump.

Dealer Copy -- Not for Resale

Remove the two mounting bolts (Item 2) [Figure 20-61-
19] from the hydraulic pump.

Installation: Tighten the mounting bolts to 75 - 85 N•m

(55 - 60 ft-lb) torque.

Remove the hydraulic pump (Item 3) [Figure 20-61-19]

from the loader.

Figure 20-61-22

P-43940 P-43938A

Replace the O-ring (Item 1) [Figure 20-61-22] on the

hydraulic pump.

Reverse the removal procedure to install the hydraulic

pump.

223 of 822 20-61-11 T870 Service Manual

Hydraulic Pump Startup Avoid running over the relief valve setting at the end
of cylinder stroke.
NOTE: This procedure is necessary to prevent a dry
startup of the hydraulic pump. With the loader parked on a level surface and lift arms
down, check and fill the hydraulic reservoir as required.
Fill the system with hydraulic fluid. (See Removing And Check for hydraulic leaks.
Replacing Hydraulic Fluid on Page 10-120-2.)

Figure 20-61-23

P100685

Dealer Copy -- Not for Resale

Figure 20-61-24

P100352

Attach a push button starter switch (MEL1712) (Item 1)

[Figure 20-61-23] to the starter terminal S (Item 1) and
the positive battery cable (Item 2) [Figure 20-61-24].

Crank the engine for 15 seconds, then stop for at least 30

seconds. Again, crank the engine for 15 seconds.
Remove the starter bypass tool.

Start the loader from the operators cab and run the
engine at low idle for 1 - 2 minutes without operating the
hydraulics.

After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
arms several times or until air is purged from the system.

224 of 822 20-61-12 T870 Service Manual

Parts Identification

Figure 20-61-25

21

1. Stem
22
2. Valve
5 3. Wear Plate
4 4. Seal Section
3
6 5. Rear Housing
6. Bolt
7. Pre-load Seal
8. Load Seal
22 9. Spline Connector
24 10. Pin
11. Gear Set
1 12. Gear Housing
10 13. Gear Housing
2
14. Gear Set
3
11 15. Gear Housing
9

Dealer Copy -- Not for Resale

8 16. Gear Set
23 7
4 17. Center Housing
10
17 12 18. Center Housing
19. Front Housing
4 20. Shaft Seal
3
21. High Flow Relief
22. Seal
10 23. Nut
3 24. Coil
9 14
8
7
4
10 13
18
4
3

10

4
8
7
4 15
16
19
20
10

MS1456S

225 of 822 20-61-13 T870 Service Manual

HYDRAULIC PUMP (HIGH FLOW) (CONT'D)

Disassembly And Assembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Mark the pump sections for correct assembly.

To disassemble and assemble the hydraulic pump, follow

the Parts Identification page (See Parts Identification on
Page 20-61-13.) for proper placement of components
along with the information below.

NOTE: A seal kit is available through Bobcat Service

Dealer Copy -- Not for Resale

Parts.

Assembly: Tighten the eight pump housing bolts (Item 6)

[Figure 20-61-25] to 50 N•m (37 ft-lb) torque.

NOTE: Position the wear plate (Item 3) [Figure 20-61-

19] inlets and traps as shown with the bronze
side toward the gears on all wear plates.

NOTE: Inspect all gears, shafts and pump end

sections. If any of these components have
excessive wear or damage is visible, the
complete pump must be replaced.

NOTE: The relief valve and the solenoid can be

replaced along with the O-rings and back-up
washers.

226 of 822 20-61-14 T870 Service Manual

HYDRAULIC / HYDROSTATIC FILTERS Figure 20-70-1

Description

The hydraulic / hydrostatic filters help to remove 2

2
contaminants from the fluid when the hydraulic /
hydrostatic systems are operating.

The hydraulic / hydrostatic filter system consists of one

main filter and one charge flow filter.

The main filter removes contaminants before entering

1
gear pumps including oil returning from the main valve.

The charge flow filter removes contaminants after the

charge pump. P100205

Housing Removal And Installation

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
DANGER Raise the operator cab. (See Raising on Page 10-30-1.)

Drain the fluid from the reservoir. (See Removing And

Dealer Copy -- Not for Resale

Replacing Hydraulic Fluid on Page 10-120-2.)

Disconnect the electrical connector (Item 1) [Figure 20-

70-1] from the hydraulic / hydrostatic filter sender.

Remove and plug the three hoses (Item 2) [Figure 20-

P-90328 70-1] from the hydraulic / hydrostatic filter housing.
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409

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

227 of 822 20-70-1 T870 Service Manual

HYDRAULIC / HYDROSTATIC FILTERS (CONT’D)

Housing Removal And Installation (Cont’d)

Figure 20-70-2

P-90011

Remove and plug the two hoses (Item 1) [Figure 20-70-

2] from the bottom of the hydraulic / hydrostatic filter

Dealer Copy -- Not for Resale

housing.

Figure 20-70-3

P100247A

Remove the two bolts (Item 1) [Figure 20-70-3].

Remove the hydraulic / hydrostatic filter housing from the

loader.

228 of 822 20-70-2 T870 Service Manual

HYDRAULIC FLUID RESERVOIR Figure 20-80-2

Description

The hydraulic fluid reservoir is a storage container for the

loader’s hydraulic / hydrostatic fluid. The reservoir
contains a vented fill cap with a fluid screen to prevent
contaminants from entering the reservoir while adding
fluid. 1
The hydraulic fluid reservoir is located behind the
operator’s cab under the rear grille on the right side of the
loader.

Removal And Installation

P-90579
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Remove the two bolts (Item 1) [Figure 20-80-2].
Raise the operator cab. (See Raising on Page 10-30-1.)
Remove the hydraulic fluid reservoir from the loader.
Drain the fluid from the reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) Installation: Tighten the mount bolts and nuts to 21,7 -
24,4 N•m (16 - 18 ft-lb) torque.

Dealer Copy -- Not for Resale

Remove the Hydraulic / Hydrostatic Filter Housing (See
Housing Removal And Installation on Page 20-70-1.)

Remove the rear grille (See Removing on Page 50-60-1.)

Figure 20-80-1

P-90013

Remove the clamp and the hose (Item 1) [Figure 20-80-

1].

229 of 822 20-80-1 T870 Service Manual

HYDRAULIC FLUID RESERVOIR (CONT'D)

Hydraulic Fluid Screen

Remove the rear grille (See Removing on Page 50-60-1.)

Figure 20-80-3

P-90506

Dealer Copy -- Not for Resale

Remove the hydraulic fluid reservoir breather cap
[Figure 20-80-3] from the reservoir.

Remove the hydraulic fluid screen (Item 1) [Figure 20-

80-3] from the reservoir.

Wash the screen in clean solvent and air dry, before

replacing.

230 of 822 20-80-2 T870 Service Manual

OIL COOLER Figure 20-90-2

Description

The oil cooler is used to cool the loaders hydraulic and 1

hydrostatic oil. Oil passages are coiled into a heat
exchanger. Air is forced, with the cooling fan, around the
passages cooling the oil.

The oil cooler is located underneath the rear grille

between the A/C condenser (if so equipped) and the 2
radiator.

Removal And Installation

P100252

IMPORTANT Remove hose clamp (Item 1) and hose (Item 2) [Figure

20-90-2].
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all Cap or plug all hoses and fittings.
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly Figure 20-90-3

Dealer Copy -- Not for Resale

damage the system.
I-2003-0888 4 4
2
Remove the rear grille from the loader. (See Removing 5
on Page 50-60-1.)
3
Figure 20-90-1
2

1
1
P100181

Undo the rubber straps (Item 1) [Figure 20-90-3]

Remove the bolts (Item 2) and remove the condenser

guards (Item 3) [Figure 20-90-3].
P100251
Remove the clips and pins (Item 4) [Figure 20-90-3].

Remove hose (Item 1) [Figure 20-90-1]. Remove the bolt (Item 5) [Figure 20-90-3] from the prop
rod.
Cap or plug all hoses and fittings.
Lift up the oil cooler and remove the cooler from the
loader.

231 of 822 20-90-1 T870 Service Manual

 Dealer Copy -- Not for Resale

232 of 822 20-90-2 T870 Service Manual

BUCKET POSITION VALVE Remove the two bolts (Item 1), and remove the fuel inlet
assembly (Item 2) [Figure 20-100-1].
Description
Cover the fuel tank inlet.
The Bucket Position Valve is an option that allows the
operator to hold the attachment at the same angle from Figure 20-100-2
the ground to maximum lift height without using the tilt
function.

The bucket position valve is mounted to the inside lower 3

right rear side of the loader frame.

See Hydraulic Schematic for more circuit information.

2
Solenoid Removal And Installation

DANGER
1 P-90197

Disconnect the wire harness connector (Item 1) [Figure

20-100-2] from the bucket position shut-off solenoid.

Dealer Copy -- Not for Resale

Disconnect the cap the two tubelines (Item 2) [Figure 20-
100-2].

P-90328 Remove the solenoid nut, coil, and stem (Item 3) from the
bucket positioning valve [Figure 20-100-2].
AVOID DEATH
• Disconnecting or loosening any hydraulic Installation: Put oil on O-rings and back-up washers and
tubeline, hose, fitting, component or a part failure tighten the solenoid stem to 40,7 - 50,2 N•m (30 - 40 ft-lb)
can cause lift arms to drop. torque.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm Installation: Tighten the solenoid nut to 8 N•m (6 ft-lb)
support. Replace if damaged. torque. Overtightening may cause valve failure.
D-1009-0409
NOTE: The engine is shown removed for photo
clarity.
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) Figure 20-100-3

Figure 20-100-1

1
1
2

N-18191

Inspect the solenoid stem and replace the O-rings (Item

P100253
1) and the back-up washer (Item 2) [Figure 20-100-3].

233 of 822 20-100-1 T870 Service Manual

BUCKET POSITION VALVE (CONT'D) Figure 20-100-5

Solenoid Testing

Refer to Bobcat Advanced Troubleshooting System

(B.A.T.S.) for electrical testing and troubleshooting
information. It is recommended that these procedures be
performed by authorized Bobcat Service Personnel only.

Removal And Installation

DANGER
1 P-90197

NOTE: The engine is shown removed for photo

clarity.

NOTE: Mark all hoses and tubelines for correct

installation.
P-90328

Dealer Copy -- Not for Resale

Disconnect the electric solenoid connector (Item 1)
AVOID DEATH [Figure 20-100-5].
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure Figure 20-100-6
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409 1

Drain the hydraulic reservoir. (See Removing And

Replacing Hydraulic Fluid on Page 10-120-2.)

Figure 20-100-4
2

1 4 3

P-90188

Disconnect and cap the tilt base inlet hose (Item 1), the
2 tilt rod inlet hose (Item 2), the lift rod inlet hose (Item 3),
and the lift base inlet hose (Item 4) [Figure 20-100-6]
that route from the control valve.

P100253

Remove the two bolts (Item 1), and remove the fuel inlet
assembly (Item 2) [Figure 20-100-4].

Cover the fuel tank inlet.

234 of 822 20-100-2 T870 Service Manual

BUCKET POSITION VALVE (CONT'D) Figure 20-100-9

Removal And Installation (Cont'd)

Figure 20-100-7

P-90190A

2
1
Remove the mounting screws (Item 1) [Figure 20-100-
P-90189A 9].

Remove the bucket position valve from the loader.

Disconnect and cap the tilt cylinder hose (Item 1) and the
tilt cylinder base end hose (Item 2) [Figure 20-100-7]

Dealer Copy -- Not for Resale

from the valve block.

Figure 20-100-8

2
2

1
P-90197A

Disconnect and cap the lift base outlet hose and tubeline
(Item 1) and the lift rod outlet hose and tubeline (Item 2)
[Figure 20-100-8] that route from the lift cylinders.

235 of 822 20-100-3 T870 Service Manual

BUCKET POSITION VALVE (CONT'D) Figure 20-100-12

Disassembly And Assembly

Figure 20-100-10
3
1

2
1 3
2

P-90194

Remove the tilt cylinder check valve (Item 1), spring (Item
P-90192 2), and plug (Item 3) [Figure 20-100-12]. Inspect for
wear, inspect the O-ring and replace as needed.

Remove the solenoid nut (Item 1), coil (Item 2), and the Assembly: Tighten the plug to 75,9 - 86,8 N•m (56 - 64
stem (Item 3) [Figure 20-100-10]. ft-lb) torque.

Dealer Copy -- Not for Resale

Assembly: Tighten the nut to a maximum of 8 N•m (6 ft- Figure 20-100-13
lb) torque. Overtightening may cause valve failure.

Assembly: Put oil on O-rings and back-up washers and

tighten the solenoid stem to 40,7 - 50,2 N•m (30 - 40 ft-lb)
1
torque. 2 3

Figure 20-100-11

P-90193

Remove the plug (Item 1), spring (Item 2) and unloading

spool (Item 3) [Figure 20-100-13].

Inspect all parts and replace as needed. Install a new O-

P-90195 ring on the plug before installing.

Assembly: Tighten the plug to torque.

Remove the flow adjustment valve and O-ring (Item 1)
[Figure 20-100-11].

Assembly: Tighten the flow adjustment valve to 36,6 -

48,8 N•m (27 - 36 ft-lb) torque.

NOTE: Always install new O-rings before any parts

are installed into the valve. Inspect the parts
for wear or damage and replace as needed.

236 of 822 20-100-4 T870 Service Manual

REAR AUXILIARY DIVERTER VALVE

Description

The rear auxiliary diverter valve is an optional valve that

diverts oil from the main valve inlet to two sets of rear
auxiliary couplers. The couplers are used for rear
mounted attachments.The right side auxiliaries are used
for older attachments.

The rear couplers are located, one set on each side of

the rear frame uprights.

See Hydraulic Schematic for more circuit information.

Solenoid Testing

Figure 20-110-1

Dealer Copy -- Not for Resale

P9137

Use a test meter to measure coil resistance [Figure 20-

110-1]. Coil wires do not have polarity. Correct resistance
is 8.6 - 9.5 ohm.

Replace the test meter with 12 volt power. You can see
and hear the spool shift.

237 of 822 20-110-1 T870 Service Manual

REAR AUXILIARY DIVERTER VALVE (CONT'D) Figure 20-110-3

Removal And Installation

1
DANGER 1

P-93303
P-90328

AVOID DEATH Disconnect and cap the tubelines (Item 1) [Figure 20-
• Disconnecting or loosening any hydraulic 110-3]
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. Figure 20-110-4
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.

Dealer Copy -- Not for Resale

D-1009-0409

1
Put jackstands under the rear corners of the loader.

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)

Raise the operator cab. (See Raising on Page 10-30-1.)

Drain the hydraulic reservoir. (See Removing And

Replacing Hydraulic Fluid on Page 10-120-2.)
P-93312

Figure 20-110-2
Disconnect the accessory wiring harness (Item 1)
[Figure 20-110-4] from the main harness.

P-90583

Disconnect and cap the tubelines (Item 1) [Figure 20-

110-2]

238 of 822 20-110-2 T870 Service Manual

REAR AUXILIARY DIVERTER VALVE (CONT'D) Disassembly And Assembly

Removal And Installation (Cont’d) Figure 20-110-6

Figure 20-110-5

1
1

P-48751

P-90581
Figure 20-110-7

Remove the two bolts (Item 1) and remove the valve

(Item 2) [Figure 20-110-5]

Dealer Copy -- Not for Resale

1

P-48752

Clean the diverter valve to remove dirt before

disassembly. Valve ports are labeled for correct
assembly.

Several plugs (Item 1) [Figure 20-110-6] and [Figure 20-

110-7] are located all over the diverter valve and can be
removed for clean out purposes.

Assembly: Put oil on O-rings and back-up

washers.Tighten to 13,6 N•m (10 ft-lb) torque.

239 of 822 20-110-3 T870 Service Manual

REAR AUXILIARY DIVERTER VALVE (CONT'D) Figure 20-110-10

Disassembly And Assembly (Cont'd)

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888

P-48755
Figure 20-110-8

Figure 20-110-11

1
2
2

Dealer Copy -- Not for Resale

1

P-48755

P-48757
Figure 20-110-9

Remove the differential sensing valve (Item 1) [Figure

20-110-10] and [Figure 20-110-11] from diverter valve
and inspect the O-rings and back-up washers (Item 2)
[Figure 20-110-11] for damage.
2
2 2
Assembly: Put oil on O-ring and back-up washers.
1 Tighten to 68 - 75 N•m (50 - 55 ft-lb) torque.

P-48756

Remove the shuttle valve (Item 1) [Figure 20-110-8] and

[Figure 20-110-9] from diverter valve and inspect the O-
rings and back-up washers (Item 2) [Figure 20-110-9] for
damage.

Assembly: Put oil on the O-rings and back-up washers.

Tighten to 14 - 16 N•m (10 - 12 ft-lb) torque.

240 of 822 20-110-4 T870 Service Manual

REAR AUXILIARY DIVERTER VALVE (CONT'D) Figure 20-110-14

Disassembly And Assembly (Cont'd)

Figure 20-110-12

P-48759
1

Figure 20-110-15
P-48753

Figure 20-110-13

Dealer Copy -- Not for Resale

1
3

1
2 2
P-48760

NOTE: Before removing the solenoid coils mark the

P-48754 coils for proper alignment.

Remove the nut (Item 1) [Figure 20-110-14] and [Figure

Remove the relief valve (Item 1) [Figure 20-110-12] and 20-110-15] from the solenoid valve stem.
[Figure 20-110-13] from the diverter valve and inspect
the O-rings and back-up washers (Item 2) [Figure 20- Assembly: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)
110-13] for damage. torque.

Assembly: Put oil on O-ring and back-up washers. Remove the spacer (Item 2) and solenoid valve coils
Tighten to 27 - 34 N•m (20 - 25 ft-lb) torque. (Item 3) [Figure 20-110-15].

241 of 822 20-110-5 T870 Service Manual

REAR AUXILIARY DIVERTER VALVE (CONT'D) Figure 20-110-17

Disassembly And Assembly (Cont'd)

Figure 20-110-16

1
1

P-48762

Figure 20-110-18
P-48761

NOTE: Before removing the solenoid coils mark the

coils for proper alignment.

Dealer Copy -- Not for Resale

Remove the nuts (Item 1) [Figure 20-110-16] from the
solenoid valve stems.

Assembly: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)

2 2
torque. 1 1

P-48763

Remove the solenoid valve stem (Item 1) [Figure 20-

110-17] and [Figure 20-110-18] and inspect the O-rings
and back-up washers (Item 2) [Figure 20-110-18] for
damage.

Assembly: Put oil on O-rings and back-up washers.

Tighten to 27 - 34 N•m (20 - 25 ft-lb) torque.

242 of 822 20-110-6 T870 Service Manual

REAR AUXILIARY DIVERTER VALVE (CONT'D) Figure 20-110-21

Disassembly And Assembly (Cont'd)

Figure 20-110-19

P-48765

Remove the plug (Item 1) [Figure 20-110-21].

P-48763A
Assembly: Tighten the plug to 51,5 N•m (38 ft-lb) torque.

Figure 20-110-20 Figure 20-110-22

Dealer Copy -- Not for Resale

1 2

1
P-48764 P-48766

Remove the solenoid valve stem (Item 1) [Figure 20- Remove and inspect the orifice (Item 1) [Figure 20-110-
110-19] and [Figure 20-110-20] and inspect the O-rings 22] for dirt and debris.
and back-up washers (Item 2) [Figure 20-110-20] for
damage. Assembly: Tighten the orifice to 29,8 N•m (22 ft-lb)
torque.
Assembly: Put oil on O-rings and back-up washers.
Tighten to 41 - 47 N•m (30 - 35 ft-lb) torque.

243 of 822 20-110-7 T870 Service Manual

REAR AUXILIARY DIVERTER VALVE (CONT'D) Figure 20-110-25

Disassembly And Assembly (Cont'd)

Figure 20-110-23

1
1

P-48758

Remove the plugs (Item 1) [Figure 20-110-25].

P-48765
Assembly: Tighten the plug to 19 N•m (14 ft-lb) torque.

Remove the plug (Item 1) [Figure 20-110-23]. Inspect cartridges, check valves, solenoid valves and
sealing washers for contamination or damage. Wash all

Dealer Copy -- Not for Resale

Assembly: Tighten the plug to 13,6 N•m (10 ft-lb) torque. parts in clean solvent. Use air pressure for drying them.
Install new O-rings and back-up washers.
Figure 20-110-24
Inspect diverter valve cavities for contamination. Wash
valve in clean solvent. Use air pressure to dry.

P-48786

Remove the orifice (Item 1) [Figure 20-110-24].

Assembly: Tighten the orifice to 4,5 N•m (3.3 ft-lb)

torque.

244 of 822 20-110-8 T870 Service Manual

BOB-TACH (POWER) BLOCK Removal And Installation

Description

The power Bob-Tach is an option that allows the operator

to hydraulically control the Bob-Tach levers for mounting
WARNING
and dismounting the attachments.
Never work on a machine with the lift arms up unless
The power Bob-Tach is operated by a switch on the right the lift arms are secured by an approved lift arm
switch panel. support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
The power Bob-Tach block is mounted on the right side to fall and cause injury or death.
of the machine in front of the engine on the back side of W-2059-0598
the hydraulic pump.

DANGER

Dealer Copy -- Not for Resale

P-90328

AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

245 of 822 20-120-1 T870 Service Manual

BOB-TACH (POWER) BLOCK (CONT'D) Figure 20-120-2

Removal And Installation (Cont'd)

1
Figure 20-120-1
2
2

2
1
P-90007

Disconnect and cap the outlet hose (Item 1) [Figure 20-

P-26244 120-2] from block.

Mark the hydraulic hoses for proper installation.

Lift and block the loader. (See Procedure on Page 10-10-
1.) Disconnect and cap the hoses (Item 2) [Figure 20-120-2]

Dealer Copy -- Not for Resale

from block.
Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.) Figure 20-120-3

Raise the operator cab. (See Raising on Page 10-30-1.)

1
Drain the hydraulic reservoir. (See Removing And 1
Replacing Hydraulic Fluid on Page 10-120-2.)

Disconnect the two electrical solenoid connectors (Item

1) [Figure 20-120-1] from the loader electrical harness. 1

P-90009

Remove the four mounting bolts (Item 1) [Figure 20-120-

3].

Installation: Tighten the mounting bolts to 48 - 54 N•m

(35 - 40 ft-lb) torque.

Remove the power Bob-Tach block.

246 of 822 20-120-2 T870 Service Manual

BOB-TACH (POWER) BLOCK (CONT'D) Figure 20-120-5

Disassembly And Assembly

Figure 20-120-4

1 3

2
2
1
P-48120

Remove the spring guide (Item 1), spring (Item 2) and the
P-48115 spool (Item 3) [Figure 20-120-5].

Inspect the O-ring (Item 4) [Figure 20-120-5] on the plug

Clean the block (Item 1) [Figure 20-120-4] to remove dirt and replace as needed.
before disassembly. Block ports are labeled for correct

Dealer Copy -- Not for Resale

assembly. Figure 20-120-6

Remove the plug (Item 2) [Figure 20-120-4].

Installation: Tighten the plug to 34 - 40,6 N•m (25 - 30 ft-

lb) torque.

IMPORTANT 1

When repairing hydrostatic and hydraulic systems,

clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
P-48116
damage the system.
I-2003-0888
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage may occur and
the plug and O-ring must be replaced.

Do not remove the plug (Item 1) [Figure 20-120-6].

Installation: Tighten the plug to 16,3 - 19 N•m (12 - 14 ft-

lb) torque.

247 of 822 20-120-3 T870 Service Manual

BOB-TACH (POWER) BLOCK (CONT'D) Figure 20-120-9

Disassembly And Assembly (Cont'd)

Figure 20-120-7

1
1
P-48122

Do not remove the plugs (Item 1) [Figure 20-120-9].

P-48382
NOTE: Do not remove plugs. If the plugs are removed
the internal pressure relieving spring setting
Remove the check valve (Item 1) [Figure 20-120-7]. will be altered.

Dealer Copy -- Not for Resale

Installation: Oil the check valve and O-rings and tighten Figure 20-120-10
the check valve to 27,1 - 34 N•m (20 - 25 ft-lb) torque.

Figure 20-120-8

1
2
1

P-48384
3

P-48119 Remove the plug (Item 1) [Figure 20-120-10], inspect

the O-ring and replace as needed.

Inspect the check valve (Item 1) and piston assembly Installation: Tighten the plug (Item 1) [Figure 20-120-
(Item 2) [Figure 20-120-8]. 10] to 16,3 - 19 N•m (12 - 14 ft-lb) torque.

Inspect the O-rings and back-up washers (Item 3)

[Figure 20-120-8] on the check valve and piston
assembly and replace as needed.

248 of 822 20-120-4 T870 Service Manual

BOB-TACH (POWER) BLOCK (CONT'D) Figure 20-120-13

Disassembly And Assembly (Cont'd)

Figure 20-120-11 2

2
1
P-48106A

Remove the first solenoid coil (Item 1) and the second

P-48664 solenoid coil (Item 2) [Figure 20-120-13].

NOTE: Remember the solenoid coil orientation for

Remove the orifice screw (Item 2) located behind the ease of installation.
plug (Item 1) [Figure 20-120-11].

Dealer Copy -- Not for Resale

Figure 20-120-14
Installation: Tighten the orifice screw (Item 2) [Figure
20-120-11] to 8,1 - 10,8 N•m (6 - 8 ft-lb) torque.

Figure 20-120-12

1
1
2
P-48386

Remove the solenoid stem (Item 1) [Figure 20-120-14].

P-48127
Installation: Tighten the solenoid stem to 27,1 - 34 N•m
(20 - 25 ft-lb) torque.
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage may occur and
the plug and O-ring must be replaced.

Do not remove the plug (Item 1) [Figure 20-120-12].

Remove the solenoid nut (Item 2) [Figure 20-120-12].

Installation: Tighten the solenoid valve stem nut to 1,7 -

5,1 N•m (15 - 45 in-lb) torque.

249 of 822 20-120-5 T870 Service Manual

BOB-TACH (POWER) BLOCK (CONT'D) Figure 20-120-17

Disassembly And Assembly (Cont'd)

Figure 20-120-15
1

P-48174
1

Remove the screened orifice plug (Item 1) [Figure 20-

P-48175 120-17].

Installation: Tighten the screened orifice plug to 14,9 -

Remove the armature assembly (Item 1) [Figure 20-120- 16,3 N•m (11 - 12 ft-lb) torque.
15].

Dealer Copy -- Not for Resale

Figure 20-120-18
Figure 20-120-16

2 2

1 1

P-48138
P-48173

Inspect the screened orifice plug (Item 1) [Figure 20-

Inspect the solenoid stem (Item 1), armature assembly 120-18] for damage replace as needed. If the screened
(Item 2) and the spool (Item 3) for damage [Figure 20- orifice plug is blocked replace with a new plug.
120-16].
Inspect the O-ring (Item 2) [Figure 20-120-18] and
NOTE: If the solenoid stem is damaged (Item 1) replace as needed.
inspect the armature assembly (Item 2) for
damage.

The armature assembly (Item 2) and spool

(Item 3) are non-serviceable parts. If they are
damaged, order a new power Bob-Tach block
assembly from Bobcat parts [Figure 20-120-
16].

250 of 822 20-120-6 T870 Service Manual

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly

Description Figure 20-130-2

The front auxiliary hydraulic coupler block is the 1

connection block that houses the two main auxiliary
couplers along with a case drain coupler. These couplers
are for suppling hydraulic flow for various attachments.
2
The front auxiliary coupler block is located at the front of
the left side lift arm.

Removal And Installation 3

IMPORTANT P-90002

When repairing hydrostatic and hydraulic systems,

clean the work area before disassembly and keep all Figure 20-130-3
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. 3

Dealer Copy -- Not for Resale

I-2003-0888

Figure 20-130-1 2

P-90003

P-85281

Remove the two mounting bolts (Item 1) [Figure 20-130-

1].

Pull the block away from the lift arms and disconnect the
auxiliary hoses from the coupler block [Figure 20-130-1].

251 of 822 20-130-1 T870 Service Manual

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-130-5
(CONT’D)

Disassembly And Assembly (Cont’d)

1
Figure 20-130-4

4
4 1
4

4 2
2

P-34665
3

Inspect the O-rings (Item 1) back-up O-rings (Item 2) for

damage and replace as needed [Figure 20-130-5].
P-90001
Figure 20-130-6
Remove the male coupler, spring, and fitting (Item 1)
[Figure 20-130-2], [Figure 20-130-3] and [Figure 20-

Dealer Copy -- Not for Resale

1
130-4]

Assembly: Tighten the male coupler (Item 1) [Figure 20-

130-3] and [Figure 20-130-4] to 80 N•m (59 ft-lb)

Remove the drain coupler, spring, and fitting (Item 2)

[Figure 20-130-2], [Figure 20-130-3] and [Figure 20-
130-4].

Assembly: Tighten the drain coupler (Item 2) [Figure 2

20-130-3] and [Figure 20-130-4] to 50 N•m (37 ft-lb)
P-34664
Remove the female coupler, spring, and fitting (Item 3)
[Figure 20-130-2], [Figure 20-130-3] and [Figure 20-
130-4]. Inspect the O-rings (Item 1) back-up O-rings (Item 2) for
damage and replace as needed [Figure 20-130-6].
Assembly: Tighten the female coupler (Item 3) [Figure
20-130-3] and [Figure 20-130-4] to 80 N•m (59 ft-lb)

Inspect the O-rings (Item 4) [Figure 20-130-4] and

replace as needed.

252 of 822 20-130-2 T870 Service Manual

 HYDROSTATIC SYSTEM

HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2

HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-6

HYDROSTATIC DRIVE MOTOR (TWO SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-4
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-6

CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Dealer Copy -- Not for Resale

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-3
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-4

HYDROSTATIC PUMP (SJC AND SCPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Hydraulic Controller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-4
Hydrostatic Pump Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-6
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-7
High Pressure Relief And Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-8
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-9
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-10
Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-23
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-26

DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Tensioner Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-3
Tensioner Pulley Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-3

DRAIN MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Drain Manifold Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

253 of 822 30-01 T870 Service Manual

 Dealer Copy -- Not for Resale

254 of 822 30-02 T870 Service Manual

HYDROSTATIC SYSTEM INFORMATION

Description

The hydrostatic system consists of tandem hydrostatic

pump and two hydrostatic motors. The hydrostatic
system allows forward and reverse motion in the loader.

The hydrostatic pump is connected to the engine by a

drive belt and provides fluid to the hydrostatic motors.
The charge pressure system assists in replenishing the
fluid that is lost do to internal leakage in the components
of the hydrostatic system.

Dealer Copy -- Not for Resale

255 of 822 30-10-1 T870 Service Manual

HYDROSTATIC SYSTEM INFORMATION (CONT’D)

Troubleshooting
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are
Check for correct function after adjustments, repairs
most common. Many of the recommended procedures
or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel
adjustments can cause injury or death.
only. W-2004-1285

If a service code appears in the left instrument panel.

(See DIAGNOSTIC SERVICE CODES on Page 60-90-
1.)

PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4
The loader does not move in a straight line. 2, 3, 4, 5, 9
The hydrostatic system is overheating. 6,7,8

KEY TO CORRECT THE CAUSE

Dealer Copy -- Not for Resale

1. The hydrostatic pump replenishing valves not seating.
2. The steering linkage needs adjustment.
3. The hydrostatic pump has damage.
4. The hydrostatic motor has damage.
5. Track tension is to tight, on one side.
6. The hydrostatic fluid is not at the correct level.
7. The oil cooler has a restriction.
8. The loader is not being operated at the correct rpm.
9. The hydrostatic pump is to properly calibrated, and / or incorrect steering drift compensation setting.

256 of 822 30-10-2 T870 Service Manual

HYDROSTATIC DRIVE MOTOR Removing And Replacing Oil

Description For the correct service interval (See SERVICE

SCHEDULE on Page 10-70-1.)
The hydrostatic drive motors are driven by the hydrostatic
pump. Machines equipped with SJC / SCPA are Park the loader so that the plug in the hydrostatic drive
monitored by a sensor mounted onto the motor housing. motor is at the bottom.
The sensor is used for detection of motion and for rate of
speed for the SJC / SCPA options. Remove the plug and let the oil drain from the hydrostatic
drive motor.
The hydrostatic drive motors contain a spring applied
pressure release braking system. In addition there is a Figure 30-20-1
separate oil chamber in the motor that is filled with high
performance synthetic oil for maximum durability, this oil
has a recommended service interval. (See SERVICE
SCHEDULE on Page 10-70-1.)

There are two hydrostatic drive motors and they are

located on the track carriage.
1

Dealer Copy -- Not for Resale

P-90680B

Rotate the hydrostatic drive motor so that the plug (Item

1) [Figure 30-20-1] is at the top. Add high performance
synthetic oil (P/N 7003026). (See Capacities on Page
SPEC-10-4.)

Clean the threads of the plug and drain hole. Apply

Loctite® 243 to the plug threads. Install and tighten the
plug.

Repeat for the other hydrostatic drive motor.

Recycle or dispose of the used oil in an environmentally

safe manner.

257 of 822 30-20-1 T870 Service Manual

HYDROSTATIC MOTOR (CONT'D) Remove the track. (See Track Removal And Installation
on Page 40-20-4.)
Removal And Installation
Figure 30-20-2

IMPORTANT 1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, 1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Place the loader on jackstands. (See Procedure on Page

10-10-1.)
P100811

DANGER Remove the mounting bolts (Item 1) [Figure 30-20-2]

from the access cover and remove the cover from the
loader.

Dealer Copy -- Not for Resale

Remove the sprocket. (See Sprocket Removal And
Installation (Single Speed) on Page 40-20-13.)

Disconnect and remove the speed sensor. (See Removal

And Installation on Page 60-80-3.)

P-90328 NOTE: Speed sensor removal is recommended to

prevent damage while removing the
AVOID DEATH hydrostatic motor from the track carriage.
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409

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

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)

258 of 822 30-20-2 T870 Service Manual

HYDROSTATIC MOTOR (CONT'D) Figure 30-20-5

Removal And Installation (Cont'd)

Figure 30-20-3 1 1

1
P-85991

3 With an arm hoist support the hydrostatic motor.

P-85992 Remove the ten hydraulic motor mounting bolts (Item 1)

[Figure 30-20-5].
Remove the case drain hydraulic hose (Item 1) [Figure
30-20-3] from the motor. Installation: Tighten the motor mounting bolts to 257,6

Dealer Copy -- Not for Resale

N•m (190 ft-lb) torque.
Remove the hydraulic brake hose (Item 2) [Figure 30-
20-3] from the motor. Remove the hydrostatic motor from the loader.

Remove the eight flange bolts (Item 3) from the main

drive hoses. Remove the flanges and drive hoses (Item
4) [Figure 30-20-3].

Installation: Fill the main drive hose ports on the motor

with new hydraulic oil before installing the drive hoses.

Figure 30-20-4

2 3

4 1

P100901

Installation: Install both flanges and tighten the bolts to

half of the required torque in the sequence shown in
[Figure 30-20-4]. Retighten all bolts to required torque in
the same sequence.

259 of 822 30-20-3 T870 Service Manual

HYDROSTATIC MOTOR (CONT'D)

Parts Identification

10

9
8
7
6
5

4 25
3 24
2 12
23
22
21
11
10

Dealer Copy -- Not for Resale

1
20

14
13
17 15
16 63

18
16 54
15 53
46
52
51
19 38 50
49
48
40

27 3332 31
29 35 39 47 61
30 33
26
28
34
42
41
37
36
60
44
43 59
45 55
58
57

56
62
MS2290S

260 of 822 30-20-4 T870 Service Manual

HYDROSTATIC MOTOR (CONT'D)

Parts Identification (Cont’d)

Ref. Description Ref. Description

1. PLUG 33. SPRING
2. SHAFT 34. SPOOL
3. SEAL 35. WASHER
4. BEARING 36. O-RING
5. HOUSING / FRONT 37. PLUG
6. SEAL 38. DOWEL
7. BEARING 39. PIN
8. WASHER 40. O-RING
9. SPLIT RINGS 41. O-RING
10. O-RING 42. PLUG
11. NUT 43. GASKET / COVER
12. STUD 44. BOLT
13. RPM TARGET DISC 45. HOUSING / REAR
14. ROLL PIN 46. HOUSING / BRAKE
15. SNAP RING 47. SHAFT
16. RETAINER 48. SHIM

Dealer Copy -- Not for Resale

17. ROLLER 49. SHIM
18. PISTON 50. DISC / OUTER
19. BLOCK 51. DISC / INNER
20. CAM 52. SEAL
21. DISTRIBUTOR 53. WASHER
22. SPRING 54. BOLT
23. SEAL W / O-RING 55. BUSHING
24. SEAL W / O-RING 56. PISTON
25. SEAL W / O-RING 57. SEAL
26. PLUG 58. DISC SPRING
27. O-RING 59. GASKET
28. SPRING 60. COVER PLATE
29. SHIM 61. BOLT
30. POPPET 62. SNAP RING
31. PLUG 63. SNAP RING
32. O-RING

261 of 822 30-20-5 T870 Service Manual

HYDROSTATIC MOTOR (CONT'D) Figure 30-20-8

Disassembly And Assembly

Figure 30-20-6

1
1

N-18296

Remove the disc spring (Item 1) [Figure 30-20-8] from

P100796 the brake housing.

NOTE: Mark the top side of the disc spring for proper
NOTE: Mark the motor, brake and motor housings for installation.
proper alignment during assembly [Figure 30-

Dealer Copy -- Not for Resale

20-6]. Assembly: Put multi-purpose moly grease on the
surface of the disc spring where it contacts the piston.
Drain the oil from the motor casing.

Check for the vendor motor serial number (Item 1)

[Figure 30-20-6], these serial numbers may be needed
when ordering replacement parts.

Figure 30-20-7

P100799

Remove the mounting bolts (Item 1) and the brake cover

plate (Item 2) [Figure 30-20-7].

NOTE: Remove every other bolt, then uniformly

remove the last twelve bolts to maintain equal
preload on the brake cover plate.

Assembly: Replace the gasket and torque bolts to 35 -

39 N•m (26 - 29 ft-lb).

262 of 822 30-20-6 T870 Service Manual

HYDROSTATIC MOTOR (CONT'D) Figure 30-20-11

Disassembly And Assembly (Cont'd)

Figure 30-20-9

1
2

P100798

1
Check the piston surface (Item 1) and the bushing
P100804 surface (Item 2) [Figure 30-20-11] in the brake shaft.

NOTE: The bushing (Item 2) [Figure 30-20-11] can be

Remove the piston from the brake housing [Figure 30- replaced in the brake shaft. When the bushing
20-9]. is replaced, install the bushing flush with the

Dealer Copy -- Not for Resale

top of the brake shaft.
NOTE: The use of air pressure through the brake line
connection (Item 1) [Figure 30-20-9] will aid in
piston removal.

Figure 30-20-10

2
P100801

Check the brake piston (Item 1) [Figure 30-20-10] for

damage including the surface that contacts the brake
shaft.

Replace the seal (Item 2) [Figure 30-20-10].

Assembly: Apply oil to the seal (Item 2) [Figure 30-20-

10] for added protection when installing the brake piston.

263 of 822 30-20-7 T870 Service Manual

HYDROSTATIC MOTOR (CONT'D) Figure 30-20-13

Disassembly And Assembly (Cont'd)

Figure 30-20-12

2 1

3
N-18347

1
Assembly: Clamp the disc pack in a vise and check the
1
P100795 disc pack height [Figure 30-20-13].

Assembly: The correct disc pack reference

Remove the eight mounting bolts (Item 1) [Figure 30-20- specifications is 37,7 + 0,05 mm (1.48 + 0.002 in).
12] and washers from the brake housing.

Dealer Copy -- Not for Resale

Assembly: Extra outer disc's are used to reduce the
Remove the brake housing (Item 2) [Figure 30-20-12] number of required shims [Figure 30-20-13] to make up
from the rear housing. the required thickness for the brake pack.

Remove the snap ring and inner piston seal (Item 3) NOTE: Brake pack height is for reference only.
[Figure 30-20-12].
Figure 30-20-14
NOTE: Install seal with metal case end towards the
brake pack.

Assembly: Use the reference marks to install the brake

housing on the rear housing. 1

Assembly: Install new washers on the brake housing

mount bolts (Item 1) [Figure 30-20-12].

Assembly: Apply Loctite® #243 or equivalent

threadlocker to the bolts and install bolts and washers
into the rear housing. Start each bolt by hand, tighten
opposite bolts to maintain squareness.

Assembly: Tighten bolts to 117 - 122 N•m (86 - 90 ft-lb) N-18350

torque.

Assembly: Install the needed amount of shims (Item 1)

[Figure 30-20-14]. Outer discs can also be used as
shims.

264 of 822 30-20-8 T870 Service Manual

HYDROSTATIC MOTOR (CONT'D) Figure 30-20-17

Disassembly And Assembly (Cont'd)

Figure 30-20-15

1
2
3

N-18301

1
Disassembly: Remove the brake discs (Item 1) [Figure
P100805 30-20-17] and shims from the brake shaft.

Assembly: Assemble the brake discs into a pack making Figure 30-20-18
sure the inner discs (Item 1), alternate with the outer disc
(Item 2) and an outer disc is placed at each end of the

Dealer Copy -- Not for Resale

disc pack with the shims (Item 3) [Figure 30-20-15] and
the base of the pack.
1
Figure 30-20-16
2

2
N-18302

Remove the brake shaft (Item 1) [Figure 30-20-18] from

the rear housing.
3
P100800 NOTE: Be sure shaft seats fully into the cylinder
block.
Assembly: Assemble the brake piston into the brake
housing without the inner brake piston seal (Item 3) Assembly: Install new O-ring (Item 2) [Figure 30-20-18]
[Figure 30-20-12] and brake piston outer seal (Item 2) on the rear housing.
[Figure 30-20-10]. Apply 20 kN (4500 lbf) to set the
brake pack. Using a depth gauge (Item 1), measure from
the gasket mating surface (Item 2) to the inner machined
groove (Item 3) on the brake piston [Figure 30-20-15].
The dimensional measurement must be 8,7 ± 0,1mm
(0.343 ± 0.003), if not adjust brake pack discs to the
required measurement.
NOTE: The 20 kN (4500 lbf) is NOT the amount of
pressure required by the press. It is the
amount of downward force applied by the
press.

265 of 822 30-20-9 T870 Service Manual

HYDROSTATIC MOTOR (CONT'D) Figure 30-20-21

Disassembly And Assembly (Cont'd) 1

Figure 30-20-19

1
2

1 1

P-48686

1 1
Remove and replace with a new O-ring (Item 1) [Figure
P-48684 30-20-21].

Remove the distributor (Item 2) [Figure 30-20-21] from

Remove the eight mounting bolts (Item 1) [Figure 30-20- the rear housing.
19] from the rear housing.

Dealer Copy -- Not for Resale

Assembly: Install the distributor (Item 2) [Figure 30-20-
Assembly: Use Loctite® #243 on the threads and install 21] by using the alignment pin.
the eight mounting bolts (Item 1) [Figure 30-20-19].
Figure 30-20-22
Assembly: Tighten the bolts to 282 - 300 N•m (208 - 221
ft-lb) torque.

Figure 30-20-20

1
1

N-18318

Remove the two seals and back-up O-rings (Item 1)

P-48685 [Figure 30-20-22] under the seals, from the rear
housing.

Remove the rear housing assembly (Item 1) [Figure 30- Assembly: Apply a slight amount of oil to the O-rings
20-20] from the rotating group / front housing assembly. and seals (Item 1) [Figure 30-20-22].

Remove and inspect the stop pin (Item 2) [Figure 30-20-

22].

266 of 822 30-20-10 T870 Service Manual

HYDROSTATIC MOTOR (CONT'D) Figure 30-20-25

Disassembly And Assembly (Cont'd)

Figure 30-20-23

1
1

P100794
2

Remove the plug (Item 1) [Figure 30-20-25] from the

P100813 rear housing assembly.

Remove the springs from the distributor (Item 1) [Figure Remove the spring (Item 1), spool (Item 2), and washer
30-20-23]. (Item 3) and rear spring (Item 4) [Figure 30-20-26].

Dealer Copy -- Not for Resale

Remove and replace the two seals and back-up O-rings Figure 30-20-26
(Item 2) [Figure 30-20-23] under the seals, from the
distributor.
4
Inspect the distributor surfaces for scratches. 3

Assembly: Apply a small amount of grease to the

springs to hold them in place during installation.
2
Figure 30-20-24

N-18315
2

Inspect all parts and replace as needed [Figure 30-20-

26].

P100812

Assembly: When installing the distributor align the stop

pin (Item 1) with the notch in the distributor (Item 2)
[Figure 30-20-24].

When the distributor is aligned correctly, the distributor

can be depressed slightly by hand and will return to its
original position.

267 of 822 30-20-11 T870 Service Manual

HYDROSTATIC MOTOR (CONT'D) Figure 30-20-29

Disassembly And Assembly (Cont'd)

Figure 30-20-27 2

N-18312

Remove the internal plug (Item 1) [Figure 30-20-29].

N-18310
Check the O-ring (Item 2) [Figure 30-20-29] and replace
as needed.
Remove the drain plug (Item 1) [Figure 30-20-27].
Figure 30-20-30

Dealer Copy -- Not for Resale

Figure 30-20-28

N-18313
N-18311

Remove the plug (Item 1) [Figure 30-20-30].

Check the O-ring (Item 1) [Figure 30-20-28] on the plug
and replace as needed.

268 of 822 30-20-12 T870 Service Manual

HYDROSTATIC MOTOR (CONT'D) Figure 30-20-33

Disassembly And Assembly (Cont'd)

2
Figure 30-20-31 1

4
1
3
2

P-48688

Remove and replace the O-ring (Item 1) [Figure 30-20-

N-18314 33] from the front housing assembly.

Assembly: Slightly smear the O-ring (Item 1) [Figure

Remove the spring (Item 1) shim (Item 2) and poppet 30-20-33] with grease to hold in place.
(Item 3) [Figure 30-20-31].

Dealer Copy -- Not for Resale

Remove the rotating group (Item 2) [Figure 30-20-33]
Inspect all parts and replace as needed. from the front housing assembly.

Install a new O-ring (Item 4) [Figure 30-20-31] on the Figure 30-20-34

plug before installation.

Figure 30-20-32

1
2

1
P-48690

P-48687 Remove the snap ring (Item 1) [Figure 30-20-34] from

the bottom side of the rotating group.

Remove the cam ring (Item 1) [Figure 30-20-32] from the

front housing assembly.

Check the cam ring inside surface for wear and

scratches.

Assembly: Align the marks (Item 2) [Figure 30-20-32]

on the cam rings to the front housing.

269 of 822 30-20-13 T870 Service Manual

HYDROSTATIC MOTOR (CONT'D) Figure 30-20-37

Disassembly And Assembly (Cont'd)

Figure 30-20-35

P-48694

1 The retainer ring (Item 1) [Figure 30-20-37] cannot be

P-48691 removed from the top side of the rotating group, because
the rpm target disc is attached directly to the rotating
group.
Remove the retainer ring (Item 1) [Figure 30-20-35] from
the bottom side of the rotating group. Figure 30-20-38

Dealer Copy -- Not for Resale

Figure 30-20-36

P-48695
1
P-48689
Lift the retaining ring (Item 1) [Figure 30-20-38].

Remove the snap ring (Item 1) [Figure 30-20-36] from Use low air pressure and remove the roller / piston
the top side of the rotating group. assembly (Item 2) [Figure 30-20-38] from the cylinder
block.

NOTE: Soak the roller / piston assembles (Item 2)

[Figure 30-20-38] in oil and put all roller /
piston assembles back in the original bore.

NOTE: The roller / piston assembly (Item 2) [Figure

30-20-38] is not a serviceable part.

270 of 822 30-20-14 T870 Service Manual

HYDROSTATIC MOTOR (CONT'D) Figure 30-20-41

Disassembly And Assembly (Cont'd)

1
Figure 30-20-39 2

N-18345

Assembly: Install the front housing (Item 1) and bearing

P100802
over the shaft. Install the special tool (MEL1562) (Item 2)
[Figure 30-20-41] over the bearing and press the
bearing onto the shaft. Apply 40 kN (9000 lbf) to set the
Disassembly: Remove the oil fill plug (Item 1) [Figure bearing. Rotate the housing to check for free travel.
30-20-39] from the housing to drain the oil from the
NOTE: The 40 kN (9000 lbf) is NOT the amount of

Dealer Copy -- Not for Resale

bearing and face seal area.
pressure required by the press. It is the
Assembly: Install drain plug using Loctite® 243, tighten amount of downward force applied by the
flush with the face of the hub. press.

Figure 30-20-40 Assembly: Install the split ring (Item 3) [Figure 30-20-
41] with a feeler gauge measure the distance between
the split ring and the top of the bearing inner race.

Assembly: Add the necessary washer to get closest to

the measurement and re install the split ring.

1 Assembly: Release the pressure from the bearing and

remove the tool.
1

N-18343

Disassembly: With a hammer and punch remove the

split ring and the preload washer located under the split
ring (Item 1) [Figure 30-20-40].

271 of 822 30-20-15 T870 Service Manual

HYDROSTATIC MOTOR (CONT'D) Figure 30-20-44

Disassembly And Assembly (Cont'd)

Figure 30-20-42

2
2
1
1

P13083

Assembly: Remove and replace the face seal (Item 1)

P0020 [Figure 30-20-44] from the shaft.

Assembly: Install a new bearing (Item 2) [Figure 30-20-

Disassembly: Install the bearing puller (Item 1) [Figure 44] onto the shaft.
30-20-42] under the front housing and support the puller

Dealer Copy -- Not for Resale

and housing with blocks. Figure 30-20-45

Disassembly: Press the shaft (Item 2) [Figure 30-20-42]

from the housing. 2
1
Figure 30-20-43

P0123

Remove and replace the face seal (Item 1) [Figure 30-

20-45] on the front housing.
P0682
NOTE: When installing face seals, apply a layer of
good quality lithium grease to the mating
Disassembly: Use a bearing puller to remove the surfaces of the face seal.
bearing from the shaft [Figure 30-20-43].
Remove and replace the bearing cup (Item 2) [Figure
NOTE: The bearing will be destroyed during the 30-20-45] on the front housing.
removal procedure. Be sure to have a new
bearing on hand before removing the old NOTE: The bearing cup in the housing may be loose
bearing. after installation. The bearing cup will tighten
in its bore after the motor is completely
assembled.

272 of 822 30-20-16 T870 Service Manual

HYDROSTATIC MOTOR (CONT'D) Figure 30-20-48

Disassembly And Assembly (Cont'd)

Figure 30-20-46
1

P100802A

P0122
Rotate the hydrostatic drive motor so that the drain plug
(Item 1) [Figure 30-20-48] is vertical with the center of
Remove and inspect the bearing (Item 1) [Figure 30-20- the hydrostatic drive motor. Fill housing with 180 mL (6.1
46] located in the front housing. U.S. fl oz) high performance synthetic oil (P/N 7003026).

Dealer Copy -- Not for Resale

Replace the bearing if worn or damaged. Clean the threads of the plug and drain hole. Apply
Loctite® 243 to the plug threads. Install and tighten the
Figure 30-20-47 plug.

1
3

P0126

Remove the shaft seal (Item 1) [Figure 30-20-47].

Replace the outer O-ring and inner shaft seal (Item 2)

[Figure 30-20-47].

Remove the bearing cup (Item 3) [Figure 30-20-47] if it

needs replacement.

273 of 822 30-20-17 T870 Service Manual

 Dealer Copy -- Not for Resale

274 of 822 30-20-18 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO SPEED) Removing And Replacing Oil

Description For the correct service interval (See SERVICE

SCHEDULE on Page 10-70-1.)
The hydrostatic drive motors are driven by the hydrostatic
pump. Machines equipped with SJC / SCPA are Park the loader so that the plug in the hydrostatic drive
monitored by a sensor mounted onto the motor housing. motor is at the bottom.
The sensor is used for detection of motion and for rate of
speed for the SJC / SCPA options. Remove the plug and let the oil drain from the hydrostatic
drive motor.
The hydrostatic drive motors contain a spring applied
pressure release braking system. In addition there is a Figure 30-21-1
separate oil chamber in the motor that is filled with high
performance synthetic oil for maximum durability, this oil
has a recommended service interval. (See SERVICE
SCHEDULE on Page 10-70-1.)

There are two hydrostatic drive motors and they are

located on the track carriage. 1

Dealer Copy -- Not for Resale

P100737A

Rotate the hydrostatic drive motor so that the plug (Item

1) [Figure 30-21-1] is vertical with the center of the
hydrostatic drive motor. Add high performance synthetic
oil (P/N 7003026). (See Capacities on Page SPEC-10-4.)

Clean the threads of the plug and drain hole. Apply

Loctite® 243 to the plug threads. Install and tighten the
plug.

Repeat for the other hydrostatic drive motor.

Recycle or dispose of the used oil in an environmentally

safe manner.

275 of 822 30-21-1 T870 Service Manual

HYDROSTATIC MOTOR (TWO SPEED) (CONT’D)) Remove the track. (See Track Removal And Installation
on Page 40-20-4.)
Removal And Installation
Figure 30-21-1

IMPORTANT 1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, 1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Place the loader on jackstands. (See Procedure on Page

10-10-1.)
P100811

DANGER Remove the mounting bolts (Item 1) [Figure 30-21-1]

from the access cover and remove the cover from the
loader.

Dealer Copy -- Not for Resale

Remove the sprocket. (See Sprocket Removal And
Installation (Two Speed) on Page 40-20-13.)

Disconnect and remove the speed sensor. (See Removal

And Installation on Page 60-80-3.)

P-90328 NOTE: Speed sensor removal is recommended to

prevent damage while removing the
AVOID DEATH hydrostatic motor from the track carriage.
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409

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

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)

276 of 822 30-21-2 T870 Service Manual

HYDROSTATIC MOTOR (TWO SPEED) (CONT’D) Figure 30-21-4

Removal And Installation (Cont'd)

Figure 30-21-2 1 1

1
P-85991

3 With an arm hoist support the hydrostatic motor.

P-85992 Remove the ten hydraulic motor mounting bolts (Item 1)

[Figure 30-21-4].
Remove the case drain hydraulic hose (Item 1) [Figure
30-21-2] from the motor. Installation: Tighten the motor mounting bolts to 257,6

Dealer Copy -- Not for Resale

N•m (190 ft-lb) torque.
Remove the hydraulic brake hose (Item 2) [Figure 30-
21-2] from the motor. Remove the hydrostatic motor from the loader.

Remove the eight flange bolts (Item 3) from the main

drive hoses. Remove the flanges and drive hoses (Item
4) [Figure 30-21-2].

Installation: Fill the main drive hose ports on the motor

with new hydraulic oil before installing the drive hoses.

Figure 30-21-3

2 3

4 1

P100901

Installation: Install both flanges and tighten the bolts to

half of the required torque in the sequence shown in
[Figure 30-21-3]. Retighten all bolts to required torque in
the same sequence.

277 of 822 30-21-3 T870 Service Manual

HYDROSTATIC MOTOR (TWO SPEED) (CONT’D)

Parts Identification

10

9
8
65 7

6
5

4
3
12
2 23

11 22
65
21
10

Dealer Copy -- Not for Resale

20
1

14
40
39
17

18
38
13 36 37

15 41
16
36
19 42
16 29 42
15 35 30
31
43
34 64
24 32 44 36
25 33
31
26 28 45
27 46
47
48
49 50
51 63
52
53 62
61
55 54 60
59
58
57 NA2870s
56

278 of 822 30-21-4 T870 Service Manual

HYDROSTATIC MOTOR (TWO SPEED) (CONT’D)

Parts Identification (Cont’d)

Ref. Description Ref. Description

1. PLUG 34. BOLT
2. SHAFT 35. BOLT
3. SEAL 36. PIN
4. BEARING 37. WASHER
5. HOUSING / FRONT 38. BOLT
6. SEAL 39. DISC / OUTER
7. BEARING 40. DISC / INNER
8. WASHER 41. BUSHING
9. SPLIT RINGS 42. SHIM
10. O-RING 43. HOUSING / BRAKE
11. NUT 44. SHAFT
12. STUD 45. O-RING
13. RPM TARGET DISC 46. BOLT
14. ROLL PIN 47. COVER PLATE
15. SNAP RING 48. GASKET
16. RETAINER 49. PIN

Dealer Copy -- Not for Resale

17. ROLLER 50. SEAL
18. PISTON 51. CLIP
19. BLOCK 52. SPRING
20. CAM 53. SPOOL
21. DISTRIBUTOR 54. PLUG
22. SPRING 55. HOUSING / REAR
23. SEAL W / O-RING 56. SEAL
24. PLUG 57. O-RING
25. O-RING 58. SNAP RING
26. SPRING 59. PISTON
27. SHIM 60. SEAL
28. POPPET 61. DISC SPRING
29. PLUG 62. GASKET
30. O-RING 63. COVER PLATE
31. SPRING 64. BOLT
32. WASHER 65. PLUG
33. SPOOL

279 of 822 30-21-5 T870 Service Manual

HYDROSTATIC MOTOR (TWO SPEED) (CONT’D) Figure 30-21-7

Disassembly And Assembly

Figure 30-21-5

1
N-18296

Remove the disc spring (Item 1) [Figure 30-21-7] from

P100869 the brake housing.

NOTE: Mark the top side of the disc spring for proper
NOTE: Mark the motor, brake and motor housings for installation.
proper alignment during assembly [Figure 30-

Dealer Copy -- Not for Resale

21-5]. Assembly: Put multi-purpose moly grease on the
surface of the disc spring where it contacts the piston.
Drain the oil from the motor casing.

Inspect for the vendor motor serial number (Item 1)

[Figure 30-21-5], these serial numbers may be needed
when ordering replacement parts.

Figure 30-21-6

P100799

Remove the mounting bolts (Item 1) and the brake cover

plate (Item 2) [Figure 30-21-6].

NOTE: Remove every other bolt, then uniformly

remove the last twelve bolts to maintain equal
preload on the brake cover plate.

Assembly: Replace the gasket and torque bolts to 35 -

39 N•m (26 - 29 ft-lb).

280 of 822 30-21-6 T870 Service Manual

HYDROSTATIC MOTOR (TWO SPEED) (CONT’D) Figure 30-21-10

Disassembly And Assembly (Cont'd)

Figure 30-21-8

1
2

P100868

1
Inspect the piston surface (Item 1) and the bushing
P100804 surface (Item 2) [Figure 30-21-10] in the brake shaft.

NOTE: The bushing (Item 2) [Figure 30-21-10] can be

Remove the piston from the brake housing [Figure 30- replaced in the brake shaft. When the bushing
21-8]. is replaced, install the bushing flush with the

Dealer Copy -- Not for Resale

top of the brake shaft.
NOTE: The use of air pressure through the brake line
connection (Item 1) [Figure 30-21-8] will aid in
piston removal.

Figure 30-21-9

2
P100801

Inspect the brake piston (Item 1) [Figure 30-21-9] for

damage including the surface that contacts the brake
shaft.

Replace the seal (Item 2) [Figure 30-21-9].

Assembly: Apply oil to the seal (Item 2) [Figure 30-21-9]

for added protection when installing the brake piston.

281 of 822 30-21-7 T870 Service Manual

HYDROSTATIC MOTOR (TWO SPEED) (CONT’D) Figure 30-21-12

Disassembly And Assembly (Cont'd)

Figure 30-21-11

3 N-18347
2

Assembly: Clamp the disc pack in a vise and inspect the

1 P100866 disc pack height [Figure 30-21-12].

Assembly: The correct disc pack reference

Remove the five mounting bolts (Item 1) [Figure 30-21- specifications is 37,7 mm (1.48 in).
11] and washers from the brake housing.

Dealer Copy -- Not for Resale

Assembly: Extra outer disc's are used to reduce the
Remove the brake housing (Item 2) [Figure 30-21-11] number of required shims [Figure 30-21-12] to make up
from the rear housing. the required thickness for the brake pack.

Remove the snap ring and inner piston seal (Item 3) NOTE: Brake pack height is for reference only.
[Figure 30-21-11].
Figure 30-21-13
NOTE: Install seal with metal case end towards the
brake pack.

Assembly: Use the reference marks to install the brake

housing on the rear housing.

Assembly: Install new washers on the brake housing

1
mount bolts (Item 1) [Figure 30-21-11].

Assembly: Apply Loctite® #243 or equivalent

threadlocker to the bolts and install bolts and washers
into the rear housing. Start each bolt by hand, tighten
opposite bolts to maintain squareness.

Assembly: Tighten bolts to 117 - 122 N•m (86 - 90 ft-lb) P100867

torque.

Assembly: Install the needed amount of shims (Item 1)

[Figure 30-21-13]. Outer discs can also be used as
shims.

282 of 822 30-21-8 T870 Service Manual

HYDROSTATIC MOTOR (TWO SPEED) (CONT’D) Figure 30-21-16

Disassembly And Assembly (Cont'd)

Figure 30-21-14
1

2
3

P100858

1
Disassembly: Remove the brake discs (Item 1) [Figure
P100805 30-21-16] and shims from the brake shaft.

Assembly: Assemble the brake discs into a pack making Figure 30-21-17
sure the inner discs (Item 1), alternate with the outer disc
(Item 2) and an outer disc is placed at each end of the

Dealer Copy -- Not for Resale

disc pack with the shims (Item 3) [Figure 30-21-14] and
the base of the pack.
1
Figure 30-21-15
2

P100859

Remove the brake shaft (Item 1) [Figure 30-21-17] from

the rear housing.
3
P100800 NOTE: Be sure shaft seats fully into the cylinder
block.
Assembly: Assemble the brake piston into the brake
housing without the inner brake piston seal (Item 3) Assembly: Install new O-ring (Item 2) [Figure 30-21-17]
[Figure 30-21-11] and brake piston outer seal (Item 2) on the rear housing.
[Figure 30-21-9]. Apply 20 kN (4500 lbf) to set the brake
pack. Using a depth gauge (Item 1), measure from the
gasket mating surface (Item 2) to the inner machined
groove (Item 3) on the brake piston [Figure 30-21-14].
The dimensional measurement must be 8,7 ± 0,1mm
(0.343 ± 0.003), if not adjust brake pack discs to the
required measurement.
NOTE: The 20 kN (4500 lbf) is NOT the amount of
pressure required by the press. It is the
amount of downward force applied by the
press.

283 of 822 30-21-9 T870 Service Manual

HYDROSTATIC MOTOR (TWO SPEED) (CONT’D) Figure 30-21-20

Disassembly And Assembly (Cont'd)

Figure 30-21-18

P100872

Remove the plug (Item 1) [Figure 30-21-19] from the

P100870 rear housing.

Figure 30-21-21
Remove the two speed spool assembly (Item 1) [Figure
30-21-17] from the rear housing.

Dealer Copy -- Not for Resale

Figure 30-21-19

1
1
2

2 P100871
4
3
Remove the spool (Item 1) [Figure 30-21-19].
N-22501
Assembly: Install new O-ring (Item 2) [Figure 30-21-17]
on the plug and torque to 50 N•m (37 ft-lb)
Inspect the spool (Item 1), the spring (Item 2), washer
(Item 3) and the snap ring (Item 4) and replace as
needed [Figure 30-21-19].

NOTE: If the spool (Item 1) [Figure 30-21-19] is

damaged the entire rear housing assembly
has to be replaced.

284 of 822 30-21-10 T870 Service Manual

HYDROSTATIC MOTOR (TWO SPEED) (CONT’D) Figure 30-21-23

Disassembly And Assembly (Cont'd)

Figure 30-21-22 1
1 1

1
2 4 3
1 1

1
2 2

P100861

Remove the ten mounting bolts (Item 1) [Figure 30-21-

N-22504 23] from the rear housing.

Remove the two (8 mm) cam ring mount bolts (Item 2)

Remove the spring (Item 1), washer (Item 2) and rear [Figure 30-21-23].
spring (Item 3) from the spool (Item 4) [Figure 30-21-22].

Dealer Copy -- Not for Resale

Turn the housing, cam ring, and rotating group assembly
Inspect all parts and replace as needed. over and place on a stand.

Assembly: Clean the threads on the bolts and front

housing assembly. Apply Loctite® #243 and tighten the
ten bolts (Item 1) [Figure 30-21-23] to 210 - 220 N•m
(154 - 162 ft-lb) torque. Clean the threads on the two (8
mm) bolts (Item 2) [Figure 30-21-23] and the cam ring.
Apply Loctite® #243 and tighten the bolts to 70 - 77 N•m
(52 - 57 ft-lb).

285 of 822 30-21-11 T870 Service Manual

HYDROSTATIC MOTOR (TWO SPEED) (CONT’D) Figure 30-21-26

Disassembly And Assembly (Cont'd)

Figure 30-21-24

1
1

P100856

Remove the springs from the distributor (Item 1) [Figure

30-21-26].
P100860

Inspect the distributor surfaces for scratches.

Remove and replace with a new O-ring (Item 1) [Figure
30-21-24]. Assembly: Apply a small amount of grease to the
springs to hold them in place during installation.

Dealer Copy -- Not for Resale

Remove the distributor (Item 2) [Figure 30-21-24] from
the rear housing. Figure 30-21-27

Assembly: Install the distributor (Item 2) [Figure 30-21-

24] by using the alignment pin.

Figure 30-21-25

2 1
1

P100855

Remove the six seals (Item 1), and six back-up O-rings
2 (Item 2) [Figure 30-21-26] from the distributor.

N-18318

Remove the seal and back-up O-ring (Item 1) [Figure 30-

21-25] under the seal, from the rear housing.

Assembly: Apply a slight amount of oil to the O-rings

and seals (Item 1) [Figure 30-21-25].

Remove and inspect the stop pin (Item 2) [Figure 30-21-

25].

286 of 822 30-21-12 T870 Service Manual

HYDROSTATIC MOTOR (TWO SPEED) (CONT’D) Figure 30-21-30

Disassembly And Assembly (Cont'd)

Figure 30-21-28

1 P100873

Inspect the O-ring (Item 1) [Figure 30-21-30] on the plug

P100812 and replace as needed. Torque to 60 N•m (44 ft-lb)

Figure 30-21-31
Assembly: When installing the distributor align the stop
pin (Item 1) with the notch in the distributor (Item 2)

Dealer Copy -- Not for Resale

[Figure 30-21-28].

When the distributor is aligned correctly, the distributor

can be depressed slightly by hand and will return to its 1
original position.

Figure 30-21-29

1
P100875

Remove the plug (Item 1) [Figure 30-21-31].

P100874

Remove the drain plug (Item 1) [Figure 30-21-29].

287 of 822 30-21-13 T870 Service Manual

HYDROSTATIC MOTOR (TWO SPEED) (CONT’D) Figure 30-21-34

Disassembly And Assembly (Cont'd)

2
Figure 30-21-32 1

4
1
3
2

P100924

Remove and replace the O-ring (Item 1) [Figure 30-21-

N-18314 34] from the front housing assembly.

Assembly: Slightly smear the O-ring (Item 1) [Figure

Remove the spring (Item 1) shim (Item 2) and poppet 30-21-34] with grease to hold in place.
(Item 3) [Figure 30-21-32].

Dealer Copy -- Not for Resale

Remove the rotating group (Item 2) [Figure 30-21-34]
Inspect all parts and replace as needed. from the front housing assembly.

Install a new O-ring (Item 4) [Figure 30-21-32] on the Figure 30-21-35

plug and replace as needed. Torque to 25 N•m (18 ft-lb)

Figure 30-21-33

2
1

1
P-48690

P100925 Remove the snap ring (Item 1) [Figure 30-21-35] from

the bottom side of the rotating group.

Remove the cam ring (Item 1) [Figure 30-21-33] from the

front housing assembly.

Inspect the cam ring inside surface for wear and

scratches.

Assembly: Align the marks (Item 2) [Figure 30-21-33]

on the cam rings to the front housing.

288 of 822 30-21-14 T870 Service Manual

HYDROSTATIC MOTOR (TWO SPEED) (CONT’D) Figure 30-21-38

Disassembly And Assembly (Cont'd)

Figure 30-21-36

P100927

1 The retainer ring (Item 1) [Figure 30-21-38] cannot be

P-48691 removed from the top side of the rotating group, because
the rpm target disc is attached directly to the rotating
group.
Remove the retainer ring (Item 1) [Figure 30-21-36] from
the bottom side of the rotating group. Figure 30-21-39

Dealer Copy -- Not for Resale

Figure 30-21-37

1 2

P100928

P100926
Lift the retaining ring (Item 1) [Figure 30-21-39].

Remove the snap ring (Item 1) [Figure 30-21-37] from Use low air pressure and remove the roller / piston
the top side of the rotating group. assembly (Item 2) [Figure 30-21-39] from the cylinder
block.

NOTE: Soak the roller / piston assembles (Item 2)

[Figure 30-21-39] in oil and put all roller /
piston assembles back in the original bore.

NOTE: The roller / piston assembly (Item 2) [Figure

30-21-39] is not a serviceable part.

289 of 822 30-21-15 T870 Service Manual

HYDROSTATIC MOTOR (TWO SPEED) (CONT’D) Figure 30-21-42

Disassembly And Assembly (Cont'd)

1
Figure 30-21-40 2

P100932

Assembly: Install the front housing (Item 1) and bearing

P100929
over the shaft. Install the special tool (MEL1562) (Item 2)
[Figure 30-21-42] over the bearing and press the
bearing onto the shaft. Apply 40 kN (9000 lbf) to set the
Disassembly: Remove the oil fill plug (Item 1) [Figure bearing. Rotate the housing to inspect for free travel.
30-21-40] from the housing to drain the oil from the
NOTE: The 40 kN (9000 lbf) is NOT the amount of

Dealer Copy -- Not for Resale

bearing and face seal area.
pressure required by the press. It is the
Clean the threads of the plug and drain hole. Apply amount of downward force applied by the
Loctite® 243 to the plug threads. Install and tighten the press.
plug. Assembly: Install the split ring (Item 3) [Figure 30-21-
42] with a feeler gauge measure the distance between
Figure 30-21-41 the split ring and the top of the bearing inner race.

Assembly: Add the necessary preload washer to get

closest to the measurement and re install the split ring.

Assembly: Release the pressure from the bearing and

1 remove the tool.

P100931

Disassembly: With a hammer and punch remove the

split ring and the preload washer located under the split
ring (Item 1) [Figure 30-21-41].

290 of 822 30-21-16 T870 Service Manual

HYDROSTATIC MOTOR (TWO SPEED) (CONT’D) Figure 30-21-45

Disassembly And Assembly (Cont'd)

Figure 30-21-43

1
2

P13083

Assembly: Remove and replace the face seal (Item 1)

P100934 [Figure 30-21-45] from the shaft.

Assembly: Install a new bearing (Item 2) [Figure 30-21-

Disassembly: Install the bearing puller (Item 1) [Figure 45] onto the shaft.
30-21-43] under the front housing and support the puller

Dealer Copy -- Not for Resale

and housing with blocks. Figure 30-21-46

Disassembly: Press the shaft (Item 2) [Figure 30-21-43]

from the housing. 1

Figure 30-21-44

P100941

Remove and inspect the bearing (Item 1) [Figure 30-21-

46] located in the front housing.
P0682
Replace the bearing and bearing cup if worn or
damaged.
Disassembly: Use a bearing puller to remove the
bearing from the shaft [Figure 30-21-44].

NOTE: The bearing will become unserviceable during

the removal procedure. Be sure to have a new
bearing on hand before removing the old
bearing.

291 of 822 30-21-17 T870 Service Manual

HYDROSTATIC MOTOR (TWO SPEED) (CONT’D) Figure 30-21-48

Disassembly And Assembly (Cont'd)

Figure 30-21-47
2 1
2
1

P100940

Remove the shaft seal (Item 1) [Figure 30-21-48].

P100939
Remove the bearing cup (Item 2) [Figure 30-21-48] if it
needs replacement.
Remove and replace the face seal (Item 1) [Figure 30-
21-47] on the front housing. Figure 30-21-49

Dealer Copy -- Not for Resale

NOTE: When installing face seals, apply a layer of
good quality lithium grease to the mating
surfaces of the face seal.
1
Remove and replace the bearing cup (Item 2) [Figure
30-21-47] on the front housing.

NOTE: The bearing cup in the housing may be loose

after installation. The bearing cup will tighten
in its bore after the motor is completely
assembled.

P100930

Rotate the hydrostatic drive motor so that the drain plug

(Item 1) [Figure 30-21-49] is vertical with the center of
the hydrostatic drive motor. Fill housing with 180 mL (6.1
U.S. fl oz) high performance synthetic oil (P/N 7003026).

Clean the threads of the plug and drain hole. Apply

Loctite® 243 to the plug threads. Install and tighten the
plug.

292 of 822 30-21-18 T870 Service Manual

CHARGE PRESSURE Testing

Description Figure 30-30-1

Charge pressure is a supply of oil to the hydrostatic

pumps. Charge pressure is regulated by a charge relief
valve located inside the hydrostatic pump. Charge
pressure is used to replenish hydrostatic fluid removed
from the drive circuit, pump and motor “internal leakage”
and from the hydrostatic motors shuttle (flushing) valve.

Charge pressure is also used to operate other hydraulic

functions, such as shifting the auxiliary spool, and to pilot
open the BICS™ system for the lift and tilt in the main
2 4
hydraulic control valve. 1 3

The charge pressure sender is located on the hydraulic

fan motor. Charge pressure alarm settings are pre- P-43196
programmed into the main controller and are based on
loader type and options installed.
The tools needed to test charge pressure, hydraulic hose
(Item 1), T fitting (P/N 13K5) (Item 2), Hydraulic gauge
6,9 MPa (68,9 bar) (1000 psi) (Item 3) and adapter fitting
(P/N 93F5) (Item 4) [Figure 30-30-1].

Dealer Copy -- Not for Resale

Figure 30-30-1

3
2

P-43197

Connect the gauge (Item 1), to the adapter fitting (P/N

93F5) (Item 2) [Figure 30-30-1].

Connect the hydraulic hose (Item 3) [Figure 30-30-1] to

the adapter fitting. Tighten all connections.

293 of 822 30-30-1 T870 Service Manual

CHARGE PRESSURE (CONT’D) Figure 30-30-3

Testing (Cont’d)

WARNING
1
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death. 2
W-2059-0598 3
P-90301
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
Install the T fitting (P/N 13K5) (Item 1) [Figure 30-30-3].
Place the loader on jackstands. (See Procedure on Page
10-10-1.) Install the hose (Item 2) [Figure 30-30-3], that was
disconnected from the motor, to the T fitting.
Raise the operator cab. (See Raising on Page 10-30-1.)
Install the hose (Item 3) [Figure 30-30-3], that is

Dealer Copy -- Not for Resale

Figure 30-30-2 attached to the pressure gauge, to the T fitting.

Tighten the hydraulic fittings.

Connect the remote start tool. (See REMOTE START

TOOL KIT-MEL1563 on Page 10-60-1.) or (See
REMOTE START TOOL (SERVICE TOOL) KIT -
7003031 on Page 10-61-1.)

Start the loader and warm the hydraulic fluid to 60°C

(140°F).
1
Charge pressure at high idle, with the fluid temperature of
60°C (140°F) is 3 - 3,65 MPa (29,6 - 36,5 bar) (430 - 530
psi) with the pump in neutral.
P-90302

Disconnect the hydraulic hose (Item 1) [Figure 30-30-2].

294 of 822 30-30-2 T870 Service Manual

CHARGE PRESSURE (CONT’D)

Sender Removal And Installation

Figure 30-30-4

P-90302

Disconnect the wire (Item 1) [Figure 30-30-4] from the

sender.

Dealer Copy -- Not for Resale

Remove the sender (Item 2) [Figure 30-30-4] from the
motor.

Installation: Tighten the charge pressure sender to 10 -

10,9 N•m (7.4 - 8.1 ft-lb) torque.

NOTE: Inspect the O-ring on the sender before

installation.

295 of 822 30-30-3 T870 Service Manual

CHARGE PRESSURE (CONT’D) Figure 30-30-6

Adjusting

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, 1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P-64435
Figure 30-30-5

Inspect the poppet and spring for wear or damage.

Inspect the seat inside the hydrostatic pump case for

wear or damage.

There are several different thickness of shims (Item 1)

Dealer Copy -- Not for Resale

1 [Figure 30-30-6] used to adjust the charge pressure.

NOTE: 1,0 mm shim (Item 1) [Figure 30-30-6] = 299,9

kPa (3 bar) (43.5 psi) in pressure change.
Adding shims increases charge pressure.
Removing shims decreases charge pressure.

P-64431 The charge pressure should be set at 3 - 3,65 MPa (29,6

- 36,5 bar) (430 - 530 psi).

If the charge pressure is not correct remove the charge

relief valve (Item 1) [Figure 30-30-5].

NOTE: The pump has been removed for photo clarity.

The charge pressure relief valve is located on
the engine side of the hydrostatic pump when
installed in the loader.

Assembly: Always use a new O-ring. Tighten the plug to

41 - 68 N•m (30 - 50 ft-lb) torque.

296 of 822 30-30-4 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) The servo piston strokes the swash plate in the rotating
group. The rotating group generates flow to the A or B
Description ports on the hydrostatic pump. The flow from the A and B
ports is sent to the hydrostatic drive motors where
The SJC and SCPA hydrostatic pump is a fully forward or reverse drive motor rotation is obtained.
proportional dual piston pump in one pump casing. The
endcaps are removable to gain access to the rotating There are swash plate angle sensors on the bottom of
assemblies. the pump that monitor swash plate movement.

The hydraulic controllers are fed charge pressure from Ports are labeled on the hydrostatic pump casting.
an external charge pump. 12 volt electrical solenoids shift
a spool in the hydraulic controller that directs flow to a
servo piston.

Figure 30-40-1

Dealer Copy -- Not for Resale

P-90206

297 of 822 30-40-1 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-3

Hydraulic Controller Removal And Installation

The loader’s right hand side hydraulic controller can be

removed with the hydrostatic pump still in the loader. The
loader’s left hand side hydraulic controller can only be 1
removed when the hydrostatic pump is separated from
the engine / hydrostatic pump cast mount.

Controller solenoids can be bled of trapped air in the

controller. This should be performed when hydraulic
controllers are replaced, removed or uncommanded
oscillations in the controls are present.
1
Raise the lift arms and install an approved lift arm support P-90239
device. (See Installing on Page 10-20-1.)

Place the loader on jackstands. (See Procedure on Page Disconnect the electrical harness connectors (Item 1)
10-10-1.) [Figure 30-40-3] from both sides of the hydrostatic
pump.

Removal:
WARNING

Dealer Copy -- Not for Resale

Put jackstands under the front axles and rear corners
of the frame before running the engine for service. IMPORTANT
Failure to use jackstands can allow the machine to
fall or move and cause injury or death. When repairing hydrostatic and hydraulic systems,
W-2017-0286 clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
Raise the operator cab. (See Raising on Page 10-30-1.) tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Figure 30-40-2 I-2003-0888

Figure 30-40-4

1
1
1

P-90207

P-90208
Locate the two hydraulic controllers (Item 1) [Figure 30-
40-2] on the hydrostatic pumps.
Remove the four mount bolts (Item 1) [Figure 30-40-4]
from the hydraulic controller.

298 of 822 30-40-2 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Use a small amount of grease on a new gasket and
install the gasket on the hydraulic controller (Item 1)
Hydraulic Controller Removal And Installation [Figure 30-40-5].
(Cont'd)
Figure 30-40-7
Figure 30-40-5

1
1 2

3 1

P-90210
P-90210

Alternately tighten bolts (Item 1) [Figure 30-40-7] to 10,4

Remove the controller (Item 1) [Figure 30-40-5] from the N•m (7.7 ft-lb) torque. Ensure bolts are tightened to

Dealer Copy -- Not for Resale

pump. specifications.

Remove the controller gaskets (Item 2) [Figure 30-40-5] NOTE: When a hydraulic controller is replaced, the
from the pump. hydrostatic pumps must be calibrated. (See
Hydraulic Controller Neutral Adjustment on
Installation: Page 30-40-26.)

Figure 30-40-6

2 2

P-90209

NOTE: Do NOT remove the three screens (Item 2)

[Figure 30-40-6] they will be damaged during
removal and must be replaced.

Be sure the feedback lever (Item 3) [Figure 30-40-5] is in

the center of the servo piston groove (Item 1) [Figure 30-
40-6].

299 of 822 30-40-3 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-9

Removal And Installation

Remove the hydrostatic pump / engine assembly from

the loader. (See Engine Removal And Installation on
Page 70-10-7.)

Remove the Hydraulic Pump. (See Removal And

Installation on Page 20-60-6.)

Remove the Drive Belt. (See DRIVE BELT on Page 30- 1

50-1.)

P-90222

IMPORTANT
Use a puller (Item 1) [Figure 30-40-9] to loosen the
When repairing hydrostatic and hydraulic systems, pulley from the pump drive shaft.
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, NOTE: DO NOT strike puller or pump shaft with a
tubelines and ports to keep dirt out. Dirt can quickly hammer. Internal pump damage may result.
damage the system.

Dealer Copy -- Not for Resale

I-2003-0888 Remove the nut and washer from the pump drive shaft.

Figure 30-40-8 Remove the pump pulley from the pump drive shaft.

Figure 30-40-10

1
1

P-90221

P-90223
Loosen the nut (Item 1) [Figure 30-40-8] on the
hydrostatic pump drive shaft.
Remove the two mounting bolts and nuts (Item 1)
Installation: Tighten the nut to 258 - 325 N•m (190 - 240 [Figure 30-40-10].
ft-lb) torque
Installation: Tighten the mounting bolts and nuts to 88 -
95 N•m (65 - 70 ft-lb) torque.

300 of 822 30-40-4 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D)

Removal And Installation (Cont’d)

Figure 30-40-11

P-90224

Remove the two mounting bolts (Item 1) [Figure 30-40-

11] at the hydraulic pump mounting bracket.

Dealer Copy -- Not for Resale

Installation: Tighten mounting bolt to 125 - 135 N•m (90
- 100 ft-lb)

Remove the hydrostatic pump from the mounting bracket

and drive belt housing.

BEFORE START UP: Fill the hydrostatic pump with

hydraulic oil. This will remove trapped air in the
hydrostatic pumps before start up. (See Hydrostatic
Pump Start Up on Page 30-40-6.)

301 of 822 30-40-5 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D)

Hydrostatic Pump Start Up

Before putting a hydrostatic pump back into operation,

the hydrostatic pump should be filled with hydrostatic
fluid. This should be performed when installing a new
hydrostatic pump or a pump that has been disassembled.

Starting a hydrostatic pump dry may cause premature

wear or permanent pump damage.

Under normal operation, the charge pump will keep the

hydrostatic pumps filled.

Filling the hydrostatic pump is best done by removing a

plug at the top of the hydrostatic pump. A clean funnel
should be used to avoid washing contaminants into the
hydrostatic pump. The goal is to fill the hydrostatic pump
as much as possible before start up.

Figure 30-40-12

Dealer Copy -- Not for Resale

1

P-90226

Remove the air bleed plugs (Item 1) [Figure 30-40-12].

BEFORE START UP: Fill one of the air bleed ports with
new hydraulic oil until the hydraulic oil flows out of the
other air bleed port. This will remove trapped air in the
hydrostatic pumps before start up.

Assembly: Tighten plugs to 25 N•m (18 ft-lb) torque.

302 of 822 30-40-6 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D)

Parts Identification

3 1
1. O-ring 5 4
2. Bolt
3. End Housing 7
4. O-ring 6
5. Right Rotating Assembly 8
6. Timing Pin
7. Bearing
8. Spacer / Coupler
9. Pin
10. Positioning Pin
11. O-ring 10
12. O-ring 11 9 2
13. Position Sensor 12
14. Washer 13
15. Bolt 14
15
16
22 17
21 19
24

Dealer Copy -- Not for Resale

23
20 18
26

18

25 27
19
29 26

16. Steel Cover

17. Bolt
18. Hydraulic Controller
19. High Pressure Relief
20. Case Housing
6 21. Bolt
2 7 22. Plug
23. Plug
24. Dowel Pin
28 25. Charge Pressure Relief
26. Left Servo
4 27. Right Servo
28. Left Rotating Assembly
29. End Housing

P-90240

303 of 822 30-40-7 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-15

High Pressure Relief And Bypass Valve

Figure 30-40-13

1
1

P-64437

Check the valve seat surface (Item 1) [Figure 30-40-15]

P-64431 for scratches and replace as needed.

Inspect the spring (Item 2) [Figure 30-40-15] for

There are four system check relief valves (Item 1) breakage.
[Figure 30-40-13] in the back of the hydrostatic pump.

Dealer Copy -- Not for Resale

Inspect seats inside case housing.
Remove the relief valve cap (Item 1) [Figure 30-40-13].
Do not disassemble the relief valve assembly. If
Assembly: Tighten cap to 150 - 170 N•m (111 - 125 ft-lb) replacement is required, replace as an assembly.
torque.
Factory setting on the relief valve is 36,2 MPa (362 bar)
Figure 30-40-14 (5250 psi).

4
3

2 1

P-64436

Check the valve cap O-ring (Item 1) and back-up ring

(Item 2) [Figure 30-40-14], replace as needed.

Remove relief valve assembly (Item 3) [Figure 30-40-14]

from the valve cap.

Check the conical spring (Item 4) [Figure 30-40-14] to

ensure it is not broken or flattened.

304 of 822 30-40-8 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-18

Charge Relief Valve

Figure 30-40-16 3 4
2 5
1

1 P-64435

Inspect the poppet (Item 1) and the mating seat (Item 2)

P-64431 [Figure 30-40-18] for damage or foreign material. Ensure
the poppet moves freely in it’s bore.

The charge relief valve (Item 1) [Figure 30-40-16] is Inspect the sealing ring (Item 3) [Figure 30-40-18] and
located on the back of the hydrostatic pump. the mating seat in the pump housing for damage or

Dealer Copy -- Not for Resale

foreign material.
Remove the charge relief valve.
Inspect the spring (Item 4) and the charge relief valve
Assembly: Tighten charge relief valve to 70 N•m (52 ft- shims (Item 5) [Figure 30-40-18].
lb) torque.
NOTE: 1,0 mm shim (Item 5) [Figure 30-40-18] = 299,9
Figure 30-40-17 kPa (3 bar) (43.5 psi) in pressure change.
Adding shims increases charge pressure.
Removing shims decreases charge pressure.
1

P-64435

Check and replace the O-ring (Item 1) [Figure 30-40-17].

305 of 822 30-40-9 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-21

Disassembly And Assembly

Remove the hydrostatic pump / engine assembly from

the loader. (See Engine Removal And Installation on
Page 70-10-7.) 1

Remove the hydrostatic pump. (See Removal And

Installation on Page 30-40-4.)

Figure 30-40-19
1

2
P-90228

1 Remove the mounting bolts (Item 1) for the swash plate

1 angle sensor (Item 2) [Figure 30-40-21].

Assembly: Tighten bolts to 3,1 N•m (27.4 in-lb) torque.

Dealer Copy -- Not for Resale

P-90226

Remove the hydraulic controllers (Item 1) [Figure 30-40-

19]. (See Hydraulic Controller Removal And Installation
on Page 30-40-2.)

Figure 30-40-20
3 3
2 2
1 1

3
3

P-90227

Swash plate angle sensors (Item 1) are mounted on the

bottom of the hydrostatic pump. They are protected by
steel covers (Item 2) [Figure 30-40-20].

Remove the two bolts (Item 3) and the steel cover (Item
2) [Figure 30-40-20] from both sides.

Assembly: Tighten bolts to 51 N•m (38 ft-lb) torque.

NOTE: The connectors are faced towards each other.

306 of 822 30-40-10 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Right End Housing

Disassembly And Assembly (Cont'd) Figure 30-40-24

Figure 30-40-22
3
1

1
1
P-64445

P-90217
Left End Housing

Assembly: Note the slotted portion (Item 1) of the Figure 30-40-25

positioning pin tightly fits the machined section on the

Dealer Copy -- Not for Resale

swash plate angle sensor shaft (Item 2) [Figure 30-40- 3 1
22].

Figure 30-40-23

1
2

P-64447

Remove the four mount bolts (Item 1) securing the end

housing (Item 2) to the main case housing (Item 3)
P-90218 [Figure 30-40-24] and [Figure 30-40-25].

Assembly: Alternately, tighten mount bolts to 130 N•m

Check and replace the O-ring (Item 1) [Figure 30-40-23]. (96 ft-lb) torque.

307 of 822 30-40-11 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-28

Disassembly And Assembly (Cont'd)

Figure 30-40-26

P-64466

Ensure servo follower (Item 2) [Figure 30-40-27] is

P-64464 swung out for proper engagement with the notch in the
servo piston (Item 1) [Figure 30-40-28].

Pull the end housings from the case housing [Figure 30- Figure 30-40-29
40-26].

Dealer Copy -- Not for Resale

Figure 30-40-27

1 1 2
2

P-64463

P-64465 Assembly: Ensure dowel pin (Item 1) is aligned with hole

in case housing (Item 2) [Figure 30-40-29] before
tightening screws.
Replace O-ring (Item 1) [Figure 30-40-27].

308 of 822 30-40-12 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D)

Disassembly And Assembly (Cont'd)

Figure 30-40-30

RIGHT SIDE

P-64454

Figure 30-40-31

Dealer Copy -- Not for Resale

LEFT SIDE

P-64501

Remove valve plate (Item 1) [Figure 30-40-30] and

[Figure 30-40-31] from the case housing.

Inspect valve plate for scratches or scoring. Replace a

valve plate if the scratches are deep enough to catch with
a fingernail.

NOTE: Pay attention to the notches (Item 2) [Figure

30-40-30] and [Figure 30-40-31] in the valve
plate for assembly reasons. There are
different valve plates for the left and right
side. The valve plates are NOT
interchangeable.

309 of 822 30-40-13 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-35

Disassembly And Assembly (Cont'd)

LEFT SIDE
Figure 30-40-32 1
2
RIGHT SIDE

1 P-64503

2
Assembly: Align the timing pin (Item 1) [Figure 30-40-
P-64455 32] and [Figure 30-40-33] in the case housing with the
notch (Item 1) [Figure 30-40-34] and [Figure 30-40-35]
that does not go through the valve plate.
Figure 30-40-33
Align the shoulder of the roller bearing (Item 2) [Figure

Dealer Copy -- Not for Resale

LEFT SIDE 30-40-32] and [Figure 30-40-33] with the beveled edge
on the valve plate (Item 2) [Figure 30-40-34] and [Figure
30-40-35].

NOTE: Valve plate should sit FLUSH with the case

housing when properly installed.

1
2

P-64502

Figure 30-40-34

RIGHT SIDE

1
2

P-64456

310 of 822 30-40-14 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-38

Disassembly And Assembly (Cont'd)

Figure 30-40-36
1

P-64469

Remove the piston assembly (Item 1) [Figure 30-40-38].

B25012
Figure 30-40-39

Right Side Rotating Group [Figure 30-40-36].

Dealer Copy -- Not for Resale

Figure 30-40-37
1

P-64475

Remove the pistons (Item 1) [Figure 30-40-39] from the

B25011 rotating block.

Left Side Rotating Group [Figure 30-40-37].

311 of 822 30-40-15 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-42

Disassembly And Assembly (Cont'd)

1
Figure 30-40-40

P-64471

Remove the spherical washer (Item 1) [Figure 30-40-

P-64476 42].

Figure 30-40-43
Inspect the pistons, look for scoring and scratches.
Ensure the holes (Item 1) [Figure 30-40-40] in the
1

Dealer Copy -- Not for Resale

slippers, are not plugged.

Figure 30-40-41
1

P-64472

Inspect the pins (Item 1) [Figure 30-40-43]. They should

be all the same length. Do not remove.
P-64477

Inspect the mating surface of the spherical washer for

scoring or scratches (Item 1) [Figure 30-40-41].

312 of 822 30-40-16 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-46

Disassembly And Assembly (Cont'd)

3
Figure 30-40-44
1
1

P-64479

Inspect mating surface for the slippers on the swash

P-64474 plate (Item 1) [Figure 30-40-46].

Remove the swash plate from the endcap housing (Item

Inspect the spherical washer for scoring and wear (Item 2) [Figure 30-40-46].
1) [Figure 30-40-44].

Dealer Copy -- Not for Resale

Remove the slide ring (Item 3) [Figure 30-40-46], ensure
Figure 30-40-45 it pivots freely.

Figure 30-40-47
1

3 1

P-64478

P-64480
Inspect the back surface of the rotating block (Item 1)
[Figure 30-40-45] where the valve plate seals. Ensure
there is no scratches or scoring. Assembly: Carefully align bearing pin eyelets (Item 1)
into holes in endcap housing (Item 2) [Figure 30-40-47].
Visually ensure spring (Item 2) and c-clip (Item 3) [Figure
30-40-45] are not bent or damaged.

313 of 822 30-40-17 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-50

Disassembly And Assembly (Cont'd) 2

1 1
Figure 30-40-48

1 P-64483

Remove the shell bearing races (Item 1) [Figure 30-40-

P-64481 50].

Assembly: Note shell bearing races have an edge (Item

Assembly: Ensure bearing pins are in the holes of the 2) [Figure 30-40-50] on them. The edges face towards
swash plate (Item 1) [Figure 30-40-48]. the outside of the endcap housing

Dealer Copy -- Not for Resale

Figure 30-40-49 Inspect bearing surfaces for scratches or scoring.

Remove the positioning pin (Item 3) [Figure 30-40-50].

2
Figure 30-40-51

2 1

P-64482

Remove the shell bearing (Item 1) [Figure 30-40-49].

P-64485
Inspect individual roller bearings and machined surfaces
(Item 2) [Figure 30-40-49] on swash plate.
Replace O-ring (Item 1) [Figure 30-40-51].

Inspect wear surfaces (Item 2) [Figure 30-40-51] for

scratches or scoring. Ensure positioning pin can rotate
smoothly in the end housing without excessive play.

314 of 822 30-40-18 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-54

Disassembly And Assembly (Cont'd)

Figure 30-40-52

LEFT SIDE

1
P-76742

The pump seal (Item 1) [Figure 30-40-54] is removed by

P-64486 inserting a screw into the seal and prying out.

Figure 30-40-55
Figure 30-40-53

RIGHT SIDE

Dealer Copy -- Not for Resale

1

P-64488
P-76743

The drive shaft can be tapped out of the end housing with
Remove the snap ring (Item 1) [Figure 30-40-52] and a rubber mallet.
[Figure 30-40-53] from the end housing.
Inspect wear surfaces for scratches, and inspect splines
for excessive wear.

Inspect bearing (Item 1); if bearing needs replacement,

remove snap ring (Item 2) [Figure 30-40-55] and remove
bearing.

315 of 822 30-40-19 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-58

Disassembly And Assembly (Cont'd)

Figure 30-40-56

1 1

P-90232

Remove servo piston mounting bolts (Item 1) [Figure 30-

40-58].

Installation: Tighten bolts to 10,4 N•m (7.7 ft-lb) torque.

Figure 30-40-59

Dealer Copy -- Not for Resale

B25013

Servo Piston Assembly [Figure 30-40-56].

1
The Servo Piston Assembly [Figure 30-40-56] cannot be
removed unless the hydraulic controller and rotating
group is removed first.

Figure 30-40-57

P-90231

Use a rubber mallet to rotate servo piston cover (Item 1)

[Figure 30-40-59].

P-64490

Measure and record servo piston depth at the adjustment

screw [Figure 30-40-57].

316 of 822 30-40-20 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-62

Disassembly And Assembly (Cont'd)

Figure 30-40-60

P-64467

Measure with a straight-edge [Figure 30-40-62].

P-90237
Figure 30-40-63

Slide the servo piston assembly out of the bore. [Figure

30-40-60].

Dealer Copy -- Not for Resale

1
Figure 30-40-61
2
1

2
1

P-64493

Remove the bushings (Item 1), seals and O-rings (Item

2) [Figure 30-40-63] from the pump housing.
P-64466

Assembly: Align the servo piston so the guide slot

(Item 1) [Figure 30-40-61] is parallel to the driveshaft
centerline.

317 of 822 30-40-21 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-66

Disassembly And Assembly (Cont'd)

Figure 30-40-64 1

2
P-64496

3 Remove the servo cover (Item 1) [Figure 30-40-66] from

P-64494 the servo piston.

Figure 30-40-67
Each servo has a pair of bushings (Item 1), O-rings (Item
2) and square-cut seals (Item 3) [Figure 30-40-64].

Dealer Copy -- Not for Resale

Figure 30-40-65

P-64497
1
Remove snap ring (Item 1) [Figure 30-40-67] from the
P-64495 servo piston.

Remove the lock nut (Item 1) [Figure 30-40-65] from the

servo piston.

Assembly: Tighten lock nut to 30 N•m (22 ft-lb) torque.

318 of 822 30-40-22 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Mechanical Neutral Adjustment

Disassembly And Assembly (Cont'd) The pump mechanical neutral adjustment sets the
position of the servo piston and pump swash plate
Figure 30-40-68 relative to the hydraulic controller. This procedure should
be followed if the hydrostatic pump has been
1 disassembled for servicing the servo piston and the
2 setting has been disrupted.

Place the loader on jackstands. (See Procedure on Page

10-10-1.)

WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
P-64498
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Remove the piston stop adjustment mechanism (Item 1)
[Figure 30-40-68] from the servo piston. Raise the lift arms, and install an approved lift arm

Dealer Copy -- Not for Resale

support device. (See Installing on Page 10-20-1.)
Inspect mechanism for broken parts.
Raise the operator cab. (See Raising on Page 10-30-1.)
Replace O-ring (Item 2) [Figure 30-40-68]
Connect the remote start tool. (See REMOTE START
Figure 30-40-69 TOOL KIT-MEL1563 on Page 10-60-1.) or (See
REMOTE START TOOL (SERVICE TOOL) KIT -
7003031 on Page 10-61-1.)

Disconnect the swash plate angle sensors in the

electrical harness. This prevents unwanted swash plate
movement error codes from occurring during
2 adjustments. Disconnecting the sensors does not have to
be done directly at the sensor, follow the harness back to
1 find an accessible connector to disconnect.

Disconnect the speed sensors located on the top of the

motor carriers. This prevents uncommanded wheel
movement error codes from occurring during
adjustments.
P-64502

Bearings (Item 1) [Figure 30-40-69] in case housing are

replaced by using a press and bearing driver. WARNING
Inspect center coupler (Item 2) [Figure 30-40-69].
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290

319 of 822 30-40-23 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-72

Mechanical Neutral Adjustment (Cont’d)

Figure 30-40-70
1

P-64438

Remove the plugs (Item 1) [Figure 30-40-72] from the

P-64973 MA ports on the bottom of the pump, and install 52 MPa
(517 bar) (7500 psi) pressure gauges.

Connect a hydraulic hose (Item 1) [Figure 30-40-70] Figure 30-40-73

between port X1 and port X2 on each side of the

Dealer Copy -- Not for Resale

hydrostatic pump, to equalize the pressures on both ends
of the servo pistons.

Figure 30-40-71
1 1
1
1

1 1

P-90243

Remove drive hoses from the A and B ports (Item 1)

[Figure 30-40-73]. Plug the ports with metal caps. The
P-90242 caps must be able to handle at least 51,7 MPa (517 bar)
(7500 psi). Plugging the A and B ports eliminates leakage
at the drive motors from causing errors in the pump
Remove the plugs (Item 1) [Figure 30-40-71] from the mechanical neutral setting.
MB ports on the front side of the pump, and install 51,7
MPa (517 bar) (7500 psi) pressure gauges.

320 of 822 30-40-24 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-76

Mechanical Neutral Adjustment (Cont’d)

Figure 30-40-74

1 1

P-90238

Turn the adjustment screw (Item 1) [Figure 30-40-76]

P-90226 counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the
adjustment screw.
Loosen the pump neutral adjustment lock nut (Item 1)
[Figure 30-40-74]. Figure 30-40-77

Dealer Copy -- Not for Resale

Start the loader using the remote start tool and run at idle.

WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297

1
Figure 30-40-75

P-90238

Turn the adjustment screw (Item 1) [Figure 30-40-77]

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.

P-90238

Turn the adjustment screw (Item 1) [Figure 30-40-75]

clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.

321 of 822 30-40-25 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Hydraulic Controller Neutral Adjustment

Mechanical Neutral Adjustment (Cont’d) The hydraulic controller neutral adjustment, aligns the
pump swash plate and the control spool so that a zero
Figure 30-40-78 angle control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
any part of the control or swash plate mechanisms are
adjusted or removed or after the pump mechanical
neutral setting is adjusted. Ensure the pump mechanical
neutral setting is correct before performing hydraulic
controller neutral adjustments.

NOTE: Procedure is shown for the left side hydraulic

2
controller. Procedure is the same for the right
side hydraulic controller, except you
disconnect the electrical connectors for the
1 right side hydraulic controller and connect
pressure gauges in the X1 and X2 ports on the
right side of the pump.
P-90238
Place the loader on jackstands. (See Procedure on Page
10-10-1.)
While holding the adjustment screw (Item 1) in position,
tighten the lock nut (Item 2) [Figure 30-40-78] to 30 N•m

Dealer Copy -- Not for Resale

(22 ft-lb) torque.

Shut loader OFF.

WARNING
Remove the hydraulic hose from the X1 and X2 ports on Put jackstands under the front axles and rear corners
the pump. Install the plugs and tighten to 25 N•m (18 ft- of the frame before running the engine for service.
lb) torque. Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
Remove the pressure gauges from the MA and MB ports W-2017-0286
on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque. Raise the lift arms, and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
NOTE: The Hydraulic Controller Neutral Adjustment
must be performed whenever the Mechanical Raise the operator cab. (See Raising on Page 10-30-1.)
Neutral Adjustment is done. (See Hydraulic
Controller Neutral Adjustment on Page 30-40- Connect the remote start tool. (See REMOTE START
26.) TOOL KIT-MEL1563 on Page 10-60-1.) or (See
REMOTE START TOOL (SERVICE TOOL) KIT -
7003031 on Page 10-61-1.)

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

322 of 822 30-40-26 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-81

Hydraulic Controller Neutral Adjustment (Cont’d)

Figure 30-40-79

P-64975

1 Install 2,44 MPa (34,5 bar) (500 psi) pressure gauges in

P-90239 the X1 and X2 ports pertaining to the side of the
hydrostatic pump you are adjusting.

Disconnect the hydraulic controller connectors (Item 1) Figure 30-40-82

[Figure 30-40-79] from the loader wiring harness for the

Dealer Copy -- Not for Resale

hydraulic controller you are adjusting.

Figure 30-40-80

1
1

P-90236

Loosen the locking screw (Item 1) [Figure 30-40-82].

P-90226
Start the loader using the remote start tool and run at an
idle.
Remove the X1 plug (Item 1) and X2 plug (Item 2)
[Figure 30-40-80] pertaining to the side of the hydrostatic
pump you are adjusting.

WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297

323 of 822 30-40-27 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-85

Hydraulic Controller Neutral Adjustment (Cont’d)

Figure 30-40-83

P-90236

Turn the adjustment screw (Item 1) [Figure 30-40-85]

P-90236 clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
Turn the adjustment screw (Item 1) [Figure 30-40-83]
clockwise, until one of the gauges registers an increase Figure 30-40-86

Dealer Copy -- Not for Resale

in system pressure. Mark the position of the adjustment
screw.

Figure 30-40-84

1
2

P-90236

While holding the adjustment screw (Item 1) in position,

P-90236 tighten the locking screw (Item 2) [Figure 30-40-86] to
6,1 N•m (4.5 ft-lb) torque.

Turn the adjustment screw (Item 1) [Figure 30-40-84] Shut loader OFF.
counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the Remove the pressure gauges from the X1 and X2 ports
adjustment screw. on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque.

Connect the hydraulic controller wire connectors to the

loader wiring harness.

Perform a controller calibration procedure. (See

CALIBRATION on Page 60-150-1.)

324 of 822 30-40-28 T870 Service Manual

DRIVE BELT Belt Replacement

Belt Adjustment Stop the engine and open the rear door.

The drive belt does not need adjustment. The belt has a Remove the battery. (See Removal And Installation on
spring loaded idler which constantly maintains the correct Page 60-20-1.)
belt tension.
Figure 30-50-3
Stop Adjustment

See your SERVICE SCHEDULE for the correct interval to

check the idler stop adjustment. (See SERVICE
SCHEDULE on Page 10-70-1.)
1
Stop the engine and open the rear door.

Figure 30-50-1

P-90724A

Dealer Copy -- Not for Resale

2 Remove the drive belt shield bolt (Item 1) [Figure 30-50-
3].

Figure 30-50-4

P-90470

1
Loosen the spring loaded idler adjustment bolt (Item 1)
and insert a 12,7 mm (0.5 in) breaker bar (Item 2)
[Figure 30-50-1] into the slot provided in the stop arm as
shown.
2
Figure 30-50-2

1
P-90467

Do NOT loosen the drive belt shield mounting bolts (top

bolt shown) (Item 1). Slide the drive belt shield (Item 2)
toward the back of the loader to unseat the shield from
the top and bottom drive belt shield mounting bolts.
Remove the drive belt shield (Item 2) [Figure 30-50-4].
P-90471

Move the breaker bar to adjust the stop arm until a gap of
3,2 mm (0.125 in) (Item 1) [Figure 30-50-2] is achieved.

Tighten the spring loaded idler adjustment bolt (Item 1)

[Figure 30-50-1] to 105 - 115 N•m (78 - 85 ft-lb) torque.

325 of 822 30-50-1 T870 Service Manual

DRIVE BELT (CONT’D) Figure 30-50-7

Belt Replacement (Cont’d) Top Mounting Bolt

Figure 30-50-5

P-90468A

2
Bottom Mounting Bolt

P-90470

Loosen the spring loaded idler adjustment bolt (Item 1).

Insert a 12,7 mm (0.5 in) breaker bar (Item 2) [Figure 30-
50-5] into the slot provided in the stop arm as shown and P-90469A

Dealer Copy -- Not for Resale

push breaker bar down to release tension on drive belt.
Tighten the adjustment bolt (Item 1) [Figure 30-50-5] to Position the drive belt shield over the drive belt shield
hold the spring loaded idler off the drive belt. mounting bolts and slide the drive belt shield toward the
Remove the drive belt from the hydrostatic pump pulley front of the loader to fully seat the shield onto the top and
and flywheel pulley. Inspect the pulleys for wear. bottom mounting bolts (Items 1 and 2) [Figure 30-50-7].

Install new drive belt. Figure 30-50-8

Loosen the spring loaded idler adjustment bolt (Item 1)
[Figure 30-50-5] and allow the idler to contact the drive
belt.
Figure 30-50-6

P-90724A

Install the drive belt shield bolt (Item 1) [Figure 30-50-8].

P-90471 Install the battery. (See Removal And Installation on

Page 60-20-1.)
Move the breaker bar to adjust the stop arm until a gap of
3,2 mm (0.125 in) (Item 1) [Figure 30-50-6] is achieved. Close the rear door.

Tighten the spring loaded idler adjustment bolt (Item 1)

[Figure 30-50-5] to 105 - 115 N•m (78 - 85 ft-lb) torque.

326 of 822 30-50-2 T870 Service Manual

DRIVE BELT (CONT’D) Tensioner Pulley Disassembly And Assembly

Tensioner Pulley Removal And Installation Figure 30-50-11

Remove the engine air cleaner. (See Housing Removal

And Installation on Page 70-40-1.)
1
Remove the belt. (See Belt Replacement on Page 30-50-
1.)

Figure 30-50-9 2

1
1

3
P-90306

2
Loosen the two bolts (Item 1) [Figure 30-50-11] but do
not remove.

Release the spring tension by allowing the adjustment

Dealer Copy -- Not for Resale

plate (Item 2) to slide past the tensioner pulley stop (Item
P-85520 3) [Figure 30-50-11].

Remove the two bolts (Item 1) and the adjustment plate

Loosen the spring loaded idler adjustment bolt (Item 1). (Item 2) [Figure 30-50-11].
Insert a 1/2 in breaker bar (Item 2) [Figure 30-50-9] into
the slot provided in the stop arm as shown and push Figure 30-50-12
breaker bar down to release tension on drive belt.

Tighten adjustment bolt (Item 1) [Figure 30-50-9] to hold

the spring loaded idler off the drive belt.

Figure 30-50-10

1 1
2

P-90304

Remove the pivot sleeve (Item 1) [Figure 30-50-12].

P-85741

Remove the two mounting bolts (Item 1) [Figure 30-50-

10].

Remove the tensioner pulley (Item 2) [Figure 30-50-10].

327 of 822 30-50-3 T870 Service Manual

DRIVE BELT (CONT'D)

Tensioner Pulley Disassembly And Assembly

(Cont’d)

Figure 30-50-13

P-90303

Disassembly the tensioner pulley as shown [Figure 30-

Dealer Copy -- Not for Resale

50-13].

Check the parts for wear and replace as needed.

NOTE: The wheel and arm assembly (Item 1) [Figure

30-50-13] are not serviceable and must be
replaced as a complete assembly.

328 of 822 30-50-4 T870 Service Manual

DRAIN MANIFOLD Figure 30-60-2

Description

The drain manifold is an external assembly in the drain

circuit that returns the hydraulic oil to the reservoir.
2
Drain Manifold Removal And Installation

IMPORTANT 2

2
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
P100002
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Disconnect the wiring harness from the oil temperature
I-2003-0888 switch (Item 1) [Figure 30-60-2].

Raise the operator cab. (See Raising on Page 10-30-1.) Remove the three hoses (Item 2) [Figure 30-60-2].

Drain the hydraulic reservoir. (See Removing And Mark and cap all hoses and tubelines.

Dealer Copy -- Not for Resale

Replacing Hydraulic Fluid on Page 10-120-2.)
Figure 30-60-3
Figure 30-60-1

1
1

1
2

P100003
P100001

Remove the two hoses (Item 1) [Figure 30-60-3].

Remove the tubeline (Item 1) [Figure 30-60-1] from the
drain manifold. Remove the two bolts and nuts (Item 2) [Figure 30-60-3].

Mark and cap all hoses and tubelines. Mark and cap all hoses and tubelines.

329 of 822 30-60-1 T870 Service Manual

 Dealer Copy -- Not for Resale

330 of 822 30-60-2 T870 Service Manual

 DRIVE SYSTEM

BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-2

TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION) . . . . . . . . . . . 40-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Checking Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
Adjusting Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-3
Track Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-4
Idler (Front) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-6
Track Tensioner Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-9
Idler (Rear) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-20-11
Roller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-20-11
Leaf Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-12
Sprocket Removal And Installation (Single Speed) . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-13
Sprocket Removal And Installation (Two Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-13
Track Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-14

Dealer Copy -- Not for Resale

TRACK MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Track Damage Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

331 of 822 40-01 T870 Service Manual

 Dealer Copy -- Not for Resale

332 of 822 40-02 T870 Service Manual

BRAKE

Description WARNING
Figure 40-10-1
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)

1 Raise the operator cab. (See Raising on Page 10-30-1.)

Figure 40-10-2

P-85426

The brake is used to hold the machine in place. The

brake is operated by a switch (Item 1) [Figure 40-10-1] 2
3

Dealer Copy -- Not for Resale

located on the left panel.
2
Block Removal And Installation 3

2
DANGER 1

P100374

Disconnect the electrical connector (Item 1) [Figure 40-

10-2] located on the side of the transmission.

Mark the hydraulic hoses for proper installation.

P-90328 Remove and cap the four hydraulic hoses (Item 2)

[Figure 40-10-2].
AVOID DEATH
• Disconnecting or loosening any hydraulic
Remove the two mount bolts (Item 3) [Figure 40-10-2].
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Remove the brake block from the loader.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409

333 of 822 40-10-1 T870 Service Manual

BRAKE (CONT'D) Figure 40-10-5

Block Disassembly And Assembly 1

2 1
Figure 40-10-3 2 1

2
2 3
1
2

P-85432

2
Inspect the O-rings (Item 1) and back-up ring (Item 2)
P-85431 [Figure 40-10-5] on the solenoid valve and replace as
needed.

Loosen the electrical brake solenoid nut (Item 1) and the Check the screens (Item 3) [Figure 40-10-5] and clean
three fittings (Item 2)[Figure 40-10-3]. with solvent.

Dealer Copy -- Not for Resale

Assembly: Tighten the solenoid nut to 5,4 - 6,8 N•m (48 - Assembly: Tighten the solenoid valve to torque.
60 in-lb) torque.

Figure 40-10-4

2
1

P-85429

Remove the solenoid nut (Item 1) and solenoid coil (Item

2) [Figure 40-10-4].

Remove the solenoid valve (Item 3) [Figure 40-10-4]

from the block.

334 of 822 40-10-2 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER
SUSPENSION)

Description

Figure 40-20-1

Dealer Copy -- Not for Resale

P-85368

The track carriage components consist of front and rear

idlers, rollers, leaf springs, the track, track tensioner, the
drive sprocket and the track housing [Figure 40-20-1].

335 of 822 40-20-1 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Figure 40-20-3
SUSPENSION) (CONT'D)

Checking Tension

Correct track tension is important for good performance

and to prevent the tracks from derailing or wearing
prematurely.

NOTE: The wear of track rollers vary with the working

conditions and different types of soil
conditions.

Park the loader on a level surface.

Figure 40-20-2
P-85379B

Figure 40-20-4

Dealer Copy -- Not for Resale

13 mm Track
Roller
(1/2 in)

P100255B

Track
Raise one side of the loader and put jackstands at the B-18896C
front and rear of the loader frame so that the track is
about 76,2 mm (3 in) off the ground [Figure 40-20-2].
Lower the loader to the jackstands. Be sure the DO NOT put your fingers into the pinch points between
jackstands do not touch the tracks. the track and the roller. Use a 13 mm (1/2 in) bolt, dowel
or block to check the gap [Figure 40-20-3] and [Figure
Measure the track sag at either middle track roller (Item 40-20-4].
1) [Figure 40-20-2]. The correct gap is 13 mm (1/2 in).

WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
checking the track tension.
W-2142-0903

336 of 822 40-20-2 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Figure 40-20-6
SUSPENSION) (CONT'D)

Adjusting Tension

Figure 40-20-5

2 1

1
2 P-76047

Pressure must be released from the grease cylinder to

1 decrease track tension.

P-76325
Install the bleed tool (MEL-1560) on the bleed fitting (Item
1), adjust and tighten the collar (Item 2) [Figure 40-20-6]
to fit behind the edge of the access cover.
Loosen the access cover bolts and pivot the access
cover open [Figure 40-20-5].

Dealer Copy -- Not for Resale

Figure 40-20-7

NOTE: Fittings may be oriented differently than

shown. You MUST select the correct fitting for
the task required. The grease fitting (Item 1) is
used to add grease. The bleed fitting (Item 2)
[Figure 40-20-5] is used to remove grease. 1

Increase Track Tension

Add grease to the grease fitting (Item 1) [Figure 40-20-5]

until the track adjustment is correct [Figure 40-20-3] and
[Figure 40-20-4].

NOTE: Do not remove grease fitting unless pressure P-76837

is released using the bleed fitting. (See
[Figure 40-20-6] on Page 40-20-3)
Tighten the access cover bolt (Item 1) [Figure 40-20-7]
NOTE: If replacement is necessary, always replace to secure the tool.
grease fitting (Item 1) [Figure 40-20-5] with
genuine Bobcat Parts. The fitting is a special Turn the tool 90° counterclockwise and let the grease
fitting designed for high pressure. flow into a container. Release pressure [Figure 40-20-7]
until the track adjustment is correct [Figure 40-20-3] and
Decrease Track Tension [Figure 40-20-4].

Tighten the bleed fitting. Pivot the access cover closed

WARNING and tighten the access cover bolts.

Raise the loader. Remove the jackstands.

HIGH PRESSURE GREASE CAN
CAUSE SERIOUS INJURY Repeat the procedure for the other track.
• Do not loosen grease fitting.
• Do not loosen bleed fitting more than 1 - 1/2 Dispose of grease in an environmentally safe manner.
turns.
W-2781-0109

337 of 822 40-20-3 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER
SUSPENSION) (CONT'D)

Track Removal And Installation IMPORTANT

Fluid such as engine oil, hydraulic fluid, coolants,

DANGER grease, etc. must be disposed of in an

environmentally safe manner. Some regulations
require that certain spills and leaks on the ground
must be cleaned in a specific manner. See local, state
and federal regulations for the correct disposal.
I-2067-0499

It may be necessary to adjust the MEL tool to loosen the

bleed fitting an additional turn after the pressure is
released from the first 90° turn. This will allow the grease
P-90328 to flow out faster when lifting the track in the next step.
You MUST pivot the access cover against the MEL tool
AVOID DEATH and tighten the mount bolt (Item 1) [Figure 40-20-7]
• Disconnecting or loosening any hydraulic before continuing.
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. Figure 40-20-8
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm

Dealer Copy -- Not for Resale

support. Replace if damaged.
D-1009-0409

Lift and block the loader. (See Procedure on Page 10-10-

1.)

Raise the lift arms and install an approved lift arm support 1
device. (See Installing on Page 10-20-1.)

WARNING P-85380

Never work on a machine with the lift arms up unless

the lift arms are secured by an approved lift arm With a chain hoist, lift on the track moving the front idler
support device. Failure to use an approved lift arm assembly toward the rear of the track housing assembly
support device can allow the lift arms or attachment until all track tension has been released [Figure 40-20-
to fall and cause injury or death. 8].
W-2059-0598
Tighten the bleed fitting using the MEL1560 tool (Item 1)
Decrease the track tension. (See Adjusting Tension on [Figure 40-20-8].
Page 40-20-3.)

NOTE: When the loader is on jack stands be sure the

bottom of the track clears the floor by at least
76,2 mm (3 in).

338 of 822 40-20-4 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Figure 40-20-10
SUSPENSION) (CONT'D)

Track Removal And Installation (Cont’d)

Figure 40-20-9

P-85369

With a chain hoist lift the track clear of the drive sprocket
and remove the track from the loader [Figure 40-20-10].
P-85370
Installation: Completely retract the front idler / track
tensioner.
With pry bars, pry the track up and over the front idler
[Figure 40-20-9].

Dealer Copy -- Not for Resale

Put the track on the front idler wheel.

Completely remove the track from the front track Put the track over the rear drive sprocket lugs.
assembly.
Slide the track under the rollers.

Put the track over the rear idler.

NOTE: Check the alignment of the grease tube (Item

1) [Figure 40-20-19] before adjusting the track.

Adjust the track to the proper tension. (See Adjusting

Tension on Page 40-20-3.)

339 of 822 40-20-5 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Figure 40-20-13
SUSPENSION) (CONT'D)

Idler (Front) Removal And Installation

1 1
Remove the track. (See Track Removal And Installation
on Page 40-20-4.)

Figure 40-20-11

P-73967

Installation: Two short 9,5 mm (3/8 in) bolts (Item 1)

1 [Figure 40-20-13] may be inserted to keep the front idler
wheel in place until the track is installed.

NOTE: The bolts must be removed before completing

P-76843 track installation. It will not be possible to

Dealer Copy -- Not for Resale

remove the bolts after track tension has been
set.
Slide the front idler wheel out of the track housing
[Figure 40-20-11].

NOTE: The notch on the front idler wheel frame (Item

1) [Figure 40-20-11] is toward the top of the
track housing for installation.

Figure 40-20-12

P-76051

Installation: Make sure the pins (Item 1) [Figure 40-20-

12] on the front idler wheel frame engage the holes in the
track tensioner.

340 of 822 40-20-6 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Figure 40-20-16
SUSPENSION) (CONT'D)

Idler (Front) Removal And Installation (Cont’d)

Figure 40-20-14

P-76325

Installation: Track tensioner must be seated properly

against the end of the track housing [Figure 40-20-16].

Dealer Copy -- Not for Resale

P-76844

Slide the track tensioner (Item 1) [Figure 40-20-14] out

of the track housing.

Installation: Track tensioner must be oriented as shown

in [Figure 40-20-14] before sliding it into the track
housing.

Figure 40-20-15

1 2
P-76850

Installation: Track tensioner (Item 1) must slide into the

guide tube (Item 2) [Figure 40-20-15].

341 of 822 40-20-7 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Figure 40-20-19
SUSPENSION) (CONT'D)

Idler (Front) Removal And Installation (Cont'd) CORRECT

Figure 40-20-17

WRONG

2 2

1
1
P-85014A

Installation: When installing the track tensioner into the

loader verify the grease tube (Item 1) is properly seated
P-85371 against the coil spring assembly (Item 2) [Figure 40-20-
19].

Figure 40-20-18

Dealer Copy -- Not for Resale

WRONG

P-85014

Installation: [Figure 40-20-17] and [Figure 40-20-18]

shows the grease tube (Item 1) misaligned and not
seated properly against the coil spring assembly (Item 2).
[Figure 40-20-19] shows the grease tube (Item 1) and
the coil spring assembly (Item 2) properly assembled.

342 of 822 40-20-8 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Figure 40-20-21
SUSPENSION) (CONT'D)

Track Tensioner Disassembly And Assembly

WARNING 4

3
2

P-85018

P-62574
Remove the seal (Item 1), back-up ring (Item 2), O-ring
(Item 3), and wear ring (Item 4) [Figure 40-20-21] from
AVOID INJURY OR DEATH the grease tube.
• Spring loaded components under pressure can
cause serious injury or death. Installation: Apply oil to new O-ring, back-up ring, seal,
• Do not disassemble the coil spring assembly. and wear ring before installation.

Dealer Copy -- Not for Resale

W-2617-1004

Installation: Apply grease to area between seal and O-

Figure 40-20-20 ring before installing.

NOTE: The grease tube must be completely retracted

onto the chrome shaft before replacing the
2 grease fitting and adding grease, to prevent
air from being trapped in the grease tube.

P-85036

Remove the grease fitting (Item 1). Carefully apply low

pressure air to the grease fitting opening until the grease
tube (Item 2) slowly separates from the chrome shaft
(Item 3) [Figure 40-20-20].

343 of 822 40-20-9 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Figure 40-20-23
SUSPENSION) (CONT'D)

Track Tensioner Disassembly And Assembly (Cont’d) 8

WARNING
1 2 3 4 5 6 7

P-85019

Inspect and replace any damaged parts.

P-62574
The items listed below refer to [Figure 40-20-23].

AVOID INJURY OR DEATH 1. Coil Spring Assembly

• Spring loaded components under pressure can 2. O-ring
cause serious injury or death. 3. Chrome Shaft
• Do not disassemble the coil spring assembly. 4. Seal

Dealer Copy -- Not for Resale

W-2617-1004 5. Back-up Ring
6. O-ring
Figure 40-20-22 7. Wear Ring
8. Grease Tube
1
NOTE: The O-ring (Item 2) is used to secure the
chrome shaft (Item 3) to the coil spring
assembly (Item 1) [Figure 40-20-23] during the
installation of the track tensioner into the
track housing.

P-85372

DO NOT DISASSEMBLE OR REPAIR THE COIL

SPRING ASSEMBLY. THE COMPRESSION FORCE OF
THE SPRING EXCEEDS 4536 kg (10,000 lb).

NOTE: The coil spring assembly (Item 1) [Figure 40-

20-22] is only sold as a complete assembly
from Bobcat Parts.

344 of 822 40-20-10 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Roller Removal And Installation
SUSPENSION) (CONT'D)
Remove the track from the loader. (See Track Removal
Idler (Rear) Removal And Installation And Installation on Page 40-20-4.)

Remove the track. (See Track Removal And Installation Figure 40-20-25
on Page 40-20-4.)

Figure 40-20-24

1
1

2
2 P-85374

P-76847 Remove the bolt and washer (Item 1) [Figure 40-20-25]

Dealer Copy -- Not for Resale

from the roller shaft. (Both ends of the roller shaft.)

Remove the two mount bolts and washers (Item 1) Remove the roller from the track assembly.
[Figure 40-20-24].
Installation: Support the roller from underneath with a
Remove the rear idler from the loader. hydraulic floor jack and tighten the bolts to 1084,6 N•m
(800 ft-lb) torque.
Installation: Align the square sides of the idler shaft with
the notches in the track housing (Item 2) [Figure 40-20-
24].

Align the holes in the housing with the holes in the shaft.

Install the bolts and washers and tighten to 1084,6 N•m

(800 ft-lb) torque.

345 of 822 40-20-11 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Installation: Tighten the leaf spring bolts (Item 2)
SUSPENSION) (CONT'D) [Figure 40-20-26] and (Item 1) [Figure 40-20-27] to
406,7 N•m (300 ft-lb) torque.
Leaf Spring Removal And Installation
Figure 40-20-28
Remove the track from the loader. (See Track Removal
And Installation on Page 40-20-4.)

Figure 40-20-26

1
3
P-76930

Remove the leaf spring assembly [Figure 40-20-28] from

P-85375 the track housing.

Dealer Copy -- Not for Resale

NOTE: The leaf spring assembly [Figure 40-20-28] is
Remove the roller bolt and washer (Item 1) [Figure 40- only sold as a complete left-hand or right
20-26] from the roller shaft. (Both ends of the roller shaft.) hand assembly from Bobcat Parts.

Remove the roller from the track housing. Figure 40-20-29

Installation: Support the roller from underneath with a

hydraulic floor jack and tighten the bolts to 1084,6 N•m
(800 ft-lb) torque.

Remove the leaf spring bolts (Item 2) [Figure 40-20-26]

from the leaf spring mounts. (Both sides of the track
housing.)
1
Figure 40-20-27

P-76027

1 The upper and lower leaf spring mounts are wider on one
side to prevent the leafs from rubbing on the track
housing during operation.

Installation: The leaf springs are installed correctly when

P-85377 there is a slight gap (Item 1) [Figure 40-20-29] between
the leafs and the track housing. (Cutaway view shown for
clarity.) The gap is easily seen at the roller end of the leaf
Access the front, inside leaf spring assembly bolts (Item spring (Item 3) [Figure 40-20-26].
1) [Figure 40-20-27] from underneath the loader through
an access hole in the track housing.

346 of 822 40-20-12 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Sprocket Removal And Installation (Two Speed)
SUSPENSION) (CONT'D)
Figure 40-20-31
Sprocket Removal And Installation (Single Speed)

Figure 40-20-30 1

2
2
1
2

2
2
P100737A
2

P-85407 Remove the eight nuts (Item 1) [Figure 40-20-31] and

remove the drive sprocket from the motor.

Remove the six nuts (Item 1) [Figure 40-20-30] and NOTE: Install four (1/2” - 13UNC x 3 in) long bolts in
remove the drive sprocket from the motor.

Dealer Copy -- Not for Resale

the sprocket holes (Item 2) [Figure 40-20-31]
to aid in the removal of the sprocket.
NOTE: Install three (1/2” - 13UNC x 3 in) long bolts in
the sprocket holes (Item 2) [Figure 40-20-30] Installation: Tighten the nuts to 492 - 544 N•m (363 -
to aid in the removal of the sprocket. 401 ft-lb) torque.

Installation: Tighten the nuts to 280 - 300 N•m (207 -

222 ft-lb) torque.

347 of 822 40-20-13 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Figure 40-20-33
SUSPENSION) (CONT'D)

Track Housing Removal And Installation

NOTE: Jackstands used when removing the track

must not interfere with track housing removal. 1

Remove the track from the loader. (See Track Removal

And Installation on Page 40-20-4.)

Remove the hydrostatic motor from the track housing.

(See Removal And Installation on Page 30-20-2.)

Support the track housing.

P-76864
Figure 40-20-32

At the rear of the loader remove the two mount bolts

(Item 1) [Figure 40-20-33].

Installation: Tighten the mount bolts to 450 N•m (330 ft-

lb) torque.

Dealer Copy -- Not for Resale

1 Figure 40-20-34

1
1

P100387

Remove the six mounting bolts (Item 1) [Figure 40-20-

32] from the bottom track housing mount plate. (At the
front and rear of the loader.)

Installation: Tighten the mount bolts to 450 N•m (330 ft-

lb) torque.
P100388

At the front of the loader remove the two mount bolts

(Item 1) [Figure 40-20-34].

Remove the track housing from the loader.

Installation: Tighten the mount bolts to torque.

348 of 822 40-20-14 T870 Service Manual

TRACK MAINTENANCE Driving over sharp objects should be avoided. If this
is impossible, do not make turns while driving over
Track Damage Identification sharp objects.

The following pages show photos and illustrations of Cutting Of Steel Cords
track damage and the probable cause of the damage. It
is intended to be used for identifying the reason for track Figure 40-30-2
damage and how to avoid future track damage.

Track and Sprocket Rotation:

Figure 40-30-1
Move Sprockets to opposite sides of the loader

P-3864

Remove track

Dealer Copy -- Not for Resale

Reinstall 180° Figure 40-30-3

P-85440

NOTE: All applications and conditions will cause

wear on the track inbeds and sprocket teeth.
Rotating the tracks and sprockets will extend Steel Cords
their life. The track can be removed and PI-13034
reinstalled 180 degrees. The sprocket can be
removed and installed on the opposite side of
the loader [Figure 40-30-1]. Damage:

Prevention: Embedded steel cords are cut off [Figure 40-30-2]

and [Figure 40-30-3].
The following preventions should be taken to minimize
the risk of this damage:

Recommended track tension should be periodically

checked. (See DRIVE SYSTEM TOC on Page 40-
01.)

Avoiding quick turns on bumpy and rocky fields.

Drive carefully to avoid having stones and other

articles clog the rubber tracks.

349 of 822 40-30-1 T870 Service Manual

TRACK MAINTENANCE (CONT'D) Causes of the damage:

Track Damage Identification (Cont'd) When the track rollers, sprockets and idler gears roll over
the embedded metals, abrasion of embedded metals is
Abrasion Of Embedded Metals inevitable. The following cases sometimes accelerate
their abrasion:
Figure 40-30-4
Rubber tracks are driven with an extraordinary heavy
load on them.

Rubber tracks are used on sandy fields.

Prevention:

As long as rubber tracks are used under normal

operating conditions, abnormal abrasion is unlikely to
occur. The level of abrasion should be carefully checked
when the machines are used for dozing which generate a
heavy load for rubber tracks, and when they are operated
under a sandy field condition for a long time.

P-3865 Figure 40-30-6

Dealer Copy -- Not for Resale

Damage:

Embedded metals will gradually wear away by friction Minimum Wear

[Figure 40-30-4].

Figure 40-30-5

Excessive Wear

PI-13037A

Track Rotation:

Certain applications or conditions can cause wear on the

track inbeds and sprocket teeth. Rotating the tracks 180
degrees will help extend track life [Figure 40-30-6]. (See
PI-13037 Track Damage Identification on Page 40-30-1.)

Remove the track and rotate it 180 degrees on the same

Replacement: side of the loader. (See DRIVE SYSTEM TOC on Page
40-01.)
When track embedded metals are worn
approximately 50% or more, replace the track.
Example of excessive wear is shown in [Figure 40-
30-4] and [Figure 40-30-5].

350 of 822 40-30-2 T870 Service Manual

TRACK MAINTENANCE (CONT'D) Figure 40-30-8

Track Damage Identification (Cont'd)

Separation Of Embedded Metals

Figure 40-30-7
Idler

Rubber
track

PI-13039

Causes of the damage:

Embedded metals are adhered between the steel cords

P-4379 and the rubber body. The following cases generate
external forces greater than the adhesion strength,
causing separation of the embedded metals:

Dealer Copy -- Not for Resale

Damage:
When the idler continually rides on the projections of
Extraordinary outer forces applied to embedded embedded metals, the embedded metals will
metals cause their separation from the rubber track's eventually peel off [Figure 40-30-8].
body [Figure 40-30-7].
Figure 40-30-9
Replacement:

Even a partial separation of embedded metals

requires replacement of the track.
Guide

PI-13040

When a rubber track is detracked, it becomes stuck

between the guide or the undercarriage frame,
causing the separation of embedded metals [Figure
40-30-9].

351 of 822 40-30-3 T870 Service Manual

TRACK MAINTENANCE (CONT'D) Figure 40-30-11

Track Damage Identification (Cont'd)

Figure 40-30-10

Minimum
wear

Excessive
wear

PI-13041A

Sprocket Rotation:
PI-13041
Certain applications or conditions can cause wear on the
sprockets. Rotating the sprockets to the opposite side of
Excessively worn sprockets, example shown [Figure the loader will help extend sprocket life [Figure 40-30-
40-30-10] will pull embedded metals out of the track. 11]. (See Track Damage Identification on Page 40-30-1.)

Dealer Copy -- Not for Resale

Prevention: Remove the sprocket. (See DRIVE SYSTEM TOC on
Page 40-01.)
Similar to the prevention against the cutting of the steel
cords:

Recommended track tension should be periodically

checked. (See DRIVE SYSTEM TOC on Page 40-
01.)

Quick turns on bumpy and rocky fields should be

avoided.

352 of 822 40-30-4 T870 Service Manual

TRACK MAINTENANCE (CONT'D) Figure 40-30-13

Track Damage Identification (Cont'd) Embedded metal

Separation Of Embedded Metals Due To Corrosion

Figure 40-30-12
Good

Separation of
bonded rubber
cover

PI-13043

Causes of the damage:

Embedded metals are bonded to the rubber body. The

P-4378 following operating conditions cause embedded metals
to corrode, causing deterioration of the bonding, and
finally resulting in separation of the embedded metals

Dealer Copy -- Not for Resale

Damage: from the rubber body [Figure 40-30-13].

Due to corrosion of embedded metals, the adhesion Excessively salty fields, like the sea shore
to the rubber body deteriorates, resulting in complete
separation [Figure 40-30-12]. Strong acidic or alkali soil conditions

Replacement: Compost spread grounds

Even a partial separation of embedded metals On tracks that are out of adjustment, the track rollers,
requires a rubber track replacement. idlers and sprockets will gradually wear the rubber
surface at track roller side, causing exposure of the
embedded metals. Consequently the embedded metals
will corrode resulting in their separation from the rubber
body.

Prevention:

If rubber tracks are used under such field conditions as

described under (Causes of the damage), they should be
washed with plenty of water. After being completely
dried, they should be stored correctly.

When the bonded rubber cover is separated from the

embedded metal projections and the metals in the rubber
body become loose, it is time to consider replacement of
the rubber track.

353 of 822 40-30-5 T870 Service Manual

TRACK MAINTENANCE (CONT'D) Figure 40-30-15

Track Damage Identification (Cont'd)

Cuts On The Lug Side Rubber Cuts

Figure 40-30-14

PI-13045

Causes of the damage:

When rubber tracks drive over projections or sharp

P-4377 stones in the fields, the concentrated forces applied
cause cuts on the lug side rubber surface. In case of
making turns on projections, the lug side rubber surface

Dealer Copy -- Not for Resale

Damage: will have an even higher chance to be cut. If the cuts run
through the embedded steel cords, it might result in the
Cuts on the lug side rubber often occurs as one of the steel cords' breakage due to their corrosion. It is highly
most typical failure modes [Figure 40-30-14]. recommended to repair the cuts with cold vulcanization
rubber as soon as they are observed [Figure 40-30-15].
Replacement:
Prevention:
When a cut on the lug side rubber reaches the
embedded steel cords, it should be immediately Machine operators are requested to drive with great
repaired with cold vulcanization rubber. attention to the ground's surface especially in terrains of
the following type:

Construction sites

Demolition sites

Paths covered with rocks and wood

Concrete ridges

Stumpy fields

When operating on terrains as mentioned above, high

speed, quick turns and overloading should be avoided.

354 of 822 40-30-6 T870 Service Manual

TRACK MAINTENANCE (CONT'D) Causes of the damage:

Track Damage Identification (Cont'd) Because of wound stress applied to rubber tracks around
the undercarriage parts during operation, the fatigue
Cracks On The Lug Side Rubber Due To Fatigue especially causes cracks on the lug side rubber surface.
Once the cracks occur, they gradually deteriorate with
Figure 40-30-16 even small external cracks. Also when operating near
seashores or under cold temperatures, rubber tracks are
more likely to suffer from ozone cracks.

Prevention:

Rubber tracks are designed with special rubber

compounds to prevent cracks due to fatigue. However,
external injuries on the lug side rubber sometimes cause
more chance of cracking. Machine operators should
observe soil conditions when driving, so as not to cause
external injuries to the lug side rubber. In order to
minimize the occurrence of ozone cracks, attention
should be paid to the following instructions for
maintenance:
P-4382
Avoid exposing stored tracks to direct sun light.

Dealer Copy -- Not for Resale

Figure 40-30-17 Avoid exposing stored tracks to direct rain and snow
fall.

Store tracks in well ventilated warehouses.

Use the tracks at least once a month.

P-4380

Damage:

Small cracks around the root of the lug as a result from

operation fatigue [Figure 40-30-16] and [Figure 40-30-
17].

Replacement:

When the cracks reach so deep that they expose the

steel cords, track replacement is required.

355 of 822 40-30-7 T870 Service Manual

TRACK MAINTENANCE (CONT'D) Causes of the damage:

Track Damage Identification (Cont'd) Lug abrasion is more or less inevitable. Even if lug
abrasion is proceeding, the rubber track can be used.
Lug Abrasion However, as the traction performance deteriorates
accordingly, it is highly recommended to replace the
Figure 40-30-18 abraded tracks with new ones when the lug height
becomes less than 5 MM.

Prevention:

In order to prevent the rubber track from abnormal or

premature abrasion, the following operating conditions
should be avoided:

Making quick and repeated turns on concrete and

asphalt roads

Driving up and down hilly paths with slippage

Making frequent turns on paths covered with rocks

P-4381 and wood

Dealer Copy -- Not for Resale

Figure 40-30-19

Lug abrasion

PI-13049

Damage:

As its service time proceeds, the lug side inevitably

undergoes abrasion [Figure 40-30-18] and [Figure
40-30-19].

Replacement:

No replacement is required.

356 of 822 40-30-8 T870 Service Manual

TRACK MAINTENANCE (CONT'D) Figure 40-30-21

Track Damage Identification (Cont'd)

Cracks And Cuts On The Lug Side Rubber

Crack at the edge of Cut on lug side
Figure 40-30-20 embedded metal rubber

PI-13051

Causes of the damage:

When rubber tracks drive over sharp projections,

CD-13050 intensive stress is applied to the lug side rubber surface,
especially at the edges of embedded metals, causing
cracks and cuts in the area around the embedded metals

Dealer Copy -- Not for Resale

Damage: [Figure 40-30-21].

Sometimes cracks and cuts on the lug side rubber at Prevention:

the edges of the embedded metals can be observed
[Figure 40-30-20]. To avoid extensive stress applied to the lug root where
metals are embedded, machine operators are requested
Replacement: to avoid driving over stumps and ridges.

Basically, no replacement is required unless the cuts on

the lug side rubber are discovered all around the edges
of the embedded metals, as this will result in a complete
cut off.

357 of 822 40-30-9 T870 Service Manual

TRACK MAINTENANCE (CONT'D) Figure 40-30-23

Track Damage Identification (Cont'd)

Abrasion Of The Track Roller Side

Track roller
Figure 40-30-22
Abrasion

PI-13053

Causes of the damage:

The abrasion of the track roller side rubber surface

P-4383 occurs because of sand and gravel being clogged
between the rubber and the outside surface of the track
rollers. The stress pushes the sand and gravel against

Dealer Copy -- Not for Resale

Damage: the side of the rubber track to cause the abrasion [Figure
40-30-23].
The rubber surface on which track rollers run is
gradually abraded. It will end in the exposure of the The level of abrasion is highly dependent on terrain
embedded metals [Figure 40-30-22]. conditions. A higher level of abrasion will occur when the
rubber tracks are operated in fields covered with many
Replacement: stones and gravel. Small stones hardened with mud,
stuck to the track rollers increase the abrasion level. After
It is recommended to replace the rubber track when an extended period of abrasion, it will be more likely for
more than half of the embedded metals are exposed embedded metals to catch moisture through the
completely exposed. inside steel cords, which can cause breakage of steel
cords and separation of the metals from the rubber body.

Prevention:

After operation in wet fields containing many small

stones, wash off the mud that is stuck to the track rollers
completely. When operating on gravel paths and stony
grounds, machines should be driven slowly and the
turning radius should be big enough to prevent stones
and gravel from getting stuck to the track roller side
rubber.

358 of 822 40-30-10 T870 Service Manual

TRACK MAINTENANCE (CONT'D) Figure 40-30-26

Track Damage Identification (Cont'd)

Cuts On The Edges Of Track Roller Side

Figure 40-30-24

PI-13056

Causes of the damage:

This damage is caused by objects on the field or by

P-4384 interference with the machine frame.

In case of damage by objects on the operating ground:

Dealer Copy -- Not for Resale

Figure 40-30-25
The edges of rubber track are often deformed largely
due to a bumpy ground surface, stones and other
objects, which cause extensive stress on the edges
resulting in the damage. Especially, when a machine
drives over concrete ridges, this type of damage
Edge Edge easily occurs [Figure 40-30-26].

PI-13055

Damage:

Both edges of a rubber track have no special

reinforcements. It sometimes occurs during operation
that they are cut or torn off [Figure 40-30-24] and
[Figure 40-30-25].

Replacement:

In such case, the rubber track does not have to be

replaced.

359 of 822 40-30-11 T870 Service Manual

TRACK MAINTENANCE (CONT'D)

Track Damage Identification (Cont'd)

Cuts On The Edges Of Track Roller Side (Cont’d)

Figure 40-30-27

Cut

Tear

PI-13057

Dealer Copy -- Not for Resale

In case of damage by interference with the machine
frame

If a machine continues operating with rubber tracks

being detracked, the rubber tracks may get caught up
in the machine frame or undercarriage parts resulting
in damage. Furthermore, when a machine travels
along side slopes, the rubber tracks are deformed so
much that they come into contact with the machine
frame and undercarriage parts, which causes cutting,
gouging and rubbing of rubber tracks in the end
[Figure 40-30-27].

Prevention:

When traveling, a machine operator should be careful not

to drive over any projections on the ground. He should
also prevent rubber tracks from coming into contact with
concrete walls, ditches and ridges. If rubber tracks are
detracked, the machine should be stopped immediately
for retracting.

360 of 822 40-30-12 T870 Service Manual

 MAINFRAME

SEAT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2
Compression Spring Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-3

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Gas Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Gas Spring Bracket Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2

OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Lower Cushion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Lower Cushion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3
Back Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-4

Dealer Copy -- Not for Resale

3-Point Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-4

BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-40-5

BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-4
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-41-5

LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Stabilizer Bar Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Link Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-3

REAR GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

REAR DOOR (TAILGATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Striker Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-3

361 of 822 50-01 T870 Service Manual

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
Fuel Level Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
Fuel Fill Screen Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3

FUEL TANK (AUXILIARY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-81-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-81-1

CONTROL PEDALS AND LINKAGES (SCPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-3
Floor Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-4

CONTROL PANEL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

CONTROL PANEL (SCPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1

Dealer Copy -- Not for Resale

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1

CONTROL HANDLE / LEVER (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-110-1
Joystick Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-110-1
Joystick Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-110-2

CONTROL HANDLE / LEVER (SCPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Steering Handle Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Steering Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-2

ACCESS PANEL (INSIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

ACCESS PANEL (INSIDE) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1

WINDOW (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1

WINDOW (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1

WINDOW (SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1

362 of 822 50-02 T870 Service Manual

CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-2
Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-3
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-4
Checking Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-4

ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-3

LEFT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-3

RIGHT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-2

Dealer Copy -- Not for Resale

HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1

363 of 822 50-03 T870 Service Manual

 Dealer Copy -- Not for Resale

364 of 822 50-04 T870 Service Manual

SEAT BAR Installation: Tighten the nuts to 34 - 38 N•m (25 - 28 ft-
lb) torque.
Description
Lower the operator cab. (See Lowering on Page 10-30-
The seat bar is the secondary restraint system that has a 2.)
sensor that automatically stops the loader functions until
the seat bar is lowered. Figure 50-10-3

The seat bar is located in the operator cab.

Removal And Installation

Figure 50-10-1 1

P100290

Dealer Copy -- Not for Resale

2 Remove the seat bar (Item 1) [Figure 50-10-3] from the
operator cab.

P-85653 P100289 Reverse the above procedure to install the seat bar into
the operator cab.

Raise the seat bar (Item 1) [Figure 50-10-1].

Disconnect the seat bar sensor (Item 2) [Figure 50-10-1]

from the cab harness.

Lower the seat bar.

Raise the operator cab. (See Raising on Page 10-30-1.)

Figure 50-10-2

P-85652

Remove the seat bar mounting nuts (Item 1) [Figure 50-

10-2] (both sides).

365 of 822 50-10-1 T870 Service Manual

SEAT BAR (CONT'D) Installation: Tighten the mounting bolt (Item 2) [Figure
50-10-4] and [Figure 50-10-5] to 34 - 38 N•m (25 - 28 ft-
Disassembly And Assembly lb) torque.

Figure 50-10-4 Figure 50-10-6

4 6
5 5
7 4 6

3 3

2 9 8 2 7
10
1

1
P-90022 P-90023

Figure 50-10-5 Figure 50-10-7

Dealer Copy -- Not for Resale

4 4
5 5
9 8
3 6
3 6 2
2 10 7
1
7
1

N-19219 N-19220

Assemble the parts as shown for the left side of the seat Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-4] and [Figure 50-10- bar pivot assembly [Figure 50-10-6] and [Figure 50-10-
5]. 7].

Seat Bar Mount (Item 1) Seat Bar Mount (Item 1)

Mounting Bolt (Item 2) Mounting Nut (Item 2)
Keyed Plastic Bushing (Item 3) Pivot Bushing (Item 3)
Seat Bar (Item 4) Spacer Bushing (Item 4)
Magnetic Bushing Assembly (Item 5) Seat Bar (Item 5)
Pivot Bushing (Item 6) Keyed Plastic Bushing (Item 6)
Sensor Bracket (Item 7) Mounting Bolt (Item 7)
Sensor Mounting Nut (Item 8)
Sensor Mounting Bolt (Item 9) Installation: Tighten the mounting bolt (Item 7) [Figure
Mounting Nut (Item 10) 50-10-6] and [Figure 50-10-7] to 34 - 38 N•m (25 - 28 ft-
lb) torque.
Installation: Tighten the mounting bolt (Item 9) [Figure
50-10-4] and [Figure 50-10-5] to 5,6 - 7,9 N•m (50 - 70
in-lb) torque.

366 of 822 50-10-2 T870 Service Manual

SEAT BAR (CONT'D) Figure 50-10-9

Compression Spring Disassembly And Assembly

6 7
Figure 50-10-8

5
4 8

3
2
1
P-90028

Disassemble and assemble the seat bar compression

N-19222 spring and parts as shown in [Figure 50-10-9].

Bolt (Item 1)
Turn the bolt (Item 1) [Figure 50-10-8] and [Figure 50- Bushing (Item 2)
10-9] out of the clevis. Spring (Item 3)

Dealer Copy -- Not for Resale

Bushing (Item 4)
Assembly: Apply Loctite® #518 adhesive to the bolt Clevis (Item 5)
threads. Adjust the compression spring by turning the Pin (Item 6)
bolt in past the end of the clevis three turns. Bushing (Item 7)
Rue Ring (Item 8)
NOTE: For procedures requiring the use of Loctite®
#518 adhesive, thoroughly clean and dry
affected parts before the application of
Loctite® #518.

367 of 822 50-10-3 T870 Service Manual

 Dealer Copy -- Not for Resale

368 of 822 50-10-4 T870 Service Manual

OPERATOR CAB Figure 50-20-2

Gas Spring Removal And Installation

WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or 1
death.
W-2113-0288

Raise the operator cab (See Raising on Page 10-30-1.)

P-85657

WARNING Remove the two bolts (Item 1) [Figure 50-20-2].

Figure 50-20-3
AVOID INJURY OR DEATH
Attach a chain hoist to the grab handles of the

Dealer Copy -- Not for Resale

operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without
the gas spring(s) operational, the cab will fall and
could cause injury or death.
W-2760-0309

2
Figure 50-20-1 1

3
1
P-85652

Remove the retaining pin (Item 1), the pin (Item 2), and
the gas spring (Item 3) [Figure 50-20-3] from the loader.

NOTE: If the loader is equipped with a second gas

spring repeat the procedure for the other side.

P-85662

Install a strap and hoist (Item 1) [Figure 50-20-1] to the

cab handles.

Lift the cab with the hoist to release the pressure on the
gas spring(s).

369 of 822 50-20-1 T870 Service Manual

OPERATOR CAB (CONT’D) Removal And Installation

Gas Spring Bracket Disassembly And Assembly

Figure 50-20-4
WARNING
AVOID INJURY OR DEATH
Attach a chain hoist to the grab handles of the
3 operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without
the gas spring(s) operational, the cab will fall and
could cause injury or death.
1 W-2760-0309
1

2 Remove the throttle cable from the cab. (See Cable

Removal And Installation on Page 70-20-2.)

Remove the operator cab gas spring(s). (See Gas Spring

P-85661
Removal And Installation on Page 50-20-1.)

Remove the clevis (Item 1) from both ends, and the outer NOTE: Use the hoist connected to the operator cab
housing (Item 2) from the gas spring (Item 3) [Figure 50- grab handles to lower or (raise) the operator
cab when the gas spring(s) are disconnected.

Dealer Copy -- Not for Resale

20-4].

Installation: Apply a small amount of thread-locker on Figure 50-20-5

the threads of the gas spring rod before installing the
clevis (Item 1) [Figure 50-20-4].

WARNING
AVOID INJURY 1
Cylinders for raising and lowering operator cab have
gas under pressure. Do not open cylinder. Only
qualified service personnel can remove the cylinder.
W-2112-0987

P-85663

Disconnect the cab harness connector screw (Item 1)

[Figure 50-20-5].

Installation: Tighten the connector screw to 3,39 - 3,96

N•m (30 - 35 in-lb) torque.

370 of 822 50-20-2 T870 Service Manual

OPERATOR CAB (CONT’D)

Removal And Installation (Cont’d)

Figure 50-20-6

P-85658

Remove the two cab mount bolts and nuts (Item 1)

[Figure 50-20-6] from both sides of the cab.

Dealer Copy -- Not for Resale

Installation: Tighten the cab mount bolts and nuts to
24,4 - 29,8 N•m (18 - 22 ft-lb) torque.

Figure 50-20-7

P-85662

Using a strap and a hoist remove the cab from the loader.

371 of 822 50-20-3 T870 Service Manual

 Dealer Copy -- Not for Resale

372 of 822 50-20-4 T870 Service Manual

OPERATOR SEAT (SUSPENSION) Slide Rail Removal And Installation

Removal And Installation Figure 50-30-2

Figure 50-30-1

1 1

P-85769

P-85776
Remove the operator seat. (See Removal And
Installation on Page 50-30-1.)
Raise the operator cab. (See Raising on Page 10-30-1.)
Remove the two slide rail mounting bolts (Item 1) [Figure

Dealer Copy -- Not for Resale

Remove the four seat mounting nuts (Item 1) [Figure 50- 50-30-2].
30-1] and washers from the operator seat mounting
studs. Figure 50-30-3

Lower the operator cab. (See Lowering on Page 10-30-

2.)

Remove the seat. 2

NOTE: With the seat removed, the cab may raise.

P-85770

Remove the two slide rails mounting bolts (Item 1)

[Figure 50-30-3].

Remove the slide rail (Item 2) [Figure 50-30-3] from the

bottom of the seat frame.

373 of 822 50-30-1 T870 Service Manual

OPERATOR SEAT (SUSPENSION) (CONT’D) Lower Cushion Removal

Seat Belt Removal And Installation Figure 50-30-6

Figure 50-30-4

1 1

P-85773

P-85771
Lift up and push forward on the rear of the seat cushion
(Item 1) [Figure 50-30-6].
Remove the nut (Item 1) [Figure 50-30-4] from the seat
belt mount.

Dealer Copy -- Not for Resale

Figure 50-30-5

P-85772

Remove the nut (Item 1) [Figure 50-30-5] from the seat

belt mount.

Remove the seat belt.

374 of 822 50-30-2 T870 Service Manual

OPERATOR SEAT (SUSPENSION) (CONT’D) Back Cushion Removal And Installation

Lower Cushion Installation Figure 50-30-9

Figure 50-30-7

2 1

1
2
P-85774

P-85773

P-85778
Tilt the seat all the way forward.

Insert the tab (Item 1) into the slot (Item 2) [Figure 50-30- Remove the two screws (Item 1) [Figure 50-30-9] and tilt
7]. the seat back to the upright position.

Dealer Copy -- Not for Resale

Figure 50-30-8 Remove the back cushion from the seat

1 1

P-85775

Push down on the front of the seat (Item 1) and push

back (Item 2) [Figure 50-30-8] to lock the seat into
position.

375 of 822 50-30-3 T870 Service Manual

OPERATOR SEAT (SUSPENSION) (CONT’D) 3-Point Seat Belt Removal And Installation

Shock Removal And Installation Remove the operator seat. (See Removal And
Installation on Page 50-30-1.)
Figure 50-30-10
Figure 50-30-11

1
1
2
1

P-85777

P-85785

Remove the operator seat. (See Removal And

Installation on Page 50-30-1.) Remove the mounting nut (Item 1) [Figure 50-30-11].

Dealer Copy -- Not for Resale

Remove the seat shock clips (Item 1) [Figure 50-30-10]. Remove the end release buckle (Item 2) [Figure 50-30-
(Both ends.) 11].

Remove the seat shock (Item 2) [Figure 50-30-10]. Figure 50-30-12

P-85784

Remove the mounting nut (Item 1) [Figure 50-30-12].

Remove the seat belt retractor (Item 2) [Figure 50-30-

12].

376 of 822 50-30-4 T870 Service Manual

OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-30-15

3-Point Seat Belt Removal And Installation (Cont’d)

2
Figure 50-30-13

1 3

1
P-85788

Remove the nut (Item 1) [Figure 50-30-15].

P-85786
Remove the shoulder harness guide and bushing (Item
2) and hardened washer (Item 3) [Figure 50-30-15].
Remove the two mounting bolts (Item 1) [Figure 50-30-
13].

Dealer Copy -- Not for Resale

Figure 50-30-14

P-85787

Remove the shoulder harness retractor (Item 1) [Figure

50-30-14].

377 of 822 50-30-5 T870 Service Manual

 Dealer Copy -- Not for Resale

378 of 822 50-30-6 T870 Service Manual

BOB-TACH (HAND LEVER) Figure 50-40-2

Description 1

The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Hand Lever Bob-Tach uses
two manually operated, spring assisted, locking wedge
and lever assemblies to secure the attachment the Bob-
Tach.

The Bob-Tach is located on the front of the loader

connected to the loader lift arms.

Removal And Installation

Figure 50-40-1 P-85649

Remove the rod end pivot pin (Item 1) [Figure 50-40-2].

Dealer Copy -- Not for Resale

P-85554

Tilt the Bob-Tach forward, so it is parallel to the floor. Put

blocks (approximately 76,2 mm [3 in]) under each side of
the Bob-Tach [Figure 50-40-1].

Lower the Bob-Tach onto the blocks.

Remove the retainer bolt and nut (Item 1) [Figure 50-40-

1] from the rod end pivot pin.

Installation: Tighten the retainer nut to 48 - 54 N•m (35 -

40 ft-lb) torque.

379 of 822 50-40-1 T870 Service Manual

BOB-TACH (HAND LEVER) (CONT'D) Figure 50-40-5

Removal And Installation (Cont’d)

Figure 50-40-3

1 P-31405

Check and replace O-ring (Item 1) [Figure 50-40-5] on

P-31402 the grease plug.

Figure 50-40-6
Remove the snap ring (Item 1) [Figure 50-40-3] from the
Bob-Tach pivot pin grease plug (both sides).

Dealer Copy -- Not for Resale

Figure 50-40-4

P-31403

1
Remove the nut (Item 1) [Figure 50-40-6] from the Bob-
P-31404 Tach pivot pin retaining bolt (both sides).

Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-40-4].

380 of 822 50-40-2 T870 Service Manual

BOB-TACH (HAND LEVER) (CONT'D) Lever And Wedge Disassembly And Assembly

Removal And Installation (Cont’d) Figure 50-40-9

Figure 50-40-7

P-85664

P-31406
Remove the lever mounting nut (Item 1) [Figure 50-40-
9].
Remove the retainer bolt (Item 1) [Figure 50-40-7] from
the Bob-Tach pin. Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb)

Dealer Copy -- Not for Resale

torque.
Installation: Tighten the retainer nut and bolt (Item 1)
[Figure 50-40-6] and [Figure 50-40-7] to 446 N•m (330 Figure 50-40-10
ft-lb) torque.

Figure 50-40-8

2
P-85665
1

P-31407 Remove the washer and spring, (Item 1) and the lever
assembly (Item 2) [Figure 50-40-10].

With a 0,875 mm (7/8 in) punch (Item 1) [Figure 50-40-8]

and a hammer, drive the pivot pin out of the lift arm and
Bob-Tach.

381 of 822 50-40-3 T870 Service Manual

BOB-TACH (HAND LEVER) (CONT'D) Figure 50-40-13

Lever And Wedge Disassembly And Assembly

(Cont'd) 4

Figure 50-40-11

1 3 2

P-85668

If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) [Figure 50-40-13] are damaged, put the
P-85666 assembly in a vise.

Remove the bolt and replace the damaged parts as

Use a punch and hammer to remove the roll pin (Item 1) needed.

Dealer Copy -- Not for Resale

[Figure 50-40-11] from the Bob-Tach wedge and spring
clevis. Assembly: Clean threads and apply Loctite® 242 to the
bolt (Item 1) [Figure 50-40-13], torque to 88,0 - 95,0 N•m
Remove the spring clevis assembly (Item 2) [Figure 50- (65 - 70 ft-lb).
40-11].

Figure 50-40-12

P-85667

Remove the wedge (Item 1) [Figure 50-40-12] out the

bottom of the Bob-Tach.

Always replace bent or broken wedges.

382 of 822 50-40-4 T870 Service Manual

BOB-TACH (HAND LEVER) (CONT'D)

Pivot Pin Bushing And Seal Removal And Installation

Figure 50-40-14

2 1

P-85669

Remove the Bob-Tach. (See Removal And Installation on

Page 50-40-1.)

Dealer Copy -- Not for Resale

Use a seal pick to remove seal (Item 1) [Figure 50-40-
14] from the Bob-Tach.

Remove and replace bushing (Item 2) [Figure 50-40-14]

with a driver tool and hammer.

Figure 50-40-15
3

NA5472

Installation: The seal (Item 1) needs to be seated in the

Bob-Tach (Item 2) to a depth of 1,27 mm (0.050 in) (Item
3) [Figure 50-40-15].

383 of 822 50-40-5 T870 Service Manual

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384 of 822 50-40-6 T870 Service Manual

BOB-TACH (POWER) Removal And Installation

Description Figure 50-41-1

The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Power Bob-Tach option uses
two hydraulically operated, spring assisted, locking
wedge and lever assemblies to secure the attachment to
the Bob-Tach.

The hydraulically operated Power Bob-Tach has a

hydraulic cylinder that opens and closes both wedge and
1
lever assemblies by pressing a switch on the right switch 2 2
panel. The switch activates the Power Bob-Tach block to
allow flow into or out of the hydraulic cylinder connected
to the levers on the Bob-Tach.

The Power Bob-Tach block is located on the rear of the P-85570

gear pump.

The Bob-Tach is located on the front of the loader Tilt the Bob-Tach forward, so it is parallel to the floor. Put
connected to the loader lift arms. blocks (approximately 76,2 mm [3 in]) under each side of
the Bob-Tach [Figure 50-41-1].

Dealer Copy -- Not for Resale

Lower the Bob-Tach onto the blocks.

Mark the hoses (Item 1) [Figure 50-41-1] for correct

installation.

Remove and cap the hoses from the cylinder.

Remove the washers and bolts (Item 2) [Figure 50-41-1]

from the cylinder (both ends).

Installation: Tighten the retainer nut to 48 - 54 N•m (35 -

40 ft-lb) torque.

Remove the cylinder from the Bob-Tach.

385 of 822 50-41-1 T870 Service Manual

BOB-TACH (POWER) (CONT'D) Figure 50-41-4

Removal And Installation (Cont’d)

Figure 50-41-2

1 1

P-31402

Remove the snap ring (Item 1) [Figure 50-41-4] at the

P-85554 Bob-Tach pivot pin grease plug (both sides).

Figure 50-41-5
Remove the retainer bolt and nut (Item 1) [Figure 50-41-
2] from the rod end pivot pin.

Dealer Copy -- Not for Resale

Installation: Tighten the retainer nut to 48 - 54 N•m (35 -
40 ft-lb) torque.

Figure 50-41-3

P-31404

Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-41-5] (both sides).

P-85649

Remove the rod end pivot pin (Item 1) [Figure 50-41-3].

386 of 822 50-41-2 T870 Service Manual

BOB-TACH (POWER) (CONT’D) Figure 50-41-8

Removal And Installation (Cont’d)

Figure 50-41-6

P-31406

1
Remove the retainer bolt (Item 1) [Figure 50-41-8] from
P-31405 the Bob-Tach pivot pin (both sides).

Installation: Tighten the retainer nut and bolt (Item 1)

Check and replace the O-ring (Item 1) [Figure 50-41-6] [Figure 50-41-7] and [Figure 50-41-8] to 446 N•m (330
on the grease plug. ft-lb) torque.

Dealer Copy -- Not for Resale

Figure 50-41-7 Figure 50-41-9

1
P-31403 P-31407

Remove the nut (Item 1) [Figure 50-41-7] from the Bob- With a 0,875 mm (7/8 in) punch (Item 1) [Figure 50-41-9]
Tach pivot pin retaining bolt (both sides). and a hammer, drive the pivot pin out of the lift arm and
Bob-Tach (both sides).

Remove the Bob-Tach from the loader.

387 of 822 50-41-3 T870 Service Manual

BOB-TACH (POWER) (CONT'D) Figure 50-41-12

Lever And Wedge Disassembly And Assembly

Figure 50-41-10

1 1 2
P-85665

Remove the washer and spring, (Item 1) and the lever

P-85570 assembly (Item 2) [Figure 50-41-12].

Figure 50-41-13
Remove the washers and bolts (Item 1) [Figure 50-41-
10] from the cylinder (both ends).

Dealer Copy -- Not for Resale

Installation: Tighten the bolts to 48 - 54 N•m (35 - 40 ft-
lb) torque.

Remove the cylinder from the lever pivots.

1
Figure 50-41-11

P-85666

1 Use a punch and hammer to remove the roll pin (Item 1)

[Figure 50-41-13] from the Bob-Tach wedge and spring
clevis.

Remove the spring clevis assembly (Item 2) [Figure 50-

41-13].
P-85664

Remove the lever mounting nut (Item 1) [Figure 50-41-

11].

Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb)

torque.

388 of 822 50-41-4 T870 Service Manual

BOB-TACH (POWER) (CONT'D) Pivot Pin Bushing And Seal Removal And Installation

Lever And Wedge Disassembly And Assembly Figure 50-41-16

(Cont'd)

Figure 50-41-14

2 1

P-85669

P-85667 Remove the Power Bob-Tach. (See Removal And

Installation on Page 50-41-1.)

Remove the wedge (Item 1) [Figure 50-41-14] out the Use a seal pick to remove seal (Item 1) [Figure 50-41-

Dealer Copy -- Not for Resale

bottom of the Bob-Tach. 16] from the Bob-Tach.

Always replace bent or broken wedges. Remove and replace bushing (Item 2) [Figure 50-41-16]
with a driver tool and hammer.
Figure 50-41-15
Figure 50-41-17

4 3

1
2

3 2
1

P-85668
NA5472

If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) [Figure 50-41-15] are damaged, put the Installation: The seal (Item 1) needs to be seated in the
assembly in a vise. Bob-Tach (Item 2) to a depth of 1,27 mm (0.050 in) (Item
3) [Figure 50-41-17].
Remove the bolt and replace the damaged parts as
needed.

Assembly: Clean threads and apply Loctite® 242 to the

bolt (Item 1) [Figure 50-41-15], torque to 88, - 95,0 N•m
(65 - 70 ft-lb).

389 of 822 50-41-5 T870 Service Manual

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390 of 822 50-41-6 T870 Service Manual

LIFT ARMS Figure 50-50-3

Stabilizer Bar Removal And Installation

Figure 50-50-1
1

1
2

P-90591

With a slide hammer, remove the rear lift arm stabilizer

P-90592 pin (Item 1) [Figure 50-50-3].

Remove the stabilizer bar from the loader.

Raise the operator cab. (See Raising on Page 10-30-1.)
Figure 50-50-4

Dealer Copy -- Not for Resale

NOTE: Remove the lift arm stabilizer bar from one
side of the loader at a time.

Remove the retainer bolt (Item 1) [Figure 50-50-1] and

nut from the front stabilizer bar pivot pin.

Remove the stabilizer bar pivot pin (Item 2) [Figure 50-

50-1].
1
Figure 50-50-2

P-31595

Remove the bushings (Item 1) [Figure 50-50-4] from the

stabilizer bar (both ends).

Inspect the bushings and replace as needed.

1

P-90593

Remove the retainer bolt (Item 1) [Figure 50-50-2] from

the stabilizer bar rear pivot pin at the lift arm.

391 of 822 50-50-1 T870 Service Manual

LIFT ARMS (CONT'D) Figure 50-50-7

Link Removal And Installation

1
Figure 50-50-5

P-90594

Remove the retainer bolt and nut (Item 1) [Figure 50-50-

P100217 7] from the lift arm link pivot pin (both sides).

Figure 50-50-8(Item 1)
Install a sling and chain hoist on the lift arm link [Figure
50-50-5].

Dealer Copy -- Not for Resale

Figure 50-50-6

1 2
2
1

P100713

Remove the grease fitting (Item 1) from the lift arm pivot
P100714 pin and then with a slide hammer remove the lift arm
pivot pin (Item 2) [Figure 50-50-8] (both sides).

Remove the retaining ring (Item 1) and the washer (Item

2) [Figure 50-50-6] from the lift arm pivot pin (both
sides).

392 of 822 50-50-2 T870 Service Manual

LIFT ARMS (CONT'D) Removal And Installation

Link Removal And Installation (CONT’D) Put jackstands under the rear corners of the loader.

Figure 50-50-9 Raise the operator cab. (See Raising on Page 10-30-1.)

Drain the hydraulic reservoir. (See Removing And

Replacing Hydraulic Fluid on Page 10-120-2.)

1 Figure 50-50-10

4
3

2
P-90610

Remove the lift arm link pivot pin (Item 1) [Figure 50-50-
9] (both sides).

Dealer Copy -- Not for Resale

1 P100262
Remove the lift arm link from the loader.

At the right side upright disconnect and cap the two tilt
cylinder hoses (Item 1) [Figure 50-50-10].

At the right side upright disconnect and cap the power

Bob-Tach hoses (Item 2) [Figure 50-50-10].(If equipped.)

NOTE: Mark the hoses for proper installation.

Remove hose clamp mounting bolt (Item 3) [Figure 50-

50-10].

Remove Bob-Tach hose clamp mounting bolt (Item 4)

[Figure 50-50-10] (If equipped).

393 of 822 50-50-3 T870 Service Manual

LIFT ARMS (CONT'D) Figure 50-50-13

Removal And Installation

Figure 50-50-11
1

1 P100264

At the left side upright remove both of the auxiliary hose

P100263 mounting clamp bolts (Item 1) [Figure 50-50-11].

Figure 50-50-14
At the base of the left side upright disconnect and cap the
two auxiliary hydraulic hoses (Item 1) [Figure 50-50-11].

Dealer Copy -- Not for Resale

NOTE: Mark the hoses for proper installation.

Figure 50-50-12
1

1
P100225

Disconnect the electrical controls harness (Item 1)

[Figure 50-50-14]. (If equipped.)

P100265

At the left side upright disconnect and cap the auxiliary

hydraulic hose (Item 1) [Figure 50-50-11].

NOTE: Mark the hoses for proper installation.

394 of 822 50-50-4 T870 Service Manual

LIFT ARMS (CONT'D) Figure 50-50-17

Removal And Installation (CONT’D)

Figure 50-50-15

1
1
1

P100220

Install slings (Item 1) [Figure 50-50-17] on the lift arms

P100226 and connect to a chain hoist.

Figure 50-50-18
Remove the retaining bolt and nut (Item 1) [Figure 50-
50-15] from the pin on the rod end of the lift cylinder (both

Dealer Copy -- Not for Resale

sides).

Installation: Tighten the retainer bolt and nut to 48 - 54

N•m (35 - 40 ft-lb) torque.

Figure 50-50-16
1

1
P100219

NOTE: Be sure the slings on the lift arms are in a

position to balance the lift arms when being
remove. See (Item 1) [Figure 50-50-18].

P100227

With a slide hammer remove the pin (Item 1) [Figure 50-

50-16] from the rod end of the lift cylinder (both sides).

395 of 822 50-50-5 T870 Service Manual

LIFT ARMS (CONT'D)

Removal And Installation (CONT’D)

Figure 50-50-19

P-90605

Position the front sling in the middle of the Bob-Tach as

shown in (Item 1) [Figure 50-50-19].

Dealer Copy -- Not for Resale

Support the lift arms with the chain hoist.

Figure 50-50-20

1
1

P100216

Remove the retainer bolt and nut (Item 1) [Figure 50-50-

20] from the lift arm pivot pin (both sides).

Remove the retaining bolt and nut (Item 1) and the pin
(Item 2) [Figure 50-50-20] (both sides).

Installation: Tighten the retainer bolt and nut to 48 - 54

N•m (35 - 40 ft-lb) torque.

Remove the lift arms from the loader.

396 of 822 50-50-6 T870 Service Manual

REAR GRILLE Installing

Removing Figure 50-60-3

Figure 50-60-1

P100807

P100808
Align the tabs of the two side covers into the slots in the
loader frame and lower [Figure 50-60-3].
Flip the lockable handle (Item 1) [Figure 50-60-1] up and
turn the handle one-quarter turn counterclockwise. Lift Figure 50-60-4

Dealer Copy -- Not for Resale

and pull the rear grille backward to remove from the
loader.

Figure 50-60-2

P-85604

Align the edge of the rear grille under the loader frame
and slide rear grille in while lowering [Figure 50-60-4].
P100809A
Turn the lockable handle one-quarter turn clockwise and
fold the handle down [Figure 50-60-1].
Lift and remove the two side covers (Item 1) [Figure 50-
60-2].

397 of 822 50-60-1 T870 Service Manual

 Dealer Copy -- Not for Resale

398 of 822 50-60-2 T870 Service Manual

REAR DOOR (TAILGATE) Figure 50-70-3

Removal And Installation

Figure 50-70-1 1

3
2

P-85695
1

Remove the top and bottom door hinge mounting bolts

P-85697 and nuts (Item 1) [Figure 50-70-3].

NOTE: Install the door stop (Item 2) and the door stop
Disconnect the light harness connector (Item 1) [Figure
retainer (Item 3) in the top hinge as shown
50-70-1] from the main frame harness.
[Figure 50-70-3].

Dealer Copy -- Not for Resale

Remove both rear lights (Item 2) [Figure 50-70-1] from
Installation: Tighten the mounting bolts and nuts to 34 -
the door. (See Rear Removal And Installation on Page
38 N•m (25 - 28 ft-lb) torque.
60-60-2.)
Lift the door away from the loader frame and put the door
Figure 50-70-2
flat on the floor.
2

1 1

P-90584

Secure the chain hooks (Item 1) [Figure 50-70-2] to the

door as shown.

Connect a chain hoist (Item 2) [Figure 50-70-2] to the

lifting chain.

399 of 822 50-70-1 T870 Service Manual

REAR DOOR (TAILGATE) (CONT’D) Striker (Adjusting)

Striker Removal And Installation

Figure 50-70-4 WARNING

1
AVOID INJURY OR DEATH
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497

Figure 50-70-6
1
1

P-85698

Remove the two striker mount bolts (Item 1) [Figure 50- 1

70-4].

Dealer Copy -- Not for Resale

Remove the striker assembly from the loader.

Striker Disassembly And Assembly

P-85698

Figure 50-70-5
Loosen the striker assembly mount bolts (Item 1) [Figure
50-70-6].
2 2
3 Align the striker assembly in the center of the mounting
holes.

NOTE: Tighten the striker assembly, top mount bolt

only, until it will hold the striker assembly in
the center of the mounting slots.
4
1 Close the rear door. (This will align the striker assembly
to the correct position.)

Open the door.

P-31320
Tighten both striker mount bolts (Item 1) [Figure 50-70-6]
to 125 - 135 N•m (90 - 100 ft-lb) torque.
Remove the lock nut (Item 1) [Figure 50-70-5].
Close the rear door.
Remove the rollers (Item 2) and the spacer (Item 3) from
the bolt (Item 4) [Figure 50-70-5].

Check the parts for wear and replace as needed.

Installation: Tighten the bolt (Item 4) and nut (Item 1) to

34 - 38 N•m (25 - 28 ft-lb) torque.

400 of 822 50-70-2 T870 Service Manual

REAR DOOR (TAILGATE) (CONT’D) Figure 50-70-9

Latch Removal And Installation

Figure 50-70-7
1

1
P-85701

Remove the door handle (Item 1) [Figure 50-70-9] from

P-85699 the rear door.

Disconnect the spring (Item 1) [Figure 50-70-7] from the

rear door.

Dealer Copy -- Not for Resale

Remove the bolt and nut (Item 2) [Figure 50-70-7] from
the latch.

Figure 50-70-8

P-85700

Remove the spring (Item 1) [Figure 50-70-8] from the

door handle.

Remove the spring (Item 2) [Figure 50-70-8] from the

door latch.

Remove the door latch (Item 3) [Figure 50-70-8] from the

door handle.

401 of 822 50-70-3 T870 Service Manual

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402 of 822 50-70-4 T870 Service Manual

FUEL TANK Figure 50-80-3

Removal And Installation

Lift and block the loader. (See Procedure on Page 10-10-

1.)

Remove the engine / hydrostatic pump assembly from 1

2
the loader. (See Engine Removal And Installation on
Page 70-10-7.)

Figure 50-80-1

P-85707

Disconnect the fuel vent hose (Item 1) and remove the

two bolts (Item 2) [Figure 50-80-3].

1 Figure 50-80-4
1 4

Dealer Copy -- Not for Resale

P-85714

2 3
Remove the three mount bolts (Item 1) [Figure 50-80-1]
from the access cover at the rear of the loader frame.

Remove the access cover.

Figure 50-80-2
1
P-85708

Disconnect the two fuel lines (Item 1) [Figure 50-80-4].

1
Disconnect the wire harness connector (Item 2) [Figure
50-80-4] from the fuel level sender.

Remove the two mounting bolts (Item 3) and remove the

bracket (Item 4) [Figure 50-80-4].

P-85713

Remove the drain plug (Item 1) [Figure 50-80-2].

Drain the fuel into a container.

403 of 822 50-80-1 T870 Service Manual

FUEL TANK (CONT'D) Figure 50-80-7

Removal And Installation (Cont'd)

Figure 50-80-5

1
1

1 1

P-85711

At the right side of the loader, remove the two main frame
P-85710 mount bolts and nuts (Item 1) [Figure 50-80-7].

Installation: Tighten the main frame mount bolts to 407 -

Remove the bolts (Item 1) [Figure 50-80-5] from the 447 N•m (300 - 330 ft-lb) torque.
battery hold down plate.

Dealer Copy -- Not for Resale

Figure 50-80-8
Remove the hold down plate from the loader.

Figure 50-80-6

1 1 1

P-85712

2
P-85709 At the left side of the loader, remove the two main frame
mount bolts and nuts (Item 1) [Figure 50-80-7].

Remove the two mounting bolts (Item 1) and the bracket Installation: Tighten the main frame mount bolts to 407 -
(Item 2) [Figure 50-80-6]. 447 N•m (300 - 330 ft-lb) torque.

Lift the fuel tank and remove it from the loader frame.

NOTE: When installing the fuel tank, avoid striking

the tank with heavy objects to prevent
damage.

404 of 822 50-80-2 T870 Service Manual

FUEL TANK (CONT'D) Fuel Fill Screen Removal And Installation

Fuel Level Sender Removal And Installation Figure 50-80-11

Figure 50-80-9

1
1

P-85707

P-85708
Remove the two bolts (Item 1) and disconnect the fuel fill
hose (Item 2) [Figure 50-80-11].
Disconnect the wire harness connector (Item 1) [Figure
50-80-9] from the fuel level sender. Figure 50-80-12

Dealer Copy -- Not for Resale

Remove the fuel level sender.

Figure 50-80-10

P-85715

Remove the fuel fill screen (Item 1) [Figure 50-80-12].

P-85716
Inspect and replace as needed.

Inspect the fuel level sender and replace if worn or

damaged.

405 of 822 50-80-3 T870 Service Manual

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406 of 822 50-80-4 T870 Service Manual

FUEL TANK (AUXILIARY) Figure 50-81-1

Removal And Installation

Raise the lift arms and install an approved lift arm support
device.(See Installing on Page 10-20-1.)

Lift and block the loader. (See Procedure on Page 10-10-

1.)

WARNING 1

Never work on a machine with the lift arms up unless

P-85714
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Remove the three mount bolts (Item 1) [Figure 50-81-1]
to fall and cause injury or death. from the access cover at the rear of the loader frame.
W-2059-0598

Remove the access cover.

Raise the operator cab.(See Raising on Page 10-30-1.)
Figure 50-81-2

Dealer Copy -- Not for Resale

DANGER
1

P-90328

AVOID DEATH
P-85713
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. Remove the drain plug (Item 1) [Figure 50-81-2].
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm Drain the fuel into a container.
support. Replace if damaged.
D-1009-0409

Remove the control panel. (See Removal And Installation

on Page 50-100-1.)

Remove the pedals (if equipped). (See Pedal Removal

And Installation on Page 50-90-1.)

Remove the access panels. (See ACCESS PANEL

(INSIDE) on Page 50-120-1.)

Remove the floor pan. (See Floor Pan Removal And

Installation on Page 50-90-4.)

407 of 822 50-81-1 T870 Service Manual

FUEL TANK (AUXILIARY) (CONT'D) Figure 50-81-5

Removal And Installation (Cont'd)

Figure 50-81-3

1 P-90985

Remove the auxiliary fuel tank (Item 1) by lifting the rear

P-90983 of the tank upwards [Figure 50-81-5].

Disconnect and plug the two fuel hoses (Item 1) [Figure

50-81-3].

Dealer Copy -- Not for Resale

Figure 50-81-4

P-90984

Remove the four bolts (Item 1) and the bracket (Item 2)

[Figure 50-81-4].

408 of 822 50-81-2 T870 Service Manual

CONTROL PEDALS AND LINKAGES (SCPA) Figure 50-90-1

Description
1
The control pedals and linkages are connected to the
control valve. The control pedals will mechanically move
the lift and tilt spools on the control valve.

The control pedals and linkages are located on the lower

mainframe at the operators feet.

Pedal Removal And Installation

WARNING P-85675

Never work on a machine with the lift arms up unless Remove the bolt (Item 1) [Figure 50-90-1] and nut from
the lift arms are secured by an approved lift arm the pedal linkage.
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Check the bushing in the pedal for wear and replace as
to fall and cause injury or death. needed.
W-2059-0598

Dealer Copy -- Not for Resale

Figure 50-90-2
Raise the lift arms and install an approved lift arm support
device.(See Installing on Page 10-20-1.)

Raise the operator cab.(See Raising on Page 10-30-1.)

DANGER
1

P-85676

P-90328 Remove the two nuts (Item 1) [Figure 50-90-2] from the
pedal mounting bracket.
AVOID DEATH
• Disconnecting or loosening any hydraulic Remove the pedal assembly from the loader.
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409

409 of 822 50-90-1 T870 Service Manual

CONTROL PEDALS AND LINKAGES (SCPA) Figure 50-90-5
(CONT’D)

Linkage Removal And Installation

Figure 50-90-3

1 2

P-85679

Remove the crossbar pivot bolt (Item 1) [Figure 50-90-

5].
P-85678
Remove the crossbar from the pivot (Item 2) [Figure 50-
90-6].
Remove the bolt and nut (Item 1) [Figure 50-90-3] to
disconnect the lift pedal linkage from the crossbar.

Dealer Copy -- Not for Resale

Figure 50-90-6

Figure 50-90-4

2 1

1
P-85681

P-85680
Installation: Check the nylon bushing (Item 1) [Figure
50-90-6] for wear and replace as needed.
Remove the hairpin clips (Item 1) and cross-pins (Item 2)
[Figure 50-90-4] from the control valve lift spool.

Disconnect the crossbar from the control valve.

410 of 822 50-90-2 T870 Service Manual

CONTROL PEDALS AND LINKAGES (SCPA) Pedal (Adjusting)
(CONT’D)
After installing the pedal, adjust the pedal angle so that
Linkage Removal And Installation (Cont’d) there is clearance under the rear of the pedal. The valve
spool must travel full stroke without the pedal hitting the
Figure 50-90-7 floor panel.
The pedals should be positioned at a comfortable angle
so full movement of the pedal can be reached easily
1 while properly sitting in the loader seat.
Figure 50-90-9
2

P-85675

Remove the bolt (Item 1) [Figure 50-90-7] and nut from

the pedal linkage.

Dealer Copy -- Not for Resale

P-85676
Remove the linkage (Item 2) [Figure 50-90-7].
Loosen the two mounting bolts (Item 1) [Figure 50-90-9]
Figure 50-90-8 from the pedal mounting bracket.

Figure 50-90-10
1
2 1

P-85675A

P-85675
Remove the bolt (Item 1) [Figure 50-90-8] and nut from
the pedal linkage. Loosen the bolt (Item 1) [Figure 50-90-10] and nut on
the pedal linkage.
Remove the linkage (Item 2) [Figure 50-90-8].
Check the bushing in the pedal for wear and replace as
needed.
Tilt the pedal back and forth until an acceptable “neutral”
angle is achieved on the pedal.
Tighten the two nuts (Item 2) and pivot bolt (Item 1)
[Figure 50-90-10] on the pedal assembly to standard
torque.

411 of 822 50-90-3 T870 Service Manual

CONTROL PEDALS AND LINKAGES (SCPA)
(CONT’D)

Floor Pan Removal And Installation

Remove the control panel. (See Removal And Installation

on Page 50-100-1.)

Remove the pedals. (See Pedal Removal And

Installation on Page 50-90-1.)

Remove the access panels. (See ACCESS PANEL

(INSIDE) on Page 50-120-1.)

Figure 50-90-11

Dealer Copy -- Not for Resale

1
1

P-85859 P-85860

Figure 50-90-12

1 1

P-85858

Remove the clips (Item 1) [Figure 50-90-11] and [Figure

50-90-12] from the sides of the floor pan.

Remove the floor pan (Item 2) [Figure 50-90-12].

412 of 822 50-90-4 T870 Service Manual

CONTROL PANEL (SJC) Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Description
Raise the operator cab. (See Raising on Page 10-30-1.)
The control panel is connected to the lower main frame
and wraps around the operator seat. There are no Figure 50-100-1
mechanical linkages connecting to the hydrostatic pumps
or the control valve. 1

Removal And Installation

WARNING
Put jackstands under the front axles and rear corners
1
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P-85879

Remove the three mount bolts (Item 1) [Figure 50-100-1]

Dealer Copy -- Not for Resale

DANGER that secure the controller.

Figure 50-100-2

1
1
1

2
1
P-90328

AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. 3
1 1
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
P-85881
support. Replace if damaged.
D-1009-0409
Remove the 10 panel mount bolts (Item 1) [Figure 50-
100-2].

Remove the lift arm bypass knob and rubber washer

WARNING (Item 2) [Figure 50-100-2].

Remove the control panel (Item 3) [Figure 50-100-2].

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

413 of 822 50-100-1 T870 Service Manual

 Dealer Copy -- Not for Resale

414 of 822 50-100-2 T870 Service Manual

CONTROL PANEL (SCPA) Raise the operator cab. (See Raising on Page 10-30-1.)

Description Figure 50-101-1

The control panel is connected to the lower main frame

and wraps around the operator seat. There are
mechanical linkages connected to the control valve.

Removal And Installation 1

WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
P100348
fall or move and cause injury or death.
W-2017-0286

Remove the three mount bolts (Item 1) [Figure 50-101-1]

that secure the controller.

DANGER Figure 50-101-2

Dealer Copy -- Not for Resale

1
1
1

2
1
P-90328

AVOID DEATH
• Disconnecting or loosening any hydraulic 1 1
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. 3
P100350
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged. Remove the 10 panel mount bolts (Item 1) [Figure 50-
D-1009-0409 101-2].

Remove the lift arm bypass knob and rubber washer

(Item 2) [Figure 50-101-2].

WARNING Remove the control panel (Item 3) [Figure 50-101-2].

Never work on a machine with the lift arms up unless

the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)

415 of 822 50-101-1 T870 Service Manual

 Dealer Copy -- Not for Resale

416 of 822 50-101-2 T870 Service Manual

CONTROL HANDLE / LEVER (SJC)

Description

The operators seat has two joysticks attached that

control the drive, steering, lift and tilt functions. There are
no mechanical connections to the hydrostatic pumps or
the control valve.

Joystick Testing

Refer to Service Analyzer help to check function.

Dealer Copy -- Not for Resale

417 of 822 50-110-1 T870 Service Manual

CONTROL HANDLE / LEVER (SJC) (CONT'D) Figure 50-110-3

Joystick Removal And Installation

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.) 1

Figure 50-110-1

P-85891

1 Disconnect the joystick connector (Item 1) [Figure 50-

110-3] from the harness connector.

P-85890

Dealer Copy -- Not for Resale

Lift the rubber boot (Item 1) [Figure 50-110-1].

Figure 50-110-2

1
1

P-85889

Remove the four screws (Item 1) [Figure 50-110-2] and

lift the joystick from the base.

418 of 822 50-110-2 T870 Service Manual

CONTROL HANDLE / LEVER (SCPA)

Description

The operators seat has two electronic handles attached

that control the drive and steering functions. There are no
mechanical connections to the hydrostatic pumps or the
control valve.

Steering Handle Testing

Refer to Service Analyzer help to check function.

Dealer Copy -- Not for Resale

419 of 822 50-111-1 T870 Service Manual

CONTROL HANDLE / LEVER (SCPA) (CONT'D) Figure 50-111-3

Steering Handle Removal And Installation

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.) 1

Figure 50-111-1

P-85891

1 Disconnect the steering handle connector (Item 1)

[Figure 50-111-3] from the harness connector.

P-85890

Dealer Copy -- Not for Resale

Lift the rubber boot (Item 1) [Figure 50-111-1].

Figure 50-111-2

1
1

P-85889

Remove the four screws (Item 1) [Figure 50-111-2] and

lift the steering handle from the base.

420 of 822 50-111-2 T870 Service Manual

ACCESS PANEL (INSIDE) Removal And Installation (Right)

Removal And Installation (Left) Remove the control pedal. (See Pedal Removal And
Installation on Page 50-90-1.)
Remove the control pedal. (See Pedal Removal And
Installation on Page 50-90-1.) Figure 50-120-2

Figure 50-120-1

1 1
1
1

2
P-85677A

P-85677
Remove the top mounting screw (Item 1), and loosen the

Dealer Copy -- Not for Resale

two bottom mounting screws (Item 2) [Figure 50-120-2]
Remove the four mounting screws (Item 1), and remove from the front access panel.
the left access panel (Item 2) [Figure 50-120-1].
Remove the front access panel from the loader.
Remove the front access panel from the loader.

421 of 822 50-120-1 T870 Service Manual

 Dealer Copy -- Not for Resale

422 of 822 50-120-2 T870 Service Manual

ACCESS PANEL (INSIDE) (SJC) Removal And Installation (Right)

Removal And Installation (Left) Figure 50-121-3

Figure 50-121-1

2 1

1
2
P-90587

P-85887
Remove the two mounting nuts (Item 1), and remove the
foot rest (Item 2) [Figure 50-121-3].
Remove the two mounting nuts (Item 1), and remove the
foot rest (Item 2) [Figure 50-121-1]. Figure 50-121-4

Dealer Copy -- Not for Resale

Figure 50-121-2
2

3 2

1 2
1

1
2

P-90588

P-85884
Remove the bolt and throttle pedal (Item 1), and remove
the mounting screws (Item 2) [Figure 50-121-4].
Remove the mounting screws (Item 1), and remove the
inside left access panel (Item 2) [Figure 50-121-2]. Remove the right inside access panel (Item 3) [Figure
50-121-4].

423 of 822 50-121-1 T870 Service Manual

 Dealer Copy -- Not for Resale

424 of 822 50-121-2 T870 Service Manual

WINDOW (REAR) Disassembly And Assembly

Removal And Installation Figure 50-130-2

WARNING
1
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907

P-85705
Figure 50-130-1

Remove the screw (Item 1) from the latch [Figure 50-

130-2].

Installation: Tighten the screw (Item 1) [Figure 50-130-

Dealer Copy -- Not for Resale

2] to 21 - 23 N•m (180 - 200 in-lb) torque.
1 1
Figure 50-130-3

7
6
1

P-85706

5
Remove the rear window assembly by turning the two
latches (Item 1) [Figure 50-130-1] in until they disengage
from the window frame. 2
3
Push the rear window out the rear of the operator cab. 4
P-85704
NOTE: If rear window is broken, remove all glass
fragments from the rubber molding before
installing a new window. Inspect and replace any damaged parts.

Clean the area before installing the rear window The items listed below refer to [Figure 50-130-3].
assembly.
1. Latch
Reverse the procedure to install the rear window.
2. Spacer
3. Bushing
4. Washer
5. Screw
6. Rear Window
7. Seal

425 of 822 50-130-1 T870 Service Manual

 Dealer Copy -- Not for Resale

426 of 822 50-130-2 T870 Service Manual

WINDOW (TOP)

Removal And Installation

Figure 50-131-1

1 1

P-85807

Install the bolts (Item 1) [Figure 50-131-1] through the

window grommets and through the cab holes.

Dealer Copy -- Not for Resale

Figure 50-131-2

1 1

1 1

P-85808

From inside the operator cab, install and tighten the four
nuts (Item 1) [Figure 50-131-2] on the window bolts.

Tighten the nuts (Item 1) [Figure 50-131-2] to 9 - 10 N•m

(80 - 90 in-lb) torque.

427 of 822 50-131-1 T870 Service Manual

 Dealer Copy -- Not for Resale

428 of 822 50-131-2 T870 Service Manual

WINDOW (SIDE) Figure 50-132-3

Removal And Installation

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
1 1
Figure 50-132-1
1
1
1
1
2

P-90586

Support the window assembly and remove the six bolts

(Item 1) [Figure 50-132-3] from the window frame and
the operator cab.

P-85821 Installation: Tighten the six bolts (Item 1) [Figure 50-

132-3] to 9 - 10 N•m (80 - 90 in-lb) torque.

Dealer Copy -- Not for Resale

Figure 50-132-2 Remove the window assembly.

NOTE: The window assembly can only be replaced

as a complete unit.

1 3 4 5
2

P-85819

From inside the operator cab, remove the plastic cap

(Item 1), nut (Item 2), spring (Item 3), knob (Item 4), and
sleeve (Item 5) [Figure 50-132-1] and [Figure 50-132-2]
from the window assembly.

Installation: Tighten the nut (Item 2) [Figure 50-132-1]

flush to the end of the bolt.

429 of 822 50-132-1 T870 Service Manual

 Dealer Copy -- Not for Resale

430 of 822 50-132-2 T870 Service Manual

CAB DOOR Figure 50-140-3

Description

The standard cab door is available as an option or dealer

1
installed kit.

Removal And Installation

Figure 50-140-1

P-85828

Lift the door (Item 1) [Figure 50-140-3] off the hinges.

Figure 50-140-4
2

Dealer Copy -- Not for Resale

P-85781A 1
2

Open the cab door.

Disconnect electrical connector (Item 2) and washer fluid

hose (Item 1) [Figure 50-140-1].

Figure 50-140-2

2
3

2 1
1

P-85837
P-85588A P-85589A

Remove the four bolts and nuts (Item 2) [Figure 50-140-

Rotate and pull the clip (Item 1) out of the gas spring 4] from the cab.
socket. Pull the gas spring socket (Item 3) straight off the
ball stud fitting (Item 2) [Figure 50-140-2]. Remove the hinges (Item 1) [Figure 50-140-4] from the
cab.

Installation: Install the hinges (Item 1) on the cab and

use the bolts and nuts (Item 2) [Figure 50-140-4] to
secure the hinges. Tighten to 9,6 - 10,7 N•m (85 - 90 in-
lb) torque.

431 of 822 50-140-1 T870 Service Manual

CAB DOOR (CONT’D) Figure 50-140-7

Disassembly And Assembly

2
Figure 50-140-5

4
3

1
1
1

P-85834
1 2

Remove the three bolts (Item 1) and the wiper motor

P-85829 assembly (Item 2) [Figure 50-140-7].

Figure 50-140-8
Remove the nuts (Items 1 and 2) and the wiper arms
(Item 3) [Figure 50-140-5].

Dealer Copy -- Not for Resale

2
Installation: Tighten the nut (Item 1) to 20 - 24 N•m (177
- 212 in-lb) torque and nut (Item 2) to 9 - 11 N•m (80 - 97 1
in-lb) torque.

Remove the wiper motor shaft nut (Item 4) [Figure 50-

140-5].

Installation: Tighten the nut (Item 4) to 9,9 - 14 N•m (88

4
- 124 in-lb) torque.
3
Remove the door from the loader. (See Removal And
4
Installation on Page 50-140-1.) P-85835

Figure 50-140-6
Remove the bolt (Item 1), the latch (Item 2), and spring
(Item 3) [Figure 50-140-8].
2
Remove the two nuts and bolts (Item 4) [Figure 50-140-
8].

1 Installation: Tighten the nuts (Item 4) to 31 - 34 N•m

(270 - 300 in-lb) torque.

1 1

P-85841

Remove the three tie straps (Item 1) and the wiper motor
assembly cover (Item 2) [Figure 50-140-6].

432 of 822 50-140-2 T870 Service Manual

CAB DOOR (CONT’D) Aligning

Disassembly And Assembly (Cont’d) Figure 50-140-11

Figure 50-140-9 WRONG WRONG

4
P-85832A P-85839A
3
4
P-85836
Figure 50-140-12

Remove the bolt (Item 1), the latch (Item 2), and spring CORRECT CORRECT
(Item 3) [Figure 50-140-9].

Dealer Copy -- Not for Resale

Remove the two nuts and bolts (Item 4) [Figure 50-140-
9].

Installation: Tighten the nuts (Item 4) to 31 - 34 N•m

(270 - 300 in-lb) torque.

Figure 50-140-10
1
1
3
P-85833A P-85838A

1
When the striker or latch is NOT adjusted properly there
will be a gap (Item 1) [Figure 50-140-11] between the
door and the cab or the striker and the latch.

If adjustment is needed. (See Adjusting on Page 50-140-

4.)

2 2
When the striker or latch is adjusted properly there will be
P-85830A no gap (Item 1) [Figure 50-140-12] between the door
and the cab or the striker and the latch.

Disconnect the harness (Item 1) [Figure 50-140-10]. After verifying alignment check for proper operation. (See
Checking Operation on Page 50-140-4.)
Remove the two bolts (Item 2), and the latch assembly
(Item 3) from the cab door [Figure 50-140-10].

Remove the glass from the frame.

433 of 822 50-140-3 T870 Service Manual

CAB DOOR (CONT’D) Checking Operation

Adjusting Figure 50-140-15

Figure 50-140-13

1
1

P-85413

P-85830
Sit in operator’s seat. Turn key ON, lower seat bar and
close the door. Press the PRESS TO OPERATE
Loosen the two bolts (Item 1) [Figure 50-140-13] and LOADER button (Item 1) [Figure 50-140-15].
adjust the latch as needed.

Dealer Copy -- Not for Resale

Open the door. The LIFT & TILT VALVE light (Item 2)
Figure 50-140-14 [Figure 50-140-15] will flash, an audible tone will sound,
and the message [DOOR] will appear in the display.

Close the door and the LIFT & TILT VALVE light (Item 2)
[Figure 50-140-15] will go out and the display will return
to machine hours.

P-85831

Loosen the striker and adjust as needed (Item 1) [Figure

50-140-14].

After adjusting the striker and latch recheck the

alignment of the door sensor. (See Aligning on Page 50-
140-3.)

434 of 822 50-140-4 T870 Service Manual

ARMREST

Description

The armrests are located on each side of the seat. They

are adjustable for comfort.

Figure 50-150-1

P-90837

Dealer Copy -- Not for Resale

Adjustable armrests (Item 1) [Figure 50-150-1].

435 of 822 50-150-1 T870 Service Manual

ARMREST (CONT’D) Figure 50-150-4

Removal And Installation

Slide the seat and the backrest all the way forward.
1
Remove the seat belt. (See Seat Belt Removal And
Installation on Page 50-30-2.)

Figure 50-150-2

P-90845

Remove the top spacer (Item 1) and the bottom spacer

(Item 2) [Figure 50-150-4] from the seat.
1 Repeat for the other side.

Dealer Copy -- Not for Resale

P-90835

Remove the two nuts and bolts (Item 1) [Figure 50-150-

2].

Figure 50-150-3

P-90836

Remove the tie strap (Item 1) and disconnect the wire

harness connector (Item 2) [Figure 50-150-3].

Remove the nut (Item 3) [Figure 50-150-3].

Remove the armrest (Item 4) [Figure 50-150-3] from the

seat.

436 of 822 50-150-2 T870 Service Manual

ARMREST (CONT’D) Figure 50-150-7

Disassembly And Assembly

Remove the Joystick. (See Joystick Removal And

Installation on Page 50-110-2.)

Remove the armrest. (See Removal And Installation on

Page 50-150-2.)

Figure 50-150-5

1
1

P-90840

Remove the two washers (Item 1) [Figure 50-150-7].

Figure 50-150-8

Dealer Copy -- Not for Resale

1
P-90838

2
Lift up on one edge and remove armrest cover (Item 1)
[Figure 50-150-5].

Figure 50-150-6

1 P-90841

2
Remove the two nuts and bolts (Item 1) and the support
tube (Item 2) [Figure 50-150-8].

1 1

P-90839

Remove the two bolts and washers (Item 1) and the

armrest shell (Item 2) [Figure 50-150-6].

437 of 822 50-150-3 T870 Service Manual

ARMREST (CONT’D) Figure 50-150-11

Disassembly And Assembly (Cont’d)

Figure 50-150-9

1 1
3
2
2
P-90844
1

Remove the two nuts (Item 1) and the slide rail (Item 2)
P-90842 [Figure 50-150-11] from the armrest mount.

Repeat for the other side.

Figure 50-150-10

Dealer Copy -- Not for Resale

3
6
5 2
4 1

P-90843

Remove the nut (Item 1), washer (Item 2), and the plastic
washer (Item 3) [Figure 50-150-9] and [Figure 50-150-
10].

Remove the spacer (Item 4), plastic washer (Item 5), and
the bolt (Item 6) [Figure 50-150-10].

Installation: Tighten the nut to 21 - 23 N•m (180 - 200 in-

lb) torque.

438 of 822 50-150-4 T870 Service Manual

LEFT SIDE LOWER PANEL Figure 50-160-3

Removal And Installation

Raise the operator’s cab.

Figure 50-160-1

1
1

1 1
P-90863 P-90856
1
Disconnect the wiper washer pump (Item 1) (if equipped)
1
[Figure 50-160-3] from the left side lower panel.

P-90897 Figure 50-160-4

Remove the five plastic rivets (Item 1) [Figure 50-160-1].

Dealer Copy -- Not for Resale

Remove the seat. (See Removal And Installation on
Page 50-30-1.)
1
Remove the 3-Point seat belt retractor (If equipped).
(See 3-Point Seat Belt Removal And Installation on Page 1
50-30-4.)

Lower the operator’s cab. 1

NOTE: With the seat removed, the cab may raise.

Figure 50-160-2 P-90856

Remove three plastic screws and the anchors (Item 1)

[Figure 50-160-4] from the left side lower panel.

P-90867

Remove the storage compartment (Item 1) (if equipped)

[Figure 50-160-3] from the left side lower panel.

439 of 822 50-160-1 T870 Service Manual

LEFT SIDE LOWER PANEL (CONT’D) Figure 50-160-7

Removal And Installation (Cont’d)

Figure 50-160-5

2
1 1

P-90858

1 Disconnect the hose (if equipped) (Item 1) and remove

P-90855 the hose (Item 2) [Figure 50-160-7] from the panel.

Figure 50-160-8
Remove the three plastic rivets and anchors (Item 1) and
the screw (Item 2) [Figure 50-160-5].

Dealer Copy -- Not for Resale

Figure 50-160-6

2 1

1
P-90852

Pull the left side lower panel (Item 1) [Figure 50-160-8]

P-90857 rear out and away from the side of the cab.

NOTE: Pull the left side lower panel away from the
Remove the two screws (Item 1) and the plastic rivet side of the cab far enough to access the wire
(Item 2) [Figure 50-160-6]. harness.

440 of 822 50-160-2 T870 Service Manual

LEFT SIDE LOWER PANEL (CONT’D) Disassembly And Assembly

Removal And Installation (Cont’d) Figure 50-160-10

Figure 50-160-9 1

1 1

1 1
1

1
P-90860

P-90859
Press the four tabs (Item 1) [Figure 50-160-10] and
remove the HVAC control out of the left side lower panel.
Disconnect the HVAC or radio wire harnesses (Item 1)
[Figure 50-160-9] (if equipped). Figure 50-160-11

Dealer Copy -- Not for Resale

1

P-90865

NOTE: If the three clips (Item 1) [Figure 50-160-11] are

removed the cup holder will need to be
replaced.

441 of 822 50-160-3 T870 Service Manual

LEFT SIDE LOWER PANEL (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 50-160-12

1 1

1
1

P-90866

Remove the four screws (Item 1) [Figure 50-160-12] and

remove the speaker from the left side lower panel.

Dealer Copy -- Not for Resale

Figure 50-160-13

P-90864

Remove the three screws (Item 1) [Figure 50-160-13]

and remove the washer tank from the left side lower
panel.

442 of 822 50-160-4 T870 Service Manual

RIGHT SIDE LOWER PANEL Figure 50-170-3

Removal And Installation 2

Raise the operator’s cab.

1
Figure 50-170-1
1

1 1

1
P-90870

1
Remove the three plastic rivets and anchors (Item 1) and
1 the screw (Item 2) [Figure 50-170-3].

P-90897 Figure 50-170-4

Dealer Copy -- Not for Resale

Remove the five plastic rivets (Item 1) [Figure 50-170-1].

Remove the seat. (See Removal And Installation on

Page 50-30-1.)
2
1
Lower the operator’s cab.

NOTE: With the seat removed, the cab may raise.

Figure 50-170-2 1

1
1 P-90871

1
Remove the two screws (Item 1) and the plastic rivet
(Item 2) [Figure 50-170-4].

P-90869

Remove the three plastic screws and the anchors (Item

1) [Figure 50-170-2] from the right side lower panel.

443 of 822 50-170-1 T870 Service Manual

RIGHT SIDE LOWER PANEL (CONT’D) Disassembly And Assembly

Removal And Installation (Cont’d) Figure 50-170-7

Figure 50-170-5

P-90879

P-90872
Remove the plastic nut and the lock washer (Item 1)
[Figure 50-170-7] from power port and remove the
Pull the right side lower panel (Item 1) [Figure 50-170-5] power port from the right side lower panel.
rear out and away from the side of the cab.

Dealer Copy -- Not for Resale

NOTE: The power port lock washer must be replaced
NOTE: Pull the right side lower panel away from the with a new when it has been removed.
side of the cab far enough to access the wire
harness. Figure 50-170-8

Figure 50-170-6

2 1

1
P-90877
2

1
P-90881

P-90873
Depress the tab (Item 1) [Figure 50-170-8] and remove
the radio from the right side lower panel.
Disconnect the wire harnesses (Item 1) and the antenna
(Item 2) [Figure 50-170-6] (if equipped with radio). Installation: Insert a screwdriver into the slot (Item 2)
[Figure 50-170-8] to lock the tab into place.
NOTE: Install the right side lower panel with the radio
removed to assist in connecting the power
port wire.

444 of 822 50-170-2 T870 Service Manual

RIGHT SIDE LOWER PANEL (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 50-170-9

P-90875

Remove the nut, washer, and cover, (Item 1) [Figure 50-

170-9] from the input.

Dealer Copy -- Not for Resale

Remove the input from the right side lower panel.

Figure 50-170-10

1
1

1
1

P-90876

Remove the four screws (Item 1) [Figure 50-170-10] and

remove the speaker from the right side lower panel.

445 of 822 50-170-3 T870 Service Manual

 Dealer Copy -- Not for Resale

446 of 822 50-170-4 T870 Service Manual

HEADLINER Figure 50-180-3

Removal And Installation

Figure 50-180-1

1 1
1

P-90895
2
Remove the air duct (Item 1) [Figure 50-180-3] (if
P-90893 equipped).

Remove the cab light (if equipped). (See Cab Light

Remove the two screws (Item 1) and the rear shelf (Item Removal And Installation on Page 60-60-2.)
2) [Figure 50-180-1] (if equipped).

Dealer Copy -- Not for Resale

Figure 50-180-4
NOTE: The rear shelf has two panel clips on the
underneath side, lift vertically to disengage.

Installation: Tighten the screws to 2,3 N•m (20 in-lb)

torque.
1
1
Figure 50-180-2

1
1

2
1 P-90896

Remove the four retainers (Item 1) and remove the

headliner (Item 2) [Figure 50-180-4].

Installation: Route the cab light wire harness in the

P-90894 grove on the topside of the headliner (if equipped with
HVAC).

Remove the air duct (Item 1) [Figure 50-180-2] (if NOTE: Replace the retainers if needed.
equipped).

447 of 822 50-180-1 T870 Service Manual

 Dealer Copy -- Not for Resale

448 of 822 50-180-2 T870 Service Manual

 ELECTRICAL SYSTEM & ANALYSIS

ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Deluxe Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Mainframe Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-11

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3

Dealer Copy -- Not for Resale

Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-6

STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2

INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Left Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Right Panel (Standard Key Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4
Right Panel (Keyless Start Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Right Panel (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Left Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
Right Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
Left Side Lower Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-9
Right Side Lower Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-9
Left Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-10
Right Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-10
Key Switch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-50-11
Alarm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-50-11
Left Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12
Right Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12

449 of 822 60-01 T870 Service Manual

LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Cab Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2

BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) . . . . . . . . . . . . . . . . . . . . . . 60-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-8

BOBCAT CONTROLLER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1
Connector And Wire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-3

BOBCAT CONTROLLER (SJC) (DRIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-4

BOBCAT CONTROLLER (SCPA) (DRIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-73-1

Dealer Copy -- Not for Resale

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-73-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-73-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-73-4

SPEED SENSORS (SJC AND SCPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-3

DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Inspecting The BICS™ (Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Lift Arm Bypass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of Lift And Tilt Functions (SJC) . . . . . . . . . . . . . . . . . . . . 60-100-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3

450 of 822 60-02 T870 Service Manual

SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-3
Bobcat Interlock Control System (BICS™) Circuit Test . . . . . . . . . . . . . . . . . . . . . .60-110-6

TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-2
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-3

ELECTRICAL / HYDRAULIC CONTROLS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-2
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-3
Identification Chart ACD Group 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-4
Identification Chart ACD Group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-5
Identification Chart ACD Group 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-6

ELECTRICAL / HYDRAULIC CONTROLS (SCPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-131-1

Dealer Copy -- Not for Resale

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-131-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-131-2
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-131-3
Identification Chart ACD Group 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-131-4
Identification Chart ACD Group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-131-5
Identification Chart ACD Group 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-131-6

SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Connecting Remote Start Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Lift And Tilt Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-4
Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-6
Hydrostatic Pump Calibration (SCPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-150-11

STEERING DRIFT COMPENSATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1

FLYWHEEL RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1

CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1

Right Panel Setup (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1

451 of 822 60-03 T870 Service Manual

PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) . . . . . . . . . . . . . . . . . 60-190-1
Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Changing The User Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2

PASSWORD SETUP (KEYLESS START PANEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1

Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1

MAINTENANCE CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-2
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-5

BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-2
Alarm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-3

Dealer Copy -- Not for Resale

FRONT HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-1
Front Horn Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-2
Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-3

452 of 822 60-04 T870 Service Manual

 Dealer Copy -- Not for Resale

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 LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX
PARTIAL CONNECTOR
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2

CAB DISPLAY
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6 CONNECTOR
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CAB PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK CONTROLS PAGE 10 WIRE BREAK
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11 (TWO WIRE BREAKS
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12 JOIN ONE WIRE)
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13 SHEET #
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT

T13
BUZZER (+)
SHEET 3 1940, RNG/WHT
C499
LEFT PANEL
Press To Operate Loader
BUZZER
(PTOL)
C479
T2
LEFT PANEL (BLACK) 1930, RNG/WHT 1
BUZZER (-) SHEET 3 SWITCHED POWER
2940, BLK 3
9320, PUR 10 SHEET 4 GROUND
BUZZER
C408
2920, BLK 2 CAB-MFR HARN
SHEET 4 GROUND
1960, RNG/WHT 1440, RED/WHT 1 20 9380, PUR 1 9380, PUR 2
SHEET 3 SHEET 3 UNSWITCHED POWER PTOL OUTPUT
SW9 1620, RNG/WHT 5 SWITCHED POWER
SHEET 3 19 9370, PUR 37 9370, PUR 4
TRAVEL CONTROL PTOL LED
6450, PNK 11 J1A
SWITCH (OPTIONAL) SHEET 13 LEFT BLINKER INPUT
GWY CTRLR
C500
5 6 6550, PNK 8
4 SHEET 13 RIGHT BLINKER INPUT RIGHT KEY SWITCH PANEL
2700, BLK 2 3 4730, LGN 7 24 9360, PUR 4 9360, PUR 2
SHEET 4 TRAVEL CONTROL INPUT START
1 9
4500, LGN
PARK BRAKE INPUT
SW1 6
3 2 BRAKE SWITCH Dealer Copy -- Not for Resale
1 C480 J1B 22 9350, PUR 40 4
LEFT PANEL (GRAY) 9350, PUR RUN/ENTER SWITCH
9310, PUR 4 5 GWY CTRLR
1775, RNG/WHT 4750, LGN 12
SHEET 3 6 SHEET 9 DOOR SIGNAL
2930, BLK 11 1950, RNG/WHT 5
SHEET 4 SHEET 3 SWITCHED POWER
10 1420, RED/WHT 1
SHEET 3 UNSWITCHED POWER
9 2960, BLK 3
SHEET 4 GROUND
9310, PUR 2
PARK BRAKE OUTPUT
8
7 C503
6 RIGHT DELUXE PANEL
5 1590, RNG/WHT 5
4 SHEET 3 SWITCHED POWER
3 1240, RED/WHT 1
SHEET 3 UNSWITCHED POWER
1 2250, BLK 3
SHEET 4 GROUND
6

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WIRING SCHEMATIC
(STANDARD MACHINE)
T870 (S/N A3PG11001 AND ABOVE)
(S/N A3PH11001 AND ABOVE)
Sheet 3 of 13
(PRINTED JUNE 2010)
Printed
455 of 822 In U.S.A.
719067
 Dealer Copy -- Not for Resale

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 Dealer Copy -- Not for Resale

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478 of 822
ELECTRICAL SYSTEM INFORMATION

Glossary Of Electrical Symbols

SYMBOL DESCRIPTION SYMBOL DESCRIPTION

CONNECTIONS COMPONENTS
CONNECTOR - Harness - Used for GROUND - Frame - Used to
3500 A A 3500 connecting 2 harnesses together or a represent an component that is
C107

3520 C C 3520
3510 B B 3510
harness to a component. The internally grounded.
connector can vary from a single pin
to any number of pins (Example: 3 pin
connectors shown). The connector
LIGHT -
C107 pins can be numbered alphabetical
3500
A A
3500 (shown) or numerical (1, 2, 3 etc.).
C C
3520
B B
3520 The harness wires numbers are
3510 3510
called out next to the connector
(Example: 3500). SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or

Dealer Copy -- Not for Resale

connector. SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Closed.

COMPONENTS

- + BATTERY - Used for supplying and SWITCH - Single Pole - Double

storing electrical power for the Throw (ON-OFF-ON) - This switch
machine. can be in any of three positions.
(Some switches are spring activated
to return them to a certain position
+ POSITIVE ELECTRICAL CIRCUIT -
when released.)
Indicates positive battery circuit.
SWITCH - Double Pole - Single
Throw (ON-OFF) Open and Closed
positions will be specified depending
- NEGATIVE ELECTRICAL CIRCUIT - on switch application.)
Indicates battery ground circuit.
SWITCH - Double Pole - Double
Throw (ON-OFF) Open and Closed
ALTERNATOR - Used to create the positions will be specified depending
on switch application.
G electrical current to supply voltage to
the battery and components.
POTENTIOMETER - Variable
+ - resistance - Provides variable
STARTER - Uses battery current to resistance.
M start the machine engine.

GROUND - Used to represent an

external ground connection.

479 of 822 60-10-1 T870 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Glossary Of Electrical Symbols (Cont’d)

SYMBOL DESCRIPTION SYMBOL DESCRIPTION

COMPONENTS SOLENOID - Fuel and Traction Lock -

HOLD PULL
15 ohm B
Dual solenoids. (The ohm rating of
I SWITCH - Ignition - Multi position 0.5 ohm A the solenoid coils are listed next to
B
switch to activate various start the component [if available]). The pull
ST functions at different positions. solenoid is energized for a short time.

START
HORN - Audible alarm. Sound is
R U N
O FF
activated manually by a switch.

BUZZER - Audible alarm. Sounds at

1 SWITCH - Light - Multi position switch a predetermined setting to warn the
2 to activate various lights at different operator of a component condition.
3
positions.
4 5 RESISTOR - Limits current flow.
6

Dealer Copy -- Not for Resale

DIODE - Allows electrical current to
ROTARY CONTROL - Provides flow in 1 direction only.
variable voltage proportional to
position.
L MOTOR - HVAC - Multi speed motor.
M
H M
GRD

87A 87 86 RELAY - Uses a low amp switch to GRD MOTOR - Wiper - Single or multi
control a high amp component. PARK V speed motor.
30 85 M
HIGH

FUSE - Used to protect the wire MOTOR - Washer - Single speed.

M
harness from an overloaded circuit.
25A (The fuse rating is listed next to the
fuse.)
PUMP - FUEL

3
700 3
710 SPLICE (•) - Used to show when
3
110 multiple wires are connected together
on the schematic. HOURMETER - Records the time the
H
+ - engine is running.
SOLENOID - ON / OFF - Electrically
1 activated coil that controls movement
2 magnetically. (The ohm rating of the POWER PLUG - Supplies 12 volt
- +
7.7 ohm
solenoid coil is listed next to the power for customer supplied
component [if available]). accessories.

SOLENOID - VARIABLE - Electrically GAUGE - Instrument - Indicates

A G certain engine or other component
activated coil that controls movement
B conditions. (The different types of
7.5 ohm magnetically. (The ohm rating and I S
gauge are marked with a icon that
12V
voltage of the solenoid coil is listed represents what function the gauge is
next to the component [if available]). monitoring. Example: the gauge
shown is for fuel.)

480 of 822 60-10-2 T870 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Glossary Of Electrical Symbols (Cont’d)

SYMBOL DESCRIPTION

SENDERS AND SENSORS

+
A
PRESSURE SENDER - Provides a
A variable voltage proportional to
C
- C pressure. (Sender voltage rating is
B
B
0.5 - 7.5 V listed to show volts at high and low
setting.)

B
PRESSURE SWITCH - Switch opens
A or closes at a predetermined
pressure to active a function or to turn
on a warning light. (Switch is shown
in the open position.)

to TEMPERATURE SENDER - Provides

B a variable resistance (ohm) signal
A proportional to temperature. (Sender
500-3000ohm ohm rating is listed to show ohm at

Dealer Copy -- Not for Resale

high and low setting.)

A TEMPERATURE SWITCH - The

B switch opens or closes at a
predetermined temperature to active
a function or to turn on a warning
light. (Switch is shown in the closed
position.)

B FUEL SENDER - Provides a variable

resistance, based on the fuel level in
A
the tank. (Sender ohm rating is listed
30-270 ohm to show ohm at full and empty
setting.)

C HALL EFFECT SENSOR - Detects

B linear or rotary position and provides
A a proportional variable voltage.

A SPEED SENSOR - magnetic pickup -

detects rpm.
B

481 of 822 60-10-3 T870 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Deluxe Cab Harness Connectors

C209

C670 C479 C434-1

C480 C434-2

C499
T13
C482 T2
SW1
SW3
C500

Dealer Copy -- Not for Resale

C503 SW2
SW6
C435-1
C435-2
SW4
C667
C426
SW5
SW9
C611 C252
C630
C635

C126
C129 C253
C277 C279
C449 C483
C450 S3
T3

C278
C676
C212

MS2827

482 of 822 60-10-4 T870 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Mainframe Harness Connectors

C426
C405
C103 C 350
408

T11 T6
T1

Dealer Copy -- Not for Resale

T8 C355
T10 T4
C101 C105
C110 C104
C362
T12 C107
FRC1
C486 C446 FC1
C108 FC2
C423 C362
C441 C489
C415 C497
J2A
C409 J2B
C419 J1A
C420 C410 J1B
C418 C404 C411
C421 C437 C412
C422
C425

C492
C493

MS2825

483 of 822 60-10-5 T870 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Description

Figure 60-10-1

P-13849

P-90658

The loader has a 12 volt, negative ground, alternator

charging system.

Dealer Copy -- Not for Resale

The electrical system is protected by fuses located under
the operator cab and a 100 amp master fuse [Figure 60-
10-1] located above the battery in the engine
compartment.

The fuses will protect the electrical system when there is

an electrical overload. The reason for the overload must
be found before starting the engine again.

484 of 822 60-10-6 T870 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Troubleshooting WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0807

PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9

Dealer Copy -- Not for Resale

KEY TO CORRECT THE CAUSE
1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or solenoid is damaged.
9. Check the fuses.

485 of 822 60-10-7 T870 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Fuse And Relay Location / Identification

Earlier Models

Raise the operator cab. (See Raising on Page 10-30-1.)

Figure 60-10-2

P-85411

Dealer Copy -- Not for Resale

The electrical system is protected from overload by fuses
and relays located under three fuse panel covers (Item 1)
[Figure 60-10-2].

Figure 60-10-3

P-85412

Remove the covers to check or replace the fuses [Figure

60-10-3].

A decal is located inside the large cover to show location

and amperage ratings.

A table is provided with details on amperage ratings and

circuits affected by each fuse and relay. [Figure 60-10-7
on Page 60-10-10]

486 of 822 60-10-8 T870 Service Manual

ELECTRICAL SYSTEM (CONT’D) Figure 60-10-6

Fuse And Relay Location / Identification (Cont’d)

Later Models

Figure 60-10-4

P100416

Remove the covers to check or replace the fuses [Figure

1
60-10-6].

P100414 A decal is located inside the access panel to show

location and amperage ratings.

Dealer Copy -- Not for Resale

The fuse / relay panels are located behind an access Line up the clips on the back of the access panel with the
panel near the left foot pedal / footrest. Pull the panel at slots provided and push the panel into place when
each end (Item 1) [Figure 60-10-4] to remove. finished [Figure 60-10-4]. A locating pin prevents the
panel from being installed upside down.
Figure 60-10-5
A table is provided with details on amperage ratings and
circuits affected by each fuse and relay. [Figure 60-10-7
on Page 60-10-10]

P100415

The electrical system is protected from overload by fuses

and relays located under three fuse panel covers (Item 1)
[Figure 60-10-5].

487 of 822 60-10-9 T870 Service Manual

ELECTRICAL SYSTEM (CONT’D)

Fuse And Relay Location / Identification (Cont’d)

Figure 60-10-7

1 13 21 25
17
5 7 9 11
2 22 26
14 18

3 15 19 23 27
6 8 10 12
4 16 20 24 28

The location and amperage ratings are shown in the table below and on the decal [Figure 60-10-7]. Relays are identified
by the letter “R” in the AMP column.

REF ICON DESCRIPTION AMP REF ICON DESCRIPTION AMP REF ICON DESCRIPTION AMP

Dealer Copy -- Not for Resale

1 Alternator 15 11 Glow Plugs R 21 Bobcat Controller 25

2 Heater / HVAC 25 12 Fuel Shutoff R 22 ACS Controller 25

Cab Switched
3 Front Lights 20 13 5 23 Attachments 25
Power

4 Rear Lights 15 14 Bucket Position 15 24 Not Used --

Auxiliary
5 Starter R 15 Wiper / Washer 25 25 25
Controller

Drive Controller
6 Front Lights R 16 Switched Power 25 26 and Back-up 25
Alarm

Accessories and
7 Heater / HVAC R 17 Switched Power 25 27 25
Front Horn

8 Rear Lights R 18 Switched Power 25 28 Power Port 15

9 Switched Power R 19 Traction 30

10 Traction R 20 Fuel Shutoff 30

488 of 822 60-10-10 T870 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Solenoid Testing

Figure 60-10-8

P9175

Use a test meter to measure coil resistance [Figure 60-

10-8]. Coil wires do not have polarity. Correct resistance

Dealer Copy -- Not for Resale

for the pressure relief (small) coil is 7 - 10 ohm and the
other coils 5 - 8 ohm.

Replace the test meter with 12 volt power. You can see
and hear the spool shift.

489 of 822 60-10-11 T870 Service Manual

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490 of 822 60-10-12 T870 Service Manual

BATTERY Figure 60-20-2

Removal And Installation

WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention P-09589 P-09590
and wash eye with clean, cool water for at least 15
minutes.
Always clean the battery terminals and cable ends when
If electrolyte is taken internally drink large quantities installing a new or used battery [Figure 60-20-2].
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. When installing the battery in the loader, do not touch any
W-2065-0807 metal parts with the battery terminals.

Dealer Copy -- Not for Resale

Connect the negative (-) cable last to prevent sparks.
Open the rear door.
Connect and tighten the battery cables.
Figure 60-20-1
Install and tighten the battery hold down.

WARNING
1
BATTERY GAS CAN EXPLODE AND CAUSE
SERIOUS INJURY OR DEATH
2
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.

Do not jump start or charge a frozen or damaged

P100285
battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before
Disconnect the negative (-) cable (Item 1) [Figure 60-20- connecting or disconnecting cables to battery. Never
1]. lean over battery while boosting, testing or charging.
W-2066-0910
Remove the battery hold down clamp (Item 2) [Figure
60-20-1].

Disconnect the positive (+) cable (Item 3) [Figure 60-20-

1] from the battery.

Remove the battery from the loader.

491 of 822 60-20-1 T870 Service Manual

BATTERY (CONT’D)

Servicing

Figure 60-20-3

P-09589 P-09590

The battery cables must be clean and tight [Figure 60-

20-3]. Check electrolyte level in the battery. Add distilled

Dealer Copy -- Not for Resale

water as needed. Remove acid or corrosion from battery
and cables with sodium bicarbonate (baking soda) and
water solution.

Put Bobcat Battery Saver or grease on the battery

terminals and cable ends to prevent corrosion.

WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.

If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807

492 of 822 60-20-2 T870 Service Manual

BATTERY (CONT’D) Keep cables away from moving parts. Start the engine.

Using A Booster Battery (Jump Starting) After the engine has started, remove the negative (-)
cable (Item 4) [Figure 60-20-4] first. Remove the cable
If it is necessary to use a booster battery to start the from the positive terminal (Item 2) [Figure 60-20-4].
engine, BE CAREFUL! There must be one person in the
operator’s seat and one person to connect and
disconnect the battery cables.

The key switch must be OFF or the STOP button must be

pressed. The booster battery must be 12 volt.
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
WARNING • Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
BATTERY GAS CAN EXPLODE AND CAUSE • Extra battery cables (booster cables) are
SERIOUS INJURY OR DEATH connected wrong.
Keep arcs, sparks, flames and lighted tobacco away I-2023-1285
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.

Do not jump start or charge a frozen or damaged

Dealer Copy -- Not for Resale

battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
W-2066-0910

Figure 60-20-4

2
4

3 1

P-90660A

Connect the end of the first cable (Item 1) [Figure 60-20-

4] to the positive (+) terminal of the booster battery.
Connect the other end of the same cable (Item 2) [Figure
60-20-4] to the positive terminal on the loader starter.

Connect the end of the second cable (Item 3) [Figure 60-

20-4] to the negative terminal of the booster battery.
Connect the other end of the same cable (Item 4) [Figure
60-20-4] to the engine.

493 of 822 60-20-3 T870 Service Manual

 Dealer Copy -- Not for Resale

494 of 822 60-20-4 T870 Service Manual

ALTERNATOR Move the alternator toward the engine as far as it will go
and remove the belt from the pulleys. Inspect the pulleys
Belt Adjustment for wear.

The alternator belt is a special maintenance free type that Install new belt.
is pretensioned over the pulleys. This belt eliminates the
need for a tensioning device and does not require Figure 60-30-3
periodic adjustment. Contact your Bobcat dealer for
replacement parts.

Belt Replacement

Stop the engine and open the rear door (See REAR
DOOR (TAILGATE) on Page 50-70-1.).

Remove the air conditioning belt. (See Compressor Drive

Belt Replacement on Page 80-20-2.)
1
Figure 60-30-1

P100038

Dealer Copy -- Not for Resale

Use a prybar (Item 1) [Figure 60-30-3] to move the
1 alternator until the bottom alternator mounting bolt (Item
2) [Figure 60-30-2] can be installed.

Tighten the top alternator mounting nut (Item 1) and

3 bottom alternator mounting bolt (Item 2) [Figure 60-30-
2].

P100231 Install the air conditioning belt. (See Compressor Drive

Belt Replacement on Page 80-20-2.)

Remove the clamp nut and bolt (Item 1). Remove the belt Install the belt shield, mounting nuts and bolts, and clamp
shield mounting nuts and bolts (Item 2) and remove the nut and bolt [Figure 60-30-1].
belt shield (Item 3) [Figure 60-30-1].
Close the rear door.
Figure 60-30-2

P100034

Remove the bottom alternator mounting bolt (Item 2) and

loosen the top alternator mounting nut (Item 1) [Figure
60-30-2].

495 of 822 60-30-1 T870 Service Manual

ALTERNATOR (CONT’D) Figure 60-30-4

Charging System Inspection

1

WARNING 2

AVOID INJURY OR DEATH

Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention P100281
and wash eye with clean, cool water for at least 15
minutes. If the charging system malfunctions check the following:
If electrolyte is taken internally drink large quantities Check the condition and tension of the alternator belt.
of water or milk! DO NOT induce vomiting. Get (See Belt Adjustment on Page 60-30-1.) Replace belt if
prompt medical attention. worn or deteriorated.
W-2065-0807
Inspect the alternator wiring harness and connectors at
alternator. Harness and connectors must be clean and

Dealer Copy -- Not for Resale

tight.
Check the fuse for the alternator in the fuse panel. If fuse
WARNING is burned, find the cause and repair / replace. If fuse is in
doubt, remove it and check for continuity.

BATTERY GAS CAN EXPLODE AND CAUSE Check the electrolyte level in the battery. Add distilled
SERIOUS INJURY OR DEATH water as needed. (Does not apply to maintenance free
Keep arcs, sparks, flames and lighted tobacco away batteries.)
from batteries. When jumping from booster battery Verify the charge of the battery. Make sure battery is fully
make final connection (negative) at machine frame. charged.

Do not jump start or charge a frozen or damaged Disconnect the battery cables (negative first, then
battery. Warm battery to 16°C (60°F) before positive). Inspect the cable clamps and battery posts for
corrosion. Remove acid or corrosion from the battery and
connecting to a charger. Unplug charger before
cables with a sodium bicarbonate and water solution. Put
connecting or disconnecting cables to battery. Never grease on the cable ends and battery terminals to
lean over battery while boosting, testing or charging. prevent corrosion. Reconnect the cable to the positive
W-2066-0910 terminal.
With the key off, connect a test light between the
negative battery post and the disconnected negative
cable clamp.

IMPORTANT 1. If the test light does not light up, reattach the clamp
and proceed to alternator voltage test.
Damage to the alternator can occur if: 2. If the test light lights up, there is a short (drain) in the
• Engine is operated with battery cables electrical system of the loader. The short must be
disconnected. repaired before the charging system can be checked.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove 3. Disconnect the alternator B+ terminal (Item 1) and L
both cables from the battery.) and S terminal connector (Item 2) [Figure 60-30-4]
• Extra battery cables (booster cables) are and if the test light goes out, the alternator is faulty. If
connected wrong. the test light stays on, find the short in the system and
I-2023-1285 repair it.

496 of 822 60-30-2 T870 Service Manual

ALTERNATOR (CONT’D) Low Voltage Testing

Alternator Voltage Testing Figure 60-30-6

Figure 60-30-5

P100281

P-85916
Turn engine OFF and remove the L and S terminal
connector (Item 1) [Figure 60-30-6] from the alternator.
Open rear door.
Turn the remote start tool key to the ON position.

Dealer Copy -- Not for Resale

Connect the remote start tool to the loader. (See
REMOTE START TOOL KIT-MEL1563 on Page 10-60- Figure 60-30-7
1.)

Turn the engine on with the remote start tool and run at
idle. With a voltmeter, check the voltage between the B+
terminal and ground at the starter [Figure 60-30-5].

The voltage must be higher than 13.5 volts but lower than
14.7 volts at 21°C (70°F) (Alternator Temperature). 2

If the voltage is higher that 14.7 volts, proceed to the

following high voltage test. 1

If the voltage is lower than 13.5 volts, run the engine at

high idle and recheck voltage. If voltage is still below 13.5
volts, proceed with the following low voltage test. P100282

Check the voltage across the “L” terminal (Item 1) and

ground (Item 2) [Figure 60-30-7]. The voltage should be
what the battery voltage is. If not, check wire harness,
relay and fuses. If the wire harness, relay and fuses are
okay remove alternator for replacement or repair.

497 of 822 60-30-3 T870 Service Manual

ALTERNATOR (CONT’D)

High Voltage Testing

Figure 60-30-8

1
2

P100280

Turn engine OFF and remove the L and S Terminal

connector (Item 1) [Figure 60-30-6] off the alternator.

Dealer Copy -- Not for Resale

Check the continuity between the “S” terminal (Item 1)
[Figure 60-30-8] and the positive (+) terminal on the
battery or starter terminal (Item 2) [Figure 60-30-8].
There should be continuity. If no continuity, replace wire
harness.

If voltage is still above 14.7 volts at 21°C (70°F)

(Alternator Temperature), then remove alternator for
replacement or repair.

498 of 822 60-30-4 T870 Service Manual

ALTERNATOR (CONT’D) Figure 60-30-10

Removal And Installation

Remove the air conditioning belt. (See Compressor Drive 1

Belt Replacement on Page 80-20-2.) 2

IMPORTANT
1
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast P100283
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are Remove the alternator rain shield mounting nut and bolts
connected wrong. (Item 1) and remove the alternator rain shield (Item 2)
I-2023-1285 [Figure 60-30-10].

Figure 60-30-11
Figure 60-30-9

Dealer Copy -- Not for Resale

1 1

2
2

P100034
P100281

Remove the top alternator mounting bolt (Item 1) and the

Disconnect the negative (-) cable from the battery. bottom alternator mounting bolt (Item 2) [Figure 60-30-
11].
Disconnect the red wire (Item 1) [Figure 60-30-9] from
the alternator which comes from the battery. Remove the belt and alternator from the loader.
Disconnect the wiring harness connector (Item 2) [Figure
60-30-9] from the alternator.

499 of 822 60-30-5 T870 Service Manual

ALTERNATOR (CONT’D)

Parts Identification

Figure 60-30-12
1. Alternator 11. Bearing
2. Nut 12. Stator
3. Pulley 13. Bracket
4. Spacer 14. Sleeve
5. Bolt 15. Regulator
6. Bracket 16. Rectifier
7. Bolt 17. Cover
8. Bearing 18. Spacer
9. Retainer 19. Nut
10. Rotor
7
1
6

4 7 13 14
3 12
2

10 11
5
9

Dealer Copy -- Not for Resale

8

19

18
17
16
15 C-3529B

500 of 822 60-30-6 T870 Service Manual

STARTER Removal And Installation

Testing Figure 60-40-3

Figure 60-40-1 2
3

Bat
S
1
M

3
Cranking
Motor

P100279

A-1992
Open the rear door.
The key switch must be in the OFF position. Disconnect the negative (-) cable from the battery.
The battery must be at full charge.

Dealer Copy -- Not for Resale

Disconnect the wires and positive (+) cable (Item 1)
[Figure 60-40-3] from the starter solenoid.
The cable connections on the battery must be clean and
tight.
Installation: Tighten the nut to 14,7 - 16,7 N•m (10.8 -
Connect a jumper wire between S terminal and BAT 12.3 ft-lb) torque.
terminal [Figure 60-40-1].
Disconnect the wire connector (Item 2) [Figure 60-40-3]
If the starter turns but does not turn the engine, the from the two solenoid wires.
starter drive has a defect.
Remove the three mounting bolts (Item 3) [Figure 60-40-
Figure 60-40-2 3].

Remove the starter from the engine.

Bat
S
M

Cranking
Motor

A-1991

Connect a jumper wire (of at least 4 gauge in size)

between the M terminal and the BAT terminal [Figure 60-
40-2].

If the starter turns, the defect is in the solenoid.

If the starter does not turn, the starter is defective.

501 of 822 60-40-1 T870 Service Manual

STARTER (CONT'D)

Parts Identification

1. Starter 30 13. Lever

2. Shaft 14. Gear
3. Gear 15. Bracket
4. Washer 16. Spring
5. Shaft 17. Gear
6. Stop Ring 34 18. Stop
33
7. Lever 19. Stop Ring
8. Holder 13 20. Ball
9. Spring 21. Armature
10. Spring 36 22. Washer
11. Plate 8 23. Seal
11
12. Seal 9
10
31
32 7
21

15
12 37

Dealer Copy -- Not for Resale

16
14
17 20
19 18

14

6
29
1 4
3
28
2
27

24. Yoke
35 25. Holder
26. Bracket
27. Ring
22 26
28. Bolt
29. Bolt
23 25 30. Switch
31. Seal
23 32. Bolt
33. Washer
34. Nut
35. Boot
24
36. Bracket
37. Bearing
B-19824

502 of 822 60-40-2 T870 Service Manual

INSTRUMENT PANELS

Left Panel

Figure 60-50-1

2 3
12

7
1
16
4 13

6 8 9 10 11 15

5 14

Dealer Copy -- Not for Resale

17
20
18 19

21 22

23

P-90726B

The left instrument panel [Figure 60-50-1] is the same The table on the facing page shows the DESCRIPTION
for Standard Key Panel, Keyless Start Panel and Deluxe and FUNCTION / OPERATION for each of the
Instrumentation Panel equipped machines. components of the left panel.

503 of 822 60-50-1 T870 Service Manual

INSTRUMENT PANELS (CONT’D)
Left Panel (Cont’d)
REF.
DESCRIPTION FUNCTION / OPERATION
NO.
1 ENGINE TEMPERATURE GAUGE Shows the engine coolant temperature.
2 LEFT DIRECTION INDICATOR (Option) Indicates left flasher signals are ON.
3 GENERAL WARNING Malfunction with one or more machine functions. (See Service Codes*)
4 TWO-SPEED High range selected.
5 ENGINE MALFUNCTION Engine malfunction or failure. (See Service Codes*)
6 ENGINE COOLANT TEMPERATURE Engine coolant temperature high or sensor error.
7 DISPLAY SCREEN Displays information. (See Display Screen in this manual.)
8 SEAT BELT Instructs operator to fasten seat belt. Remains lit for 45 seconds.
9 SEAT BAR The light comes on when the seat bar is UP.
10 LIFT AND TILT VALVE The light comes on when the lift and tilt functions cannot be operated.
11 PARKING BRAKE The light comes on when the loader cannot be driven.
12 RIGHT DIRECTION INDICATOR (Option) Indicates right flasher signals are ON.
13 SHOULDER BELT Instructs operator to fasten shoulder belt when operating in high range.
Remains lit while in high range.
14 HYDRAULIC SYSTEM MALFUNCTION Hydraulic system malfunction or failure. (See Service Codes*)

Dealer Copy -- Not for Resale

15 FUEL Fuel level low or sensor error.
16 FUEL GAUGE Shows the amount of fuel in the tank.
17 LIGHTS Press once for FRONT work lights and REAR taillights. (Left green
LED will light.) Press a second time to add REAR work lights. (Left and
right green LEDs will light.) Press a third time to turn all lights off. (Left
and right green LEDs will be off.)
Press and hold five seconds to display software version in display
screen.
18 HIGH-FLOW (Option) Press once to engage the HIGH-FLOW auxiliary hydraulics. (Left green
LED will light.) Press a second time to disengage.
19 AUXILIARY HYDRAULICS Press once to activate the auxiliary hydraulic system. (Left green LED
will light.) Press a second time to deactivate the system.
20 INFORMATION Cycles through (after each button press):
• Hourmeter (On start up)
• Engine rpm
• Battery voltage
• Maintenance clock (Press and hold for seven seconds when
displayed to reset the maintenance clock.)
• Service codes*
21 TRACTION LOCK OVERRIDE Functions only when the seat bar is raised and the engine is running.
Press once to unlock the brakes. Allows you to use the steering
handles or joystick(s) to move the loader forward or backward when
using the backhoe attachment or for service. (See TRACTION LOCK
OVERRIDE in this manual.) Press a second time to lock the brakes.
22 PRESS TO OPERATE LOADER Press to activate the BICS™ when the seat bar is down and operator is
seated in operating position. Button will light.
Press and hold three seconds to access Drive Response and Steering
Drift Compensation adjustment menus. (See DRIVE RESPONSE and
STEERING DRIFT COMPENSATION in this manual.)
23 PARKING BRAKE (Standard on all Press the top to engage the Parking Brake. Press the bottom to
loaders) disengage. (See PARKING BRAKE in this manual.)
* See SYSTEM SETUP & ANALYSIS for Service Code description. (See DIAGNOSTIC SERVICE CODES on Page 60-
90-1.)

504 of 822 60-50-2 T870 Service Manual

INSTRUMENT PANELS (CONT’D)

Display Screen

The display screen can display the following information:

• Operating hours.
• Engine revolutions per minute (rpm).
• Speed management setting.
• Maintenance clock countdown.
• Battery voltage.
• Service codes.
• Engine preheat countdown.
• Steering drift compensation setting.
• Drive response setting.

Figure 60-50-2

Dealer Copy -- Not for Resale

2

3 4 5 6 7
P-76461A

The display screen is shown in [Figure 60-50-2]. The

data display will show operating hours upon startup.

1. Data Display

2. Hourmeter

3. Speed Management

4. Engine Preheat

5. Engine Revolutions Per Minute

6. Battery / Charging Voltage

7. Service

505 of 822 60-50-3 T870 Service Manual

INSTRUMENT PANELS (CONT’D)

Right Panel (Standard Key Panel)

Figure 60-50-3

Dealer Copy -- Not for Resale

2

P-85285C

This machine may be equipped with a Standard Key

Panel [Figure 60-50-3].

1. Key Switch: Used to turn the loaders electrical

system on and off, and to start and stop the engine.

2. Selectable Joystick Controls (SJC) Control

Pattern Switch (Option): Press the top to select
‘ISO’ Control Pattern; bottom to select ‘H’ Control
Pattern.

506 of 822 60-50-4 T870 Service Manual

INSTRUMENT PANELS (CONT’D) 6. RUN Button: Used to turn on the loaders electrical
system.
Right Panel (Keyless Start Panel)
7. Selectable Joystick Controls (SJC) Control
Figure 60-50-4 Pattern Switch (Option): Press the top to select
‘ISO’ Control Pattern; bottom to select ‘H’ Control
Pattern.

2 3

Dealer Copy -- Not for Resale

6

P-90819E

This machine may be equipped with a Keyless Start

Panel [Figure 60-50-4].

1. Keypad (keys 1 through 0): Used to enter a number

code (password) to allow starting the engine. An
asterisk will show in the left panel display screen for
each key press.

2. LOCK Key: Used to lock keypad. The lock key will

display a red light to indicate a password is required
to start the loader. (See Password Lockout Feature
on Page 60-191-1.)

3. UNLOCK Key: Used to unlock keypad. The unlock

key will display a green light to indicate the loader can
be started without a password. (See Password
Lockout Feature on Page 60-191-1.)

4. START Button: Used to start the engine.

5. STOP Button: Used to stop the engine and shut

down the loaders electrical system.

507 of 822 60-50-5 T870 Service Manual

INSTRUMENT PANELS (CONT’D) 6. STOP Button: Used to stop the engine and shut
down the loaders electrical system.
Right Panel (Deluxe Instrumentation Panel)
7. RUN Button: Used to turn on the loaders electrical
Figure 60-50-5 system.

8. Selectable Joystick Controls (SJC) Control

1 Pattern Switch (Option): Press the top to select
‘ISO’ Control Pattern; bottom to select ‘H’ Control
Pattern.
2

5
6

Dealer Copy -- Not for Resale

7

P-90212F

This machine may be equipped with a Deluxe

Instrumentation Panel [Figure 60-50-5].

1. Keypad (1 through 0): The keypad has two

functions:

- To enter a number code (password) to allow starting

the engine.
- To enter a number as directed for further use of the
display screen.

2. Display Screen: The Display Screen is where all

system setup, monitoring and error conditions are
displayed.

3. Scroll Buttons: Used to scroll through display screen

choices.

4. ENTER Button: Used to make selections on the

display screen.

5. START Button: Used to start the engine.

508 of 822 60-50-6 T870 Service Manual

INSTRUMENT PANELS (CONT’D) Enter The Password:

Right Panel (Deluxe Instrumentation Panel) (Cont’d) Use the numbers on the keypad to enter the password,
then press the [ENTER] button. A symbol will appear on
Figure 60-50-6 the display screen for each number entered [Figure 60-
50-6]. The left scroll button can be used to backspace if
an incorrect number is entered.

If the correct password is not entered, [INVALID

PASSWORD TRY AGAIN] will appear on the display
screen and the password will have to be reentered.

See CONTROL PANEL SETUP for further description of

screens to setup the system for your use. (See
CONTROL PANEL SETUP on Page 60-180-1.)

NA3017

The first screen you will see on your new loader will be as
shown in [Figure 60-50-6].

Dealer Copy -- Not for Resale

When this screen is on the display you can enter the
password and start the engine or change the default
language.

NOTE: Your new loader (with Deluxe Instrumentation

Panel) will have an Owner Password. Your
dealer will provide you with this password.
Change the password to one that you will
easily remember to prevent unauthorized use
of your loader. (See Changing The Owner
Password on Page 60-190-1.) Keep your
password in a safe place for future needs.

Change Language:

Press the left or right scroll button to cycle through the

languages. The language that is stopped on will be the
default language used for the deluxe instrumentation
panel [Figure 60-50-6].

The language can be changed at any time. (See

CONTROL PANEL SETUP on Page 60-180-1.)

509 of 822 60-50-7 T870 Service Manual

INSTRUMENT PANELS (CONT’D) Right Switch Panel

Left Switch Panel Figure 60-50-8

Figure 60-50-7

Dealer Copy -- Not for Resale

3

P-85320

P-85319

REF.
DESCRIPTION FUNCTION / OPERATION
NO.
REF.
DESCRIPTION FUNCTION / OPERATION 1 POWER Press and hold the up arrow to
NO.
BOB-TACH disengage the Bob-Tach
1 FOUR-WAY Press the top to turn lights ON; (Option) wedges. Press and hold the
FLASHER bottom to turn OFF. down arrow to engage the
LIGHTS (Option) Bob-Tach wedges into the
2 ROTATING Press the top to turn light ON; attachment mounting frame
BEACON (Option) bottom to turn OFF. holes.
or 2 NOT USED ---
STROBE LIGHT
(Option)
3 HYDRAULIC Press the top to engage
BUCKET Hydraulic Bucket Positioning;
POSITIONING bottom to disengage.
(Option)

510 of 822 60-50-8 T870 Service Manual

INSTRUMENT PANELS (CONT’D) Right Side Lower Panel

Left Side Lower Panel Figure 60-50-10

Figure 60-50-9 1
2

3
1 2 4

4
P-85267C

P-85282

REF.
DESCRIPTION FUNCTION / OPERATION
NO.
REF.
DESCRIPTION FUNCTION / OPERATION 1 POWER PORT Provides a 12 volt

Dealer Copy -- Not for Resale

NO.
receptacle for accessories.
1 FAN MOTOR Turn clockwise to increase
2 RADIO (Option) See Radio in this manual.
(Option) fan speed;
counterclockwise to 3 HEADPHONE JACK Used to connect
decrease. There are four (Option) headphones to the optional
positions; OFF-1-2-3. radio output. Automatically
silences speakers when
2 AIR CONDITIONING Press top of switch to start;
used.
/ DEFROST SWITCH bottom to stop. Switch will
(Option) light blue when started. Fan 4 SPEAKER (Option) Right speaker used with
Motor (Item 1) must be ON optional radio.
for A/C to operate.
3 TEMPERATURE Turn clockwise to increase
CONTROL (Option) the temperature;
counterclockwise to
decrease.
4 SPEAKER (Option) Left speaker used with
optional radio.

511 of 822 60-50-9 T870 Service Manual

INSTRUMENT PANELS (CONT’D) Right Panel Removal And Installation

Left Panel Removal And Installation Figure 60-50-13

Figure 60-50-11

1 1

2
1 1

2 P-85929

P-85928
Remove the two mounting bolts (Item 1) and the fastener
(Item 2) [Figure 60-50-13].
Remove the two mounting bolts (Item 1) and the fastener
(Item 2) [Figure 60-50-11]. Installation: Be careful to not overtighten the instrument

Dealer Copy -- Not for Resale

panel mounting bolts to prevent stripping of the threaded
Installation: Be careful to not overtighten the instrument holes in the panels.
panel mounting bolts to prevent stripping of the threaded
holes in the panels. Figure 60-50-14

Figure 60-50-12

1
1

1
P-85931
1
P-85930
Pull the right instrument panel down and disconnect the
wire harness connector (Item 1) [Figure 60-50-14].
Pull the right instrument panel down and disconnect the
wire harness connectors (Item 1) [Figure 60-50-12] from Remove the panel from the loader cab.
the panel.

Remove the panel from the loader cab.

512 of 822 60-50-10 T870 Service Manual

INSTRUMENT PANELS (CONT’D) Alarm Disassembly And Assembly

Key Switch Disassembly And Assembly Remove the left instrument panel. (See Left Panel
Removal And Installation on Page 60-50-10.)
Remove the right instrument panel. (See Left Panel
Removal And Installation on Page 60-50-10.) Figure 60-50-16

Disconnect the key switch wiring harness.

Figure 60-50-15

2
P-85947

Remove the left side instrument panel.

Dealer Copy -- Not for Resale

P-85948
Remove the retaining nut (Item 1) [Figure 60-50-16]
from the loader alarm.
Remove the ignition key (Item 1) from the switch.
Remove the ignition switch retaining nut (Item 2) [Figure Remove the alarm from the loader instrument panel.
60-50-15] from the switch.

Remove the ignition switch from the control panel.

513 of 822 60-50-11 T870 Service Manual

INSTRUMENT PANELS (CONT’D) Right Switch Panel Removal And Installation

Left Switch Panel Removal And Installation Remove the right panel. (See Right Panel Removal And
Installation on Page 60-50-10.)
Remove the left panel. (See Left Panel Removal And
Installation on Page 60-50-10.) Figure 60-50-19

Figure 60-50-17

1 2

1
P-85943
1
P-85945
Remove the two fasteners (Item 1) and the knob (item 2)

Dealer Copy -- Not for Resale

[Figure 60-50-19].
Remove the two fasteners (Item 1) [Figure 60-50-17].
Figure 60-50-20
Figure 60-50-18

1 1

P-85944
P-85946

Remove the fastener (Item 1) and the left side panel

Remove the fastener (Item 1) and the left side panel (Item 2) [Figure 60-50-20].
(Item 2) [Figure 60-50-18].

514 of 822 60-50-12 T870 Service Manual

LIGHTS Figure 60-60-3

Front Removal And Installation 1

Disconnect the negative(-) cable from the battery. (See

Removal And Installation on Page 60-20-1.)

Figure 60-60-1
1

P-85436

1
Figure 60-60-4

P-85433

Dealer Copy -- Not for Resale

Remove the two bolts (Item 1) [Figure 60-60-1].

Figure 60-60-2

1
P-85435

1
Remove the two bulbs (Item 1) [Figure 60-60-3] and
[Figure 60-60-4] from the housing by turning bulb a 1/4
turn.

NOTE: Two different light bulbs are used, take note

when removing to assure correct installation.
P-85434

Disconnect the bulbs (Item 1) [Figure 60-60-2] from the

wire harness connectors.

515 of 822 60-60-1 T870 Service Manual

LIGHTS (CONT’D) Cab Light Removal And Installation

Rear Removal And Installation Figure 60-60-7

Figure 60-60-5

1 2

P-85274

P-85438
Remove the screws (Items 1) [Figure 60-60-7] from the
cab light.
Remove the bulb assembly (Items 1 and 2) from the light
housing (Item 3) [Figure 60-60-5] by turning bulb NOTE: Do not pull the cab light to far away from the

Dealer Copy -- Not for Resale

assembly a 1/4 turn. headliner to prevent damage to the wires.

Figure 60-60-6 Figure 60-60-8

P-85437 P-85783

Using care press the rear light and housing from the door Disconnect the cab light (Item 1) [Figure 60-60-8].
[Figure 60-60-6].

516 of 822 60-60-2 T870 Service Manual

BOBCAT CONTROLLERS (GATEWAY AND
AUXILIARY)

Description

The Gateway controller is the main controller, it provides

information to all other controllers. All loaders have a
Gateway and Auxiliary controller.

The Gateway and Auxiliary controller are located behind

the access panel near the operators left foot.

Dealer Copy -- Not for Resale

517 of 822 60-70-1 T870 Service Manual

BOBCAT CONTROLLERS (GATEWAY AND
AUXILIARY) (CONT’D)

Connector Identification

Gateway Controller

1 1

34 26

J1A J1B

Dealer Copy -- Not for Resale

Harness Connector View Harness Connector View

9 7 5 3 7 5 3
1 1

17 10 13 8

25 18 19 14

34 32 28 26 26 25 21 20

P-76622
J1A J1B P-76623
P-76624

518 of 822 60-70-2 T870 Service Manual

BOBCAT CONTROLLERS (GATEWAY AND
AUXILIARY) (CONT’D)

Connector Identification (Cont’d)

J1A

WIRE
PIN COLOR DESCRIPTION
NUMBER
1 2410 BLACK HYD LOCK VALVE SOLENOID GROUND
2 2380 BLACK LIFT SPOOL SOLENOID GROUND
3 8110 TAN FUEL RELAY SIGNAL
4 8000 TAN SWITCHED POWER RELAY SIGNAL
5 6320 PINK MRKR LIGHT PWR RELAY SIGNAL
6 8510 TAN GLOW PLUG RELAY SIGNAL
7 8210 TAN STARTER RELAY SIGNAL
8 4110 LGN TRACTION LOCK RELAY SIGNAL
9 OPEN NA NA
10 2370 BLACK TILT SPOOL LOCK SOLENOID GROUND
11 7023 WHITE AC SIGNAL MONITOR

Dealer Copy -- Not for Resale

12 OPEN NA NA
13 4150 LGN TRACTION LOCK RELAY FEEDBACK
14 8550 TAN GLOW PLUG RELAY FEEDBACK
15 3600 LBL ENGINE SPEED SENSOR SIGNAL
16 3700 LBL AIR FILTER SENDER SIGNAL
17 6210 PINK REAR LIGHT RELAY SIGNAL
18 2910 BLACK HYDRAULIC FAN GROUND
19 9370 PURPLE PTOL LED
20 9380 PURPLE PTOL SWITCH
21 8020 TAN SWITCHED POWER RELAY FEEDBACK
22 8250 TAN STARTER RELAY FEEDBACK
23 3440 LBL HYD FAN DIFF PRESS SWITCH SIGNAL
24 9360 PURPLE START ENGINE
25 3520 LBL ENGINE OIL PRESS SENDER POWER
26 2350 BLACK TWO SPEED GROUND
27 2360 BLACK TWO SPEED MAKEUP GROUND
28 6230 PINK REAR LIGHT RELAY FEEDBACK
29 OPEN NA NA
30 8150 TAN FUEL RELAY FEEDBACK
31 6330 PINK MRKR LIGHT PWR RELAY FEEDBACK
32 3300 LBL HYD TEMP SIGNAL
33 OPEN NA NA
34 3430 LBL HYD FILTER DIFF PRESS

519 of 822 60-70-3 T870 Service Manual

BOBCAT CONTROLLERS (GATEWAY AND
AUXILIARY) (CONT’D)

Connector Identification (Cont’d)

J1B

WIRE
PIN COLOR DESCRIPTION
NUMBER
1 3420 LBL HYD CHARGE PRESS SENDER SIGNAL
2 1110 RED/WHT COMPUTER FUSE POWER OUT
3 1130 RED/WHT COMPUTER FUSE POWER OUT
4 8800 TAN FUEL SHUTOFF SOLENOID HOLD
5 4380 LGN LIFT SPOOL LOCK SOLENOID SIGNAL
6 4200 LGN TRACTION SOLENOID OUTPUT
7 4370 LGN TILT SPOOL LOCK SOLENOID SIGNAL
8 9210 PUR/WHT CAN LO 0
9 9110 PUR/WHT CAN HI 0
10 OPEN NA NA
11 3920 LBL SEAT BAR SENSOR SIGNAL

Dealer Copy -- Not for Resale

12 3100 LBL FUEL SENDER SIGNAL
13 4410 LGN HYD LOCK SOLENOID SIGNAL
14 9500 PUR/WHT CAN HIGH 1
15 2500 BLACK COMPUTER GROUND
16 2510 BLACK COMPUTER GROUND
17 3010 LBL SENSOR GROUND
18 3200 LBL ENGINE COOLANT SENSOR SIGNAL
19 4010 LGN HYDRAULIC FAN SIGNAL
20 9600 PURPLE CAN LOW 1
21 9800 PURPLE REMOTE ATTACHMENT SIGNAL
22 9350 PURPLE RUN / ENTER
23 3400 LBL HYDRAULIC CHARGE PRESSURE
24 3930 LBL +5V SUPPLY
25 4360 LGN TWO SPEED MAKEUP
26 4350 LGN TWO SPEED SIGNAL

520 of 822 60-70-4 T870 Service Manual

BOBCAT CONTROLLERS (GATEWAY AND
AUXILIARY) (CONT’D)

Connector Identification (Cont’d)

Auxiliary Controller

1 1

34 26

J2A J2B

Dealer Copy -- Not for Resale

Harness Connector View Harness Connector View

9 7 5 3 7 5 3
1 1

17 10 13 8

25 18 19 14

34 32 28 26 26 25 21 20

P-76647
J2A J2B P-76646
P-76645

521 of 822 60-70-5 T870 Service Manual

BOBCAT CONTROLLERS (GATEWAY AND
AUXILIARY) (CONT’D)

Connector Identification (Cont’d)

J2A

WIRE
PIN COLOR DESCRIPTION
NUMBER
1 2340 BLACK FRONT BASE SOLENOID GROUND
2 2440 BLACK JEM BLOCK REAR BASE SOLENOID GROUND
3 6520 PINK LEFT BLINKER SIGNAL
4 6420 PINK RIGHT BLINKER SIGNAL
5 7200 WHITE HORN SIGNAL
6 OPEN NA NA
7 OPEN NA NA
8 OPEN NA NA
9 OPEN NA NA
10 2430 BLACK JEM BLOCK REAR ROD SOLENOID GROUND
11 4810 LGN LEFT HANDLE PADDLE RIGHT

Dealer Copy -- Not for Resale

12 4820 LGN LEFT HANDLE PADDLE LEFT
13 4910 LGN RIGHT HANDLE RIGHT ROCKER UP
14 OPEN NA NA
15 OPEN NA NA
16 OPEN NA NA
17 OPEN NA NA
18 2330 BLACK FRONT ROD SOLENOID GROUND
19 OPEN NA NA
20 4640 LGN FLOAT SIGNAL
21 OPEN NA NA
22 4830 LGN LEFT HANDLE RIGHT ROCKER DOWN
23 OPEN NA NA
24 OPEN NA NA
25 OPEN NA NA
26 2460 BLACK HIGH FLOW SOLENOID GROUND
27 OPEN NA NA
28 4840 LGN LEFT HANDLE RIGHT ROCKER UP
29 OPEN NA NA
30 4940 LGN RIGHT HANDLE LEFT ROCKER UP
31 4930 LGN RIGHT HANDLE LEFT ROCKER DOWN
32 OPEN NA NA
33 OPEN NA NA
34 OPEN NA NA

522 of 822 60-70-6 T870 Service Manual

BOBCAT CONTROLLERS (GATEWAY AND
AUXILIARY) (CONT’D)

Connector Identification (Cont’d)

J2B

WIRE
PIN COLOR DESCRIPTION
NUMBER
1 OPEN NA NA
2 1180 RED/WHT COMPUTER FUSE POWER OUT
3 1150 RED/WHT COMPUTER FUSE POWER OUT
4 4450 LGN DIVERTER SOLENOID SIGNAL
5 4440 LGN REAR BASE SIGNAL
6 4480 LGN FRONT / REAR AUXILIARY SIGNAL
7 4430 LGN REAR ROD SIGNAL
8 9220 PURPLE CAN LO 0
9 9120 PUR/WHT CAN HI 0
10 OPEN NA NA
11 OPEN NA NA

Dealer Copy -- Not for Resale

12 OPEN NA NA
13 4340 LGN FRONT BASE SOLENOID SIGNAL
14 OPEN NA NA
15 2550 BLACK AUXILIARY CONTROLLER GROUND
16 2540 BLACK AUXILIARY CONTROLLER GROUND
17 4310 LBL RIGHT HANDLE PWM LOW
18 4320 LBL RIGHT HANDLE PWM SIGNAL
19 4330 LGN FRONT ROD SOLENOID SIGNAL
20 OPEN NA NA
21 4920 LGN RIGHT HANDLE TRIGGER RETURN
22 1560 RNG SWITCHED INPUT POWER
23 4300 LGN RIGHT HANDLE PWM HIGH
24 OPEN NA NA
25 OPEN NA NA
26 4460 LGN HIGH FLOW SOLENOID SIGNAL

523 of 822 60-70-7 T870 Service Manual

BOBCAT CONTROLLERS (GATEWAY AND Figure 60-70-2
AUXILIARY) (CONT’D)

Removal And Installation

Raise the lift arms and install an approved lift arm

support device. (See Installing on Page 10-20-1.) 1 1

Lift and block the loader. (See Procedure on Page 10-10-

1.)
1 1
Raise the operator cab. (See Raising on Page 10-30-1.)

Remove the left inside access panel. (See Removal And

Installation (Left) on Page 50-120-1.)
P100284
Figure 60-70-1

Remove the controller mounting bolts (Item 1) [Figure

60-70-2] from the left fender.
2
Installation: Tighten the controller mounting bolts to 16 -
19 N•m (12 - 14 ft-lb) torque.

Dealer Copy -- Not for Resale

Remove the Gateway and Auxiliary controllers from the
loader.
1

P-85900

Unplug the two harness connectors (Item 1) [Figure 60-

70-1] from the Gateway controller.

Unplug the two harness connectors (Item 2) [Figure 60-

70-1] from the Auxiliary controller.

NOTE: The connectors are keyed and will only plug

in one way.

524 of 822 60-70-8 T870 Service Manual

BOBCAT CONTROLLER (ACS)

Description

The ACS controller is on loaders equipped with the SJC

option. This controller processes information for the lift
and tilt functions.

The ACS controller is housed in a grey colored plastic

shell with black potting. The ACS controller
communicates with the Bobcat Gateway Controller by
CAN communication wires. The ACS controller is
capable of receiving upgrades to the software.

Dealer Copy -- Not for Resale

525 of 822 60-71-1 T870 Service Manual

BOBCAT CONTROLLER (ACS) (CONT’D)

Connector And Wire Identification

G H
J J1 J3
F K
E A
D B
J3 C H
G
F J
K J2

F E
G D A
E H B
C
A J2
B
D
J1
C
J3
J1 J2

Dealer Copy -- Not for Resale

P-21843

P/N PIN DESCRIPTION P/N PIN DESCRIPTION

J1 CONNECTOR, METRI-PACK J3 CONNECTOR, METRI-PACK
Orange A 5V HALL EFFECT SUPPLY Red A TILT ACTUATOR FOR-
WARD
Orange B SWITCHED ACS POWER Red / White B UNSWITCHED ACS POWER
Green C HAND / FOOT INPUT Red / White C UNSWITCHED ACS POWER
Purple D CAN SIGNAL HIGH ACS Black D LIFT ACTUATOR REVERSE
Purple E CAN SIGNAL LOW ACS Green E HANDLE LOCK POWER
Purple F CAN SHIELD ACS Red F LIFT ACTUATOR FOR-
WARD
Black G ACS GROUND Green G PEDAL LOCK POWER
Black H ACS GROUND Black H ACS GROUND
J2 CONNECTOR, METRI-PACK Black J ACS GROUND
A OPEN Black K TILT ACTUATOR REVERSE
B OPEN
C OPEN
D OPEN
Green E TILT SPOOL SIGNAL
Green F LIFT HANDLE SIGNAL
Green G TILT HANDLE SIGNAL
Green H LIFT SPOOL SIGNAL
Green J LIFT PEDAL SIGNAL
Green K TILT PEDAL SIGNAL

526 of 822 60-71-2 T870 Service Manual

BOBCAT CONTROLLER (ACS) (CONT’D) Figure 60-71-2

Removal And Installation

Raise the lift arms and install an approved lift arm

support device. (See Installing on Page 10-20-1.)
1
Lift and block the loader. (See Procedure on Page 10-10-
1.)

Raise the operator cab. (See Raising on Page 10-30-1.)

Figure 60-71-1

1 P100291

Remove the two mounting bolts (Item 1) [Figure 60-71-

2] from the controller.

Remove the controller from the loader.

Reverse procedure for installation.

Dealer Copy -- Not for Resale

NOTE: The calibration procedure must be followed
1 when replacing a controller. (See Lift And Tilt
P100292 Calibration (SJC) on Page 60-150-4.)

NOTE: Before unplugging any controller the key

switch or run / enter must be off.

Unplug the harness connectors (Item 1) [Figure 60-71-1]

from the controller.

NOTE: The connectors are keyed and will only plug

in one way.

527 of 822 60-71-3 T870 Service Manual

 Dealer Copy -- Not for Resale

528 of 822 60-71-4 T870 Service Manual

BOBCAT CONTROLLER (SJC) (DRIVE) The SJC system uses electronic joysticks to control the
workgroup functions (lift and tilt) and the drive functions
Description of the loader. The control can be switched from ISO and
H-Pattern drive control layouts.
The drive controller is on loaders equipped with the SJC
option. This controller processes information for the drive The workgroup actuators are the same as those used on
functions. the ACS system.

The drive controller is located underneath the operator’s The hydrostatic drive pump has two electromagnetic coils
cab, attached to the control panel. on each of the two pumps to control the drive of the
loader. The coils will direct the forward and reverse
The drive controller monitors the position of the joysticks, outputs of the pump to the drive motors. The hydrostatic
pump swash plate angles, the output of the speed drive pump is equipped with position sensors mounted to
sensors and the position of the ISO and H-Pattern switch. the bottom of the swash plates to provide feedback to the
controllers to sense uncommanded swash plate
The drive controller works along with the ACS controller movement.
and communicates with the Gateway controller in an SJC
system. All these controllers are capable of software
upgrades.

RIGHT
HAND DRIVE HYDRAULIC
PANEL CONTROL MOTOR

Dealer Copy -- Not for Resale

ACS
CONTROL SPEED
LIFT / TILT SENSOR
ACTUATORS

GEAR ENGINE
INTERNAL CAN BUS

PUMP
SERIAL TT BUS

RIGHT
JOYSTICK

FWD / REV
ISO SWASH PLATE
SWITCH LEFT
JOYSTICK SENSORS

AUXILIARY DRIVE
CONTROL PUMP
LEFT SPEED
HAND SENSOR
PANEL
ACD HYDRAULIC
EXTERNAL CONTROL MOTOR
CAN BUS
GATEWAY
CONTROL
NA1208

529 of 822 60-72-1 T870 Service Manual

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)

Connector Identification

Dealer Copy -- Not for Resale

P-64295

530 of 822 60-72-2 T870 Service Manual

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)

Connector Identification (Cont'd)

Dealer Copy -- Not for Resale

P100288

531 of 822 60-72-3 T870 Service Manual

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D) Figure 60-72-3

Removal And Installation

Raise the operator cab. (See Raising on Page 10-30-1.)

Figure 60-72-1
1
1

P-64325

1
Installation: Note the keyed hole in the controller socket.
(Item 1) [Figure 60-72-3]. The keyed hole matches a tab
on the connector on the wire harness.
P-85879
Figure 60-72-4

Dealer Copy -- Not for Resale

Remove the three bolts (Item 1) [Figure 60-72-1] that
secure the controller.

Installation: Tighten the mounting bolts to 16 - 19 N•m

(12 - 14 ft-lb) torque.

Figure 60-72-2

J S
P-64325

Remove the drive controller [Figure 60-72-4].

1

P-64324

Remove the screw and wire harness (Item 1) [Figure 60-

72-2].

Installation: Tighten the connector screw to 3,39 - 3,96

N•m (30 - 35 in-lb) torque. DO NOT OVERTIGHTEN!

532 of 822 60-72-4 T870 Service Manual

SPEED SENSORS (SJC AND SCPA) Testing

Description Figure 60-80-2

Figure 60-80-1

1
P-28302

P-64765
The tools listed will be needed to do the following
procedure:
On SJC / SCPA equipped loaders, the speed sensor
[Figure 60-80-1] is used by the loader’s controllers to MEL1609-Wheel Speed Sensor Test Harness

Dealer Copy -- Not for Resale

sense if the drive motor is rotating. The end of the sensor [Figure 60-80-2]
is magnetic and counts the magnetic pulses as a rotating
disc, attached to the motor carrier shaft, rotates by the MEL1563 or 7003031-Remote Start Tool Kit
sensor end.
Multimeter
The speed sensor is sealed with an O-ring (Item 1)
[Figure 60-80-1] to keep hydraulic oil inside the motor Raise the lift arms and install an approved lift arm support
carrier and dirt out. device. (See Installing on Page 10-20-1.)

Raise the operator cab. (See Raising on Page 10-30-1.)

Connect the remote start tool. (See REMOTE START

TOOL KIT-MEL1563 on Page 10-60-1.) or (See
REMOTE START TOOL (SERVICE TOOL) KIT -
7003031 on Page 10-61-1.)

533 of 822 60-80-1 T870 Service Manual

SPEED SENSORS (SJC AND SCPA) (CONT'D) Figure 60-80-4

Testing (Cont’d)

Figure 60-80-3 2

2
1

1 3

P100258

Connect the speed sensor test harness (Item 1) [Figure

P100259 60-80-4] in line, between the loader wiring harness and
the speed sensor harness.

Locate the speed sensor (Item 1) [Figure 60-80-3] on the Turn the remote start key to ON position without starting
top of the right or left hydrostatic motor carrier. the loader.

Dealer Copy -- Not for Resale

Remove the transmission cover screw (Item 2) [Figure Take a voltage reading, with the multimeter, at the speed
60-80-3], to loosen the connector clamp. sensor test harness, between pin 1 and pin 3 (Item 2)
[Figure 60-80-4].
Installation: Tighten screw to 20 - 27 N•m (15 - 20 ft-lb)
torque. The voltage should be approximately 5 volts.

Disconnect the speed sensor wire connector (Item 3) Repeat the procedure for the opposite side speed
[Figure 60-80-3] from the loader harness wire connector. sensor. (If needed.)

534 of 822 60-80-2 T870 Service Manual

SPEED SENSORS (SJC AND SCPA) (CONT'D) Figure 60-80-7

Removal And Installation

Figure 60-80-5

P100260

1
Lift the speed sensor (Item 1) [Figure 60-80-7] out from
P100259 the motor carrier. DO NOT pull on the wires, gently pry up
with a screwdriver if necessary.

Raise the lift arms and install an approved lift arm support Figure 60-80-8
device. (See Installing on Page 10-20-1.)

Dealer Copy -- Not for Resale

Raise the operator cab. (See Raising on Page 10-30-1.)

Remove the two, speed sensor mount bolts (Item 1)

[Figure 60-80-5] from the top of the hydrostatic motor
carrier.

Remove the mount plate (Item 2) [Figure 60-80-5].

Figure 60-80-6

1
P-64765
2

Remove the speed sensor [Figure 60-80-8].

P100261

Remove the transmission cover screw (Item 1) [Figure

60-80-6], to loosen the connector clamp.

Installation: Tighten screw to 20 - 27 N•m (15 - 20 ft-lb)

torque.

Disconnect the speed sensor electrical harness

connector (Item 2) [Figure 60-80-6].

535 of 822 60-80-3 T870 Service Manual

SPEED SENSORS (SJC AND SCPA) (CONT'D) Figure 60-80-11

Removal And Installation (Cont'd)

Figure 60-80-9

1
1

P-26292

Installation: Be sure to install the speed sensor (Item 1)

P-26293 [Figure 60-80-11] pointing toward the transmission case.

Figure 60-80-12
The electrical connector can be replaced.

Dealer Copy -- Not for Resale

The connector can be found in the harness repair kit.

Remove the connector wedge (Item 1) [Figure 60-80-9].

Figure 60-80-10

1
4 1

P-26295

3 2
Installation: The alignment pin (Item 1) at the bottom of
the speed sensor must be installed in the hole (Item 2)
[Figure 60-80-12] in the motor carrier.

P-26294

With a thin screwdriver lift the tabs and remove the wires
from the connector [Figure 60-80-10].

Wire Code

1 Red
2 White
3 Black
4 Blue

536 of 822 60-80-4 T870 Service Manual

DIAGNOSTIC SERVICE CODES Deluxe Instrumentation Panel

Viewing Service Codes The optional Deluxe Instrumentation Panel offers an

additional view of service codes that includes a brief
The Service Codes will aid your dealer in diagnosing description.
conditions which can damage your machine.
The last 40 codes stored in history can also be viewed
Figure 60-90-1 using the Deluxe Instrumentation Panel.

Figure 60-90-2
Press a scroll button
2 (Item 1) repeatedly until
the Active Warnings
screen icon (Inset) is
highlighted.

1 1
The ACTIVE WARNINGS
screen displays active
1 service codes. Press [9]
P-76455G
to view the next service
code if more than one is
present. Press [4] to
Press the INFORMATION button (Item 1) to cycle the display a history of

Dealer Copy -- Not for Resale

DATA DISPLAY (Item 2) [Figure 60-90-1] until the service codes.
service code screen is displayed. If more than one
SERVICE CODE is present, the codes will scroll on the The WARNINGS
DATA DISPLAY. HISTORY screen will list
the Service Code
NOTE: Corroded or loose grounds can cause Number (CODE),
Hourmeter reading when
multiple service codes and / or abnormal the error occurred
symptoms. All instrument panel lights (HOUR), and the User
flashing, alarm sounding, headlights and (USER) who was logged
taillights flashing, could indicate a bad in to operate the machine
ground. The same symptoms could apply if when the error occurred.
the voltage is low, such as loose or corroded Press [9] to view the next eight Service Codes.
battery cables. If you observe these
symptoms, check grounds and positive leads A total of 40 Codes can be stored. When more than 40
first. codes occur, the oldest code will disappear and the
newest code will be in the number 1 position.

Press the list number

next to the service code
for more detail.

Press left scroll button to

back up one screen.

P-90378 / NA3025 / NA3000 / NA3038 / NA3035

537 of 822 60-90-1 T870 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List

Figure 60-90-3 The following word errors may be displayed:

2 [REPLY] One or both instrument panel(s) not

1
communicating with the controller.

[CODE] The controller is asking for a password.

(Keyless Start and Deluxe Instrumentation Panels
only.)

[ERROR] The wrong password was entered.

(Keyless Start and Deluxe Instrumentation Panels
P-76461H only.)
P-76461P
P-76455G
[SHTDN] A shutdown condition exists.

Service Codes may be either a word (Item 1) or a number [DOOR] Operator cab door is open. (Lift and Tilt
(Item 2) [Figure 60-90-3]. functions will not operate.)

CODE DESCRIPTION CODE DESCRIPTION

A3623 ACD not programmed A8503 ACD output ‘F’ error OFF

Dealer Copy -- Not for Resale

A8002 ACD output ‘A’ error ON A8505 ACD output ‘F’ short to battery
A8003 ACD output ‘A’ error OFF A8506 ACD output ‘F’ short to ground
A8005 ACD output ‘A’ short to battery A8507 ACD output ‘F’ open circuit
A8006 ACD output ‘A’ short to ground A8532 ACD output ‘F’ overcurrent
A8007 ACD output ‘A’ open circuit A8602 ACD output ‘G’ error ON
A8032 ACD output ‘A’ overcurrent A8603 ACD output ‘G’ error OFF
A8102 ACD output ‘B’ error ON A8605 ACD output ‘G’ short to battery
A8103 ACD output ‘B’ error OFF A8606 ACD output ‘G’ short to ground
A8105 ACD output ‘B’ short to battery A8607 ACD output ‘G’ open circuit
A8106 ACD output ‘B’ short to ground A8702 ACD output ‘H’ error ON
A8107 ACD output ‘B’ open circuit A8703 ACD output ‘H’ error OFF
A8132 ACD output ‘B’ overcurrent A8705 ACD output ‘H’ short to battery
A8202 ACD output ‘C’ error ON A8706 ACD output ‘H’ short to ground
A8203 ACD output ‘C’ error OFF A8707 ACD output ‘H’ open circuit
A8205 ACD output ‘C’ short to battery
A8206 ACD output ‘C’ short to ground D3905 Left joystick X-axis not in neutral
A8207 ACD output ‘C’ open circuit D3907 Left joystick Y-axis not in neutral
A8232 ACD output ‘C’ overcurrent D4007 Right joystick Y-axis not in neutral
A8302 ACD output ‘D’ error ON D7501 CAN joystick communication error
A8303 ACD output ‘D’ error OFF D7504 No communication from drive controller
A8305 ACD output ‘D’ short to battery D7505 Left joystick X-axis not in neutral
A8306 ACD output ‘D’ short to ground D7507 Left joystick Y-axis not in neutral
A8307 ACD output ‘D’ open circuit D7508 Right joystick Y-axis not in neutral
A8332 ACD output ‘D’ overcurrent D7509 Operating mode switch short to ground or battery
A8402 ACD output ‘E’ error ON D7513 Right front wheel angle sensor unresponsive
A8403 ACD output ‘E’ error OFF D7514 Left front wheel angle sensor unresponsive
A8405 ACD output ‘E’ short to battery D7515 Right rear wheel angle sensor unresponsive
A8406 ACD output ‘E’ short to ground D7516 Left rear wheel angle sensor unresponsive
A8407 ACD output ‘E’ open circuit D7517 Left swash plate not in neutral
A8432 ACD output ‘E’ overcurrent D7518 Right swash plate not in neutral
A8502 ACD output ‘F’ error ON D7519 Left joystick X-axis out of range high

538 of 822 60-90-2 T870 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Cont’d)

CODE DESCRIPTION CODE DESCRIPTION

D7521 Left joystick Y-axis out of range high D7572 Drive pump not calibrated
D7522 Right joystick Y-axis out of range high D7573 Operating mode switch flipped while operating
D7523 Right front wheel angle sensor out of range high D7574 Right wheel speed uncommanded motion
D7524 Left front wheel angle sensor out of range high D7575 Left wheel speed uncommanded motion
D7525 Right rear wheel angle sensor out of range high D7576 No communication from ACS controller
D7526 Left rear wheel angle sensor out of range high D7577 Left speed sensor out of range high
D7527 Left swash plate out of position D7578 Right speed sensor out of range high
D7528 Right swash plate out of position D7579 Left speed sensor out of range low
D7529 Left joystick X-axis out of range low D7580 Right speed sensor out of range low
D7531 Left joystick Y-axis out of range low D7581 Right front steer retract short to battery
D7532 Right joystick Y-axis out of range low D7582 Left front steer retract short to battery
D7533 Right front wheel angle sensor out of range low D7583 Right rear steer retract short to battery
D7534 Left front wheel angle sensor out of range low D7584 Left rear steer retract short to battery
D7535 Right rear wheel angle sensor out of range low D7585 Sensor supply 1 out of range high
D7536 Left rear wheel angle sensor out of range low D7586 Sensor supply 2 out of range high
D7537 Sensor supply 1 out of range low D7587 Software update required
D7538 Sensor supply 2 out of range low D7588 Switched power stuck ON
D7539 Left swash plate sensor out of range high D7589 Switched power error OFF

Dealer Copy -- Not for Resale

D7540 Left swash plate sensor out of range low D7591 Left swash plate sensor reversed
D7541 Right swash plate sensor out of range high D7592 Right swash plate sensor reversed
D7542 Right swash plate sensor out of range low D7593 Right speed sensor unresponsive
D7543 Left forward drive solenoid error ON D7594 Left speed sensor unresponsive
D7544 Left reverse drive solenoid error ON D7595 Left speed sensor reversed
D7545 Right forward drive solenoid error ON D7596 Right speed sensor reversed
D7546 Right reverse drive solenoid error ON D7597 Controller programmed
D7547 Right front steer extend short to battery D7598 In drive calibration mode
D7548 Left front steer extend short to battery D7599 In angle calibration mode
D7549 Right rear steer extend short to battery
D7550 Left rear steer extend short to battery H1221 Right Primary out of range high
D7551 Steer pressure short to battery H1222 Right Primary out of range low
D7552 Back-up alarm error ON H1224 Right Primary not in neutral
D7553 Left forward drive solenoid error OFF H1321 Left Primary out of range high
D7554 Left reverse drive solenoid error OFF H1322 Left Primary out of range low
D7555 Right forward drive solenoid error OFF H1324 Left Primary not in neutral
D7556 Right reverse drive solenoid error OFF H2005 Boost solenoid short to battery
D7557 Right front steer extend short to ground H2006 Boost solenoid short to ground
D7558 Right front steer retract short to ground H2007 Boost solenoid open circuit
D7559 Left front steer extend short to ground H2032 Boost solenoid overcurrent
D7560 Left front steer retract short to ground H2205 Pressure control solenoid short to battery
D7561 Right rear steer extend short to ground H2206 Pressure control solenoid short to ground
D7562 Right rear steer retract short to ground H2207 Pressure control solenoid open circuit
D7563 Left rear steer extend short to ground H2232 Pressure control solenoid overcurrent
D7564 Left rear steer retract short to ground H2305 Rear base solenoid short to battery
D7565 Steer pressure short to ground H2306 Rear base solenoid short to ground
D7566 Back-up alarm error OFF H2307 Rear base solenoid open circuit
D7567 No communication from Gateway controller H2332 Rear base solenoid overcurrent
D7568 Angle sensors not calibrated H2405 Rear rod solenoid short to battery
D7569 Battery voltage out of range high H2406 Rear rod solenoid short to ground
D7570 Interrupted power H2407 Rear rod solenoid open circuit
D7571 Battery voltage out of range low H2432 Rear rod solenoid overcurrent

539 of 822 60-90-3 T870 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Cont’d)

CODE DESCRIPTION CODE DESCRIPTION

H2505 Rear aux relief short to battery M0116 Air filter not connected
H2506 Rear aux relief short to ground M0117 Air filter plugged
H2507 Rear aux relief open circuit M0216 Hydraulic / Hydrostatic filter not connected
H2605 Front base solenoid short to battery M0217 Hydraulic / Hydrostatic filter plugged
H2606 Front base solenoid short to ground M0309 Battery voltage low
H2607 Front base solenoid open circuit M0310 Battery voltage high
H2632 Front base solenoid overcurrent M0311 Battery voltage extremely high
H2705 Front rod solenoid short to battery M0314 Battery voltage extremely low
H2706 Front rod solenoid short to ground M0322 Battery voltage out of range low
H2707 Front rod solenoid open circuit M0409 Engine oil pressure low
H2732 Front rod solenoid overcurrent M0414 Engine oil pressure extremely low
H2805 Diverter rod solenoid short to battery M0415 Engine oil pressure shutdown
H2806 Diverter rod solenoid short to ground M0421 Engine oil pressure out of range high
H2807 Diverter rod solenoid open circuit M0422 Engine oil pressure out of range low
H2905 High-flow solenoid short to battery M0509 Hydraulic charge pressure low
H2906 High-flow solenoid short to ground M0510 Hydraulic charge pressure high
H2907 High-flow solenoid open circuit M0511 Hydraulic charge pressure extremely high
H2932 High-flow solenoid overcurrent M0514 Hydraulic charge pressure extremely low

Dealer Copy -- Not for Resale

H3028 Controller memory failure M0515 Hydraulic charge pressure shutdown
H3128 Interrupted power failure M0521 Hydraulic charge pressure out of range high
H3648 ACD multiple M0522 Hydraulic charge pressure out of range low
H3913 Left joystick grip no communication M0610 Engine speed high
H3916 Left joystick not connected M0611 Engine speed extremely high
H3928 Left joystick failure M0613 Engine speed no signal
H3948 Left joystick multiple M0615 Engine speed shutdown
H4013 Right joystick grip no communication M0618 Engine speed out of range
H4016 Right joystick not connected M0710 Hydraulic oil temperature high
H4028 Right joystick failure M0711 Hydraulic oil temperature extremely high
H4048 Right joystick multiple M0715 Hydraulic oil temperature shutdown
H4302 Horn error ON M0721 Hydraulic oil temperature out of range high
H4303 Horn error OFF M0722 Hydraulic oil temperature out of range low
H4423 Auxiliary not programmed M0810 Engine coolant temperature high
H4502 Right signal error ON M0811 Engine coolant temperature extremely high
H4503 Right signal error OFF M0815 Engine coolant temperature shutdown
H4602 Left signal error ON M0821 Engine coolant temperature out of range high
H4603 Left signal error OFF M0822 Engine coolant temperature out of range low
H4721 Sensor supply 1 out of range high M0909 Fuel level low
H4722 Sensor supply 1 out of range low M0921 Fuel level out of range high
H7314 Remote control failure M0922 Fuel level out of range low
H7328 Remote control no signal M1016 Hydraulic charge filter not connected
H7404 Main controller no communication M1017 Hydraulic charge filter plugged
H7604 Left hand panel no communication M1121 Seat bar sensor out of range high
M1122 Seat bar sensor out of range low
L0102 Left panel button 1 error ON M1305 Fuel hold solenoid short to battery
L0202 Left panel button 2 error ON M1306 Fuel hold solenoid short to ground
L0302 Left panel button 3 error ON M1307 Fuel hold solenoid open circuit
L0402 Left panel button 4 error ON M1402 Fuel pull output error ON
L7404 Left panel main controller no communication M1403 Fuel pull output error OFF
L7672 Left panel programming error M1407 Fuel pull output open circuit
M1428 Fuel pull output failure

540 of 822 60-90-4 T870 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Cont’d)

CODE DESCRIPTION CODE DESCRIPTION

M1502 Traction lock pull output error ON M3805 Auxiliary hydraulic lock short to battery
M1503 Traction lock pull output error OFF M3806 Auxiliary hydraulic lock short to ground
M1507 Traction lock pull output open circuit M3807 Auxiliary hydraulic lock open circuit
M1528 Traction lock pull output failure M3832 Auxiliary hydraulic lock overcurrent
M1605 Traction lock hold solenoid short to battery M4109 Alternator low
M1606 Traction lock hold solenoid short to ground M4110 Alternator high
M1607 Traction lock hold solenoid open circuit M4304 Keyless panel no communication
M1705 Hydraulic lock valve solenoid short to battery M4404 Auxiliary no communication
M1706 Hydraulic lock valve solenoid short to ground M4621 5 volt sensor supply out of range high
M1707 Hydraulic lock valve solenoid open circuit M4622 5 volt sensor supply out of range low
M1732 Hydraulic lock valve solenoid overcurrent M4721 8 volt sensor supply out of range high
M1805 Lift spool lock short to battery M4722 8 volt sensor supply out of range low
M1806 Lift spool lock short to ground M4802 Front light relay error ON
M1807 Lift spool lock open circuit M4803 Front light relay error OFF
M1832 Lift spool lock overcurrent M4807 Front light relay open circuit
M2005 Two-speed primary short to battery M4902 Rear light relay error ON
M2006 Two-speed primary short to ground M4903 Rear light relay error OFF
M2007 Two-speed primary open circuit M4907 Rear light relay open circuit

Dealer Copy -- Not for Resale

M2032 Two-speed primary overcurrent M5002 Front light output error ON
M2102 Glow plug output error ON M5003 Front light output error OFF
M2103 Glow plug output error OFF M5007 Front light output open circuit
M2107 Glow plug output open circuit M5028 Front light output failure
M2128 Glow plug output failure M5102 Rear light output error ON
M2202 Starter output error ON M5103 Rear light output error OFF
M2203 Starter output error OFF M5107 Rear light output open circuit
M2207 Starter output open circuit M5128 Rear light output failure
M2228 Starter output failure M5202 PTOL switch error ON
M2302 Starter relay error ON M5221 PTOL switch out of range high
M2303 Starter relay error OFF M5222 PTOL switch out of range low
M2402 Fuel pull relay error ON M5305 PTOL LED short to battery
M2403 Fuel pull relay error OFF M5306 PTOL LED short to ground
M2502 Traction pull relay error ON M5405 Tilt spool lock short to battery
M2503 Traction pull relay error OFF M5406 Tilt spool lock short to ground
M2602 Glow plug relay error ON M5407 Tilt spool lock open circuit
M2603 Glow plug relay error OFF M5432 Tilt spool lock overcurrent
M2721 Throttle primary out of range high M6402 Switched power relay error ON
M2722 Throttle primary out of range low M6403 Switched power relay error OFF
M2821 Throttle secondary out of range high M6505 EEC power short to battery
M2822 Throttle secondary out of range low M6506 EEC power short to ground
M3128 Interrupted power failure M6507 EEC power open circuit
M3204 Workgroup no communication M6604 EEC power no communications
M3304 Deluxe panel no communication M7002 Switched power output error ON
M3505 Hydraulic fan short to battery M7003 Switched power output error OFF
M3506 Hydraulic fan short to ground M7007 Switched power output open circuit
M3507 Hydraulic fan open circuit M7028 Switched power output failure
M3532 Hydraulic fan overcurrent M7102 Electric fan 1 output error ON
M3705 Two-speed secondary short to battery M7103 Electric fan 1 output error OFF
M3706 Two-speed secondary short to ground M7128 Electric fan 1 output failure
M3707 Two-speed secondary open circuit M7202 Electric fan 1 relay error ON
M3732 Two-speed secondary overcurrent M7203 Electric fan 1 relay error OFF

541 of 822 60-90-5 T870 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Cont’d)

CODE DESCRIPTION CODE DESCRIPTION

M7207 Electric fan 1 relay open circuit W3251 Lift actuator short to battery
M7304 Remote control no communication W3252 Tilt actuator short to battery
M7316 Remote control no signal from transmitter W3253 Lift handle / pedal short to ground
M7423 Main controller not programmed W3254 Tilt handle / pedal short to ground
M7472 Main controller in boot code W3255 Lift handle / pedal short to battery
M7497 Main controller software updated W3256 Tilt handle / pedal short to battery
M7504 Drive no communication W3257 Lift actuator reduced performance
M7604 Left display panel no communication W3258 Tilt actuator reduced performance
M7748 Key switch multiple W3259 Lift actuator wrong direction
M7839 Hourmeter changed W3260 Tilt actuator wrong direction
M7974 Door open W3261 Handle lock short to ground
W3262 Handle lock short to battery
W3223 ACS calibration required W3263 Pedal lock short to ground
W3224 ACS calibration failed W3264 Pedal lock short to battery
W3231 Tilt actuator fault W3265 Sensor supply voltage out of range
W3232 Tilt actuator wiring fault W3266 Battery voltage out of range
W3233 Tilt handle wiring fault W3267 Handle / pedal switch flipped while operating
W3234 Tilt actuator not in neutral W3268 Lift handle information error

Dealer Copy -- Not for Resale

W3235 Tilt handle / pedal not in neutral W3270 Right hand drive short to ground
W3236 Lift actuator fault W3271 Right hand drive short to battery
W3237 Lift actuator wiring fault W3274 Left joystick X-axis out of range
W3238 Lift handle wiring fault W3275 Interrupted unswitched power
W3239 Lift actuator not in neutral W3276 CAN joystick information error
W3240 Lift handle / pedal not in neutral W3277 Remote control information error
W3241 No communication W3905 Left joystick X-axis not in neutral
W3249 Lift actuator short to ground W4005 Right joystick X-axis not in neutral
W3250 Tilt actuator short to ground W4007 Right joystick Y-axis not in neutral

542 of 822 60-90-6 T870 Service Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

Description

Figure 60-100-1

1 2 3

4
3
P-85413C

The Bobcat Interlock Control System is an electronic

system that is used to protect the operator. The system

Dealer Copy -- Not for Resale

consists of the traction lock, seat bar sensor and the lift
and tilt lockout solenoids.

These all have indicator lights on the left panel (Items 1,

2, 3) [Figure 60-100-1] of the loader cab.

The Press To Operate button (Item 4) [Figure 60-100-1]

activates the system and allows the operator to function
the loader.

543 of 822 60-100-1 T870 Service Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) Inspecting The Traction Lock (Engine RUNNING)
(CONT'D)
6. Fasten seat belt, disengage parking brake, press the
Inspecting The BICS™ (Engine STOPPED - Key ON) PRESS TO OPERATE LOADER button and raise
seat bar fully. Move steering handles or joystick(s)
Figure 60-100-2 slowly forward and backward. The TRACTION lock
must be engaged. Lower the seat bar. Press the
1 PRESS TO OPERATE LOADER button.
2 3
7. Engage parking brake and move steering handles or
joystick(s) slowly forward and backward. The
TRACTION lock must be engaged.

4 NOTE: The PARKING BRAKE light on the left

instrument panel will remain ON until the
engine is started, the PRESS TO OPERATE
LOADER button is pressed and the parking
5
brake is disengaged.

6 Inspecting The Lift Arm Bypass Control

P-85413C
8. Raise the lift arms 2 m (6 ft) off the ground. Stop
engine. Turn lift arm bypass control knob clockwise 1/
1. Sit in operator’s seat. Turn key to RUN or press RUN
4 turn. Pull up and hold lift arm bypass control knob
button. Lower seat bar and disengage parking brake.

Dealer Copy -- Not for Resale

until lift arms slowly lower.
Press the PRESS TO OPERATE LOADER button
(Item 6). Two BICS™ lights (Items 1 and 2) [Figure
Inspecting Deactivation Of Lift And Tilt Functions
60-100-2] [SEAT BAR and LIFT AND TILT VALVE] on
(SJC)
left instrument panel must be OFF. The PRESS TO
OPERATE LOADER button will light.
9. Sit in operator’s seat and fasten seat belt. Lower seat
bar, start engine and press the PRESS TO OPERATE
2. Raise seat bar fully. All three BICS™ lights (Items 1,
LOADER button.
2 and 3) [Figure 60-100-2] [SEAT BAR, LIFT AND
TILT VALVE and PARKING BRAKE] on left
10. Raise lift arms about 2 m (6 ft) off the ground.
instrument panel must be ON. The PRESS TO
OPERATE LOADER button light will turn OFF.
11. Turn key OFF or press STOP button and wait for the
engine to come to a complete stop.
Inspecting Deactivation Of The Auxiliary Hydraulics
System (Engine STOPPED - Key ON)
12. Turn key ON or press RUN button. Press the PRESS
TO OPERATE LOADER button, move the joystick to
3. Sit in operator’s seat, lower seat bar and press the
lower the lift arms. Lift arms must not lower.
PRESS TO OPERATE LOADER button (Item 6).
Press the auxiliary hydraulics button (Item 5). The
13. Move the joystick to tilt the bucket (or attachment)
auxiliary hydraulics light will be ON (Item 4) [Figure
forward. The bucket (or attachment) must not tilt
60-100-2]. Raise the seat bar. The light must be OFF.
forward.
Inspecting The Seat Bar Sensor (Engine RUNNING)

4. Sit in operator’s seat, lower seat bar, engage parking

brake and fasten seat belt. WARNING
5. Start engine and operate at low idle. Press the
PRESS TO OPERATE LOADER button. While raising AVOID INJURY OR DEATH
the lift arms, raise the seat bar fully. The lift arms must The Bobcat Interlock Control System (BICS) must
stop. Repeat using the tilt function. deactivate the lift, tilt and traction drive functions. If it
does not, contact your dealer for service. DO NOT
modify the system.
W-2151-0394

544 of 822 60-100-2 T870 Service Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
(CONT'D)

Troubleshooting
WARNING
The following troubleshooting guide is provided for Check for correct function after adjustments, repairs
assistance in locating and correcting BICS™ system or service. Failure to make correct repairs or
problems. It is recommended that these procedures be adjustments can cause injury or death.
done by authorized Bobcat Service Personnel only. W-2004-1285

PROBLEM SOLUTION#
All indicator lights flashing. 5
One of the indicator lights flashing. 1
Intermittent indicator lights. 2, 3, 4

SOLUTION SUGGESTIONS
1. Refer to BICS™ troubleshooting chart.
2. Check wire connections on Bobcat controller to make sure connectors are locked into place.
3. Check pins in connectors for pins pushed back or bent.

Dealer Copy -- Not for Resale

4. Use seat bar sensor tester MEL1428 to isolate problem between sensor and controller and wiring.
5. Possible low or high voltage.

545 of 822 60-100-3 T870 Service Manual

 Dealer Copy -- Not for Resale

546 of 822 60-100-4 T870 Service Manual

SEAT BAR SENSOR Troubleshooting

Description The following troubleshooting chart is provided for

assistance in locating and correcting BICS™ system
The seat bar sensor is part of the BICS™ system. The problems. It is recommended that these procedures be
seat bar sensor sends a signal that indicates whether the performed by authorized Bobcat Service Personnel only.
seat bar is in the down or up position.

The sensor is located on the left side of the seat bar.

WARNING
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285

PROBLEM SOLUTION #
Indicator light does not turn OFF when seat bar is lowered. 1, 2, 3, 4, 5

SOLUTION SUGGESTIONS
1. Check sensor wire connection.

Dealer Copy -- Not for Resale

2. Use the BICS™ sensor tester MEL1428 with seat bar adapter MEL1567 to check sensor and controller.
3. Check for loose hardware.
4. Check keyed bushing to make sure magnet collar rotates with seat bar.
5. Check magnet collar magnets for contamination such as metal particles.

547 of 822 60-110-1 T870 Service Manual

SEAT BAR SENSOR (CONT'D) Figure 60-110-3

Testing

Figure 60-110-1

1
P-4698

If there is no power light (Item 1) [Figure 60-110-3] on

P-85653 the sensor tester, check the tester or wiring harness.

Figure 60-110-4
Use Sensor Tester (MEL1428) and seat bar sensor
adapter (MEL1567) for the following procedure:

Dealer Copy -- Not for Resale

Connect the seat bar sensor adapter leads (MEL1567) to
the sensor tester.
1
Disconnect the seat bar sensor connector (Item 1)
[Figure 60-110-1].

Figure 60-110-2

P-4699

Lower the seat bar. The Sensor Test light (Item 1)

1 [Figure 60-110-4] should illuminate.

Raise the seat bar. The Sensor Test light (Item 1) [Figure
60-110-4] should go off.

If the above test fails, there is a problem with the seat bar
P-85925 sensor or with the sensor harness.

Disconnect the Sensor Tester.

Connect the Sensor Tester (Item 1) [Figure 60-110-2]
inline, to the seat bar sensor connectors. [Figure 60-110- Replace the Seat Bar Sensor. (See Removal And
2]. Installation on Page 60-110-3.)

Turn the key to the ON position. DO NOT START THE If the above test passes, run the seat bar sensor BICS™
ENGINE. circuit test. (See Bobcat Interlock Control System
(BICS™) Circuit Test on Page 60-110-6.)
The toggle switch (Item 2) [Figure 60-110-3] can be in
either the Absent or Present position.

548 of 822 60-110-2 T870 Service Manual

SEAT BAR SENSOR (CONT'D) Figure 60-110-7

Removal And Installation

NOTE: This procedure is performed with the seat bar

in the raised position and the technician in the 3
operators seat.

Figure 60-110-5

1 2

P100745

Remove the retaining pin (Item 1) and clevis pin (Item 2)

[Figure 60-110-7]. Remove the seat bar mounting bolt
and nut (Item 3) [Figure 60-110-7].
2

P100742

Dealer Copy -- Not for Resale

Remove the sensor mounting bolt and nut (Item 1)
[Figure 60-110-5]. Disconnect the sensor wiring
connector (Item 2) [Figure 60-110-5].

Figure 60-110-6

P100743
P100759

Tighten the clevis bolt (Item 1) until spring tension is

released from the clevis pin (Item 2) [Figure 60-110-6].

NOTE: Approximately 4 turns of the clevis bolt

should be adequate to release the spring
tension. When tension is released, the clevis
pin can easily be rotated using the retaining
pin.

549 of 822 60-110-3 T870 Service Manual

SEAT BAR SENSOR (CONT'D) Remove and save the metal pivot bushing (Item 6)
[Figure 60-110-9].
Removal And Installation (Cont’d)
Figure 60-110-10
Figure 60-110-8
3

1
4

P100748
P100746

Install the new keyed bushing (Item 1), magnet bushing

Pull the front of the seat bar down slightly from the top of (Item 2) and seat bar sensor (Item 3) [Figure 60-110-10].
the cab, while raising the sensor end of the seat bar up, Reinstall the metal pivot bushing (Item 4) [Figure 60-110-
away from the mount [Figure 60-110-8].
10].

Dealer Copy -- Not for Resale

NOTE: The sensor end of the seat bar will raise easily
ONLY if the front of the seat bar is pulled NOTE: The sensor must be centered on the metal
slightly down from the top of the cab. pivot bushing. When centered, the assembly
will slide freely into the mount.
Figure 60-110-9
Figure 60-110-11
5

3
3
1
6 1

2
2
P100747

P100749
Place a soft jaw locking pliers (Item 1) [Figure 60-110-9]
on the cab side screen to hold the seat bar above the Position the clevis (Item 1) over the mount (Item 2) and
mount. lower the end of the seat bar until the mounting bolt (Item
3) [Figure 60-110-11] is resting on the top of the mount.
Remove the clevis pin bushing (Item 2) [Figure 60-110-
9]. Apply grease to the shoulder of the bushing to help Remove the nut from the mounting bolt. Remove the
retain it during assembly. Reinstall the clevis pin bushing. mounting bolt and lower the seat bar until the seat bar
and mount holes align and the clevis is over the clevis pin
Remove and dispose of the keyed bushing (Item 3), bushing. Reinstall the seat bar mounting bolt. Apply
magnet bushing (item 4), and seat bar sensor (Item Loctite® 243 to the nut threads. Install the nut and tighten
5)[Figure 60-110-9]. to 46 N•m (34 ft.-lb.) torque.

550 of 822 60-110-4 T870 Service Manual

SEAT BAR SENSOR (CONT'D)

Removal And Installation (Cont’d)

Figure 60-110-12

1
2

Dealer Copy -- Not for Resale

P100751
P100759

Reinstall the clevis pin (Item 1), and retaining pin (Item 2)
[Figure 60-110-12].

Loosen the clevis bolt (Item 3) until the end of the bolt is
flush with the clevis, then tighten the clevis bolt three full
turns to set proper tension of the compression spring.

Reconnect the sensor wiring connector (Item 2) [Figure

60-110-5].

Reinstall the sensor mounting bolt and nut (Item 1)

[Figure 60-110-5] and tighten to 6,8 N•m (60 in.-lb.)
torque.

IMPORTANT
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095

Verify correct seat bar sensor function by performing all

of the steps in the Bobcat Interlock Control System
(BICS™) inspection as described in the loader Operation
& Maintenance Manual.

551 of 822 60-110-5 T870 Service Manual

SEAT BAR SENSOR (CONT'D) Figure 60-110-14

Bobcat Interlock Control System (BICS™) Circuit

Test

Figure 60-110-13
3

1
P-4703

Connect Sensor Tester (Item 1) [Figure 60-110-14] inline

to the seat bar sensor connectors.
P-85653
Turn the key to the ON position. DO NOT START THE
ENGINE.
Use Sensor Tester (MEL1428) and seat bar sensor

Dealer Copy -- Not for Resale

adapter (MEL1567) for the following procedure: If the above test fails, there is a problem with the seat bar
sensor or with the sensor harness.
Connect the seat bar sensor adapter leads (MEL1567) to
the sensor tester. When the power light is illuminated, move the toggle
switch (Item 2) [Figure 60-110-14] on the sensor tester
Disconnect the seat bar sensor connector (Item 1) to the Present position.
[Figure 60-110-13].
NOTE: The sensor test light (Item 3) [Figure 60-110-
14] is only activated by the seat bar. It will be
off with the seat bar up or on with the seat bar
down.

552 of 822 60-110-6 T870 Service Manual

SEAT BAR SENSOR (CONT'D)

Bobcat Interlock Control System (BICS™) Circuit

Test (Cont’d)

Figure 60-110-15

P-85413

The BICS™ seat bar indicator light (Item 1) [Figure 60-

Dealer Copy -- Not for Resale

110-15] should turn OFF.

Figure 60-110-16

P-4699

Move the toggle switch (Item 1) [Figure 60-110-16] on

the sensor tester to the Absent position.

The Seat Bar light (Item 1) [Figure 60-110-15] should

illuminate.

If the above test fails, there is a problem with the Bobcat

Controller or the wiring harness.

553 of 822 60-110-7 T870 Service Manual

 Dealer Copy -- Not for Resale

554 of 822 60-110-8 T870 Service Manual

TRACTION LOCK

Description

The Traction Lock Control System will lock the traction

drive system when the engine stops. The Traction Lock
Control System is incorporated into the Bobcat Interlock
Control System (BICS™).

Dealer Copy -- Not for Resale

555 of 822 60-120-1 T870 Service Manual

TRACTION LOCK (CONT'D)

Troubleshooting WARNING
The following troubleshooting chart is provided for quick
reference in locating and correcting traction lock Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. See adjustments can cause injury or death.
BATS for detailed troubleshooting procedures if an error W-2004-1285
code is present.

PROBLEM SOLUTION #
Brake stays engaged. 1, 2, 3, 4, 5, 6, 7
Intermittent activation of brake. 2,3,5,6,7

SOLUTION SUGGESTIONS
1. Make sure brake switch is not engaged.
2. Check the display for an error code.
3. Measure the resistance of the brake solenoid, the resistance should be approximately 9.8 ohm.
4. Check for voltage at the brake solenoid, should read battery voltage when the brake is disengaged.
5. Check wire connections for loose or disconnected connector body.

Dealer Copy -- Not for Resale

6. Check for loose or pushed back bent pins in connectors.
7. Check the left panel display for engine rpm, if no rpm check flywheel rpm sensor, wiring and adjustment.

556 of 822 60-120-2 T870 Service Manual

TRACTION LOCK (CONT'D)

Inspecting

Figure 60-120-1

P-85413

Sit in operator’s seat, lower seat bar, engage parking

brake and fasten seat belt.

Dealer Copy -- Not for Resale

Start engine and operate at low idle. Disengage the
parking brake switch, press the PRESS TO OPERATE
LOADER button (Item 1) and raise the Seat Bar fully.
Move the steering levers slowly forward and backward.
The TRACTION lock must be engaged. Lower the Seat
Bar. Press the PRESS TO OPERATE LOADER button
(Item 1) [Figure 60-120-1].

Engage the parking brake switch and move the steering

levers slowly forward and backward. The TRACTION
lock must be engaged.

NOTE: The TRACTION light on the left instrument

panel will remain ON until the engine is
started, the PRESS TO OPERATE LOADER
Button is pressed and the parking brake is
disengaged.

557 of 822 60-120-3 T870 Service Manual

 Dealer Copy -- Not for Resale

558 of 822 60-120-4 T870 Service Manual

ELECTRICAL / HYDRAULIC CONTROLS (SJC)

Identification Chart

1 2 3 4 5 13 14 15 16 17
11
8

10
9
18
6 7 19
12 B-19873A / B-15546K / B-19874A

REF. NO. DESCRIPTION

1 TWO-SPEED CONTROL

Dealer Copy -- Not for Resale

Also: SPEED MANAGEMENT
2 STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE
3 REAR AUXILIARY HYDRAULICS (Option)
Also: ATTACHMENT FUNCTION CONTROL
4 STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE
5 ATTACHMENT FUNCTION CONTROL
6 SPEED MANAGEMENT
7 FRONT HORN
8 JOYSTICKS
9 FOOTRESTS
10 ENGINE SPEED CONTROL (FOOT OPERATED)
11 ENGINE SPEED CONTROL (HAND OPERATED)
12 LIFT ARM BYPASS CONTROL
13 ATTACHMENT FUNCTION CONTROL
14 NOT USED
15 FRONT AUXILIARY HYDRAULICS
16 NOT USED
17 TURN SIGNALS (Option)
18 FLOAT CONTROL
19 CONTINUOUS FLOW CONTROL FOR AUXILIARY HYDRAULICS

559 of 822 60-130-1 T870 Service Manual

ELECTRICAL / HYDRAULIC CONTROLS (SJC) (CONT’D)

Description

The Attachment Control Device (ACD) uses a 7 or 14 pin

connector to communicate between the loader and the
attachment.

Attachments with a 14 pin connector use four different

groups to control operations and hydraulic flow. Use
service Analyzer to determine what group is being used
and to troubleshoot the attachment / loader functions. If
service analyzer is not available use a Ohmmeter to
check for jumpers on the attachment harness.

Group 0 = No Jumpers

Group 1 = Pins K,L

Group 2 = Pins K,P

Group 3 = Pins C,D

Refer to the Identification Chart ACD Group 0,1,2, or 3

Dealer Copy -- Not for Resale

for more detailed information.

560 of 822 60-130-2 T870 Service Manual

ELECTRICAL / HYDRAULIC CONTROLS (SJC) (CONT’D)

Identification Chart ACD Group 0

Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches

STD RH HFH RH / HFH Fourteen Pin

1 1 1 1, 7 1,7 K Connector
8
13 6 Viewed 2 1
10
4
12
5
7
2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
14 8 1 4,5,6 1 4,5,6 K,G
3
9 1 4,5,6 1 4,5,6 K,H
10, 11, - -- -- K No Jumpers
P-24820A 12, 13, P-24802A

Dealer Copy -- Not for Resale

P-28316A 14 P-28316A
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
3
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-140-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.

Pressing the auxiliary hydraulics button and

moving the rear auxiliary hydraulic switch to NA1892
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve. Solenoid Hydraulic Coupler Wiring
Number Number
Front Auxiliary Pressure Release is 1 Front Male (Rod) 4330
accomplished by manually pushing the male 2 Front Female (Base) 4340
and female couplers in at the front auxiliary 3 Diverter Rear (Rod) 4430
block.
4 Diverter Rear (Base) 4440
The High Flow Button in the left side 5 Bleed / Lock Valve (Base) 4480
instrument panel must be pushed ON to 6 Bleed / Lock Valve (Rod) 4450
activate solenoid number seven at the gear 7 High Flow on Pump 4460
pump.

561 of 822 60-130-3 T870 Service Manual

ELECTRICAL / HYDRAULIC CONTROLS (SJC) (CONT’D)

Identification Chart ACD Group 1

Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches

STD RH HFH RH / HFH Fourteen Pin

1 1 1 1, 7 1,7 K Connector
8
13
4
6 Viewed 2 1
10

12
5
7 2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
14 8 1 1 1 1 K,M,G
3
9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
P-24820A 12, 13, P-24802A

Dealer Copy -- Not for Resale

P-28316A 14 P-28316A
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
3
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-140-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.

Pressing the auxiliary hydraulics button and

moving the rear auxiliary hydraulic switch to NA1892
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve. Solenoid Hydraulic Coupler Wiring
Number Number
Front Auxiliary Pressure Release is 1 Front Male (Rod) 4330
accomplished by manually pushing the male 2 Front Female (Base) 4340
and female couplers in at the front auxiliary 3 Diverter Rear (Rod) 4430
block.
4 Diverter Rear (Base) 4440
The High Flow Button in the left side 5 Bleed / Lock Valve (Base) 4480
instrument panel must be pushed ON to 6 Bleed / Lock Valve (Rod) 4450
activate solenoid number seven at the gear 7 High Flow on Pump 4460
pump.

562 of 822 60-130-4 T870 Service Manual

ELECTRICAL / HYDRAULIC CONTROLS (SJC) (CONT’D)

Identification Chart ACD Group 2

Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches

STD RH HFH RH / HFH Fourteen Pin

1 1 1 1, 7 1,7 K Connector
13 6 Viewed 8
2 1
10
4
12
5
7
2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
14 8 - - - - K,G
3
9 - - - - K,H
10, 11, - -- -- K Jumpers K,P
P-24820A 12, 13, P-24802A

Dealer Copy -- Not for Resale

P-28316A 14 P-28316A
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
3
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-140-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.

Pressing the auxiliary hydraulics button and

moving the rear auxiliary hydraulic switch to NA1892
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve. Solenoid Hydraulic Coupler Wiring
Number Number
Front Auxiliary Pressure Release is 1 Front Male (Rod) 4330
accomplished by manually pushing the male 2 Front Female (Base) 4340
and female couplers in at the front auxiliary 3 Diverter Rear (Rod) 4430
block.
4 Diverter Rear (Base) 4440
The High Flow Button in the left side 5 Bleed / Lock Valve (Base) 4480
instrument panel must be pushed ON to 6 Bleed / Lock Valve (Rod) 4450
activate solenoid number seven at the gear 7 High Flow on Pump 4460
pump.

563 of 822 60-130-5 T870 Service Manual

ELECTRICAL / HYDRAULIC CONTROLS (SJC) (CONT’D)

Identification Chart ACD Group 3

Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches

STD RH HFH RH / HFH Fourteen Pin

1 1 1 - - K Connector
13 6 Viewed 8
2 1
10
4 5
2 2 2 - - K from front 9 11
12 7
(pin side of
3 1 1 - - K connector)
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
14 8 - - - - K,G
3
9 - - - - K,H
10, 11, - -- -- K Jumpers C,D
P-24820A 12, 13, P-24802A

Dealer Copy -- Not for Resale

P-28316A 14 P-28316A
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
3
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-140-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.

Pressing the auxiliary hydraulics button and

moving the rear auxiliary hydraulic switch to NA1892
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve. Solenoid Hydraulic Coupler Wiring
Number Number
Front Auxiliary Pressure Release is 1 Front Male (Rod) 4330
accomplished by manually pushing the male 2 Front Female (Base) 4340
and female couplers in at the front auxiliary 3 Diverter Rear (Rod) 4430
block.
4 Diverter Rear (Base) 4440
The High Flow Button in the left side 5 Bleed / Lock Valve (Base) 4480
instrument panel must be pushed ON to 6 Bleed / Lock Valve (Rod) 4450
activate solenoid number seven at the gear 7 High Flow on Pump 4460
pump.

564 of 822 60-130-6 T870 Service Manual

ELECTRICAL / HYDRAULIC CONTROLS (SCPA)

Identification Chart

1 2 3 4 5 13 14 15 16 17
11
8
8

9
10 10 11
18
6 7 19
12 12
19873A / B-15546K /B-19874B

REF. NO. DESCRIPTION

1 TWO-SPEED CONTROL

Dealer Copy -- Not for Resale

Also: SPEED MANAGEMENT
2 STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE
3 REAR AUXILIARY HYDRAULICS (Option)
Also: ATTACHMENT FUNCTION CONTROL
4 STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE
5 ATTACHMENT FUNCTION CONTROL
6 SPEED MANAGEMENT
7 FRONT HORN
8 STEERING HANDLES
9 LIFT ARM PEDAL
10 TILT PEDAL
11 ENGINE SPEED CONTROL (HAND OPERATED)
12 LIFT ARM BYPASS CONTROL
13 ATTACHMENT FUNCTION CONTROL
14 NOT USED
15 FRONT AUXILIARY HYDRAULICS
16 NOT USED
17 TURN SIGNALS (Option)
18 NOT USED
19 CONTINUOUS FLOW CONTROL FOR AUXILIARY HYDRAULICS

565 of 822 60-131-1 T870 Service Manual

ELECTRICAL / HYDRAULIC CONTROLS (SCPA) (CONT’D)

Description

The Attachment Control Device (ACD) uses a 7 or 14 pin

connector to communicate between the loader and the
attachment.

Attachments with a 14 pin connector use four different

groups to control operations and hydraulic flow. Use
service Analyzer to determine what group is being used
and to troubleshoot the attachment / loader functions. If
service analyzer is not available use a Ohmmeter to
check for jumpers on the attachment harness.

Group 0 = No Jumpers

Group 1 = Pins K,L

Group 2 = Pins K,P

Group 3 = Pins C,D

Refer to the Identification Chart ACD Group 0,1,2, or 3

Dealer Copy -- Not for Resale

for more detailed information.

566 of 822 60-131-2 T870 Service Manual

ELECTRICAL / HYDRAULIC CONTROLS (SCPA) (CONT’D)

Identification Chart ACD Group 0

Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches

STD RH HFH RH / HFH Fourteen Pin

1 1 1 1, 7 1,7 K Connector
8
13 6 Viewed 2 1
10
4
12
5
7
2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
14 8 1 4,5,6 1 4,5,6 K,G
3
9 1 4,5,6 1 4,5,6 K,H
10, 11, - -- -- K No Jumpers
P-24820A 12, 13, P-24802A

Dealer Copy -- Not for Resale

P-28316A 14 P-28316A
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
3
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-140-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.

Pressing the auxiliary hydraulics button and

moving the rear auxiliary hydraulic switch to NA1892
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve. Solenoid Hydraulic Coupler Wiring
Number Number
Front Auxiliary Pressure Release is 1 Front Male (Rod) 4330
accomplished by manually pushing the male 2 Front Female (Base) 4340
and female couplers in at the front auxiliary 3 Diverter Rear (Rod) 4430
block.
4 Diverter Rear (Base) 4440
The High Flow Button in the left side 5 Bleed / Lock Valve (Base) 4480
instrument panel must be pushed ON to 6 Bleed / Lock Valve (Rod) 4450
activate solenoid number seven at the gear 7 High Flow on Pump 4460
pump.

567 of 822 60-131-3 T870 Service Manual

ELECTRICAL / HYDRAULIC CONTROLS (SCPA) (CONT’D)

Identification Chart ACD Group 1

Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches

STD RH HFH RH / HFH Fourteen Pin

1 1 1 1, 7 1,7 K Connector
8
13
4
6 Viewed 2 1
10

12
5
7 2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
14 8 1 1 1 1 K,M,G
3
9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
P-24820A 12, 13, P-24802A

Dealer Copy -- Not for Resale

P-28316A 14 P-28316A
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
3
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-140-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.

Pressing the auxiliary hydraulics button and

moving the rear auxiliary hydraulic switch to NA1892
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve. Solenoid Hydraulic Coupler Wiring
Number Number
Front Auxiliary Pressure Release is 1 Front Male (Rod) 4330
accomplished by manually pushing the male 2 Front Female (Base) 4340
and female couplers in at the front auxiliary 3 Diverter Rear (Rod) 4430
block.
4 Diverter Rear (Base) 4440
The High Flow Button in the left side 5 Bleed / Lock Valve (Base) 4480
instrument panel must be pushed ON to 6 Bleed / Lock Valve (Rod) 4450
activate solenoid number seven at the gear 7 High Flow on Pump 4460
pump.

568 of 822 60-131-4 T870 Service Manual

ELECTRICAL / HYDRAULIC CONTROLS (SCPA) (CONT’D)

Identification Chart ACD Group 2

Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches

STD RH HFH RH / HFH Fourteen Pin

1 1 1 1, 7 1,7 K Connector
13 6 Viewed 8
2 1
10
4
12
5
7
2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
14 8 - - - - K,G
3
9 - - - - K,H
10, 11, - -- -- K Jumpers K,P
P-24820A 12, 13, P-24802A

Dealer Copy -- Not for Resale

P-28316A 14 P-28316A
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
3
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-140-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.

Pressing the auxiliary hydraulics button and

moving the rear auxiliary hydraulic switch to NA1892
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve. Solenoid Hydraulic Coupler Wiring
Number Number
Front Auxiliary Pressure Release is 1 Front Male (Rod) 4330
accomplished by manually pushing the male 2 Front Female (Base) 4340
and female couplers in at the front auxiliary 3 Diverter Rear (Rod) 4430
block.
4 Diverter Rear (Base) 4440
The High Flow Button in the left side 5 Bleed / Lock Valve (Base) 4480
instrument panel must be pushed ON to 6 Bleed / Lock Valve (Rod) 4450
activate solenoid number seven at the gear 7 High Flow on Pump 4460
pump.

569 of 822 60-131-5 T870 Service Manual

ELECTRICAL / HYDRAULIC CONTROLS (SCPA) (CONT’D)

Identification Chart ACD Group 3

Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches

STD RH HFH RH / HFH Fourteen Pin

1 1 1 - - K Connector
13 6 Viewed 8
2 1
10
4 5
2 2 2 - - K from front 9 11
12 7
(pin side of
3 1 1 - - K connector)
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
14 8 - - - - K,G
3
9 - - - - K,H
10, 11, - -- -- K Jumpers C,D
P-24820A 12, 13, P-24802A

Dealer Copy -- Not for Resale

P-28316A 14 P-28316A
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
3
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-140-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.

Pressing the auxiliary hydraulics button and

moving the rear auxiliary hydraulic switch to NA1892
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve. Solenoid Hydraulic Coupler Wiring
Number Number
Front Auxiliary Pressure Release is 1 Front Male (Rod) 4330
accomplished by manually pushing the male 2 Front Female (Base) 4340
and female couplers in at the front auxiliary 3 Diverter Rear (Rod) 4430
block.
4 Diverter Rear (Base) 4440
The High Flow Button in the left side 5 Bleed / Lock Valve (Base) 4480
instrument panel must be pushed ON to 6 Bleed / Lock Valve (Rod) 4450
activate solenoid number seven at the gear 7 High Flow on Pump 4460
pump.

570 of 822 60-131-6 T870 Service Manual

SERVICE PC (LAPTOP COMPUTER) Connecting Remote Start Tool (Service Tool)

Connecting Remote Start Tool Figure 60-140-2

Figure 60-140-1

1 2
2

3
1
P-76450

P16119
The tools listed will be needed to do the following
procedure:
The tools listed will be needed to do the following
procedure: Order from Bobcat Parts P/N: 7003031 - Remote Start

Dealer Copy -- Not for Resale

Tool (Service Tool) Kit
MEL1563 - Remote Start Tool Kit
MEL1566 - Service Tool Harness Communicator Kit Includes:
(Computer Interface)
NOTE: Make all connections with the key in the OFF 7003030 - Remote Start Tool (Service Tool)
position. 6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness
The Service PC (Item 1) with the Remote Start Tool (Item 6689745 - BOSS® Service Tool Harness
2) [Figure 60-140-1]. When connected to the loader, the NOTE: Make all connections with the key in the OFF
Service PC is used to monitor, conduct diagnostics, and position.
upgrade software.
The Service PC (Item 1) with the Remote Start Tool
Connect the Service Tool Harness Communicator (Service Tool) (Item 2) [Figure 60-140-2]. When
(MEL1566) (Item 3) [Figure 60-140-1] to the designated connected to the loader, the Service PC is used to
serial port on the Service PC. monitor, conduct diagnostics, and upgrade software.

NOTE: The recommended serial cable length should Connect the Remote Start Tool (Service Tool) Computer
not exceed 4,6 m (15 ft). A serial cable longer Service Tool Harness (Item 3) [Figure 60-140-2] to the
than 4,6 m (15 ft) will create a degraded signal designated serial port on the Service PC.
causing communication errors.
NOTE: The recommended serial cable length should
Connect the other end to the connector on the Remote not exceed 4,6 m (15 ft). A serial cable longer
Start Tool. than 4,6 m (15 ft) will create a degraded signal
causing communication errors.
Connect the remote start tool to the loader. (See
REMOTE START TOOL KIT-MEL1563 on Page 10-60- Connect the other end to the connector on the Remote
1.) Start Tool (Service Tool).

Connect the Remote Start Tool (Service Tool) to the

loader. (See REMOTE START TOOL (SERVICE TOOL)
KIT - 7003031 on Page 10-61-1.)

571 of 822 60-140-1 T870 Service Manual

 Dealer Copy -- Not for Resale

572 of 822 60-140-2 T870 Service Manual

CALIBRATION Actuator Testing

Description Figure 60-150-1

Calibration procedures must be followed when replacing

a hydraulic control valve, actuator, Drive / Drive+
Controller, ACS Controller, pump controller, hydrostatic
pump, or hydrostatic motor. Failure to calibrate after
component replacement may result in error codes, poor
performance or reduced life of actuator(s).

There are two methods to perform the lift and tilt

calibration, one is the Actuator Test and the other is
manually. The Actuator Test is performed with the
Service PC. The Actuator Test should be used if reduced
performance codes are present or when replacing a
controller or actuator.
CONTROL VALVE ACTUATORS
P-54336
The Lift and Tilt Calibration (SJC) is performed by
physically moving the joysticks to provide set points to
the ACS controller to actuate the lift and tilt valve. The Lift [Figure 60-150-1] Excessive actuator loading can occur
and Tilt Calibration (SJC) should be used if reduced if the actuator and valve spool components are
performance codes are present or when replacing a misaligned. Misalignment may reduce spool stroke
controller or actuator. performance and reduce the life of the actuator.

Dealer Copy -- Not for Resale

NOTE: The Actuator Test should be used as the Connect the Service PC (See SERVICE PC (LAPTOP
preferred method of lift and tilt calibration. COMPUTER) on Page 60-140-1.)

The Hydrostatic Pump Calibration (SJC / SCPA) provides If a Service PC is not available, (See Lift And Tilt
set points to the Drive controller to actuate the Calibration (SJC) on Page 60-150-4.)
hydrostatic controller that directs flow to a servo piston.
Hydrostatic Pump Calibration (SJC / SCPA) should be NOTE: Warm the hydraulic oil to room temperature
performed when a desired travel path cannot be attained 22°C (72°F), stop the engine and clear all
or replacing the hydrostatic pump, hydrostatic motor, or active service codes before running the test.
controller. After Performing a Hydrostatic Pump
Calibration (SJC / SCPA), Steering Drift Compensation Once the test is initiated, an automatic calibration
can be used to fine tune the hydrostatic pump control. sequence will start. When calibration is complete, the test
will be performed and the results can be viewed on the
For more information on Steering Drift Compensation Service PC monitor.
(See STEERING DRIFT COMPENSATION on Page 60-
161-1.)

NOTE: The Actuator Test calibrates the lift and tilt

system therefore no further lift and tilt
calibration is required if using this method.

573 of 822 60-150-1 T870 Service Manual

CALIBRATION (CONT’D) If the Actuator Test fails after the hydraulic oil is warmed,
go to the next step and loosen the bolts that mount the
Actuator Testing (Cont’d) actuator to the control valve. Loosen the bolts just
enough so the actuator can be moved slightly up / down
This test will engage both actuators to fully stroke the or side / side.
spools then allow the centering springs to return the
spools to neutral. Next, both actuators are engaged to Rerun the Actuator Test, if the test passes, check the
move the spools just past the neutral points then allow following probable causes in Column 1 [Figure 60-150-
the centering springs to return the spools to neutral. 2]. Check the probable causes in the order they are
listed. Repairing one cause may be all that is required.
When complete, the Actuator Test will show a pass mode Re-run the test to verify.
or fail mode. The pass mode indicates that no problems
were detected. The fail mode indicates one or a NOTE: Actuator and spool misalignment. Re-tighten
combination of three problems below. the two bolts evenly, turn the first bolt one
turn, then turn the other bolt one turn until
• Actuator slow return to neutral. The spool returns to both bolts are tight.
neutral too slowly.
If the Actuator Test failed due to a slow return to neutral
• Actuator did not fully extend / retract. During the test, after checking the probable causes in Column 1 [Figure
the spool was not able to fully stroke in both 60-150-2], check the following probable causes in
directions. Column 2 [Figure 60-150-2].

• Actuator out of neutral. The spool did not return to the • Contamination in the spool.
neutral window during the test.

Dealer Copy -- Not for Resale

• The spool end cap may be loose, damaged or the
NOTE: A time out will occur if the test cannot be centering spring may be broken. Inspect the end cap
completed within 8 seconds. If this happens, and the centering spring, replace if necessary.
retry the test.
• The wire harness or connectors may have an
Figure 60-150-2 intermittent short. Check the connections and wire
Run Actuator Test harnesses.

• The controller may be malfunctioning, replace the

Pass Fail controller.

Retest With Warm Hydraulic Oil

Pass Fail

Loosen Actuator

Pass Fail

Column 1 Column 2
Probable Cause Probable Cause
• Misaligned Assembly • Actuator
• Pin • End Cap / Center Spring
• Contamination in Spool • Wire Harness
• Controller
• Contamination in Spool

[Figure 60-150-2] If the initial Actuator Test results in a

fail mode due to a slow return to neutral, follow the
troubleshooting tree to pinpoint the probable cause.

574 of 822 60-150-2 T870 Service Manual

CALIBRATION (CONT’D)

Actuator Testing (Cont’d)

If the initial Actuator Test results in the fail mode actuator

did not fully extend / retract, check the following.

• The actuator connectors may be reversed between

the lift and tilt actuator. Reverse the connectors and
rerun the Actuator Test.

• The actuator may be weak, replace the actuator.

• The spool end cap may be loose, damaged or the

centering spring may be broken. Inspect the end cap
and the centering spring, replace if necessary.

• Contamination in the spool.

If the initial Actuator Test results in the fail mode actuator

out of neutral, check the following.

• The actuator may be weak, replace the actuator.

Dealer Copy -- Not for Resale

• The spool end cap may be loose, damaged or the
centering spring may be broken. Inspect the end cap
and the centering spring, replace if necessary.

• Contamination in the spool.

575 of 822 60-150-3 T870 Service Manual

CALIBRATION (CONT’D) Figure 60-150-4

Lift And Tilt Calibration (SJC)

The controller uses a calibration sequence to optimize

the control system. The optimizing ensures full spool
stroke (full flow) while preventing over stroke (loading) of
the actuator and resets the calibration points in the
controller.

NOTE: The Actuator Test is the preferred method to

calibrate the lift and tilt actuator. (See
Actuator Testing on Page 60-150-1.)

NOTE: This calibration procedure must be followed

when replacing the hydraulic control valve, lift P-85958 P-85958
or tilt actuator. Failure to calibrate after
component replacement may result in error
codes, poor performance or reduced life of Move the right joystick to the forward-right corner position
actuator(s). [Figure 60-150-4] and hold in position.

Figure 60-150-3

SJC

Dealer Copy -- Not for Resale

1

P-85307

With an operator in the seat and the seat bar down.

Close the cab door. (If loader is equipped.)

Place the loader Control Pattern Switch (Item 1) [Figure

60-150-3] in the ISO position.

576 of 822 60-150-4 T870 Service Manual

CALIBRATION (CONT’D) Figure 60-150-7

Lift And Tilt Calibration (SJC) (Cont’d)

Figure 60-150-5

P-85413C

P-85493A

At the left panel, press the PRESS TO OPERATE Button

With the seat bar down, turn the ignition key ON [Figure (Item 1) [Figure 60-150-7] while holding the right joystick
60-150-5]. in position.

NOTE: Do not start the engine. Release the joystick.

Dealer Copy -- Not for Resale

Figure 60-150-6 NOTE: During the calibration cycle, the system will
beep three times. Once the calibration is
SJC complete, code W3224 (Calibration
Performed) will be generated.

The ACS controller will cycle the actuators.

The lift and tilt calibration is complete.

P-85307

The loader Control Pattern Switch (Item 1) [Figure 60-

150-6] will start flashing and will continue to flash until the
calibration procedure is completed.

577 of 822 60-150-5 T870 Service Manual

CALIBRATION (CONT’D) Figure 60-150-9

Hydrostatic Pump Calibration (SJC)

WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286 P-85493A

Place the loader on jackstands. (See Procedure on Page

With the seat bar down, turn the ignition key ON [Figure
10-10-1.)
60-150-9].
Operator must be in the seat and the seat bar down.
NOTE: Do not start the engine.
Figure 60-150-8
Figure 60-150-10
SJC
SJC

Dealer Copy -- Not for Resale

1
1

P-85307
P-85307

Close the cab door. (If loader is so equipped.)

The Control Pattern ISO Switch (Item 1) [Figure 60-150-
10] will start flashing.
Place the loader Control Pattern Switch (Item 1) [Figure
60-150-8] in the ISO position.

Verify that the parking brake switch is in the OFF

position.

578 of 822 60-150-6 T870 Service Manual

CALIBRATION (CONT'D) Figure 60-150-13

Hydrostatic Pump Calibration (SJC) (Cont'd)

Figure 60-150-11

B-19873
P-85960

B-19873 Move the left joystick to the reverse-right corner position

P-85959 [Figure 60-150-13] and hold in position.

Figure 60-150-14
Move the left joystick to the forward-left corner position
[Figure 60-150-11] and hold in position.

Dealer Copy -- Not for Resale

Figure 60-150-12

P-85413C

1
Press the PRESS TO OPERATE LOADER Button (Item
P-85413C 1) [Figure 60-150-14] while holding the left joystick in
position.

Press the PRESS TO OPERATE LOADER Button (Item Three audible beeps will sound.
1) [Figure 60-150-12] while holding the left joystick in
position.

Three audible beeps will sound.

579 of 822 60-150-7 T870 Service Manual

CALIBRATION (CONT'D) Figure 60-150-17

Hydrostatic Pump Calibration (SJC) (Cont'd) SJC

Figure 60-150-15

P-85307

The Control Pattern ISO Switch (Item 1) [Figure 60-150-

P-85961 17] will stop flashing, and will remain ON for the rest of
the calibration procedure.

Allow the left joystick to go to the neutral position [Figure Figure 60-150-18
60-150-15].

Dealer Copy -- Not for Resale

Figure 60-150-16

P-85760A
1

P-85413C Move the throttle (Item 1) [Figure 60-150-18] to high idle.

NOTE: If at any time, during calibration, the operator

Press the PRESS TO OPERATE LOADER Button (Item needs to stop the loader, turn the key OFF, lift
1) [Figure 60-150-16]. the seat bar, or return the joystick to the
neutral position.
Three audible beeps will sound.
The calibration procedure will stop.
Start the engine from the RUN, RUN / ENTER position.
DO NOT TURN TO OFF POSITION. This would cancel To return to calibration mode, the operator
the calibration mode and the procedure would have to be must start the complete procedure from the
repeated. beginning.

580 of 822 60-150-8 T870 Service Manual

CALIBRATION (CONT'D) The loader will then “stair step” the speed (Item 2)
[Figure 60-150-20] until it reaches full speed and then
Hydrostatic Pump Calibration (SJC) (Cont'd) come to a stop.

Continue to hold the left joystick in the forward position

until the loader wheels or tracks come to a stop and an
WARNING audible beep is heard.

Forward calibration is complete.

Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
NOTE: If the wheels or tracks do not stop moving in
Failure to use jackstands can allow the machine to
Full Speed Forward in 2 minutes or less, there
fall or move and cause injury or death.
W-2017-0286
was an error in the calibration procedure. The
operator must shut the loader OFF, and start
the calibration procedure from the beginning.
Figure 60-150-19

Dealer Copy -- Not for Resale

B-19873
P-85962

Move and hold the left joystick to the forward position

[Figure 60-150-19] until the forward calibration is
completed.

Figure 60-150-20

1 2

P-64321

The loader speed will “ramp up” quickly (Item 1)

[Figure 60-150-20] and slow down 3 times in a row.

581 of 822 60-150-9 T870 Service Manual

CALIBRATION (CONT'D) NOTE: If the wheels or tracks do not stop moving in
Full Speed Reverse in 2 minutes or less, there
Hydrostatic Pump Calibration (SJC) (Cont'd) was an error in the calibration procedure. The
operator must shut the loader OFF, and start
Figure 60-150-21 the calibration procedure from the beginning.

There will be an audible beep and the PRESS TO

OPERATE LOADER and TRACTION lights will go out.
The SEAT BAR and LIFT AND TILT lights will remain on.
The 75-98 error code will clear. There should be no other
codes in the display area.

Allow the joystick to go to the neutral position.

Once the calibration procedure is complete the Steering

Drift Compensation values will be reset to [S----] or
neutral.

B-19873 Press the PRESS TO OPERATE LOADER button. Move

P-85963 the left joystick to forward position [Figure 60-150-19]
and check for normal forward wheel or track rotation.
Move and hold the left joystick to the reverse position Move the left joystick to the reverse position [Figure 60-
[Figure 60-150-21] until the reverse calibration is 150-21] and check for normal reverse wheel or track

Dealer Copy -- Not for Resale

completed. rotation.
Figure 60-150-22 Stop the engine, and remove the loader from jackstands.

The calibration procedure is completed.

1 2 After calibration is complete, use Steering Drift

Compensation for fine tuning or if an acceptable line of
drift cannot be achieved. (See STEERING DRIFT
COMPENSATION on Page 60-161-1.)

If loader does not maintain a desired travel path with

Steering Drift Compensation at maximum setting [S-R10]
or [S-L10], see the electrical and hydrostatic
troubleshooting. (See Troubleshooting on Page 30-10-2.)
or (See Troubleshooting on Page 30-10-2.)

P-64321

The loader speed will “ramp up” quickly (Item 1)

[Figure 60-150-22] and slow down 3 times in a row.

The loader will then “stair step” the speed (Item 2)

[Figure 60-150-22] until it reaches full speed and then
come to a stop.

Continue to hold the left joystick in the reverse position

until the loader wheels or tracks come to a stop and an
audible beep is heard.

Reverse calibration is complete.

582 of 822 60-150-10 T870 Service Manual

CALIBRATION (CONT’D) Figure 60-150-24

Hydrostatic Pump Calibration (SCPA)

WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286 P-85493A

Place the loader on jackstands. (See Procedure on Page

With the seat bar down, turn the ignition key ON [Figure
10-10-1.)
60-150-24].
Operator must be in the seat and the seat bar down.
NOTE: Do not start the engine.
Figure 60-150-23
Figure 60-150-25

Dealer Copy -- Not for Resale

1

P-90668A
P-85959

Close the cab door. (If loader is so equipped.)

Move the left steering handle to the forward position
[Figure 60-150-25] and hold in position.
Verify that the parking brake switch (Item 1) [Figure 60-
150-23] is in the OFF position.

583 of 822 60-150-11 T870 Service Manual

CALIBRATION (CONT'D) Figure 60-150-28

Hydrostatic Pump Calibration (SCPA) (Cont'd)

Figure 60-150-26

P-85413C

1
Press the PRESS TO OPERATE LOADER Button (Item
P-85413C 1) [Figure 60-150-28] while holding the right steering
handle in position.

Press the PRESS TO OPERATE LOADER Button (Item Three audible beeps will sound.
1) [Figure 60-150-26] while holding the left steering

Dealer Copy -- Not for Resale

handle in position.

Three audible beeps will sound.

Figure 60-150-27

P100803

Move the right steering handle to the reverse position

[Figure 60-150-27] and hold in position.

584 of 822 60-150-12 T870 Service Manual

CALIBRATION (CONT'D) Figure 60-150-31

Hydrostatic Pump Calibration (SCPA) (Cont'd)

Figure 60-150-29

P-85760A

Move the throttle (Item 1) [Figure 60-150-31] to high idle.

P-85961
NOTE: If at any time, during calibration, the operator
needs to stop the loader, turn the key OFF, lift
Allow the steering handles to go to the neutral position the seat bar, or return the steering handle to
[Figure 60-150-29]. the neutral position.

Dealer Copy -- Not for Resale

Figure 60-150-30 The calibration procedure will stop.

To return to calibration mode, the operator

must start the complete procedure from the
beginning.

P-85413C

Press the PRESS TO OPERATE LOADER Button (Item

1) [Figure 60-150-30].

Three audible beeps will sound.

Start the engine from the RUN, RUN / ENTER position.

DO NOT TURN TO OFF POSITION. This would cancel
the calibration mode and the procedure would have to be
repeated.

585 of 822 60-150-13 T870 Service Manual

CALIBRATION (CONT'D) The loader will then “stair step” the speed (Item 2)
[Figure 60-150-33] until it reaches full speed and then
Hydrostatic Pump Calibration (SCPA) (Cont'd) come to a stop.

Continue to hold the left steering handle in the forward

position until the loader wheels or tracks come to a stop
WARNING and an audible beep is heard.

Forward calibration is complete.

Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
NOTE: If the wheels or tracks do not stop moving in
Failure to use jackstands can allow the machine to
Full Speed Forward in 2 minutes or less, there
fall or move and cause injury or death.
W-2017-0286
was an error in the calibration procedure. The
operator must shut the loader OFF, and start
the calibration procedure from the beginning.
Figure 60-150-32

Dealer Copy -- Not for Resale

B-19873
P-85962

Move and hold the left steering handle to the forward

position [Figure 60-150-32] until the forward calibration
is completed.

Figure 60-150-33

1 2

P-64321

The loader speed will “ramp up” quickly (Item 1)

[Figure 60-150-33] and slow down 3 times in a row.

586 of 822 60-150-14 T870 Service Manual

CALIBRATION (CONT'D) NOTE: If the wheels or tracks do not stop moving in
Full Speed Reverse in 2 minutes or less, there
Hydrostatic Pump Calibration (SCPA) (Cont'd) was an error in the calibration procedure. The
operator must shut the loader OFF, and start
Figure 60-150-34 the calibration procedure from the beginning.

There will be an audible beep and the PRESS TO

OPERATE LOADER and TRACTION lights will go out.
The SEAT BAR and LIFT AND TILT lights will remain on.
The 75-98 error code will clear. There should be no other
codes in the display area.

Allow the steering handle to go to the neutral position.

Once the calibration procedure is complete the Steering

Drift Compensation values will be reset to [S----] or
neutral.

B-19873 Press the PRESS TO OPERATE LOADER button. Move

P-85963 the left steering handle to forward position [Figure 60-
150-32] and check for normal forward wheel or track
rotation.
Move and hold the left steering handle to the reverse
position [Figure 60-150-34] until the reverse calibration Move the left steering handle to the reverse position

Dealer Copy -- Not for Resale

is completed. [Figure 60-150-34] and check for normal reverse wheel
or track rotation.
Figure 60-150-35
Stop the engine, and remove the loader from jackstands.

The calibration procedure is completed.

1 2
After calibration is complete, use Steering Drift
Compensation for fine tuning or if an acceptable line of
drift cannot be achieved. (See STEERING DRIFT
COMPENSATION on Page 60-161-1.)

If loader does not maintain a desired travel path with

Steering Drift Compensation at maximum setting [S-R10]
or [S-L10], see the electrical and hydrostatic
troubleshooting. (See Troubleshooting on Page 30-10-2.)
or (See Troubleshooting on Page 30-10-2.)
P-64321

The loader speed will “ramp up” quickly (Item 1)

[Figure 60-150-35] and slow down 3 times in a row.

The loader will then “stair step” the speed (Item 2)

[Figure 60-150-35] until it reaches full speed and then
come to a stop.

Continue to hold the left steering handle in the reverse

position until the loader wheels or tracks come to a stop
and an audible beep is heard.

Reverse calibration is complete.

587 of 822 60-150-15 T870 Service Manual

 Dealer Copy -- Not for Resale

588 of 822 60-150-16 T870 Service Manual

STEERING DRIFT COMPENSATION Operation

Description NOTE: Changes CANNOT be performed until the seat

bar is lowered, the engine is started and the
Steering Drift Compensation can be used to reduce PRESS TO OPERATE LOADER button is
steering drift to maintain a desired travel path in both pressed to activate the BICS™.
forward and reverse directions.
Perform pre-starting and starting procedures:
Examples of applications where this feature can be used:
1. Fasten seat belt.
• To compensate for normal variations such as tire
inflation pressure, track tension, tire wear and track 2. Lower seat bar.
wear.
3. Place controls in neutral position.
• Using side shift attachments such as trenchers,
planers and silt fence installers. 4. Start the engine.

• Driving on uneven terrain such as crowned road 5. Press the PRESS TO OPERATE LOADER button.
surfaces.
6. Current drive response setting will be displayed briefly
Figure 60-160-1 in the data display.

STEERING DRIFT COMPENSATION NOTE: (SJC) Raising the seat bar or changing control
mode (ISO / H) will cause the machine to

Dealer Copy -- Not for Resale

disengage from steering drift compensation.
The last displayed setting will remain in effect
until the machine is turned OFF.

B-23580D

Steering drift compensation contains a total of 21

settings. Steering drift compensation can be set to any
point from neutral to [S-L10] left and from neutral to [S-
R10] right. [S----] is displayed when set for neutral
[Figure 60-160-1].

589 of 822 60-161-1 T870 Service Manual

STEERING DRIFT COMPENSATION (CONT’D) Press the upper right button (Item 7) on the left control to
adjust back toward center. The display will decrease
Operation (Cont’d) down to neutral displayed as [S----] (Item 4). Another
press of the upper right button will cause [S-R01] (Item 5)
Figure 60-160-2 to appear in the data display (Item 2) [Figure 60-160-2].
The number will increase by one each time you press the
button up to a maximum of [S-R10]. The higher the
number, the greater the amount of steering drift
compensation to the right. Adjustments to steering drift
compensation will be effective immediately.

Figure 60-160-3

2
1
NA1011

3 4 5

P-76461L 2
P-76461N
1

Dealer Copy -- Not for Resale

P-76461M

Left Right NA1011

3 4

P-76461K
P-76461O
6 7

P-24820C P-24802C Saving The Steering Drift Compensation Setting:

The current steering drift compensation setting can be

Press and hold the PRESS TO OPERATE LOADER
saved by pressing and holding the PRESS TO
button (Item 1) for three seconds to enter the drive
OPERATE LOADER button (Item 1) for three seconds.
response adjustment menu. Press the PRESS TO
[SET] (Item 3) will appear in the data display (Item 2)
OPERATE LOADER button (Item 1) again to adjust the
[Figure 60-160-3] and the machine will exit from the
loaders steering drift compensation setting. The current
steering drift compensation adjustment menu.
steering drift compensation setting will appear in the data
display (Item 2) [Figure 60-160-2].
OR
Press the upper left button (Item 6) on the left control to
Press the PRESS TO OPERATE LOADER button to exit
adjust the machine left. [S-L01] (Item 3) through a
from the steering drift compensation adjustment menu
maximum of [S-L10] will appear in the data display (Item
without saving the current setting. [DONE] (Item 4) will
2) [Figure 60-160-2]. The number will increase by one
appear in the data display (Item 2) [Figure 60-160-3] and
each time you press the button. The higher the number,
the upper left and upper right buttons on the left control
the greater the amount of steering drift compensation to
will no longer make changes to steering drift
the left. Adjustments to steering drift compensation will
compensation.
be effective immediately.
NOTE: The last displayed steering drift
compensation setting will remain in effect
until the machine is turned OFF. The machine
will revert back to the last saved setting the
next time it is started.

590 of 822 60-161-2 T870 Service Manual

FLYWHEEL RPM SENSOR Adjusting

Description Figure 60-170-1

The flywheel rpm sensor has a magnet located on the

end of the sensor which senses breaks between the ring
gear teeth, the sensor relays this information back to the
controller which registers the rpm of the engine.
2 1
The flywheel rpm sensor is located just above the starter
on the left side of the engine.

P100274

When reinstalling the rpm sensor, turn the rpm sensor

(Item 1) [Figure 60-170-1] in until it makes contact with
the engine flywheel.

Turn the jam nut (Item 2) [Figure 60-170-1] until it

Dealer Copy -- Not for Resale

contacts the flywheel housing. The jam nut should not be
tightened, it needs to turn with the rpm sensor when the
sensor is turned back out for adjustment.

Figure 60-170-2

P100273

Turn the rpm sensor and the jam nut out from the
flywheel. Set a clearance of 1,27 mm (0.050 in) between
the jam nut and the housing with a feeler gauge (Item 1)
[Figure 60-170-2].

Remove the feeler gauge.

Tighten the jam nut (Item 2) [Figure 60-170-2] to 20,3

N•m (15 ft-lb) torque.

NOTE: New rpm sensors have a plastic tip which is

used as a gauge during installation. The
plastic tip is designed to come off after the
engine is started.

591 of 822 60-170-1 T870 Service Manual

 Dealer Copy -- Not for Resale

592 of 822 60-170-2 T870 Service Manual

CONTROL PANEL SETUP Example

Right Panel Setup (Deluxe Instrumentation Panel) Languages

Icon Identification Figure 60-180-2

Figure 60-180-1 Press a scroll button

(Item 1) repeatedly until
the Display screen icon
(Inset) is highlighted.

1 1
Select
[2. LANGUAGES].

NA3025 Select the desired

language.

Dealer Copy -- Not for Resale

ICON DESCRIPTION

DATE / TIME

USER / HOURMETER P-90385 / NA3025 / NA3012 / NA3023

CURRENT JOB HOURS

ACTIVE WARNINGS screen icon

VITALS screen icon

SERVICE screen icon

MAIN screen icon

ATTACHMENTS screen icon

SECURITY screen icon

DISPLAY screen icon

LEFT SCROLL button

RIGHT SCROLL button

ENTER button

593 of 822 60-180-1 T870 Service Manual

CONTROL PANEL SETUP (CONT’D) The Deluxe Instrumentation Panel is easy to use.
Continue to set your own preferences for running /
Right Panel Setup (Deluxe Instrumentation Panel) monitoring your Bobcat loader.
(Cont’d)

More Examples

Clocks

Select …
DISPLAY screen icon
[1. CLOCKS]

SET TIME AND DATE

Select [1. TIME]
Use the keypad to enter date.
Press ENTER to continue.
Use the keypad to enter time.
Select AM / PM / 24hr.
Press ENTER to continue.

RESET JOB CLOCK

(Owner password required if Job Clock is locked.)
Select [2. JOB CLOCK]

Dealer Copy -- Not for Resale

Press [4] to cycle between lock and unlock.
Press [9] to reset.

SET ALARM
Select [3. ALARM CLOCK]
Select alarm 1, 2 or 3.
Press [1] to cycle between ON and OFF.
Press [2] and use the keypad to enter alarm time.
Select AM / PM / 24hr.
Press ENTER to continue.
Press [3] to cycle between ONCE, DAILY and
WEEKLY.
Selecting WEEKLY will prompt for a day selection
using number [4].
Press ENTER to continue.

Vitals (Monitor the engine, hydraulic / hydrostatic,

electrical functions when engine is running.)

Select …
VITALS screen icon
Press [6] to cycle between METRIC or ENGLISH (M /
E) readouts.

You can monitor real-time readouts of:

Engine Speed
Engine Oil Pressure
Engine Coolant Temperature
System Voltage
Hydraulic Charge Pressure
Hydraulic Oil Temperature

594 of 822 60-180-2 T870 Service Manual

PASSWORD SETUP (DELUXE INSTRUMENTATION Changing The Owner Password
PANEL)
Figure 60-190-1
Password Setup is available on machines with a Deluxe
Press a scroll button (Item
Instrumentation Panel. 1) repeatedly until the
Security screen icon
Password Description (Inset) is highlighted.

All new machines with a Deluxe Instrumentation Panel

arrive at Bobcat dealerships with the keypad in locked
1 1
mode. This means that a password must be used to start
the engine. Enter owner password and
press [ENTER].
For security purposes, your dealer may change the
password and also set it in the locked mode. Your dealer
will provide you with the password.

Master Password:
Select [1. USER
A permanent, randomly selected password set at the SETTINGS].
factory which cannot be changed. This password is
used for service by the Bobcat dealer if the owner
password is not known; or to change the owner
password.

Dealer Copy -- Not for Resale

Owner Password:
Select [1. OWNER].
Allows for full use of the loader and to setup the
Deluxe Instrumentation Panel. There is only one
owner password. It must be used to change the owner
or user passwords. Owner should change the
password as soon as possible for security of the
loader.
Select [2. CHANGE
User Password: PASSWORD].

Allows starting and operating the loader; cannot

change password or any of the other setup features.

For the procedures to change passwords (See Changing

The Owner Password on Page 60-190-1.) and (See
Enter new owner
Changing The User Passwords on Page 60-190-2.) password and press
[ENTER].

You will be prompted to

reenter the new owner
password.

Press [ENTER].

P-90399/NA3025/NA3016/NA3031/NA3033/NA3028/NA3015/NA3027

595 of 822 60-190-1 T870 Service Manual

PASSWORD SETUP (DELUXE INSTRUMENTATION Password Lockout Feature
PANEL) (CONT’D)
This feature allows the owner to unlock the password
Changing The User Passwords
feature so that a password does not need to be used
Figure 60-190-2 every time the engine is started.
Press a scroll button (Item
1) repeatedly until the Figure 60-190-3
Security screen icon Press a scroll button
(Inset) is highlighted. (Item 1) repeatedly until
the Security screen icon
(Inset) is highlighted.
1 1
Enter owner password and
press [ENTER]. 1 1
Enter owner password
and press [ENTER].

Select [1. USER

SETTINGS].

Select [2. MACHINE

Dealer Copy -- Not for Resale

LOCK].

Select user.

P-90399 / NA3025 / NA3016 / NA3031

NOTE: The procedure above can be followed to reset

Select [2. CHANGE the machine lock so that the machine requires
PASSWORD]. a password to start the engine.

Enter new user password

and press [ENTER].

Press [ENTER].

P-90399/NA3025/NA3016/NA3031/NA3033/NA3026/NA3010/NA3027

596 of 822 60-190-2 T870 Service Manual

PASSWORD SETUP (KEYLESS START PANEL) Password Lockout Feature

Password Description This feature allows the owner to unlock the password
feature so that a password does not need to be used
Master Password: every time the engine is started.

A permanent, randomly selected password set at the Press the RUN button to turn on the loaders electrical
factory which cannot be changed. This password is system.
used for service by the Bobcat dealer if the owner
password is not known; or to change the owner Enter the five digit owner password using the number
password. keys (1 through 0).

Owner Password: Figure 60-191-2

Allows for full use of the loader. It must be used to

change the owner password.

Changing The Owner Password

Press the RUN button to turn on the loaders electrical

system.

Enter the five digit owner password using the number

keys (1 through 0) if locked.

Dealer Copy -- Not for Resale

1 2
Figure 60-191-1

P-90805

Press the unlock key (Item 2) [Figure 60-191-2].

The left panel display screen will show [CODE].

Enter the five digit owner password using the number

keys (1 through 0). The unlock key green light will flash,
then become solid.
1 2
The loader can now be started without using a password.

P-90805 NOTE: Use the following procedure to reset the

machine lock so that the loader requires a
password to start the engine.
Press and hold the lock (Item 1) and unlock (Item 2)
[Figure 60-191-1] keys for two seconds. Press the RUN button to turn on the loaders electrical
system.
The lock key red light will flash and the left panel display
screen will show [ENTER]. Press the lock key (Item 1) [Figure 60-191-2].

Enter a new five digit password using the number keys (1 The lock key red light will flash and the left panel display
through 0). An asterisk will show in the left panel display screen will show [CODE].
screen for each key press.
Enter the five digit owner password using the number
The left panel display screen will show [AGAIN]. keys (1 through 0). The unlock key green light will flash,
then the lock key red light will become solid.
Enter the new five digit password again.
You must now enter the password every time to start the
The lock key red light will become solid. loader.

597 of 822 60-191-1 T870 Service Manual

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598 of 822 60-191-2 T870 Service Manual

MAINTENANCE CLOCK This message will remain for 10 seconds and will appear
for 10 seconds every time the machine is started until the
Description maintenance clock is reset.

The Maintenance Clock alerts the operator when the next Figure 60-200-3
service interval is due. EXAMPLE: The Maintenance
Clock can be set to a 500 hour interval as a reminder for
the next 500 hour planned maintenance.

Figure 60-200-1

1
1

3 NA3040

P-76461R
The Deluxe Instrumentation Panel, if equipped, will
display a bar (Item 1) [Figure 60-200-3] showing time
During machine operation, a two beep alarm will sound remaining until next service. This bar will turn red when
when there are less than 10 hours until the next planned service is past due. NEXT MAINTENANCE DUE will
maintenance. change to MAINTENANCE PAST DUE and display the

Dealer Copy -- Not for Resale

number of hours past due.
The remaining hours before maintenance is required will
appear in the data display (Item 1) for five seconds while Keys [4] and [9] can be used to adjust the service
the service icon (Item 3) and hourmeter icon (Item 2) interval when the owner is logged in [Figure 60-200-3].
[Figure 60-200-1] flash.
NOTE: Loaders equipped with a Standard Key Panel
NOTE: The display will show negative numbers after or Keyless Start Panel will not display the
counting down to zero. BobCARE PMSM message or NEXT
MAINTENANCE TYPE on the right panel.
The display will then revert back to the previous display
and will appear for five seconds every time the machine
is started until the maintenance clock is reset.

Figure 60-200-2

NA3034

The Deluxe Instrumentation Panel, if equipped, will

display a message (Item 1) [Figure 60-200-2] alerting
the operator to service the machine.

599 of 822 60-200-1 T870 Service Manual

MAINTENANCE CLOCK (CONT’D) Figure 60-200-6

Setup

Figure 60-200-4

P-76110
P-64243A

Select Install (Item 1) [Figure 60-200-6] to begin sending

The first analyzer screen has an added bar for the the dealer information to the controller.
Maintenance Clock. The clock will remain OFF until
activated. Click Continue (Item 1) [Figure 60-200-4] to Figure 60-200-7
view the next analyzer screen.

Dealer Copy -- Not for Resale

Figure 60-200-5

1
1
P-76113

3 Click SEND TO MACHINE (Item 1) [Figure 60-200-7] to

P-76110
send the dealer information to the machine controller.

Click Options (Item 1) and add your dealer name and NOTE: Verify that all correct option and kits are
phone number (Item 2). Click Save Options (Item 3) selected before clicking SEND TO MACHINE.
[Figure 60-200-5] the information is now stored.

600 of 822 60-200-2 T870 Service Manual

MAINTENANCE CLOCK (CONT’D) Figure 60-200-10

Setup (Cont’d)

Figure 60-200-8

P-76112
1
Click the right arrow (Item 1) [Figure 60-200-10] to scroll
P-76114 through the tabs.

Figure 60-200-11
A green COMPLETE (Item 1) [Figure 60-200-8]

Dealer Copy -- Not for Resale

message will be displayed when the dealer information
has been transferred to the machine controller. 1

Click Back (Item 2) [Figure 60-200-8] to return to the

Bobcat Service Analyzer screen.
3
Figure 60-200-9 4 2

P-76111

Click the Maintenance tab (Item 1) [Figure 60-200-11] to

view the maintenance clock screen.

Click ON / OFF (Item 2) to turn the maintenance clock on

or off [Figure 60-200-11].
P-76110
The default Interval (Item 3) is 250 hours, it can also be
changed by placing the cursor in the box and typing the
Select Warnings (Item 1) [Figure 60-200-9]. new interval. Click SET / RESET (Item 4) [Figure 60-
200-11] to reset and set the maintenance clock.

601 of 822 60-200-3 T870 Service Manual

MAINTENANCE CLOCK (CONT’D) Figure 60-200-14

Setup (Cont’d)

Figure 60-200-12

1
2

P-76110

Select Program / Update (Item 1) [Figure 60-200-14] to

P-76111 view the maintenance clock.

Figure 60-200-15
The current maintenance clock Length (Interval) and

Dealer Copy -- Not for Resale

Time Reset will be displayed (Item 1). This screen will 1
display the most recent 20 entries of history. Once an
entry is added, it cannot be changed. If an entry is made
and the interval is not correct, make another entry and
click SET / RESET (Item 2) [Figure 60-200-12].

NOTE: If the interval is set to 10 hours or less, the

maintenance clock will reset and log a reset
time but the wrench icon, hour interval and
service icon will NOT be removed from the left
display screen.
P-64244A
Figure 60-200-13

After the maintenance clock has been activated, the next

analyzer screen shows the hours remaining on current
maintenance interval (Item 1) [Figure 60-200-15]. If past
1 the interval, the number will reflect negative hours.

P-76111

Select Back (Item 1) [Figure 60-200-13] to return to the

main menu.

602 of 822 60-200-4 T870 Service Manual

MAINTENANCE CLOCK (CONT’D)

Reset

Figure 60-200-16

P-76455H

Press the information button (Item 2) until the display

screen (Item 1) [Figure 60-200-16] shows the
maintenance clock.

Press and hold the information button (Item 2) for seven

Dealer Copy -- Not for Resale

seconds until [RESET] (Inset) appears in the display
screen (Item 1) [Figure 60-200-16].

The maintenance clock can also be reset by clicking Set /

Reset (Item 4) [Figure 60-200-11] in service analyzer.

NOTE: If the interval is set to 10 hours or less, the

maintenance clock will reset and log a reset
time but the wrench icon, hour interval and
service icon will NOT be removed from the left
and right instrument panel display screens.

603 of 822 60-200-5 T870 Service Manual

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604 of 822 60-200-6 T870 Service Manual

BACK-UP ALARM SYSTEM Inspecting

Description Figure 60-210-1

The back-up alarm will sound when the operator moves

both steering handles or joystick(s) into the reverse
position. Slight movement of the controls into the reverse
position is required with hydrostatic transmissions, before
the back-up alarm will sound.

P-90644

Inspect for damaged or missing back-up alarm decal

(Item 1) [Figure 60-210-1]. Replace if required.

Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down. Start
the engine. Press the PRESS TO OPERATE LOADER

Dealer Copy -- Not for Resale

button. Disengage the parking brake.

Move both steering handles or joystick(s) into the reverse

position. The back-up alarm must sound when both
tracks are moving in reverse.

The back-up alarm is located on the inside of the rear

door.

Figure 60-210-2

2
P100048

Inspect the back-up alarm electrical connections (Item 1)

and wire harness (Item 2) [Figure 60-210-2] for tightness
and damage. Repair or replace any damaged
components.

605 of 822 60-210-1 T870 Service Manual

BACK-UP ALARM SYSTEM (CONT’D)

Troubleshooting (Joystick) WARNING

The following troubleshooting chart is provided for
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
NOTE: Joystick equipped machines do not have warnings and instructions in the manuals when
back-up alarm switches and cannot be making repairs, adjustments or servicing. Check for
adjusted. See your Bobcat dealer for service if correct function after adjustments, repairs or
your back-up alarm does not sound. service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807

PROBLEM CAUSE
Back-up alarm will not sound when the operator moves joystick(s) into the reverse 1, 2, 3, 4, 5, 6
position.
Back-up alarm sounds when joystick(s) in neutral / forward position. 4, 5

Dealer Copy -- Not for Resale

KEY TO CORRECT THE CAUSE
1. The ground connection is not making a good contact.
2. The alarm is damaged.
3. The alarm wires are disconnected.
4. Check the fuses.
5. The wiring is damaged.
6. The joystick controller is not working correctly.

606 of 822 60-210-2 T870 Service Manual

BACK-UP ALARM SYSTEM (CONT’D)

Alarm Removal And Installation

Stop the engine and open the rear door.

Figure 60-210-3

P100048

Disconnect the alarm connectors (Item 1) [Figure 60-

Dealer Copy -- Not for Resale

210-3] from the alarm.

Remove the two nuts (Item 2) [Figure 60-210-3].

Remove the alarm and bracket from the loader.

607 of 822 60-210-3 T870 Service Manual

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608 of 822 60-210-4 T870 Service Manual

FRONT HORN Front Horn Removal And Installation

Description Remove left side lower panel. (See Removing And

Installing on Page 50-150-1)
The front horn will sound when the operator presses the
front switch on the left lever. Figure 60-220-2

The front horn is located on the inside of the cab in the

front lower left corner.

Inspecting 1 2

Figure 60-220-1

P-93995

Disconnect the front horn wiring connector from the cab

Dealer Copy -- Not for Resale

harness (Item 1) [Figure 60-220-2].
P-93995
Remove the tie strap from the cab wire harness cable
mount (Item 2) [Figure 60-220-2].
Inspect for damaged or missing parts [Figure 60-220-1].
Replace if required. Figure 60-220-3

Depress the front button on the left lever and front horn
must sound.

P-93993

Remove the two bolts and nuts from the horn bracket to
cab (Item 1) [Figure 60-220-3].

Remove front horn from loader.

609 of 822 60-220-1 T870 Service Manual

FRONT HORN (CONT’D)

Troubleshooting WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807

PROBLEM CAUSE
Front horn will not sound when the operator presses the front horn button 1, 2, 3, 4, 5, 6, 7

KEY TO CORRECT THE CAUSE

1. The ground connection is not making a good contact.

Dealer Copy -- Not for Resale

2. The front horn switch is damaged.
3. The front horn is damaged.
4. The front horn or switch wires are disconnected.
5. Check the fuses.
6. The wiring is damaged.
7. The joystick controller is not working correctly. (SJC Equipped Machines)

610 of 822 60-220-2 T870 Service Manual

FRONT HORN (CONT’D)

Troubleshooting (Joystick) WARNING

The following troubleshooting chart is provided for
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807

PROBLEM CAUSE
Front horn will not sound when the operator presses the front horn button 1, 2, 3, 4, 5, 6

KEY TO CORRECT THE CAUSE

1. The ground connection is not making a good contact.

Dealer Copy -- Not for Resale

2. The front horn is damaged.
3. The front horn wires are disconnected.
4. Check the fuses.
5. The wiring is damaged.
6. The joystick controller is not working correctly.

611 of 822 60-220-3 T870 Service Manual

 Dealer Copy -- Not for Resale

612 of 822 60-220-4 T870 Service Manual

 ENGINE SERVICE

ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-5
Engine Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-7
Engine Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-14
Compression - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-15

ENGINE SPEED CONTROL (SCPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1
Cable Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-2

ENGINE SPEED CONTROL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-2

MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1

Dealer Copy -- Not for Resale

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Radiator Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Hydraulic Fan Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-4
Hydraulic Fan Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-5
Lower Fan Duct Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-6
Blower Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-6
Hydraulic Fan Motor Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . 70-50-7
Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-7
Hydraulic Fan Motor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-8
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-9
Water Pump Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-9
Thermostat Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-10
Thermostat - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-10

LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2
Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2
Oil Filter Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-4
Engine Oil Pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-5

613 of 822 70-01 T870 Service Manual

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Shutoff Solenoid - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Shutoff Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Injection Pump Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-2
Fuel Injection Pump Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-6
Governor Housing Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-8
Governor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-10
Fuel Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12
Fuel Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-14
Fuel Injection Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-17
Injection Pump - Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-20
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-24
Fuel Injector Nozzle Pressure - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-25
Nozzle Spraying Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-26
Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-26

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

Intake Air Heater - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Intake Air Heater Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-2
Valve Timing - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-4

Dealer Copy -- Not for Resale

Cylinder Head Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-5
Cylinder Head Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-7
Cylinder Head - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8
Valve Guide - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-9
Reconditioning The Valve And Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-80-11
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-13
Valve Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-14
Rocker Arm And Shaft - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-15
Push Rod Alignment - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-15

CRANKSHAFT AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

Piston And Connecting Rod Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Piston And Connecting Rod - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-3
Cylinder Bore - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-7
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-8
Crankshaft Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-8
Crankshaft And Bearings Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-9
Crankshaft And Bearings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-90-11
Crankshaft And Bearings - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-13

CAMSHAFT AND TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1

Timing Gearcase Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1
Timing Gears Backlash - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-2
Idler Gear And Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-100-2
Camshaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-3
Idler Gear And Shaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5

614 of 822 70-02 T870 Service Manual

TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-2

FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1

Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-2

EXHAUST GAS RECIRCULATION (EGR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-5

Dealer Copy -- Not for Resale

615 of 822 70-03 T870 Service Manual

 Dealer Copy -- Not for Resale

616 of 822 70-04 T870 Service Manual

ENGINE INFORMATION

Description

The T870 has a Kubota direct injected V3800-DI-T turbo

diesel engine with a displacement of 3,8 L (230 in3). The
engine is rated at an SAE Gross 74,0 kW (99.2 hp) and
has an open crankcase ventilation system [Figure 70-10-
1].

The engine has 4 cylinders and the rotation is counter-

clockwise (viewed from the flywheel side). It is equipped
with an air intake heater and mechanical timer with cold
start advance function for assisting in cold starts. Engine
block heaters are also available from Bobcat Parts.

To meet emission regulations it is also equipped with an

Exhaust Gas Recirculation (EGR) system to reduce
Nitrogen Oxide (NOx).

The engine serial number is stamped on the engine and

is located near the injection pump. The model number is
located on the valve cover. Use these numbers to obtain
the correct service parts.

Dealer Copy -- Not for Resale

The engine is liquid cooled with a propylene glycol /
water mixture in a radiator. Coolant flow is controlled by a
thermostat. The cooling fan is driven by a hydraulic
motor. The speed of the fan is determined by the engine
coolant temperature sensor and the hydraulic /
hydrostatic fluid temperature sensor.

Figure 70-10-1

P100153

617 of 822 70-10-1 T870 Service Manual

ENGINE INFORMATION (CONT’D)

Specifications

All dimensions are shown in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.

Valve Springs
Free Length (Intake and Exhaust) 35,1 - 35,6 (1.39 - 1.40)
Allowable Limit 34,6 (1.36)
Fitted Length (Intake and Exhaust) 31,5 (1.24)
Setting Load / Setting Length (Intake and Exhaust) 63,5 N/31,5 mm (14.3 lb/1.24 in)
Allowable Limit 45,9 N/31,5 mm (10.3 lb/1.24 in)
Tilt Allowable Limit (Intake and Exhaust) 1,0 (0.039)

Valve Timing
Intake Valve (Open) 14 degrees B.T.D.C.
(Close) 36 degrees A.B.D.C.
Exhaust Valve (Open) 45 degrees B.B.D.C.
(Close) 17 degrees A.T.D.C.

Rocker Arms

Dealer Copy -- Not for Resale

O.D. of Rocker Arm Shaft 15,973 - 15,984 (0.62886 - 0.62929)
I.D. of Rocker Arm Bushings 16,000 - 16,018 (0.62993 - 0.63062)
Oil Clearance Between Rocker Arm & Bushing 0,016 - 0,045 (0.00063 - 0.0017)
Allowable Limit 0,15 (0.0059)

Camshaft
Journal O.D. 45,934 - 45,950 (1.8085 - 1.8090)
Bearing I.D. 46,0 - 46,025 (1.8111 - 1.8120)
Oil Clearance 0,050 - 0,091 (0.002 - 0.0035)
Allowable Limit 0,15 (0.0059)
Alignment Allowable Limit 0,01 (0.0004)
Cam Lobe Height (Intake) 37,63 (1.481)
Allowable Limit (Intake) 37,13 (1.462)
Cam Lobe Height (Exhaust) 38,96 (1.534)
Allowable Limit (Exhaust) 38,46 (1.514)
Side Clearance Allowable Limit 0,30 (0.012)

Tappet
Oil Clearance Between Tappet & Guide 0,020 - 0,062 (0.0079 - 0.0024)
Allowable Limit 0,07 (0.003)
Tappet O.D. 23,959 -23,980 (0.94321 - 0.94409)
Tappet Guide I.D. 24,000 - 24,021 (0.94489 - 0.94570)

618 of 822 70-10-2 T870 Service Manual

ENGINE INFORMATION (CONT’D)

Specifications (Cont’d)

All dimensions are shown in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.

Cylinder Bore
Cylinder Bore I.D. 100,000 - 100,022 (3.93701 - 3.93787)
Allowable Limit 100,150 (3.9429)
Oversized Cylinder Bore I.D. 100,500 - 100,522 (3.95670 - 3.95755)
Allowable Limit 100,650 (3.96260)

Piston Rings
Ring Gap (Top Ring) 0,30 - 0,45 (0.012 - 0.017)
Allowable Limit 1,25 (0.0492)
Ring Gap (2nd Ring) 0,30 - 0,45 (0.012 - 0.017)
Allowable Limit 1,25 (0.0492)
Ring Gap (Oil Ring) 0,25 - 0,45 (0.0099 - 0.017)
Allowable Limit 1,25 (0.0492)
Side Clearance of Ring Groove:
Top Ring 0,05 - 0,09 (0.002 - 0.003)

Dealer Copy -- Not for Resale

Allowable Limit 0,15 (0.0059)
Second Ring 0,0930 - 0,120 (0.00367 - 0.00472)
Allowable Limit 0,0079 (0.20)
Oil Ring 0,020 - 0,060 (0.00079 - 0.0023)
Allowable Limit 0,15 (0.0059)

Pistons
Piston Pin Bore 30,000 - 30,013 (1.1811 - 1.1816)
Allowable Limit 30,05 (0.183)

Connecting Rod
Piston Pin O.D. 30,006 - 30,011 (1.1814- 1.1815)
Small End Bushing I.D. 30,031 - 30,046 (1.1824 - 1.1829)
Oil Clearance Between Piston Pin & Small End Bushing 0,020 - 0,040 (0.00079 - 0.0015)
Allowable Limit 0,15 (0.0059)
Connecting Rod Alignment Allowable Limit 0,05 (0.002)

Oil Pump
Oil Pressure Rated rpm 200,0 - 386,1 kPa (199 - 386 bar) (29 - 56 psi)
Allowable Limit 144,8 kPa (147 bar) (21 psi)
Idle Speed Allowable Limit 48,3 kPa (49 bar) (7 psi)
Clearance Between Inner Rotor & Outer Rotor 0,040 - 0,16 (0.0016 - 0.0062)
Clearance Between Outer Rotor & Pump Body 0,100 - 0,184 (0.00394 - 0.00724)
End Clearance Between Inner Rotor & Cover 0,025 - 0,075 (0.00099 - 0.0029)

619 of 822 70-10-3 T870 Service Manual

ENGINE INFORMATION (CONT’D)

Specifications (Cont’d)

All dimensions are shown in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.

Crankshaft
Crankshaft Alignment Limit Permitted 0,02 (0.0008)
Oil Clearance Between Journal & Bearing 0,00071 - 0,0024 (0.018 - 0.062)
Limit Permitted 0,020 (0.0079)
Journal O.D. 74,977 - 74,990 (2.9519 - 2.9523)
Oil Clearance Between Crank Pin & Bearing 0,018 - 0,051 (0.00071 - 0.0020)
Limit Permitted 0,20 (0.0079)
Crank Pin O.D. 52,977 - 52,990 (2.0857 - 2.0862)
Crank Pin I.D. (Blue) 56,010 - 56,020 (2.2052 - 2.2055)
Crank Pin I.D. (No Color) 56,000 - 56,010 (2.2048 - 2.2051)
Crankshaft Side Clearance 0,018 - 0,051 (0.00071 - 0.0020)
Limit Permitted 0,20 (0.0079)

Timing Gear
Timing Gear Backlash:

Dealer Copy -- Not for Resale

Crank Gear - Idle Gear 0,0490 - 0,193 (0.00193 - 0.00759)
Allowable Limit 0,22 (0.0087)
Idle Gear - Cam Gear 0,0490 - 0,189 (0.00193 - 0.0074)
Allowable Limit 0,22 (0.0087)
Idle Gear - Injection Pump Gear 0,0300 - 0,165 (0.00119 - 0.00649)
Allowable Limit 0,22 (0.0087)
Oil Clearance Between Idle Gear Shaft & Idle Gear Bushing: 0,050 - 0,091 (0.0020 - 0.0035)
Idle Gear Bushing I.D. 45,025 - 45,050 (1.7727 - 1.7736)
Idle Gear Shaft O.D. 44,959 - 44,975 (1.7701 - 1.7706)
Idle Gear Side Clearance 0,15 - 0,30 (0.0059 - 0.011)
Allowable Limit 0,90 (0.04)

Thermostat
Valve Opening Temperature 74,5 - 78,5°C (166.1 - 173°F)
Valve Fully Open 90°C (194°F)

620 of 822 70-10-4 T870 Service Manual

ENGINE INFORMATION (CONT’D)

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.

Torque Values

Thread Size Material

(Dia. x Pitch)
Head Mark 4 Head Mark 7 Head Mark 10
M5 x 0.8 4 - 5 N•m
(3 - 4 ft-lb)
M6 x 1.0 8 - 9 N•m 8 - 12 N•m
(6 - 7 ft-lb) (6 - 9 ft-lb)
M8 x 1.25 8 - 12 N•m 15 - 22 N•m 24 - 34 N•m
(6 - 9 ft-lb) (11 - 16 ft-lb) (18 - 25 ft-lb)
M10 x 1.25 18 - 24 N•m 30 - 41 N•m 49 - 68 N•m
(13 - 18 ft-lb) (22 - 30 ft-lb) (36 - 50 ft-lb)
M12 x 1.25 30 - 41 N•m 54 - 73 N•m 94 - 118 N•m
(22 - 30 ft-lb) (40 - 54 ft-lb) (69 - 87 ft-lb)
M14 x 1.5 49 - 68 N•m 79 - 108 N•m 157 - 186 N•m

Dealer Copy -- Not for Resale

(36 - 50 ft-lb) (58 - 80 ft-lb) (116 - 137 ft-lb)

Troubleshooting

The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.

PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 54
Engine will not start. 2, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 19, 27, 28, 29
Difficult to start. 1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29,54
No power for engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is misfiring. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue / white exhaust. 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration. 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure warning. 4, 33, 36
Overheating. 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure. 22, 27, 29, 30, 40, 49
Poor compression. 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Start and stop. 9, 10, 11

621 of 822 70-10-5 T870 Service Manual

ENGINE INFORMATION (CONT’D)

Troubleshooting (Cont’d)

KEY TO CORRECT THE CAUSE

1. Alternator belt is loose or damaged. 28. Worn valve and seats.
2. Bad electrical connections. 29. Broken or worn piston rings.
3. Faulty starter motor. 30. Worn valve stems or guides.
4. Incorrect grade of oil. 31. Worn or damaged bearings.
5. Low cranking speed. 32. Not enough oil in the crankcase.
6. Fuel tank empty. 33. Switch / sensor is defective.
7. Faulty stop control operation. 34. Oil pump worn.
8. Plugged fuel line. 35. Relief valve is sticking open.
9. Plugged fuel filter. 36. Relief valve is sticking closed.
10. Restriction in the air cleaner. 37. Broken relief valve spring.
11. Air in the fuel system. 38. Faulty suction pipe.
12. Faulty fuel injection pump. 39. Plugged oil filter.
13. Faulty fuel injectors. 40. Piston seizure.
14. Broken injection pump drive. 41. Incorrect piston height.
15. Incorrect injection pump timing. 42. Faulty engine mounting.
16. Incorrect valve timing. 43. Incorrect flywheel alignment.

Dealer Copy -- Not for Resale

17. Poor compression. 44. Faulty thermostat.
18. Plugged fuel tank vent. 45. Restriction in water jacket.
19. Incorrect grade of fuel. 46. Loose alternator belt.
20. Exhaust pipe restriction. 47. Plugged radiator.
21. Cylinder head gasket leaking. 48. Faulty water pump.
22. Overheating. 49. Plugged breather pipe.
23. Cold running. 50. Damaged valve stem deflectors.
24. Incorrect tappet adjustment. 51. Coolant level to low.
25. Sticking valves. 52. Plugged oil pump pipe strainer.
26. Incorrect fuel lines. 53. Broken valve spring.
27. Worn cylinder bores. 54. Damaged Battery

622 of 822 70-10-6 T870 Service Manual

ENGINE INFORMATION (CONT’D) Remove the muffler. (See Removal And Installation on
Page 70-30-1.)
Engine Removal And Installation
Figure 70-10-2

DANGER

2 1

P-90328

AVOID DEATH
• Disconnecting or loosening any hydraulic P100305

tubeline, hose, fitting, component or a part failure

can cause lift arms to drop. (SJC Equipped)
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm Loosen the engine speed control cable adjustment nuts
support. Replace if damaged.

Dealer Copy -- Not for Resale

(Item 1) and remove the engine speed control cable from
D-1009-0409 the ball pivot (Item 2). [Figure 70-10-2].

Figure 70-10-3

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

2 1
Put jackstands under the rear corners of the loader.

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.) P100304

Raise the operator cab. (See Raising on Page 10-30-1.)

(SCPA Equipped)
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) Loosen the engine speed control cable adjustment nuts
(Item 1) and remove the engine speed control cable from
Remove the battery from the loader. (See Removal And the ball pivot (Item 2) [Figure 70-10-3].
Installation on Page 60-20-1.)

Drain the engine coolant from the cooling system. (See

Removing And Replacing Coolant on Page 10-90-3.)

NOTE: If compressor is being removed for engine

removal it is not necessary to remove the A/C
hoses. Remove the mounting bolts and belt
and reposition the compressor.

623 of 822 70-10-7 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-6

Engine Removal And Installation (Cont'd)

Figure 70-10-4
1

5 4
1
2
3

2
P100312

Disconnect fuel shut-off solenoid connector (Item 1)

P100307 [Figure 70-10-6].

Remove the bolts for the wiring harness hold down

Disconnect engine ground cable (Item I) and chassis clamps (Item 2) [Figure 70-10-6].
ground cable (Item 2) [Figure 70-10-4].

Dealer Copy -- Not for Resale

Disconnect the engine starter positive cable (Item 3) Figure 70-10-7
[Figure 70-10-4].

Disconnect the starter wiring harness connector (Item 1

4)[Figure 70-10-4].

Disconnect flywheel rpm sensor (Item 5) [Figure 70-10-

4].

Figure 70-10-5

P100311

2
Disconnect fuel line (Item 1) [Figure 70-10-7] for lift
pump and plug.
2 3
Throttle cable bracket removed for photo clarity.

P100309

Disconnect engine oil pressure sender connector (Item 1)

[Figure 70-10-5].

Disconnect the alternator wiring (Item 2) [Figure 70-10-

5].

Disconnect the engine ground cable (Item 3) [Figure 70-

10-5].

624 of 822 70-10-8 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-10

Engine Removal And Installation (Cont'd)

2
Figure 70-10-8

P100323

Remove the two bolts (Item 1), coolant tube assembly

P100310 (Item 2) and hose (Item 3) [Figure 70-10-10].

Figure 70-10-11
Disconnect and plug fuel return line (Item 1) [Figure 70-
10-8].

Dealer Copy -- Not for Resale

Figure 70-10-9 1

P100314

Disconnect coolant return line (Item 1) [Figure 70-10-11].

P100313
Disconnect radiator hose (Item 2) [Figure 70-10-11] from
the thermostat housing.
Disconnect radiator hose (Item 1) [Figure 70-10-9].

625 of 822 70-10-9 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-14

Engine Removal And Installation (Cont'd) 1

2
Figure 70-10-12

2
1 1

P100319
2

Mark and disconnect the drive motor hoses (Item 1)

P100315 [Figure 70-10-14].

Disconnect the tandem pump case drain hose (Item 2)

Disconnect coolant temperature connector (Item 1) [Figure 70-10-14].
[Figure 70-10-12] from thermostat housing.

Dealer Copy -- Not for Resale

Cap or plug all hoses and fittings.
Disconnect Heater hoses (Item 2) [Figure 70-10-12] (If
equipped). NOTE: The hydraulic fittings (Item 1) [Figure 70-10-
17] on the hydrostatic pump must be
Figure 70-10-13 tightened to 128 - 138 N•m (94 - 102 ft-lb)
torque.

Figure 70-10-15

2
1 1
1

P100729

Remove and cap fan inlet hose (Item 1) [Figure 70-10-

P-85907
13].

Remove and cap fan outlet hose (Item 2) [Figure 70-10- Disconnect tandem pump suction hoses (Item 1) [Figure
13]. 70-10-15].

Disconnect the charge pump inlet hose (Item 2) [Figure

70-10-15].

Cap or plug all hoses and fittings.

626 of 822 70-10-10 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-18

Engine Removal And Installation (Cont'd)

Figure 70-10-16

1 P100321

Remove the mounting bolt (Item 1) [Figure 70-10-18]

P-85908 from the left engine mount.

Installation: Tighten the mounting bolt (Item 1) [Figure

Disconnect hydraulic control valve inlet hose (Item 1) 70-10-18] to 122 - 135 N•m (90 - 100 ft-lb) torque.
[Figure 70-10-16].

Dealer Copy -- Not for Resale

Figure 70-10-19
Cap or plug all hoses and fittings.

Figure 70-10-17

P100322

P100320 Remove the mounting bolt (Item 1) [Figure 70-10-19]

from the right engine mount.

Remove rear engine mounting bolt (Item 1) [Figure 70- Installation: Tighten the mounting bolt to 122 - 135 N•m
10-17]. (90 - 100 ft-lb) torque.

Installation: Tighten the mounting bolt to 122 - 135 N•m

(90 - 100 ft-lb) torque.

627 of 822 70-10-11 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-22

Engine Removal And Installation (Cont'd)

1
Figure 70-10-20

P100302

Install the engine removal attachments (MEL1653-2)

(Item 1) and (MEL1686) (Item 2) [Figure 70-10-22] on
the engine.

Figure 70-10-23

Dealer Copy -- Not for Resale

1

P-76872

Use the engine removal tool (MEL 1653-1) [Figure 70-

10-20] and the attachments (MEL 1653-2), (MEL1686)
P100303
[Figure 70-10-22] and (MEL1711) [Figure 70-10-21] to
aid in the removal and installation of the engine.
Install the engine removal attachment (MEL1686) (Item
Figure 70-10-21 1) [Figure 70-10-23] on the right hand side of the engine
in place of the coolant tube assembly.

Tighten all the bolts and nuts that hold the engine
removal attachment onto the engine.

P100332

628 of 822 70-10-12 T870 Service Manual

ENGINE INFORMATION (CONT’D)

Engine Removal And Installation (Cont'd)

Figure 70-10-24

1 3
2

P100300

Install the engine removal attachment (Item 1) on the left

hand muffler support bracket (Item 2), exhaust manifold

Dealer Copy -- Not for Resale

(Item 3) and engine removal bracket (Item 4) [Figure 70-
10-24].

Installation: Use 9,525 x 38,1mm (0.375 x 1.5 in) bolts

and nuts grade 5 minimum.

Figure 70-10-25

P100324

Install the engine removal tool (Item 1) into the

attachment (Item 2) and insert the pin (Item 3) [Figure
70-10-25].

Install the chain hoist on the eyelet [Figure 70-10-25] of

the removal tool.

Remove the engine / hydrostatic pump assembly from

the loader.

629 of 822 70-10-13 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-27

Engine Mount Replacement Washer

Engine
Figure 70-10-26 Mounting
Bracket

7 Engine
1
Mount

2
Snubbing Spacer
3 Washer
4
Loader
Frame P-90300
8
5
Install the new engine mount as shown in the cut away
P-85989 side view [Figure 70-10-28].

Tighten the mounting bolts to 122 - 135 N•m (90 - 100 ft-
Use the following procedure to install new rear engine lb) torque.
mount:

Dealer Copy -- Not for Resale

Figure 70-10-28
Remove the existing mount from the engine. Refer to
engine removal and installation for engine mount 1
locations. 4

Replace all three engine mounts one rear and two sides.
5 2
Use the parts shown to install the new engine mounts
[Figure 70-10-26]: 6 3
Hex Nut - (Item 1) 7

Washer - (Item 2)

Cup Washer - (Item 3)

P-85990A
Engine Mount - (Item 4)

Tube Spacer - (Item 5) Use the parts shown to install the new side engine
mounts [Figure 70-10-26].
Engine Mount - (Item 6)
Mounting Bolt - (Item 1)
Cup Washer - (Item 7)
Cup Washer - (Item 2)
Mounting Bolt - (Item 8)
Engine Mount - (Item 3)

Tube Spacer - (Item 4)

Engine Mount - (Item 5)

Cup Washer - (Item 6)

Retaining Nut - (Item 7)

630 of 822 70-10-14 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-31

Engine Mount Replacement (Cont’d)

1
Figure 70-10-29

Washer
Engine
Mounting
Bracket

Engine
Mount

Snubbing P100685
Washer
Spacer
Loader Figure 70-10-32
Frame P-85987

Install the new engine mount as shown in the cut away

side view [Figure 70-10-28]. 1

Dealer Copy -- Not for Resale

Tighten the mounting bolts to 122 - 135 N•m (90 - 100 ft-
lb) torque. 2
Compression - Checking

Figure 70-10-30

1
P100352

Attach a push button starter switch (MEL1712) (Item 1)

[Figure 70-10-31] to the starter terminal S (Item 1) and
the positive battery cable (Item 2) [Figure 70-10-32].
Engage the starter 7 - 10 seconds until a maximum
compression reading is obtained.

Repeat this procedure multiple times per cylinder until a

average compression reading is recorded.

If the measurement is below the allowable limit, apply a

P-37196 small amount of oil to the cylinder wall through the nozzle
hole and measure the compression pressure again.

After warming up the engine, stop the engine and remove If the compression pressure increase after applying oil.
check the cylinder wall and piston rings.
the muffler, high pressure pipes, cylinder head cover,
overflow pipe, all nozzle holders and all nozzle gaskets. If the compression pressure is still less than the allowable
limit, check the top clearance, valve and cylinder head.
NOTE: Disconnect the fuel shutoff solenoid wiring
NOTE: Check the compression pressure with the
harness. specified valve clearance.

Install a compression tester and nozzle adaptor Always use a fully charged battery for
performing this test.
(MEL1614) for diesel engines into the nozzle holder hole
(Item 1) [Figure 70-10-30]. Variances in cylinder compression values
should be under 10%.

631 of 822 70-10-15 T870 Service Manual

ENGINE INFORMATION (CONT’D)

Compression - Checking (Cont’d)

Compression Factory 3475 kPa / 250 rpm

pressure spec. (34,749 bar / 250 rpm)
(504 psi / 250 rpm)
Allowable 2558 kPa / 250 rpm
limit (25,579 bar / 250 rpm)
(371 psi / 250 rpm)

Tightening Nozzle holder 18 - 20 N•m

Torque clamp nut (13 - 15 ft-lb)
Overflow pipe 9,8 - 11,2 N•m
assembly retain- (7.24 - 8.31 ft-lb)
ing bolt
Cylinder head 6,9 - 11,2 N•m
cover bolt (5.1 - 8.31 ft-lb)
Injection pipe 23 - 36 N•m
retaining nut (17 - 26 ft-lb)

Dealer Copy -- Not for Resale

632 of 822 70-10-16 T870 Service Manual

ENGINE SPEED CONTROL (SCPA) Disassembly And Assembly

Removal And Installation Figure 70-20-3

Figure 70-20-1

1 2

P-85791

P-85789
Remove the nut (Item 1) and remove the two conical
washers (Item 2) [Figure 70-20-3].
Remove the two mounting bolts (Item 1) [Figure 70-20-
1]. Remove the handle (Item 3) [Figure 70-20-3].

Dealer Copy -- Not for Resale

Figure 70-20-2 Installation: Install the two conical washers with the
concave surfaces facing each other (Item 2) [Figure 70-
20-3].

Installation: Tighten the nut (Item 1) [Figure 70-20-3]

until the speed control lever moves backward and
forward at a comfortable tension.
2 1
3
Figure 70-20-4

P-85790

The speed control cable (Item 1) is connected to the

speed control handle (Item 2) by a ball and socket end
[Figure 70-20-2].

Disconnect the speed control cable (Item 1) from the

speed control handle (Item 2) [Figure 70-20-2].
P-85792

Loosen the jam nut (Item 3) [Figure 70-20-2] from the

speed control cable. Inspect and replaced any damaged parts [Figure 70-20-
4].
Remove the cable from the speed control handle.

633 of 822 70-20-1 T870 Service Manual

ENGINE SPEED CONTROL (SCPA) (CONT’D) Figure 70-20-7

Cable Removal And Installation

2
Raise the lift arms and install an approved lift arm support 1
device. (See Installing on Page 10-20-1.)

Remove the speed control lever. (See Removal And

Installation on Page 70-20-1.)

Raise the operator cab. (See Raising on Page 10-30-1.)

3
Figure 70-20-5

P100304

1 The speed control cable is connected to the linkage by a

ball and socket end [Figure 70-20-7].

Loosen the jam nut (Item 1) [Figure 70-20-7] from the

speed control cable.

Dealer Copy -- Not for Resale

Disconnect the speed control cable (Item 2) from the
linkage (Item 3) by rolling the cable away from the engine
[Figure 70-20-7].
P100326
Remove the speed control cable.

Remove the tie strap (Item 1) [Figure 70-20-5].

Figure 70-20-6

P100325

Remove the four bolts (Item 1) [Figure 70-20-6] from the

clamps that secure the cable.

634 of 822 70-20-2 T870 Service Manual

ENGINE SPEED CONTROL (SJC) Figure 70-21-3

Removal And Installation

Raise the operator cab. (See Raising on Page 10-30-1.)

1
Figure 70-21-1
2 1

1
P-90735

Remove the four bolts (Item 1) and washer (Item 2)

[Figure 70-21-3].

P-90733 Lay the assembly down.

Figure 70-21-4

Dealer Copy -- Not for Resale

Remove the two mounting nuts (Item 1) [Figure 70-21-1]
from the right side foot rest.

Remove the foot rest from the loader.

1
Figure 70-21-2
2

1 P100359

2
Loosen the engine speed control cable u-bolt nuts (Item
1) and remove the engine speed control cables from the
ball pivots (Item 2) [Figure 70-21-4].
P-90734
Remove panel assembly from the loader.

Loosen the clamping bolt (Item 1) and remove the engine

speed control foot pedal (Item 2) [Figure 70-21-2].

Installation: Install the engine speed foot pedal (Item 2)

but do not tighten the clamping bolt. Set the hand throttle
to high idle then place the foot pedal to high idle and
tighten the clamping bolt (Item 1) [Figure 70-21-2].

635 of 822 70-21-1 T870 Service Manual

ENGINE SPEED CONTROL (SJC) (CONT'D) Figure 70-21-7

Disassembly And Assembly

4
Figure 70-21-5

2 1

2
5
3
P100381

1
Remove the nuts (Item 1) and pivot bolts (Item 2) from
P100382 the engine speed control hand bracket assembly (Item 3)
[Figure 70-21-7].

Remove the spring (Item 1) from the engine speed Remove the engine speed control hand throttle cam lever
control foot pedal pivot assembly (Item 2) and the engine (Item 4) and engine throttle cable lever Item 5) [Figure

Dealer Copy -- Not for Resale

speed control hand throttle bracket (Item 3) [Figure 70- 70-21-7].
21-5]
Figure 70-21-8
Figure 70-21-6

P100380
P-90755

The pivot assemblies shown disassembled [Figure 70-

Remove the two bolts (Item 1) [Figure 70-21-6] from the 21-8].
engine speed control hand assembly.
NOTE: No lubrication is necessary or recommended
on the engine speed control.

636 of 822 70-21-2 T870 Service Manual

ENGINE SPEED CONTROL (SJC) (CONT'D) Figure 70-21-11

Disassembly And Assembly (Cont’d)

Figure 70-21-9

P100375

The engine speed control foot pedal pivot assembly roller

P-90736 bearing [Figure 70-21-11] shown disassembled.

Remove the snap ring (Item 1) [Figure 70-21-9] from the

engine speed control foot pedal pivot.

Dealer Copy -- Not for Resale

Figure 70-21-10

P100376

The engine speed control foot pedal pivot assembly

shown disassembled, [Figure 70-21-10] replace worn
parts as needed.

NOTE: No lubrication is necessary or recommended

on the engine speed control.

637 of 822 70-21-3 T870 Service Manual

 Dealer Copy -- Not for Resale

638 of 822 70-21-4 T870 Service Manual

MUFFLER

Removal And Installation

Open the rear door and remove the rear grille and side Figure 70-30-3
panels. (See Removing on Page 50-60-1.)

Figure 70-30-1

1 1
2

1 1

P100405

P100403
Remove the muffler mounting bolts (Item 1) [Figure 70-
30-3] from the left side mounting bracket.

Dealer Copy -- Not for Resale

Remove the bolts (Item 1) from the engine cover (Item 2) Figure 70-30-4
[Figure 70-30-1] and remove engine cover.

Figure 70-30-2

1 1

1
1

P100406

P100404
Remove the muffler mounting bolts (Item 1) [Figure 70-
30-4] from the exhaust manifold.

Remove the muffler mounting bolt (Item 1) [Figure 70- Remove the muffler from the loader.
30-2] from right side mounting bracket.
Reverse procedure for installation.

639 of 822 70-30-1 T870 Service Manual

 Dealer Copy -- Not for Resale

640 of 822 70-30-2 T870 Service Manual

AIR CLEANER

Housing Removal And Installation

Remove the rear grille from the loader. (See Removing

on Page 50-60-1.)

Figure 70-40-1

P100229

Dealer Copy -- Not for Resale

Remove the top two mounting bolts (Item 1) [Figure 70-
40-1] from the air cleaner assembly.

Loosen the hose clamp (Item 2) and disconnect the hose

(Item 3) [Figure 70-40-1] from the air cleaner.

Disconnect the wire connector (Item 4) [Figure 70-40-1]

from the air cleaner sender.

Disconnect the scavenger hose (Item 5) [Figure 70-40-

1].

Remove the air cleaner from the loader.

Reverse procedure for installation.

641 of 822 70-40-1 T870 Service Manual

 Dealer Copy -- Not for Resale

642 of 822 70-40-2 T870 Service Manual

ENGINE COOLING SYSTEM Figure 70-50-2

Radiator Removal And Installation

Stop the engine and open the rear door.

Remove the rear grille and side panels. (See Removing

1
on Page 50-60-1.)

Remove the oil cooler. (See Removal And Installation on

Page 20-90-1.)

WARNING
P100366

AVOID BURNS
Do not remove radiator cap when the engine is hot. Attach a hose to the coolant drain petcock (Item 1)
You can be seriously burned. [Figure 70-50-2] located to the left of the oil filter
W-2070-1203
assembly. Open the petcock and drain the coolant into a
container. Close the petcock and remove the hose.
Figure 70-50-1
Figure 70-50-3

Dealer Copy -- Not for Resale

1

P-90574
P100370

Loosen the radiator cap (Item 1) from the pressurized

expansion tank [Figure 70-50-3]. Disconnect and plug radiator air bleed hose (Item 1)
[Figure 70-50-3].

643 of 822 70-50-1 T870 Service Manual

ENGINE COOLING SYSTEM (CONT'D) Figure 70-50-6

Radiator Removal And Installation (Cont'd)

Figure 70-50-4

1
2 1

P100367

Disconnect the radiator hose (Item 1) and remove the

P100369 radiator hold down bolt (Item 2) [Figure 70-50-6].

Figure 70-50-7
Disconnect the pressurized expansion tank fill hose (Item
1) and radiator hold down bolt (Item 2) [Figure 70-50-2].

Dealer Copy -- Not for Resale

Figure 70-50-5
1

2
1

P100368P-
85952

Remove radiator hold down bolt (Item 1) [Figure 70-50-

P100365 7].

Disconnect the coolant air bleed hose (Item 1) and the

radiator hose (Item 2) [Figure 70-50-5].

644 of 822 70-50-2 T870 Service Manual

ENGINE COOLING SYSTEM (CONT'D)

Radiator Removal And Installation (Cont'd)

Figure 70-50-8

P-85954

Remove radiator hold down bolt (Item 1) [Figure 70-50-

8].

Dealer Copy -- Not for Resale

Remove the radiator (Item 2) [Figure 70-50-8].

Lift the radiator up and remove it from the loader.

NOTE: Coolant recovery tank removed for photo

clarity

645 of 822 70-50-3 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D)

Hydraulic Fan Description

The proportioning valve meters the flow through the fan

motor. The proportioning valve receives signals from the
controller which gathers information from both the engine
and hydraulic temperature sensors.

The hydraulic fan is used to cool the engine and

hydraulic / hydrostatic systems. The hydraulic fan
consists of a fan and hydraulic motor that is controlled by
a proportioning valve.

NOTE: The proportioning valve is factory set and can

not be adjusted accurately in the field due to
the adjustment being tamper proof.

The fan speed is determined by the engine coolant

temperature and the hydraulic fluid temperature.
Depending on these temperatures the fan speed (rpm)
can range from 0 - 4000 rpm.

The hydraulic fan speed at cold engine startup will range

Dealer Copy -- Not for Resale

from 0 to 500 rpm until the engine coolant and the
hydraulic fluid reach normal operating temperatures.

During normal operating temperatures the fan speed may

range from approximately 1900 - 3500 rpm.

646 of 822 70-50-4 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Installation: Install coil mounting nut with the
counterbored space (Item 4) [Figure 70-50-10] facing
Hydraulic Fan Disassembly And Assembly towards the coil and tighten securely by hand.

Figure 70-50-9 Installation: Tighten coil valve stem (Item 3) [Figure 70-
50-10] to 28 - 34 N•m (21 - 25 ft-lb) torque.

Figure 70-50-11
4

1
3

1
P-76714A 2

NOTE: The mounting gasket (Item 1), proportioning

P-76637
valve, and proportioning valve O-rings, back

Dealer Copy -- Not for Resale

up washer and coil mounting nut (Item 2) are
available from Bobcat Parts. The fan motor Inspect and replace O-rings (Item 1) and back up washer
(Item 3) [Figure 70-50-9] must be replaced as (Item 2) [Figure 70-50-11] if necessary.
an assembly if damaged.
Figure 70-50-12
Remove the filter cover (Item 4) [Figure 70-50-9].

Installation: Tighten filter cover (Item 4) [Figure 70-50-

9] to 47,5 - 54 N•m (35 - 40 ft-lb) torque.

Figure 70-50-10

1
4

3
P-76717

2
Remove the pressure transducer (Item 1) [Figure 70-50-
1 12].

P-76716A Installation: Tighten the pressure transducer (Item 1)

[Figure 70-50-12] to 10 - 10,9 N•m (7.4 - 8.1 ft-lb) torque.

Remove coil mounting nut (Item 1), the coil (Item 2), and
the coil valve stem (Item 3) [Figure 70-50-10].

NOTE: Coil mounting nut must be replaced each time

it is removed. Coil mounting nuts are
available from Bobcat Parts.

647 of 822 70-50-5 T870 Service Manual

ENGINE COOLING SYSTEM (CONT'D) Blower Housing Removal And Installation

Hydraulic Fan Disassembly And Assembly (Cont’d)

Figure 70-50-13
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Remove the air conditioning condenser if equipped. (See

1 Removal And Installation on Page 80-60-1.)

Remove the oil cooler. (See Removal And Installation on

Page 20-90-1.)
P-76726
Remove the radiator. (See Radiator Removal And
Installation on Page 70-50-1.)
Inspect and replace the O-ring (Item 1) [Figure 70-50-
13] if necessary.
Figure 70-50-15

Dealer Copy -- Not for Resale

Lower Fan Duct Removal And Installation

Figure 70-50-14

1 1

2
P-90063

1
Remove the four bolts (Item 1)[Figure 70-50-15].
P100275
Remove the blower housing (Item 2)[Figure 70-50-15]
from the loader.
Unhook the rubber straps (Item 1) [Figure 70-50-13] and
remove lower fan duct.
NOTE: Engine and hydraulic fan assembly removed
for photo clarity.

NOTE: Line up the bushings and bolts thru the fan

shroud

648 of 822 70-50-6 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Fan Removal And Installation

Hydraulic Fan Motor Assembly Removal And Figure 70-50-18

Installation

Figure 70-50-16
1

1 2

5
5

1
4 P-90313

3
P100729 Remove the four bolts (Item 1) and the cover plate (Item
2) [Figure 70-50-18].

Remove the fan motor inlet hose (Item 1) and outlet hose Installation: Tighten the bolts to 10,2 N•m (7.5 ft-lb)

Dealer Copy -- Not for Resale

(Item 2) [Figure 70-50-16]. torque.

Remove the fan case drain hose (Item 3) [Figure 70-50- Figure 70-50-19
16].

Remove the charge pressure hose (Item 4) [Figure 70-

50-16].

Cap and plug all hose’s.

1
Disconnect the electrical connectors (Item 5) [Figure 70-
50-16].

Figure 70-50-17

P-90065

1
Remove the nut (Item 1) [Figure 70-50-19] and washer
1 from the motor shaft.

Installation: Tighten the nut to 61 - 75 N•m (45 - 55 ft-lb)

torque.
2

P100729

Remove the four bolts (Item 1) [Figure 70-50-17].

Remove fan assembly (Item 2) [Figure 70-50-17].

649 of 822 70-50-7 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 70-50-22

Hydraulic Fan Motor Removal And Installation

Figure 70-50-20

2 2

P-90062

Use the following procedure to remove the fan hub from

P-90069 the fan motor shaft:

Install a bushing (Item 1) [Figure 70-50-22] in the hub to

Remove and discard the two nuts and cotter pins (Item 1) protect the fan motor shaft and threads during removal.
[Figure 70-50-20].

Dealer Copy -- Not for Resale

Use two bolts to position a puller (Item 2) on the bushing
Remove the two washers (Item 2) [Figure 70-50-20]. (Item 1) as shown [Figure 70-50-22].

Installation: Tighten the nuts to 10,2 N•m (7.5 ft-lb) NOTE: If a puller is not available one can be made if
torque. needed to remove the hub from the shaft.

Figure 70-50-21 Tighten the bolts and strike the puller with a hammer to
loosen the hub from the motor shaft.

P-90076

Remove and discard the two bolts (Item 1) [Figure 70-

50-21] then remove motor.

Installation: Tighten the bolts to 10,2 N•m (7.5 ft-lb)

torque.

NOTE: Always install new bolts, nuts, cotter pins,

and rubber gasket when installing the fan
motor.

650 of 822 70-50-8 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Water Pump Disassembly And Assembly

Water Pump Removal And Installation Figure 70-50-25

Drain the fluid from the radiator. (See Removing And

Replacing Coolant on Page 10-90-3.) 2
Figure 70-50-23 1

1 3

B-22926A

Remove the water pump assembly.

P100371 NOTE: The seal (Item 1) is not a replacement part,

order water pump assembly. The gasket (Item

Dealer Copy -- Not for Resale

2) is available from Bobcat parts [Figure 70-
Remove the alternator belt (Item 1) [Figure 70-50-23]. 50-25].

Remove the four bolts (Item 2) from the water pump

pulley (Item 3) [Figure 70-50-23].

Remove the water pump pulley (Item 3) [Figure 70-50-

23]

Remove the six water pump bolts (Item 4) [Figure 70-50-

23].

Figure 70-50-24

3EEABAC1P120A

Remove the water pump (Item 1) [Figure 70-50-24] from

the gearcase.

When mounting the water pump, use a new gasket (Item

2) [Figure 70-50-24].

651 of 822 70-50-9 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Thermostat - Checking

Thermostat Housing Removal And Installation Figure 70-50-28

Figure 70-50-26

2
1

3
4

P-37172

P100372
Push down the thermostat valve and insert a string
between the valve and the valve seat.
Figure 70-50-27
Place the thermostat and a thermometer in a container

Dealer Copy -- Not for Resale

with water and gradually heat the water [Figure 70-50-
28].
5 Hold the string to suspend the thermostat in the water.
When the water temperature rises, the thermostat valve
will open, allowing it to fall down from the string.

Continue heating the water and read the temperature

when the valve has risen by about 8 mm (0.315 in).
6 If the measurement is not acceptable, replace the
thermostat.

P-37152 Thermostat’s valve Factory 74,5 - 78,5°C

opening tempera- spec. (166.1 - 173.3°F)
ture
Remove the thermostat cover mounting bolts (Item 1),
and remove the thermostat cover (Item 2) [Figure 70-50- Temperature at Factory 90°C
26]. which thermostat spec. 194°F
completely opens
Remove the thermostat assembly (Item 3) [Figure 70-
50-26].

Apply a liquid gasket only at the thermostat cover side of

the gasket (Item 4) [Figure 70-50-26].

Attach the thermostat (Item 5) with its hole (Item 6) facing

toward the air suction side [Figure 70-50-27].

652 of 822 70-50-10 T870 Service Manual

LUBRICATION SYSTEM Figure 70-60-3

Oil Pan Removal And Installation

Remove the engine / hydrostatic pump package from the

loader. (See Engine Removal And Installation on Page
70-10-7.)

Figure 70-60-1

P-37127

Remove the oil strainer mounting bolts and remove the

oil strainer (Item 2) [Figure 70-60-3].

Install the oil strainer, using care not to damage the O-

ring.
P-37125

Dealer Copy -- Not for Resale

Apply liquid gasket to the oil pan (Item 3) [Figure 70-60-
2].
Remove the oil pan mounting bolts and remove the oil
pan (Item 1) [Figure 70-60-1]. Confirm that the liquid gasket coating surface is free of
water, dust and oil in order to maintain sealing effect.
Figure 70-60-2
Carefully apply the adhesive evenly.

NOTE: When mounting the adhesive-applied parts,

take care to fit them to the mating parts.

Assemble the adhesive-applied parts within

ten minutes.

To avoid uneven tightening, tighten mounting

bolts in diagonal order from the center.

P-37126

653 of 822 70-60-1 T870 Service Manual

LUBRICATION SYSTEM (CONT’D) Oil Pump Inspection

Oil Pump Removal And Installation Figure 70-60-5

Remove the timing gearcase cover. (See Timing

Gearcase Cover Removal And Installation on Page 70-
100-1.)

Figure 70-60-4

P-37220
1

Measure the clearance between lobes of the inner rotor

and the outer rotor with a feeler gauge [Figure 70-60-5].

P-100076 If the clearance exceeds the factory specifications,

Dealer Copy -- Not for Resale

replace the oil pump rotor assembly.

Remove the oil pump cover (Item 1) [Figure 70-60-4]. Clearance Factory spec. 0,040 - 0,16 mm
between (0.0016 - 0.0062 in)
inner rotor Allowable 0,03 mm (0.01 in)
and outer Limit
rotor

654 of 822 70-60-2 T870 Service Manual

LUBRICATION SYSTEM (CONT’D) Figure 70-60-7

Oil Pump Inspection (Cont’d)

Figure 70-60-6

P-100077

Put a strip of plastigage onto the rotor face with grease

P-37218 [Figure 70-60-7].

Install the cover and tighten the screws with the specified
Measure the clearance between the outer rotor and the torque.
pump body with a feeler gauge [Figure 70-60-6].

Dealer Copy -- Not for Resale

Remove the cover carefully, and measure the amount of
If the clearance exceeds the factory specifications, the flattening with the scale and record the clearance.
replace the oil pump rotor assembly.
If the clearance exceeds the allowable limit, replace oil
Clearance Factory 0,100 - 0,184 mm pump rotor assembly and the cover.
between outer spec. (0.00394 - 0.00724 in)
rotor and Allowable 0,3 mm (0.01 in) Clearance Factory spec. 0,025 - 0,075 mm
pump body limit between (0.00099 - 0.0029 in)
rotor and Allowable 0,225 mm
cover limit (0.00886 in)

Tightening Oil pump cover 7,9 - 9,3 N•m

torque screw (5.8 - 6.8 ft-lb)

655 of 822 70-60-3 T870 Service Manual

LUBRICATION SYSTEM (CONT’D) Oil Filter Cooler Removal And Installation

Oil Pump Inspection (Cont’d) Figure 70-60-9

Relief Valve 1

Figure 70-60-8

4 P100079

1
1 Remove the water pipe (Item 1) [Figure 70-60-9].
P100078
Remove the oil filter cartridge (Item 2) [Figure 70-60-9].

Dealer Copy -- Not for Resale

Remove the bolt (Item 1) [Figure 70-60-8]. Figure 70-60-10

Remove the relief valve (Item 2), the spring (Item 3) and
the packing (Item 4) [Figure 70-60-8].

Tightening Relief valve 69 - 78 N•m

torque (51 - 57 ft-lb)

P100080

Remove the oil cooler joint bolt (Item 1) [Figure 70-60-

10] and [Figure 70-60-11].

Installation: Tighten the oil cooler joint bolt to 40 - 44

N•m (29 - 32 ft-lb)

656 of 822 70-60-4 T870 Service Manual

LUBRICATION SYSTEM (CONT’D) Figure 70-60-13

Oil Filter Cooler Removal And Installation (Cont’d)

Figure 70-60-11

1 P-76921

Install a pressure gauge [Figure 70-60-13].

P100081
Start the engine. After warming up, measure the oil
pressure of both idling and rated speeds.
Remove the oil cooler (Item 1) [Figure 70-60-11].
If the oil pressure is less than the allowable limit, check

Dealer Copy -- Not for Resale

Engine Oil Pressure - Testing the following:

Figure 70-60-12 Engine oil insufficient

Oil pump defective
Oil strainer clogged
Oil filter cartridge
Oil gallery clogged
Excessive oil clearance of bearing
Foreign matter in the relief valve

1 At idle speed Allowable limit 48,3 kPa

(0,48 bar)
(7 psi)

At rated Factory spec. 200,0 - 386,1 kPa

speed (1,99 - 3,86 bar)
(29 - 56 psi)
P100082
Allowable limit 144,8 kPa
(1,447 bar) (21 psi)
Remove the oil switch (Item 1) [Figure 70-60-12].

657 of 822 70-60-5 T870 Service Manual

 Dealer Copy -- Not for Resale

658 of 822 70-60-6 T870 Service Manual

FUEL SYSTEM Fuel Shutoff Solenoid Removal And Installation

Fuel Shutoff Solenoid - Checking Figure 70-70-3

Figure 70-70-1
3

1
P-76053

1 P-76053
Stop the engine and open the rear door.

Stop the engine and open the rear door. The fuel shutoff solenoid connector is located between
the fuel filter and the oil filter.

Dealer Copy -- Not for Resale

The fuel shutoff solenoid connector is located between
the fuel filter and the oil filter. Disconnect the fuel shutoff solenoid connector (Item 1)
[Figure 70-70-3].
Disconnect the fuel shutoff solenoid connector (Item 1)
[Figure 70-70-1]. Remove the two mounting bolts (Item 2) [Figure 70-70-
3] from the fuel stop solenoid.
Use an ohmmeter to check the fuel shutoff solenoid.
Remove the solenoid from the injection pump assembly
Figure 70-70-2 (Item 3) [Figure 70-70-3].

P100126

The reading between electrical connector terminal C and

terminal A must be approximately 24.5 ohm [Figure 70-
70-2].

The reading between electrical connector terminal C and

terminal B must be approximately 0.33 ohm.

659 of 822 70-70-1 T870 Service Manual

FUEL SYSTEM (CONT’D) Figure 70-70-5

Fuel Injection Pump Assembly Removal

Set the number four cylinder to Top Dead Center (T.D.C.)

compression stroke.

Figure 70-70-4

P100155

Timer Gear Puller (MEL1657)

Application: Use this puller for removing the timer gear

Dealer Copy -- Not for Resale

from the governor shaft.
P100154

Timer 0 rad (0°) Restoring Jig (MEL1656)

Application: Use this for restoring 0 rad (0°) in the timer

gear.

660 of 822 70-70-2 T870 Service Manual

FUEL SYSTEM (CONT’D) Figure 70-70-8

Fuel Injection Pump Assembly Removal (Cont’d)

Figure 70-70-6

2
1

1
3

P-76996

With the number four piston at T.D.C. compression stroke

P-76933 place a mark on the timer gear and the idler gear where
the teeth engage (Item 1) [Figure 70-70-8].

Remove the lubrication tubeline (Item 1), the timer gear Pin the flywheel so that the engine does not turn.
cover mounting bolts (Item 2) and the timer gear cover

Dealer Copy -- Not for Resale

(Item 3) [Figure 70-70-6]. Figure 70-70-9

Figure 70-70-7

1 P-37513
1
P-76934
Remove the two flange bolts (Item 1) [Figure 70-70-9]
from the injection pump assembly.
Install the 0 rad (0°) Restoring Jig (MEL1656) (Item 1) on
to the timer gear (Item 2) [Figure 70-70-7].

661 of 822 70-70-3 T870 Service Manual

FUEL SYSTEM (CONT’D) Figure 70-70-12

Fuel Injection Pump Assembly Removal (Cont’d)

Figure 70-70-10 2

1 3

P-76936

Remove the timer gear nut and washer (Item 1) from the
P-37555 timer gear (Item 2) [Figure 70-70-12].

Install the timer gear puller (Item 4) onto the timer gear
Install two fuel camshaft lock bolts (Item 1 and 2) [Figure (Item 2) [Figure 70-70-12].
70-70-10] and [Figure 70-70-11] that are M8 X P1.25 X

Dealer Copy -- Not for Resale

L30 mm. Installation: Install the washer with the concave surface
(Item 3) [Figure 70-70-12] towards the timer gear.
Figure 70-70-11
Figure 70-70-13

2
1

P-37532
P-76937

Tighten the lower fuel camshaft lock bolt (Item 1) [Figure

70-70-11] until it comes into contact with the fuel Remove the timer gear (Item 1) [Figure 70-70-13].
camshaft.
NOTE: Timer Gear is not serviceable. If timer gear is
Tighten the upper fuel camshaft lock bolt (Item 2) [Figure damaged the entire assembly must be
70-70-11] until it comes into contact with the fuel replaced.
camshaft.

NOTE: Do not over tighten the lock bolts when in

contact with the camshaft.

662 of 822 70-70-4 T870 Service Manual

FUEL SYSTEM (CONT’D) Figure 70-70-16

Fuel Injection Pump Assembly Removal (Cont’d) 1

Figure 70-70-14

P-37540

Remove the two mounting bolts (Item 1) [Figure 70-70-

P-76938 16] and move the fuel filter, to allow clearance for the
injection pump assembly to be removed.

Remove the timer gear assembly (Item 1) [Figure 70-70- Figure 70-70-17
14].

Dealer Copy -- Not for Resale

Figure 70-70-15 1

1
1

P-37539

P-76945 Remove the three injection pump assembly mounting

flange nuts (Item 1) [Figure 70-70-17]. (Two on the front
side and one on the back side of the injection pump
Disconnect the lubrication oil tubeline (Item 1) [Figure assembly.)
70-70-15].

663 of 822 70-70-5 T870 Service Manual

FUEL SYSTEM (CONT’D) Fuel Injection Pump Assembly Installation

Fuel Injection Pump Assembly Removal (Cont’d) Set the number four cylinder to T.D.C. compression
stroke.
Figure 70-70-18
Figure 70-70-20
1
1
2
1
1
3
2

1
4 3
5

6
P100182

P-76939

Remove the three injection pump assembly support bolts

(Items 1) and the bracket (Item 2) [Figure 70-70-18]. Install the timer gear into the engine (Item 1) [Figure 70-

Dealer Copy -- Not for Resale

70-20].
Figure 70-70-19
NOTE: Align the marks on the timer gear to the idler
gear (Item 2) [Figure 70-70-20].

Install the 0 rad (0°) restoring jig (MEL1656) (Item 3)

[Figure 70-70-20]) onto the timer gear.

Install the injection pump assembly into the engine (Item

4) [Figure 70-70-20].
1
NOTE: Align the key (Item 5) in the keyway of the
timer gear.

Install the timer gear nut and washer (Item 6) [Figure 70-
70-20] and tighten to 74 - 83 N•m (55 - 61 ft-lb) torque.
P-76081

Remove the injection pump assembly from the engine

(Item 1) [Figure 70-70-19].

664 of 822 70-70-6 T870 Service Manual

FUEL SYSTEM (CONT’D) Figure 70-70-23

Fuel Injection Pump Assembly Installation (Cont’d)

Figure 70-70-21 3

1
3

P-76940

Install the two flange bolts (Item 1) [Figure 70-70-23] and

P-37539 tighten to 24 - 28 N•m (17 - 20 ft-lb) torque.

Move the injection pump assembly clockwise (viewed

Install the three mounting flange nuts (Item 1) [Figure from gearcase side), align the injection timing marks
70-70-21] and finger tighten (Two on the front side and (Item 2) [Figure 70-70-23] on the injection pump

Dealer Copy -- Not for Resale

one on the back side of the injection pump assembly.) assembly and on the engine gearcase.

Figure 70-70-22 Tighten the injection pump assembly mounting flange

nuts (Item 3) [Figure 70-70-23] (two on the front side and
one on the back side of the injection pump assembly) to
18 - 20 N•m (13 - 15 ft-lb) torque.

Figure 70-70-24

1
2 1

1 1

P-37532

Remove the two fuel camshaft lock bolts (Item 1) [Figure

70-70-22].
P-76944

Install the three injection pump assembly support bolts

(Items 1) and the bracket (Item 2) [Figure 70-70-24].

Tighten the injection pump assembly support bolts (Item

1) [Figure 70-70-24] to 18 - 20 N•m (13 - 15 ft-lb) torque.

665 of 822 70-70-7 T870 Service Manual

FUEL SYSTEM (CONT’D) Governor Housing Disassembly And Assembly

Fuel Injection Pump Assembly Installation (Cont’d) Figure 70-70-27

Figure 70-70-25

P-76945

P100105

Connect the lubrication oil tubeline (Item 1) [Figure 70-

70-25] and torque to 15,7 - 19,6 N•m (11.6 - 15.4 ft-lb). Jig for Governor Connecting Rod

Dealer Copy -- Not for Resale

Figure 70-70-26 Application: Use MEL1637 (Item 1) [Figure 70-70-27] for
connecting the governor connecting rod to the rack pin of
the fuel injection pump assembly.
2

3
1

P-76933

Install the gear cover (Item 1), the gear cover mounting
bolts (Item 2) and lubrication tubeline (Item 3) [Figure
70-70-26].

Tighten the mounting bolts (Item 2) [Figure 70-70-26] to

24 - 28 N•m (17 - 20 ft-lb) torque.

666 of 822 70-70-8 T870 Service Manual

FUEL SYSTEM (CONT’D) NOTE: (See Fuel Injection Pump Removal on Page
70-70-14.) for proper alignment of the
Governor Housing Disassembly And Assembly governor connecting rod procedure. The
(Cont’d) procedure will require a special tool part
number MEL1637.
Figure 70-70-28
Figure 70-70-30
2

1
3

P100084

P100086

Remove the injection pump assembly from the engine.

Dealer Copy -- Not for Resale

Slide off the governor connecting rod (Item 1) [Figure 70-
Remove the governor lubrication tubeline (Item 1) 70-29] and [Figure 70-70-30] from the rack pin of
[Figure 70-70-28]. injection pump.

Remove the stop solenoid (Item 2) [Figure 70-70-28]. For convenience, temporarily hook the start spring on the
rack pin hole of the governor connecting rod.
Detach the sight cover (Item 3) [Figure 70-70-28] from
the injection pump assembly Remove the governor housing mounting bolts.

Figure 70-70-29 Figure 70-70-31

4
1
2

P100085 P100087

Unhook the start spring (Item 1) from the rack pin (Item 2) Detach the governor housing assembly (Item 1) [Figure
[Figure 70-70-29] of injection pump assembly. 70-70-31] from the injection pump assembly.

Remove the nut (Item 3) [Figure 70-70-29]. NOTE: The injection pump assembly is lubricated
with engine oil. Oil will leak when the
NOTE: Be careful not to drop the nut inside. governor housing is removed from the
injection pump assembly.

667 of 822 70-70-9 T870 Service Manual

FUEL SYSTEM (CONT’D)

Governor Disassembly And Assembly Tightening 9,8 - 11,3 N•m

GOVERNOR
torque HOUSING (7.23 - 8.32 ft-lb)
Figure 70-70-32
MOUNTING BOLT
1
Fork Lever
4
Figure 70-70-33

1 2

P100088

When reassembling the governor housing assembly

(Item 1) [Figure 70-70-32], lightly oil each inside part.

Dealer Copy -- Not for Resale

P100089
NOTE: Use care when installing the start spring (Item
2) to the governor connecting rod (Item 3)
[Figure 70-70-32] Pull out the governor fork lever shaft (Item 1) with a bolt
(Dia. 4 mm, Pitch: 0,7 mm, Length: more than 25 mm)
After sliding on the governor connecting rod onto the rack (Item 2) [Figure 70-70-33].
pin, tighten the governor connecting rod nut to the
specified torque using the jig (MEL1637) to keep the Figure 70-70-34
governor connecting rod horizontal.

Installation: Tighten the governor connecting rod nut to 1 2

2,8 - 4,0 N•m (2.1 - 2.9 ft-lb) torque.

NOTE: The tool (JIG) part number is MEL1637 for the

governor connecting rod alignment tool (Item
1) [Figure 70-70-57].

After tightening the nut, hook the start spring on the rack
pin.

Check the movement of the control rack of the injection

pump assembly by the stop lever.
P100090
NOTE: When installing the governor housing
assembly (Item 1) to the injection pump
assembly, be careful not to damage the O-ring Unhook the governor spring (Item 1) at the governor fork
(Item 4) [Figure 70-70-32]. lever (Item 2) [Figure 70-70-34] side.

NOTE: When linking the governor connecting rod to

the rack pin of injection pump, use the jig tor
keep the governor connecting rod horizontal.
Otherwise the injection pump control rack
may become stuck, and will cause difficult
starting of the engine or hunting of idle.

668 of 822 70-70-10 T870 Service Manual

FUEL SYSTEM (CONT’D) Governor Fork

Governor Disassembly And Assembly (Cont’d) Figure 70-70-37

Figure 70-70-35
3

1 2 3

P100093

P100091
Figure 70-70-38

Remove the governor fork lever assembly from the 3 1

governor housing (Item 1) [Figure 70-70-35].

Dealer Copy -- Not for Resale

After reassembling the governor housing assembly,
check the movement of the governor fork lever (Item 2),
the speed control lever, stop lever, governor spring (Item
3) and governor fork lever shaft (item 4) [Figure 70-70-
35].
2
NOTE: When reassembling lightly oil the parts.

NOTE: Be careful not to deform the start spring.

Speed Lever P100094

Figure 70-70-36
Remove the governor lever assembly (Item 1) [Figure
1 2 70-70-38] from the governor housing.

Remove the start spring (Item 2) and the stop spring

(Item 3) [Figure 70-70-37] and [Figure 70-70-38].

P100092

Remove the speed control lever (Item 1) and the return

spring (Item 2) [Figure 70-70-36].

669 of 822 70-70-11 T870 Service Manual

FUEL SYSTEM (CONT’D) Fuel Camshaft Removal And Installation

Governor Disassembly And Assembly (Cont’d) Figure 70-70-40

Stop Lever

Figure 70-70-39 1

1 2

P100096

3
Separate the governor housing assembly from the
P100095 injection pump assembly.

Remove the fuel feed pump from the injection pump

Dealer Copy -- Not for Resale

Remove the stop lever (Item 1) and the return spring assembly.
(Item 2) [Figure 70-70-39].
Remove the governor sleeve (Item 1) [Figure 70-70-40].
Remove the stop lever shaft (Item 3) [Figure 70-70-39].
Figure 70-70-41

P100097

Remove the injection pump (Item 1) [Figure 70-70-41].

Remove the fuel camshaft lock bolts.

670 of 822 70-70-12 T870 Service Manual

FUEL SYSTEM (CONT’D) Figure 70-70-44

Fuel Camshaft Removal And Installation (Cont’d)

Figure 70-70-42 2
3
1

P100100

2 Pull out the fuel camshaft (Item 1) and bearings (Item 2)

P100098 [Figure 70-70-44] together.

After removing the bearing’s snap ring (Item 3) [Figure

Fix the fuel camshaft with a open end wrench (Item 1), 70-70-44], press out the bearings.
and remove the governor weight mounting nut and the

Dealer Copy -- Not for Resale

governor weight (Item 2) [Figure 70-70-42]. Press the bearings into the fuel camshaft.

NOTE: Do not use the fuel camshaft lock bolts, when Install the snap ring at the gear side’s bearing.
remove the governor weight mounting nut.
Otherwise, the lock bolts or injection pump Install the fuel camshaft and bearings to the injection
housing might get damaged. pump housing.

Figure 70-70-43 Install the fuel camshaft stopper and tighten the fuel
camshaft stopper mounting screws to 7,9 - 9,3 N•m (5.8 -
1 6.9 ft-lb) torque.

Attach the governor weight to the fuel camshaft and

tighten the governor weight mounting nut to 63 - 72 N•m
(47 - 53 ft-lb) torque.

P100099

Loosen the fuel camshaft stopper mounting screws and

remove the fuel camshaft stopper (Item 1) [Figure 70-70-
43].

671 of 822 70-70-13 T870 Service Manual

FUEL SYSTEM (CONT’D) Fuel Injection Pump Removal

Fuel Camshaft Removal And Installation (Cont’d) Figure 70-70-46

Figure 70-70-45 3

1
2

1
4 P-76056

P100212
NOTE: The injection pump must be removed as a
complete assembly. Do Not remove individual
Fix the fuel camshaft with lock bolts so the key way on pump barrels. If individual pump barrels are
the fuel camshaft (Item 1) [Figure 70-70-45] is facing to removed, the pump must be recalibrated in a

Dealer Copy -- Not for Resale

the four o’clock position. certified injection shop.

Install the injection pump assembly to the injection pump NOTE: The injection pump can be replaced with the
housing. engine crankshaft in any position.

Attach the O-ring and the cover and tighten the cover Disconnect and plug the fuel hose (Item 1) and fuel
mounting bolts. overflow hose (Item 2) [Figure 70-70-46].

Install the governor sleeve to the fuel camshaft. Disconnect the four injection lines (Item 3) [Figure 70-
70-46] at the injection pump.
Check the movement of the governor sleeve.
Remove the sight cover (Item 4) [Figure 70-70-46] from
NOTE: Be careful not to damage the O-ring. the injection pump assembly.

NOTE: Be careful the direction of the governor NOTE: Mount the check valve (Item 2) [Figure 70-70-
sleeve. 46] with the arrow pointing towards the fuel
tank.
NOTE: When reassembling lightly oil the parts.

672 of 822 70-70-14 T870 Service Manual

FUEL SYSTEM (CONT’D) Figure 70-70-49

Fuel Injection Pump Removal (Cont’d)

Figure 70-70-47 1

1 1

P-37524

Disconnect the starter spring hook (Item 1) [Figure 70-

P-76946 70-49].

NOTE: Be careful to not deform the starter spring.

Disconnect the four injection lines (Item 1) [Figure 70-
70-47] at the injection nozzle assemblies. Figure 70-70-50

Dealer Copy -- Not for Resale

Remove the injection lines from the loader.
1
Figure 70-70-48

2
P-37525

Remove the governor connecting rod nut (Item 1)

P-76053 [Figure 70-70-50].

NOTE: Be careful not to drop the governor

Disconnect the electrical connector (Item 1) from the fuel connecting rod nut.
stop solenoid. Then remove the two mounting bolts (Item
2) [Figure 70-70-48] from the fuel stop solenoid. Installation: Tighten the governor connecting rod nut to
2,8 - 4,0 N•m (2.1 - 2.9 ft-lb) torque.
Remove the solenoid (Item 3) [Figure 70-70-48] from the
injection pump.

673 of 822 70-70-15 T870 Service Manual

FUEL SYSTEM (CONT’D) Figure 70-70-53

Fuel Injection Pump Removal (Cont’d)

Figure 70-70-51 1

P-37527

With the injection pump mounting bolts and nuts loose,

P-37526 be sure the governor connecting rod (Item 1) [Figure 70-
70-53] clears the pin on the injection pump.

Disconnect the governor connecting rod (Item 1) [Figure Figure 70-70-54

70-70-51] from the injection pump.

Dealer Copy -- Not for Resale

Figure 70-70-52

1 1 2
1

1
2

P-37529

P-37528 Align the pin on the injection pump (Item 1) [Figure 70-
70-54] with the notch in the housing.

Remove the five injection pump mounting bolts (Item 1) Remove the injection pump from the injection pump
[Figure 70-70-52]. housing.

Remove the three injection pump mounting nuts (Item 2) NOTE: When taking out the injection pump, be
[Figure 70-70-52]. careful not to hit it against the governor
connecting rod.
Installation: Tighten the injection pump mounting bolts
to 24 - 28 N•m (17 - 20 ft-lb) torque. Tighten the injection
pump mounting nuts to 18 - 21 N•m (13 - 15 ft-lb) torque.

674 of 822 70-70-16 T870 Service Manual

FUEL SYSTEM (CONT’D) Figure 70-70-57

Fuel Injection Pump Installation

1
Figure 70-70-55

P100105

Figure 70-70-58
P100102

1
Install the injection pump (Item 1) [Figure 70-70-55] onto
the fuel injection pump assembly, and tighten the

Dealer Copy -- Not for Resale

mounting bolts and nuts.

Figure 70-70-56

P100106

Place the jig (Item 1) [Figure 70-70-57] and [Figure 70-

70-58] in the stop solenoid mounting hole of the injection
pump assembly.

NOTE: The tool (JIG) part number is MEL1637 for the

P100104 governor connecting rod alignment tool (Item
1) [Figure 70-70-57].

Hook the governor connecting rod (Item 2) [Figure 70-

70-56] to the rack pin of the injection pump assembly.

Installation: Tighten the governor connecting rod nut to

2,8 - 4,0 N•m (2.1 - 2.9 ft-lb) torque.

675 of 822 70-70-17 T870 Service Manual

FUEL SYSTEM (CONT’D) Figure 70-70-61

Fuel Injection Pump Installation (Cont’d)

1
Figure 70-70-59

2
1

P100109

Make sure the permanent magnet at the top of the jig

P100107 (Item 1) is attracted to the governor connecting rod (Item
2). To do this, turn the jig a little clockwise and
counterclockwise and look into the sight cover hole to
Figure 70-70-60 see if the governor connecting rod (Item 2) [Figure 70-
70-59] moves right and left accordingly [Figure 70-70-

Dealer Copy -- Not for Resale

60] and [Figure 70-70-61].

Figure 70-70-62

2 1

P100108

P100110

Slightly tighten the governor connecting rod nut (Item 1)

on the governor connecting rod (Item 2) [Figure 70-70-
62].

Holding down the jig (Item 3) by hand, tighten up the

governor connecting rod nut (Item 1) [Figure 70-70-62]
to 2,8 - 4,0 N•m (2.1 - 2.9 ft-lb) torque.

676 of 822 70-70-18 T870 Service Manual

FUEL SYSTEM (CONT’D) Figure 70-70-65

Fuel Injection Pump Installation (Cont’d)

Figure 70-70-63

2
P100113

Move the stop lever (Item 1) [Figure 70-70-64] and

P100111 visually check to see if the fuel injection pump connecting
rack comes smoothly back to the start position by the
counter force of the start spring. At the same time,
Hook the start spring (Item 1) [Figure 70-70-63] and visually check to see if there is no twist in the sliding point
[Figure 70-70-62] to the rack pin. (Item 2) [Figure 70-70-65] between the governor fork

Dealer Copy -- Not for Resale

lever and the governor connecting rod from the stop
Figure 70-70-64 solenoid mounting hole.

If the control rack fails to move back smoothly, remove

the start spring and the governor connecting rod nut, and
go through the above procedure starting with [Figure 70-
70-57].

Finally fit the sight cover and the stop solenoid back into
place.

P100112

677 of 822 70-70-19 T870 Service Manual

FUEL SYSTEM (CONT’D) Figure 70-70-68

Injection Pump - Timing

Figure 70-70-66

2
1

1
3

P-37538

Align the timing mark on the injection pump assembly

P-76933 (Item 1) [Figure 70-70-68] with the timing mark on the
gearcase housing.

Remove the lubrication tubeline (Item 1), the timer gear Figure 70-70-69
cover mounting bolts (Item 2) and the timer gear cover

Dealer Copy -- Not for Resale

(Item 3) [Figure 70-70-66].

Figure 70-70-67

2 1 1

2
P-76056

1
1 Disconnect the four injection lines (Item 1) [Figure 70-
P-76934 70-69] from the injection pump.

Install the 0 rad (0°) Restoring Jig (MEL1656) (Item 1) on

to the timer gear (Item 2) [Figure 70-70-67].

678 of 822 70-70-20 T870 Service Manual

FUEL SYSTEM (CONT'D) Figure 70-70-72

Injection Pump - Timing (Cont’d)

Figure 70-70-70 1

P-37543

Install a short plastic tube (Item 1) [Figure 70-70-72] in

P-76946 the number one cylinder port of the injection pump. The
tube should fit securely and point upward.

Disconnect the four injection lines (Item 1) [Figure 70- Figure 70-70-73
70-70] from the injection nozzle assemblies.

Dealer Copy -- Not for Resale

Remove the injector lines from the engine.

Figure 70-70-71
2
1
3

P100707
2

Disconnect the wiring connector (Item 1) [Figure 70-70-

73] from the engine speed control sensor.
1 P-76053
Remove the speed sensor (Item 2) [Figure 70-70-73]
from the engine.
Disconnect the electrical connector (Item 1) [Figure 70-
70-71] from the fuel shutoff solenoid.

Remove the two mount bolts (Item 2) [Figure 70-70-71]

from the fuel shutoff solenoid.

Remove the fuel shutoff solenoid from the engine (Item

3) [Figure 70-70-71].

679 of 822 70-70-21 T870 Service Manual

FUEL SYSTEM (CONT'D) Figure 70-70-76

Injection Pump - Timing (Cont’d)

Figure 70-70-74

P-37544

Check the location of the engine timing mark, by looking

P-37543 in the engine speed sensor hole on the engine flywheel
casting (Item 1) [Figure 70-70-76].

Turn the engine counterclockwise (viewed from flywheel Figure 70-70-77

end) until the fuel partially fills the plastic tube (Item 1)

Dealer Copy -- Not for Resale

[Figure 70-70-74].

Figure 70-70-75 2

P-37542B

The timing mark (Item 1) [Figure 70-70-77] should be

P-37543 located in the center of the engine speed sensor hole.

NOTE: The T.D.C. hole (Item 2) [Figure 70-70-77] in

After there is fuel rise seen in the plastic tube, rotate the the flywheel will not be visible in the speed
engine back (clockwise) at least 90°. sensor hole.

Slowly rotate the engine counterclockwise (viewed from If the timing mark is not located in the center of the hole,
flywheel end) and stop turning when the fuel begins to rotate the injection pump assembly until the injection
rise in the plastic tube (Item 1) [Figure 70-70-75]. timing is adjusted.

The injection timing is 0.128 rad (7°’s) before T.D.C.

680 of 822 70-70-22 T870 Service Manual

FUEL SYSTEM (CONT'D) Remove the 0 rad (0 °) Restoring Jig (MEL1656).

Injection Pump - Timing (Cont’d) Figure 70-70-80

Figure 70-70-78
2
1
2

3
1

P-76933

P-76073
Install the timer gear cover (Item 1), the gear cover
mounting bolts (Item 2) and lubrication tubeline (Item 3)
Make sure the injection pump assembly timing mark [Figure 70-70-80].
(Item 1) is aligned with the crankcase timing mark (Item

Dealer Copy -- Not for Resale

1) [Figure 70-70-78]. Tighten the mounting bolts (Item 2) [Figure 70-70-80] to
24 - 28 N•m (17 - 20 ft-lb) torque.
NOTE: If the injection timing is not within the
specification, rotate the injection pump Install flywheel rpm sensor. (See Adjusting on Page 60-
assembly to adjust the injection timing. 170-1.)

Figure 70-70-79

1
1

P-76079

Loosen the four fuel injection pump housing nuts (Item 1)

[Figure 70-70-79].

Rotate the injection pump (Item 2) [Figure 70-70-79]

counterclockwise (viewed from the flywheel side) to delay
the injection timing.

Rotate the injection pump (Item 2) [Figure 70-70-79]

clockwise (viewed from the flywheel side) to advance the
injection timing.

681 of 822 70-70-23 T870 Service Manual

FUEL SYSTEM (CONT'D) Figure 70-70-83

Fuel Injector Removal And Installation

Figure 70-70-81
1

P-37579

Remove the nut (Item 1) [Figure 70-70-83] from the

1 injection nozzle assembly hold down clamp.
P100114

Installation: Tighten the injection nozzle assembly hold

Remove the injection nozzle oil seal (Item 1) from the down clamp nut to 18 - 21 N•m (13 - 15 ft-lb) torque.
cylinder head cover (Item 2) [Figure 70-70-81].

Dealer Copy -- Not for Resale

Figure 70-70-84
Installation: Install new injection nozzle oil seals.

Remove the cylinder head cover (Item 2) [Figure 70-70-

81].

Installation: Tighten the valve cover bolts to 6,9 - 11,2

N•m (5.1 - 8.31 ft-lb) torque.
1
Figure 70-70-82

P-37580
1
1 Remove the nozzle hold down clamps (Item 1) [Figure
70-70-84] from the injection nozzle assembly.

P-37578

Remove the five over flow tubeline retaining bolts (Item

1) [Figure 70-70-82].

Installation: Tighten the retaining bolts to 9,8 - 11,2 N•m

(7.24 - 8.31 ft-lb) torque.

682 of 822 70-70-24 T870 Service Manual

FUEL SYSTEM (CONT'D) Fuel Injector Nozzle Pressure - Checking

Fuel Injector Removal And Installation (Cont’d) Figure 70-70-87

Figure 70-70-85

P100115

P-37581
Install the injection nozzle assembly onto the nozzle
tester (OEM1064).
Remove the injection nozzle assembly (Item 1) [Figure
70-70-85] from the engine. Slowly move the tester handle to measure the pressure

Dealer Copy -- Not for Resale

at which fuel begins jetting out from the nozzle.
Figure 70-70-86
If the measurement is not within the factory
specifications, repair or replace the injection nozzle
assembly.
1
NOTE: injection nozzle assembly gasket must be
replaced when the injection nozzle assembly
2 is removed for checking.

Injection Factory 1st 18636,5 -

pressure specification stage 19608,7 kPa
(186,4 - 196,1 bar)
(2703 - 2844 psi)

P-37583

Check the injection nozzle assembly O-rings (Item 1) and

nozzle washer (Item 2) [Figure 70-70-86].

Always replace the injection nozzle assembly O-rings

and washer before installation.

683 of 822 70-70-25 T870 Service Manual

FUEL SYSTEM (CONT'D) Valve Seat Tightness

Nozzle Spraying Condition Figure 70-70-89

Figure 70-70-88

Correct Incorrect

P100117

P100116
Install the injection nozzle assembly on to a nozzle tester
(OEM1064).
Install the injection nozzle assembly onto a nozzle tester
(OEM1064), and check the nozzle spraying condition. Raise the fuel pressure, and keep at 16,7 MPa (166,7

Dealer Copy -- Not for Resale

bar) (2418 psi) for 10 seconds.
If the spraying condition is defective, repair or replace the
injection nozzle assembly. If any fuel leak is found, repair or replace the injection
nozzle assembly.

Valve seat Factory No fuel leak at

tightness specific 16,7 MPa
ation. (166,7 bar) (2418 psi)

684 of 822 70-70-26 T870 Service Manual

CYLINDER HEAD Intake Air Heater Removal And Installation

Intake Air Heater - Testing Figure 70-80-3

Figure 70-80-1

1 2 2

P100124

P100124
Disconnect the electrical wire from the intake heater lead
(Item 1) [Figure 70-80-3]
Disconnect the electrical wire (Item 1) [Figure 70-80-1]
from the air intake heater. Remove the four mount bolts (Item 2) [Figure 70-80-3]

Dealer Copy -- Not for Resale

from the intake air heater housing.
Figure 70-80-2
Installation: Tighten the bolts to 24 - 28 N•m (17 - 20 ft-
lb) torque.

Figure 70-80-4

1
2

P100127

Measure the resistance between + terminal (Item 1) and

intake air heater body (Item 2) [Figure 70-80-2].
P-37560

If the resistance is open, the intake air heater is faulty.

NOTE: When installing the intake air heater in the
Intake air Factory spec. Approx. 0.3 ohm housing, install the intake air heater so the
heater resis- (At cold occasion) heater lines (Item 1) [Figure 70-80-4] are
tance vertical, to prevent a short-circuit in the
system.

685 of 822 70-80-1 T870 Service Manual

CYLINDER HEAD (CONT’D) Figure 70-80-7

Valve Clearance Adjustment

NOTE: Valve clearance must be checked and

adjusted when engine is cold. 1

Figure 70-80-5

P-37579

Remove the nut (Item 1) [Figure 70-80-7] from the

1 injector nozzle holder clamp.

Installation: Tighten the injector nozzle holder clamp nut

P-76089 to 18 - 20 N•m (13 - 15 ft-lb) torque.

Dealer Copy -- Not for Resale

Figure 70-80-8
Remove the high pressure pipes (Item 1) and the valve
cover (Item 2) [Figure 70-80-5].

Installation: Tighten the injection pipe retaining nut to 23

- 36 N•m (17 - 26 ft-lb) torque.

Installation: Tighten the cylinder head cover screw to

1
6,9 - 11,2 N•m (5.1 - 8.31 ft-lb) torque.

Figure 70-80-6

P-37580

1
Remove the nozzle holder clamps (Item 1) [Figure 70-
1 80-8] from the injector nozzle.

P-37578

Remove the five over flow pipe retaining bolts (Item 1)

[Figure 70-80-6].

Installation: Tighten the retaining bolts to 9,8 - 11,2 N•m

(7.24 - 8.31 ft-lb) torque.

686 of 822 70-80-2 T870 Service Manual

CYLINDER HEAD (CONT’D) the adjusting screw to the specified value, then tighten
the lock nut.
Valve Clearance Adjustment (Cont’d)
Valve clear- Factory spec. 0,23 - 0,27 mm
Figure 70-80-9 ance (0.0091 - 0.010 in)

NOTE: After adjusting, tighten the lock nut (Item 2)

[Figure 70-80-10] securely.

Adjustment IN. EX.

Location of piston cylinder
1 When No. 1 piston is 1st * *
at compression top 2nd *
dead center
2 3rd *
4th
When No. 1 piston is 1st
at overlap position 2nd *
P-37194

3rd *
Set number one piston to top dead center on the 4th * *
compression stroke.

Dealer Copy -- Not for Resale

Before adjusting the valve clearance, adjust the bridge to
set the height of valves.

Loosen the lock nut (Item 2) and turn the adjusting screw
(Item 1) [Figure 70-80-9] to adjust the bridge.

Apply pressure with your finger to the rocker arm and

screw in the adjusting screw slowly until you feel the
screw touch the top of valve stem, then tighten the lock
nut.

Figure 70-80-10

P-37195

Loosen the lock nut (Item 1) of adjusting screw (Item 2)

[Figure 70-80-10] (push rod side) and insert the feeler
gauge between the rocker arm and the bridge head. Set

687 of 822 70-80-3 T870 Service Manual

CYLINDER HEAD (CONT’D) Figure 70-80-13

Valve Timing - Checking

NOTE: Engine removed for photo clarity

Figure 70-80-11

1 2

P100143

Rotate the engine, until the timing mark on the injection

pump fuel cam gear (Item 1) is meshed with the idler
gear (Item 2) [Figure 70-80-13].
P100145
Look for a timing mark on the idler gear (Item 1), if one is
not present, mark the engaged teeth (Item 2) [Figure 70-

Dealer Copy -- Not for Resale

Remove the two bolts (Item 1) [Figure 70-80-11] from 80-13] to aid in reassembly.
the throttle linkage mount and the injection pump gear
cover. Figure 70-80-14

Figure 70-80-12

2 2

1 2

3
2
P100142

2 P100144
Any time the timing mark (Item 1) on the fuel cam gear is
meshed with the idler gear (Item 2) [Figure 70-80-14] the
Remove the timer lubricating pipe (Item 1) [Figure 70- engine is on top dead center of the compression stroke
80-12] from the injection pump gear cover and engine. on number four cylinder.

Remove the seven cover mounting bolts (Item 2) [Figure

70-80-12] from the injection pump gear cover.

Remove the injection pump gear cover (Item 3) [Figure

70-80-12] from the engine.

688 of 822 70-80-4 T870 Service Manual

CYLINDER HEAD (CONT’D) Cylinder Head Removal And Installation

Valve Timing - Checking (Cont’d) Remove the fuel injectors. (See Fuel Injector Removal
And Installation on Page 70-70-24.)
Figure 70-80-15
Figure 70-80-17

1
1

3
P-37599

P-37201

Install a 9,525 mm (0.375 in) bolt through the hole in the

flywheel casting (Item 1) [Figure 70-80-15]. Remove the rocker arm assembly (Item 1) [Figure 70-

Dealer Copy -- Not for Resale

80-17].
Figure 70-80-16
Remove the push rods (Item 2) [Figure 70-80-17].

Remove the bridge arms (Item 3) [Figure 70-80-17].

Figure 70-80-18
1

P-37519

Remove the flywheel cover from the engine flywheel

housing.
P-37158
Check to see that the bolt (Item 1) [Figure 70-80-16] is
completely through the flywheel.
Place the push rods into the tappets (Item 3) [Figure 70-
The engine is now pinned on Top Dead Center. 80-18], check to see if their ends are properly engaged
with the grooves.

NOTE: After reassembling the rocker arm, be sure to

adjust the valve clearance.

689 of 822 70-80-5 T870 Service Manual

CYLINDER HEAD (CONT’D) Figure 70-80-21

Cylinder Head Removal And Installation (Cont’d)

1
Figure 70-80-19

P-37156

Make sure to note the notch (a), (b) or (c) of cylinder

P-37228A
head gasket (Item 1) [Figure 70-80-21] in advance.

Replace the same notch (a), (b) or (c) as the original

Loosen the hose clamps and remove the water return cylinder head gasket (Item 1) [Figure 70-80-21].
hose (Item 1) [Figure 70-80-19].

Dealer Copy -- Not for Resale

Select the cylinder head gasket (Item 1) thickness to
Figure 70-80-20 meet with the top clearance when replacing the piston,
piston pin bushing, connecting rod or crank pin bearing.

Take care handling the gasket so as not to damage it.

NOTE: When replacing the piston, piston pin

bushing, connecting rod or crank pin bearing,
select the cylinder head gasket thickness to
meet with the top clearance.

P-37266

Remove the cylinder head bolts in the order of (18) to (1)

[Figure 70-80-20], and remove the cylinder head.

Remove the cylinder head gasket.

Tightening Cylinder head 98,1 - 107 N•m

torque bolts (72.4 - 79.5 ft-lb)

The cylinder head should be free of scratches and dust.

Tighten the cylinder head bolts gradually in the order of

(1) to (18) after applying engine oil to the threads.

Be sure to adjust the valve clearance. (See Valve

Clearance Adjustment on Page 70-80-2.)

690 of 822 70-80-6 T870 Service Manual

CYLINDER HEAD (CONT’D) Cylinder Head Disassembly And Assembly

Cylinder Head Removal And Installation (Cont’d) Figure 70-80-24

Figure 70-80-22
2 1

3
5

P-37204A

P-37203
Remove the valve spring collets (Item 1) after
compressing the valve spring (Item 3) with the valve
Figure 70-80-23 spring retainer (Item 2) [Figure 70-80-24].

Dealer Copy -- Not for Resale

Remove the valve seal (Item 4) and the valve (Item 5)
1 [Figure 70-80-24].

Figure 70-80-25

3EEABAC1P026A 2

Measure the piston head’s recessing or protrusion from

the crankcase cylinder face (Item 1) [Figure 70-80-22] at 3
four spots per each piston using the dial gauge as shown
P-37118
in [Figure 70-80-23] and average the four pistons.

Install the valve spring with its small-pitch end (Item 2)

downward toward the head side (Item 3) [Figure 70-80-
25].

Wash the valve stem and valve guide hole, and apply
engine oil sufficiently.

After installing the valve spring collets, lightly tap the

stem to assure proper fit with a plastic hammer.

691 of 822 70-80-7 T870 Service Manual

CYLINDER HEAD (CONT’D) Cylinder Head Top Clearance

Cylinder Head - Servicing Figure 70-80-27

Figure 70-80-26

1 2 P-37162

P-37212
If the measurement exceeds the allowable limit, correct it
with a surface grinder.
Thoroughly clean the cylinder head surface.
Place a straightedge on the cylinder head’s four sides

Dealer Copy -- Not for Resale

Measure the clearance with a straightedge (Item 1) and a and two diagonal [Figure 70-80-27].
feeler gauge (Item 2) [Figure 70-80-26].
Cylinder Head Allowable 0,05 mm
Surface Flatness Limit (0.002 in)

NOTE: Be sure to check the valve recessing after

correcting.

Select the suitable cylinder head gasket, refer to the table below.

Notch of Cylinder Head Thickness of cylinder head gasket Piston Head’s recessing
Gasket or protrusion from the
level of crankcase cylin-
der face. (average of 4
pistons)
Before tightening After tightening
2 notches (a) 0,90 mm 0,80 mm -0,07 - +0,049 mm
(0.035 in) (0.031 in) (-0.0028 - +0.0019 in)
1 notch (b) 1,00 mm 0,90 mm +0,050 - +0,149 mm
(0.0394 in) (0.035 in) (+0.0020 - +0.0058 in)
Without notch (c) 1,05 mm 0,95 mm +0,150 - +0,20 mm
(0.0413 in) (0.037 in) (+0.0059 - +0.0078 in)

692 of 822 70-80-8 T870 Service Manual

CYLINDER HEAD (CONT’D) Figure 70-80-30

Valve Guide - Checking

The tool described below is not provided. The tool is

used for inserting and removing the valve guides.Use the
dimensions below [Figure 70-80-28] and [Figure 70-80-
29] to make this tool.

Figure 70-80-28

P-37138

Remove carbon from the valve guide section.

Measure the valve stem O.D. with an outside micrometer

[Figure 70-80-30].

Figure 70-80-31

Dealer Copy -- Not for Resale

P-37187

Figure 70-80-29

P-37139

P-37188
Measure the valve guide I.D. of the cylinder head at the
most wear part as shown in [Figure 70-80-31] with a
A 20 mm dia. (0.79 in dia.) small hole gauge and calculate the clearance.
B 11,7 - 11,9 mm dia. (0.461 - 0.468 in dia.)
C 6,50 - 6,60 mm dia. (0.256 - 0.259 in dia.)
D 225 mm (8.86 in)
E 70 mm (2.8 in)
F 45 mm (1.8 in)
G 25 mm (0.98 in)
H 5 mm (0.2 in)
I 6,70 - 7,00 mm dia. (0.264 - 0.275 in dia.)
J 20 mm dia. (0.79 in dia.)
K 12,5 - 12,8 mm dia. (0.493 - 0.503 in dia.)
L 8,90 - 9,10 mm dia. (0.351 - 0.358 in dia.)
C1 Chamfer 1,0 mm (0.039 in)
C2 Chamfer 2,0 mm (0.079 in)
C0.3 Chamfer 0,3 mm (0.01 in)

693 of 822 70-80-9 T870 Service Manual

CYLINDER HEAD (CONT’D) Figure 70-80-32

Valve Guide - Checking (Cont’d)

If the clearance exceeds the allowable limit, replace the

valves. If it still exceeds the allowable limit, replace the
valve guide. 1
2
Clearance Factory Intake 0,055 - 0,085
between spec. valve mm
valve stem (0.0022 - 0.0033 3
and guide in)
Exhaust 0,055 - 0,085
valve mm
(0.0022 - 0.0033
in) P-76091

Allowable 0,1 mm (0.004 in)

limit Press the used valve guide out of the cylinder head (Item
1) [Figure 70-80-32] using the special driver tool.
Valve Factory Intake 6,960 - 6,975 mm
stem spec. valve (0.2741 - 0.2746 in) Put oil on the outside diameter of the new valve guide.
O.D. Press the new valve guide into the cylinder head from the
Exhaust 6,960 - 6,975 mm top side. Use the special driver tools (Items 2 and 3)

Dealer Copy -- Not for Resale

valve (0.2741 - 0.2746 in) [Figure 70-80-32], press the new guide until the tool
contacts the cylinder head.
Valve Factory Intake 7,030 - 7,045 mm
guide spec. valve (0.2768 - 0.2773 in) Ream the valve guide to the correct specifications.
I.D. Exhaust 7,030 - 7,045 mm
valve (0.2768 - 0.2773 in)

694 of 822 70-80-10 T870 Service Manual

CYLINDER HEAD (CONT’D) Figure 70-80-35

Reconditioning The Valve And Valve Seat 1 2

15° Exhaust
Figure 70-80-33 30° Intake

PI-9995

Check the seat surface and valve face (Item 1) [Figure

PI-9993 70-80-35].

(a) identical dimensions above and below the valve seat

Grind the valve face to the correct angle using a valve re-
facer [Figure 70-80-33]. If the seat surface (b) is too wide, use a 30 degree cutter

Dealer Copy -- Not for Resale

(Item 2) on the intake, and a 15 degree cutter on the
NOTE: Before correcting the valve and seat, check exhaust to get the correct width (Item 3) [Figure 70-80-
the valve stem and the I.D. of the valve guide 35].
section, and repair if necessary.
Valve Seat Intake 1,6 - 2,0 mm
After correcting the valve seat, be sure to Width (0.063 - 0.078 in)
check the valve recessing [Figure 70-80-37].
Exhaust 2,3 - 2,6 mm
Clean the valve seat and combustion chamber. (0.091 - 0.10 in)

Figure 70-80-34 Valve Seat & Intake 60 degrees

Face Angle Exhaust 45 degrees

Correct the valve with a valve refacer.

After resurfacing the seat, inspect for even valve seating,

apply a thin film of compound between the valve face and
valve seat, and fit them with valve lapping tool.
45° Exhaust
15° Exhaust 60° Intake Check the valve seating with prussian blue. The valve
30° Intake seating surface should show good contact all the way
around.

PI-9994

Grind the valve seat surface in the cylinder head to the

correct angle [Figure 70-80-34].

695 of 822 70-80-11 T870 Service Manual

CYLINDER HEAD (CONT’D) Valve Recessing

Reconditioning The Valve And Valve Seat (Cont’d) Figure 70-80-37

Valve Lapping

Figure 70-80-36

P-37213

Clean the cylinder head, the valve face and seat.

P-37214
Insert the valve into the valve guide.

Dealer Copy -- Not for Resale

Apply compound evenly to the valve lapping surface. Measure the valve recessing with a depth gauge [Figure
70-80-37].
Insert the valve into the valve guide. Lap the valve onto
its seat with a valve lapper [Figure 70-80-36]. If the measurement exceeds the allowable limit, replace
the valve.
After lapping the valve, wash the compound away and
apply oil, then repeat valve lapping with oil. If it still exceeds the allowable limit after replacing the
valve, correct the valve seat face of the cylinder head
Apply prussian blue to the contact surface to check the with a valve seat cutter or valve seat grinder.
percentage of the seated valve. If it is less than 70%,
repeat valve lapping again. Then, correct the cylinder head surface with a surface
grinder, or replace the cylinder head.
NOTE: When valve lapping is performed, be sure to
check the valve recessing and adjust the Valve Factory Intake 0,60 - 0,80 mm
valve clearance after assembling the valve. recessing spec. valve (0.024 - 0.031 in)
(recessing)
Exhaust 0,850 - 1,05 mm
valve (0.0335 - 0.0413
in)
(recessing)
Allowable (recessing)
limit 1,2 mm (0.047 in)

696 of 822 70-80-12 T870 Service Manual

CYLINDER HEAD (CONT’D) Figure 70-80-39

Valve Spring

Figure 70-80-38

P-37254

Measure the free length (A) with vernier calipers [Figure

P-37255 70-80-39]. If the measurement is less than the allowable
limit, replace it.

Place the valve spring on a tester and compress it to the Put the spring on a surface plate, place a square on the
same length it is actually compressed in the engine side of the spring, and check to see if the entire side is

Dealer Copy -- Not for Resale

[Figure 70-80-38]. contact with the square. Rotate the spring and measure
the maximum (B) [Figure 70-80-39]. If the measurement
Read the compression load on the gauge. exceeds the allowable limit, replace.

If the measurement is less than the allowable limit, Check the entire surface of the spring for scratches.
replace it. Replace spring, if any are found.

Setting Factory Intake 63,5 N / 31,5 mm Free Factory Intake 35,1 - 35,6 mm
load / spec. valve (14.3 lb / 1.24 in) length spec. valve (1.39 - 1.40 in)
setting (A) Exhaust 35,1 - 35,6 mm
length Exhaust 63,5 N / 31,5 mm valve (1.39 - 1.40 in)
valve (14.3 lb / 1.24 in)
Allowable Intake 34,6 mm
Allowable Intake 45,9 N / 31,5 mm limit valve (1.36 in)
limit valve (10.3 lb / 1.24 in)
Exhaust 34,6 mm
Exhaust 45,9 N / 31,5 mm valve (1.36 in)
valve (10.3 lb / 1.24 in)
Tilt (B) Allowable 1,0 mm (0.039 in)
limit

697 of 822 70-80-13 T870 Service Manual

CYLINDER HEAD (CONT’D) Figure 70-80-41

Valve Tappets

Figure 70-80-40

P-37174

Measure the tappet O.D. with an outside micrometer

P-37202 [Figure 70-80-41].

Measure the I.D. of the tappet guide bore with a cylinder

Remove the tappets (Item 1) [Figure 70-80-40] from the gauge, and calculate the oil clearance [Figure 70-80-41].
crankcase.

Dealer Copy -- Not for Resale

If the oil clearance exceeds the allowable limit or the
Before installing the tappets (Item 1) [Figure 70-80-40], tappet is damaged, replace the tappet.
apply engine oil to aid in assembly and initial start up.
Oil clearance Factory 0,020 - 0,062 mm
NOTE: Mark the cylinder number to the tappets to between tappet spec. (0.00079 - 0.0024 in)
prevent interchanging. and guide Allowable 0,07 mm (0.003 in)
limit

Tappet O.D. Factory 23,959 - 23,980 mm

spec. (0.94327 - 0.94409 in)
Tappet guide Factory 24,000 - 24,021 mm
I.D. spec. (0.94489 - 0.94570 in)

698 of 822 70-80-14 T870 Service Manual

CYLINDER HEAD (CONT’D) Push Rod Alignment - Checking

Rocker Arm And Shaft - Checking Figure 70-80-43

Figure 70-80-42

P-76926

P-37173
Place the push rod on V blocks [Figure 70-80-43].

Measure the rocker arm bearing I.D. with an inside Measure the push rod alignment [Figure 70-80-43].
micrometer [Figure 70-80-42].

Dealer Copy -- Not for Resale

If the push rod exceeds the allowable limit, replace the
Measure the rocker arm shaft O.D. with an outside push rod.
micrometer, and then calculate the oil clearance [Figure
70-80-42]. Push rod Allowable 0,25 mm (0.0098 in)
alignment limit
If the clearance exceeds the allowable limit, replace the
rocker arm and measure the oil clearance again. If it still
exceeds the allowable limit, replace the rocker arm shaft.

Oil clearance Factory 0,016 - 0,045 mm

or rocker arm spec. (0.00063 - 0.0017 in)
shaft and Allowable 0,15 mm (0.0059 in)
bearing limit

Rocker arm Factory 15,973 - 15,984 mm

shaft O.D. spec. (0.62886 - 0.62929 in)
Rocker arm Factory 16,000 - 16,018 mm
I.D. for shaft spec. (0.62993 - 0.63062 in)

699 of 822 70-80-15 T870 Service Manual

 Dealer Copy -- Not for Resale

700 of 822 70-80-16 T870 Service Manual

CRANKSHAFT AND PISTONS Figure 70-90-2

Piston And Connecting Rod Removal And

Installation

Remove the oil pan. (See Oil Pan Removal And

Installation on Page 70-60-1.)

Remove the cylinder head. (See Cylinder Head Removal

And Installation on Page 70-80-5.)
1
Figure 70-90-1

1 P-37159

Align the marks (Item 1) [Figure 70-90-2] with each

other. (Face the marks toward the injection pump.)

Apply engine oil to the connecting rod bolts and lightly

thread it in by hand then tighten it to the specified torque.
If the connecting rod bolts do not thread together

Dealer Copy -- Not for Resale

smoothly, clean the threads. If the connecting rod bolt is
still hard to thread in, replace it.
P-37128
NOTE: When using the existing crank bearing, put
marks on the crank pin bearing and the
Remove the connecting rod bolts (Item 1) [Figure 70-90- connecting rod in order to keep their position.
1] from connecting rod cap.
Insert the crank pin bearing.
Remove the connecting rod caps.
Tightening Connecting 79 - 83 N•m
torque rod screw (58 - 61 ft-lb)

701 of 822 70-90-1 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-4

Piston And Connecting Rod Removal And 1

Installation (Cont’d)

Remove the top ridge from the cylinder bore with a ridge
reamer.

Turn the flywheel and set a piston to the top dead center.

Remove the piston and connecting rod.

Installation:

Before installing the piston into the cylinder, apply engine

oil to the cylinder to aid in reassembly and initial start up. P-37233A

NOTE: Do not change the combination of cylinder

and piston. Make sure of the position of each When inserting the piston into the cylinder, face the mark
piston by marking. For example, mark “1” on (Item 1) [Figure 70-90-4] on the connecting rod toward
the No. 1 position. the injection pump.

Figure 70-90-3 Figure 70-90-5

Dealer Copy -- Not for Resale

1 Top Ring Gap Oil Ring
Gap
45° (0.79 rad.)
Piston
Pin Hole

Second Ring
Gap Oil Ring Gap

P-37208 P-37209

Install the pistons using a piston ring compressor (Item 1) NOTE: When inserting the piston into the cylinder,
[Figure 70-90-3]. place the gap of the compression ring 1 on the
opposite side of the combustion chamber and
stagger the gaps of the compression ring 2
and oil ring marking a right angle from the gap
of the compression ring 1 [Figure 70-90-5].

702 of 822 70-90-2 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-7

Piston And Connecting Rod - Servicing

7
The Small End Bushing Replacing Tool can be made
using the dimensions below. One set of dimensions is for 9
8
the press out tool and one for press fit.
6 1
Figure 70-90-6
5
4 3

P-37210

1. Piston Pin

2. Piston

P-37189
3. Piston Pin Snap Ring

Dealer Copy -- Not for Resale

4. Compression Ring 1
Small End Bushing Replacing Tool
5. Compression Ring 2
Application: Use to press out and to press fit the small
end bushing in the connection rod. 6. Oil Ring

(Press out) 7. Connecting Rod

A 157 mm (6.18 in) 8. Mark ( ↑ )

B 14,5 mm (0.571 in)
C 120 mm (4.72 in) 9. Numbering Mark
D 30 mm dia. (1.181 in dia.)
E 32,95 mm dia. (1.297 in dia.) Remove the piston rings using a piston ring tool [Figure
F 20 mm (0.79 in) 70-90-7].
a 0,0000063 mm (0.00025 in)
b 0,0000063 mm (0.00025 in) Remove the piston pin (Item 1), and separate the
C1 Chamfer 1,0 mm (0.039 in) connecting rod (Item 7) from the piston (Item 2) [Figure
C2 Chamfer 2,0 mm (0.079 in) 70-90-7].

(Press fit) Installation: When installing the piston pin, immerse the
piston in 80°C (176°F) oil for 10 to 15 minutes and insert
A 157 mm (6.18 in) the piston pin to the piston.
B 14,5 mm (0.571 in)
C 120 mm (4.7244 in) Assemble the piston to the connecting rod with the ↑
D 30 mm dia.(1.181 in dia.) mark (Item 8) and the connecting rod numbering mark
E 42,000 mm dia.(1.6535 in dia.) (Item 9) [Figure 70-90-7] facing same side.
F 20 mm (0.79 in)
a 0,0000063 mm (0.00025 in) NOTE: Mark the same number on the connecting rod
b 0,0000063 mm (0.00025 in) and the piston so as not to change the
C1 Chamfer 1,0 mm (0.039 in) combination.
C2 Chamfer 2,0 mm (0.079 in)

703 of 822 70-90-3 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-10

Piston And Connecting Rod - Servicing (Cont’d)

Figure 70-90-8

P-37161

When installing the ring, assemble the rings so that the

2 manufacture’s mark (Item 1) [Figure 70-90-10] near the
P-37211A
gap faces the top of the piston.

Be sure the crank pin bearing and the connecting rod are Figure 70-90-11
same I.D. colors (Items 1 and 2) [Figure 70-90-8].

Dealer Copy -- Not for Resale

Figure 70-90-9

P-37253

Measure the piston pin bore I.D. in both the horizontal

P-37160
and vertical directions with a cylinder gauge [Figure 70-
90-11].
When installing the oil ring onto the piston, place the
expander joint (Item 1) on the opposite side of the oil ring If the measurement exceeds the allowable limit, replace
gap (Item 2) [Figure 70-90-9]. the piston.

Piston pin Factory 30,000 - 30,013 mm

bore I.D. spec. (1.1811 - 1.1816 in)
Allowable 30,05 mm (1.183 in)
limit

704 of 822 70-90-4 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-13

Piston And Connecting Rod - Servicing (Cont’d)

Figure 70-90-12

1 2
P-37179

Press out the used bushing using a small end bushing

P-37178 replacing tool (Item 1) [Figure 70-90-13].

Figure 70-90-14
Measure the O.D. of the piston pin where it contacts the
bushing with an outside micrometer [Figure 70-90-12].

Dealer Copy -- Not for Resale

Measure the I.D. of the piston pin bushing at the
connecting rod small end with a cylinder gauge [Figure 1
70-90-12].

If the clearance exceeds the allowable limit, replace the

bushing. If it still exceeds the allowable limit, replace the
piston pin.

Oil clearance Factory 0,020 - 0,040 mm

between piston spec. (0.00079 - 0.0015 in)
pin and small Allowable 0,15 mm (0.0059 in)
end bushing limit P-37142A

Piston pin O.D. Factory 30,006 - 30,011 mm Clean a replacement small end bushing and connecting
spec. (1.1814 - 1.1815 in) rod bore, and apply engine oil to aid in assembly.
Small end bush- Factory 30,031 - 30,046 mm
ing I.D. spec. (1.1824 - 1.1829 in) Place the bushing onto the tool and press-fit it with a
press (Item 2) [Figure 70-90-13] so that the seam (Item
1) [Figure 70-90-14] of the bushing is flush with the
connecting rod.

705 of 822 70-90-5 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT'D) Piston Ring Gap

Piston And Connecting Rod - Servicing (Cont’d) Figure 70-90-16

Piston Ring Groove

Figure 70-90-15

P-37180

Insert the piston ring into the lowest part of the liner which
P-37215 is the least worn.

Measure the ring gap with a feeler gauge [Figure 70-90-

Dealer Copy -- Not for Resale

Remove carbon from the ring grooves. 16].

Measure the clearance between the ring and the groove If the gap exceeds the allowable limit, replace the piston
with a feeler gauge [Figure 70-90-15]. ring.

If the clearance exceeds allowable limit, check the new Compression Factory spec. 0,30 - 0,45 mm
rings on an old piston and if it is out of spec, replace the ring 1, 2 (0.012 - 0.017 in)
piston.
Allowable 1,25 mm (0.0492 in)
limit
Factory Compression 0,05 - 0,09 mm
spec. ring 1 (0.002 - 0.003 in)
Oil Ring Factory spec. 0,25 - 0,45 mm
Compression 0,0930 - 0,120 mm
(0.0099 - 0.017 in)
ring 2 (0.00367 - 0.00472 in)
Allowable 1,25 mm (0.0492 in)
Oil Ring 0,020 - 0,060 mm
limit
(0.00079 - 0.0023 in)
Allowable Compression 0,15 mm (0.0059 in)
limit ring 1
Compression 0,20 mm (0.0079 in)
ring 2
Oil ring 0,15 mm (0.0059 in)

706 of 822 70-90-6 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-19

Cylinder Bore - Checking

Figure 70-90-17
1

P-37164

When the cylinder is worn beyond the allowable limit

P-37169 (Item 1), bore and hone it to the specified dimension
(Item 2) [Figure 70-90-19].

Use a gauge to check the inside measurement of the Cylinder Oversize 100,500 - 100,522 mm
cylinder bore [Figure 70-90-17]. I.D. (Item 2) (+ 0,5 mm) (3.95670 - 3.95755 in)

Dealer Copy -- Not for Resale

Spec.
Figure 70-90-18
Maximum Allowable 100,65 mm (3.96260 in)
wear limit

1
Finishing Hone to 8 - 30 μin Rz.
———
(0.2 - 0.8 μm Rz.)

2 Replace the piston and piston rings with oversize 0,5 mm

ones.

NOTE: When the oversize cylinder is worn beyond

3 the allowable limit, replace the cylinder block
with a new one.

P-37163

Measure the six points with a cylinder gauge to find out

the maximum wear [Figure 70-90-18].

NOTE: Generally, position (1) in the (a, b) direction (at

about 20 mm [0.79 in] from the top) shows the
maximum wear [Figure 70-90-18]. Since
position (3) at the lower part of the bore will
show the minimum wear

Cylinder bore Factory 100,000 - 100,022 mm

I.D. spec. (3.93701 - 3.93787 in)
Allowable 100,150 mm
limit (3.9429 in)

707 of 822 70-90-7 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT'D) Crankshaft Gear Removal And Installation

Connecting Rod Alignment Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 70-
Figure 70-90-20 100-1.)

Remove the idler gear. (See Idler Gear And Camshaft

Removal And Installation on Page 70-100-2.)

Figure 70-90-21

P-37181

NOTE: Since the I.D. of the connecting rod small end

bushing is the basis of this check, check the

Dealer Copy -- Not for Resale

bushing for wear beforehand.
B-3686

Install the connecting rod on the connecting rod

alignment tool. Remove the crankshaft gear with a puller [Figure 70-90-
21].
Put a gauge over the piston pin, and move it against the
face plate [Figure 70-90-20]. Remove the crankshaft key.

If the gauge does not fit squarely against the face plate,
measure the space between the pin of the gauge and the
face plate.

If the measurement exceeds the allowable limit, replace

the connecting rod.

Connecting rod Allowable 0,05 mm (0.0020 in)

alignment limit

708 of 822 70-90-8 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-23

Crankshaft And Bearings Removal 1

Remove the flywheel housing. (See Housing Removal

And Installation on Page 70-120-2.)
3 3
Remove the oil pan. (See Oil Pan Removal And
Installation on Page 70-60-1.)

Figure 70-90-22

2
P-37130A

NOTE: Before disassembling, check the side

clearance of crankshaft. Also check it during
reassembly. Check the crankshaft side
clearance. (See Crankshaft And Bearings -
Servicing on Page 70-90-13.)

Dealer Copy -- Not for Resale

3EEABAC1P115A Remove the eight bearing case cover mounting bolts
(Item 2) [Figure 70-90-23].
Application: Use for aligning the crankcase 1 and 2. Install the two bolts removed earlier into the bolt hole
(Item 3) [Figure 70-90-23] of bearing case cover to
A 115 mm (4.53 in) remove it.
B 56 mm (2.2 in)
C 17 mm (0.67 in) NOTE: Install the bearing case cover / oil seal
D 20 mm (0.79 in) assembly with the casting mark labeled “UP”
E 14 mm dia. (0.55 in dia.) (Item 1) [Figure 70-90-23] at the top.
F 11 mm dia. (0.43 in dia.)
G 14 mm dia. (0.55 in dia.)
H 17,5 mm (0.6890 in)
I 17,5 mm (0.6890 in)
J 35 mm (1.4 in)
K 19 mm (0.75 in)

709 of 822 70-90-9 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-26

Crankshaft And Bearings Removal (Cont’d)

Figure 70-90-24
1

2
2

3EEABAC1P098A

Remove the fourth bearing case (Item 1) and the thrust

bearing (Item 2) [Figure 70-90-26].
P-37133

Figure 70-90-27
Remove the bolts (Item 1) that secure the crankcase 2
[Figure 70-90-24] to crankcase 1.

Dealer Copy -- Not for Resale

Remove the crankcase 2 (Item 2) [Figure 70-90-24].

Figure 70-90-25

1
2

P-37137

Remove the crankshaft [Figure 70-90-27].

3EEABAC1P099A

Remove the bolts (Item 1) and the bearing cases (Item 2)

[Figure 70-90-25] from crankcase 1.

710 of 822 70-90-10 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-30

Crankshaft And Bearings Installation

Figure 70-90-28
1

1
2

2
3EEABAC1P098A

NOTE: Install the main bearing case having the same

number as the one engraved on the
3EEABAC1P097A
crankcase, and set the casting mark “F/W
SIDE” on the main bearing case towards the
Install the thrust bearing (Item 1) [Figure 70-90-28] on flywheel side.
both sides of the fourth mainbearing case with the oil
groove facing out. Install the fourth bearing case (Item 1) and the thrust

Dealer Copy -- Not for Resale

bearing (Item 2) [Figure 70-90-30].
Install the main bearings (Item 2) [Figure 70-90-28].
Figure 70-90-31
Figure 70-90-29

3EEABAC1P099A
P-37137

NOTE: Install the main bearing case having the same

Install the crankshaft [Figure 70-90-29]. number as the one engraved on the
crankcase, and set the casting mark “F/W
SIDE” on the main bearing case towards the
flywheel side.

Apply oil to the bearing case bolts and tighten them to the
specified torque.

Tightening Main bearing 137 - 147 N•m

torque case screw (102 - 108 ft-lb)

711 of 822 70-90-11 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-34

Crankshaft And Bearings Installation (Cont’d)

1
Figure 70-90-32

P-37133

Tighten the crankcase 2 mounting bolts (Item 1) with

P-37134
even force on the diagonal line to secure the crankcase 2
[Figure 70-90-34] to crankcase 1.

NOTE: Make sure the crankcase 1 and 2 are clean. Tightening Crankcase 2 mounting 49 - 55 N•m
torque bolt (37 - 41 ft-lb)

Dealer Copy -- Not for Resale

Apply liquid gasket (Item 1) [Figure 70-90-32]
to the crankcase 2 as shown.

Figure 70-90-33

3EEABAC1P096A

Match the crankcase 1 (Item 1) and crankcase 2 (Item 2)

[Figure 70-90-33] referring to the flywheel’s contoured
face.

Tighten the crankcase 2 mounting bolts loosely.

Install the jig (Item 3) [Figure 70-90-33] to the specified

torque. This helps to minimize the level difference
between the crankcase 1 and the crankcase 2 (at the
flywheel side) Gap must be 0,05 mm (0.002 in) or
smaller.

Tightening Flywheel housing 78 - 90 N•m

torque bolt (58 - 66 ft-lb)

712 of 822 70-90-12 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT'D) Crankshaft And Bearings - Servicing

Crankshaft And Bearings Installation (Cont’d) The following special tools are not provided, [Figure 70-
90-37], [Figure 70-90-38] and [Figure 70-90-22].
Figure 70-90-35
Figure 70-90-37

P-37131

NOTE: When replacing the oil seal, use caution

installing the seal in the bearing case cover as
not to install it tilted. The seal should be flush
with the cover. P-37114

Dealer Copy -- Not for Resale

Apply liquid gasket (Item 1) [Figure 70-90-35] to the Gearcase Oil Seal Replacing Tool
bearing case cover evenly.
Application: Use to press fit the oil seal.
Figure 70-90-36
A 148,8 mm (5.858 in)
1
B 50 mm (2.0 in)
C 18,8 mm (0.740 in)
D 13,7 - 13,9 mm (0.540 - 0.547 in)
E 11 mm (0.43 in)
F 18 mm dia. (0.71 in dia.)
G 38 mm dia. (1.5 in dia.)
H 45 mm dia. (1.8 in dia.)
I 57,90 - 58,10 mm (2.280 - 2.287 in)
J 79,5 mm dia. (3.13 in dia.)
K 87 mm (3.4 in)
L 12 mm (0.47 in)
M 40 mm (1.6 in)
P-37130A N 120 mm (4.72 in)

NOTE: Install the bearing case cover / oil seal

assembly with the casting mark labeled “UP”
(Item 1) [Figure 70-90-36] at the top.

Tighten the bearing case cover mounting bolts with even

force on the diagonal line.

Tightening Bearing Case Cover 24 - 27 N•m

torque mounting bolt (18 - 20 ft-lb)

713 of 822 70-90-13 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT'D) Crankshaft Side Clearance

Crankshaft And Bearings - Servicing (Cont’d) Figure 70-90-39

Figure 70-90-38

3EEABAC1P105A

Set a dial indicator with its tip on the end of the crankshaft
[Figure 70-90-39].

Measure the side clearance by moving the crankshaft to

the front and rear.

Dealer Copy -- Not for Resale

Crankshaft Factory spec. 0,15 - 0,31 mm
side clearance (0.0059 - 0.012 in)
Allowable 0,50 mm (0.020 in)
limit
P-37115
If the measurement exceeds the allowable limit, replace
the thrust bearings.
Auxiliary Socket For Fixing Crankshaft Sleeve

Application: Use to fix the crankshaft sleeve of the diesel

engine.
A Rmax = 12.5 S
B 94,5 - 95,0 mm (3.72 - 3.74 in)
C 40 mm (1.6 in)
D 30 mm (1.2 in)
E 12 mm (0.47 in)
F 7,90 - 8,10 mm (0.311 - 0.318 in)
G 20 mm (0.079 in)
H 130 mm (5.12 in)
I 99,40 - 99,60 mm (3.914 - 3.921 in)
J 95,05 - 95,20 mm (3.743 - 3.748 in)
K 3 mm dia. (0.1 in dia.)
L 15 mm (0.59 in)
M 10 mm (0.39 in)
N 90 mm (3.5 in)
O 115 mm (4.53 in)
P 16,9 - 17,1 mm (0.666 - 0.673 in)
C1 Chamfer 1,0 mm (0.039 in)
C3 Chamfer 3,0 mm (0.12 in)
C5 Chamfer 5,0 mm (0.20 in)
C0.2 Chamfer 0,2 mm (0.008 in)
C0.3 Chamfer 0,3 mm (0.01 in)

714 of 822 70-90-14 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-41

Crankshaft And Bearings - Servicing (Cont’d)

Figure 70-90-40

P-37182

Support the crankshaft with V block on the surface plate

P-37144 and set a dial indicator with its tip on the intermediate
journal at right angle [Figure 70-90-41].

If the same size bearing can not be used because of the Rotate the crankshaft on the V block and get the
crankshaft journal wear, replace it with an oversized one misalignment (half of the measurement).

Dealer Copy -- Not for Resale

referring to the table and [Figure 70-90-40].
If the misalignment exceeds the allowable limit, replace
Oversize dimensions of crankshaft journal. the crankshaft.

Oversize 0,2 mm 0,4 mm Crankshaft Allowable 0,02 mm

(0.008 in) (0.016 in) alignment limit (0.0008 in)
Dimension 29,20 - 29,25 mm 29,40 - 29,45 mm
A (1.150 - 1.151 in) (1.158 - 1.159 in)
Dimension 169,10 - 169,15 169,2 - 169,25
B mm mm
(6.6575 - 6.6594 (6.6615 - 6.6633
in) in)
Dimension 2,8 - 3,2 mm radius 2,8 - 3,2 mm
C (0.11 - 0.12 in radius
radius) (0.11 - 0.12 in
radius)

The crankshaft journal must be fine-finished to higher

than (0.8-S)

715 of 822 70-90-15 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-43

Crankshaft And Bearings - Servicing (Cont’d)

1
Figure 70-90-42

P-37147

NOTE: To replace it with a specific STD service part,

P-37145 make sure the crank pin bearing has the same
ID color as the connecting rod [Figure 70-90-
43].
Clean the crank pin and crank pin bearing.
ID Connect- Crank pin bearing

Dealer Copy -- Not for Resale

Put a strip of plastigage [Figure 70-90-42] on the center Color ing rod
of the crank pin.
Large-end Class Center wall
NOTE: Never insert the plastigage into the crank pin in dia. thickness
oil hole. Be sure not to move the crankshaft Blue 56,010 - L 1,496 - 1,501
while the connecting rod bolts are tightened. 56,020 mm mm
(2.2052 - (0.05890 -
Install the connecting rod cap and tighten the connecting 2.2055 in) 0.05909 in)
rod bolts to the specified torque, and remove the cap
without 56,00 - S 1,491 - 1,496
again.
Color 56,01 mm mm
(2.2048 - (0.05870 -
Measure the amount of the flattening with the scale, and
2.2051 in) 0.05889 in)
record the oil clearance.

If the oil clearance exceeds the allowable limit, replace Undersize crank pin bearing.
the crank pin bearing.
Undersize Bearing Marking
If the same size bearing can not be used because of the 0,2 mm Crank pin bearing 02 020 US
crank pin wear, replace it with an undersized one (0.008 in)
referring to the table.
0,4 mm Crank pin bearing 04 040 US
(0.016 in)
Crank pin Factory spec. 52,977 - 52,990 mm
O.D. (2.0857 - 2.0862 in)

Oil clearance Factory 0,018 - 0,051 mm

between crank spec. (0.00071 - 0.0020 in)
pin and crank Allowable 0,20 mm (0.0079 in)
pin bearing limit

716 of 822 70-90-16 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-45

Crankshaft And Bearings - Servicing (Cont’d)

Figure 70-90-44

P-37149

Clean the crankshaft journal and crankshaft bearing.

P-37146
Put a strip of plastigage on the center of the journal
[Figure 70-90-45].
Undersize dimensions of crankpin.
NOTE: Never insert the plastigage into the oil hole of

Dealer Copy -- Not for Resale

Undersize 0,2 mm 0,4 mm the journal.
(0.008 in) (0.016 in)
Dimension 2,8 - 3,2 mm 2,8 - 3,2 mm Install the main bearing case and tighten the bolts to the
A radius radius specified torque, and remove the cases again.
(0.11 - 0.12 in (0.11 - 0.12 in
radius) radius) Measure the amount of the flattening with the scale and
record the oil clearance.
Dimension 1,0 - 1,5 mm 1,0 - 1,5 mm
B radius radius If the clearance exceeds the allowable limit, replace the
(0.040 - 0.059 in (0.040 - 0.059 in crankshaft bearing.
radius) radius)
Dimension 52,777 - 52,790 52,577 - 52,590 Crankshaft Factory spec. 74,977 - 74,990 mm
C mm mm Journal O.D. (2.9519 - 2.9523 in)
(2.0779 - 2.0783 (2.0700 - 2.0704
in) in)
Oil clearance Factory spec. 0,018 - 0,062 mm
between (0.00071 - 0.0024 in)
The crank pin must be fine-finished to higher than (0.8- crankshaft Allowable 0,20 mm (0.0079 in)
S) journal and limit
crankshaft
Holes to be de-burred and edges rounded with relief. bearing
1,0 -1,5 mm (0.040 - 0.059 in)

717 of 822 70-90-17 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT'D) Crankshaft Sleeve

Crankshaft And Bearings - Servicing (Cont’d) Figure 70-90-47

Figure 70-90-46
2
1 4

P-37148

P-37269
Remove the used crankshaft sleeve (Item 1) [Figure 70-
90-47] using a special-use puller set.
Undersize dimensions of crankshaft journal [Figure 70-
90-46]. Set the sleeve guide (Item 4) to the crankshaft (Item 2)

Dealer Copy -- Not for Resale

[Figure 70-90-47].
Undersize 0,2 mm 0,4 mm
(0.008 in) (0.016 in) Heat a new sleeve to a temperature between 150 -
Dimension 2,8 - 3,2 mm 2,8 - 3,2 mm 200°C (302 - 392°F), and fix the sleeve to the crankshaft.
A radius radius
(0.11 - 0.12 in (0.11 - 0.12 in Press the sleeve onto the shaft using the auxiliary socket
radius) radius) (Item 3) [Figure 70-90-47].

Dimension 1,0 - 1,5 mm 1,0 - 1,5 mm NOTE: Install the sleeve with the chamfered surface
B radius radius facing outward.
(0.040 - 0.059 in (0.040 - 0.059 in
radius) radius)
Dimension 74,777 - 74,790 74,577 - 74,590
C mm mm
(2.9440 - 2.9444 (2.9361 - 2.9366
in) in)

Crankshaft pin must be fine-finished to higher than

(0.8-S). Holes to be de-burred and edges rounded with
1,0 -1,5 mm (0.040 - 0.059 in) relief.

718 of 822 70-90-18 T870 Service Manual

CAMSHAFT AND TIMING GEARS Figure 70-100-3

Timing Gearcase Cover Removal And Installation

Figure 70-100-1
1
2

3EEABAC1P089A

Confirm that the liquid gasket coating surface is free of

P-37231 water, dust and oil in order to maintain sealing effect.

Carefully apply the adhesive evenly (Item 1) [Figure 70-

Install the engine flywheel pin. 100-3].

Dealer Copy -- Not for Resale

Remove the crankshaft bolt (Item 1) [Figure 70-100-1]. NOTE: Apply a liquid gasket to the gearcase cover.

Remove the drive pulley (Item 2) [Figure 70-100-1]. NOTE: Assemble the adhesive-applied parts within
the manufactures specified cure time.
NOTE: Clean the crankshaft bolt and the drive pulley
sleeve surface thoroughly and tighten the bolt
securely to specified torque. Figure 70-100-4

Tightening Crankshaft 255,0 - 274,6 N•m

torque bolt (188.1 - 202.5 ft-lb)

Figure 70-100-2

1
2

3EEABAC1P094A

Be careful not to damage the O-ring (Item 1) and water

1 pipe (Item 2) [Figure 70-100-4] when reassembling.
3
3EEABAC1P093A NOTE: Replace O-ring (Item 1) [Figure 70-100-4] when
reassembling.

Remove the gearcase cover (Item 1) [Figure 70-100-2].

NOTE: Use care when removing the gearcase cover

not to damage the water pipe (Item 2) [Figure
70-100-2].

719 of 822 70-100-1 T870 Service Manual

CAMSHAFT AND TIMING GEARS (CONT’D) Idler Gear And Camshaft Removal And Installation

Timing Gears Backlash - Checking Figure 70-100-6

Figure 70-100-5
3
2
1

P-76096

3EEABAC1P100A
Remove the three bolts (Item 1) from the idler gear
[Figure 70-100-6].
Set a dial indicator (lever type) with its tip on the gear
tooth (Item 1) [Figure 70-100-5]. Remove the Idler gear (Item 2) [Figure 70-100-6].

Dealer Copy -- Not for Resale

Move the gear to measure the backlash, holding its Align the holes (Item 3) on the camshaft gear with the
mating gear. camshaft retainer plate bolts (Item 4) [Figure 70-100-6].

If the backlash exceeds the allowable limit, check the oil Remove the bolts (Item 4) [Figure 70-100-6].
clearance of the shafts and the gear.
Remove the camshaft from the engine block.
If the oil clearance is proper, replace the gear.
Installation:
Crank gear & Factory 0,049 - 0,193 mm
Idle gear spec. (0.0019 - 0.0076 in) Figure 70-100-7
Allowable 0,22 mm
limit (0.0087 in) 1
Idle gear & Factory 0,049 - 0,189 mm
Camshaft spec. (0.0019 - 0.0074 in)
gear Allowable 0,22 mm
limit (0.0087 in) 3
Idle gear & Factory 0,030 - 0,165 mm
Injection spec. (0.0012 - 0.0065 in)
pump gear 2
Allowable 0,22 mm
limit (0.0087 in)

4
3EEABAC1P095A

Set the crankshaft at the top dead center of No. 1 and 4

cylinder and the camshaft key to the top position and
align the marks of idle gear and camshaft gear and crank
gear to assemble them [Figure 70-100-7].

720 of 822 70-100-2 T870 Service Manual

CAMSHAFT AND TIMING GEARS (CONT’D) Alignment

Camshaft - Servicing Figure 70-100-9

Side Clearance

Figure 70-100-8

P-37175

Support the camshaft with V block on the surface plate

3EEABAC1P102A and set a dial indicator with its tip on the intermediate
journal at right angle [Figure 70-100-9].

Dealer Copy -- Not for Resale

Set a dial indicator with its tip on the camshaft [Figure Rotate the camshaft on the V blocks and get the
70-100-8]. misalignment (half of the measurement).

Measure the side clearance by moving the camshaft gear If the misalignment exceeds the allowable limit, replace
to the front and rear. the camshaft.

If the measurement exceeds the allowable limit, replace Camshaft Allowable 0,01 mm
the camshaft stopper. alignment limit (0.0004 in)

Side clearance Factory 0,070 - 0,22 mm

spec. (0.0028 - 0.0086 in)
Allowable 0,030 mm
limit (0.012 in)

721 of 822 70-100-3 T870 Service Manual

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 70-100-12

Camshaft - Servicing (Cont’d)

Figure 70-100-10

P-37140

Measure the camshaft journal O.D. with an outside

P-37176 micrometer [Figure 70-100-12].

If the clearance exceeds the allowable limit, replace the

Measure the height of the camshaft lobe at its highest camshaft.
point with an outside micrometer [Figure 70-100-10].

Dealer Copy -- Not for Resale

Oil clearance Factory 0,050 - 0,091 mm
If the measurement is less than the allowable limit, of camshaft spec. (0.0020 - 0.0035 in)
replace the camshaft. journal Allowable 0,15 mm
limit (0.0059 in)
Intake and Factory Intake 37,63 mm
exhaust spec. valve (1.481 in)
camshaft Camshaft Factory 45.934 - 45.950 mm
Exhaust 38,96 mm
lobe height journal O.D. spec. (1.8084 - 1.8091 in)
valve (1.534 in)
Camshaft Factory 46,000 - 46,025 mm
Allowable Intake 37,13 mm
journal I.D. spec. (1.8110 - 1.8120 in)
limit valve (1.462 in)
Exhaust 38,46 mm
valve (1.514 in)

Figure 70-100-11

3EEABAC1P103A

Measure the cylinder block bore I.D. for camshaft with an

inside micrometer [Figure 70-100-11].

722 of 822 70-100-4 T870 Service Manual

CAMSHAFT AND TIMING GEARS (CONT’D) Side Clearance

Idler Gear And Shaft - Servicing Figure 70-100-14

Figure 70-100-13

3EEABAC1P101A

P-37189
Set a dial indicator with its tip on the idle gear [Figure 70-
100-14].
Bushing Replacing Tool
Measure the side clearance by moving the idle gear to

Dealer Copy -- Not for Resale

Application: Use to press out and press fit the bushing. the front and rear.

1. For idle gear bushing. If the measurement exceeds the allowable limit, replace
the idle gear collar.
A 196 mm (7.72 in)
B 37,5 mm (1.48 in) Side clearance Factory 0,15 - 0,30 mm
C 150 mm (5.91 in) spec. (0.0059 - 0.011 in)
D 44,95 mm dia.
Allowable 0,9 mm (0.04 in)
(1.770 in dia.)
limit
E 48,075 - 48,100 mm dia.
(1.8928 - 1.8937 in dia.)
F 20 mm dia. (0.79 in dia.)
a 0,0000063 mm (0.00025 in)
b 0,0000063 mm (0.00025 in)
C1 Chamfer 1,0 mm (0.039 in)
C2 Chamfer 2,0 mm (0.079 in)

723 of 822 70-100-5 T870 Service Manual

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 70-100-17

Idler Gear And Shaft - Servicing (Cont’d)

Figure 70-100-15

P-37177

Using an idle gear bushing replacing tool, press out the

3EEABAC1P104A used bushing.

Clean a new idle gear bushing and idle gear bore, and
Measure the idle gear shaft O.D. with an outside
apply engine oil to them.
micrometer [Figure 70-100-15].

Dealer Copy -- Not for Resale

Using an idle gear bushing replacing tool, press in a new
Figure 70-100-16
bushing to the specified dimension [Figure 70-100-17].

P-37141

Measure the idle gear bushing I.D. with an inside

micrometer, and calculate the oil clearance [Figure 70-
100-16].

If the oil clearance exceeds the allowable limit, replace

the bushing.

Clearance Factory 0,050 - 0,091 mm

between idle spec. (0.0020 - 0.0035 in)
gear shaft Allowable 0,10 mm
and idle gear limit (0.0039 in)
bushing

Idle gear Factory 45,025 - 45,050 mm

bushing I.D. spec. (1.7727 - 1.7736 in)
Idle gear Factory 44,959 - 44,975 mm
shaft O.D. spec. (1.7701 - 1.7706 in)

724 of 822 70-100-6 T870 Service Manual

TURBOCHARGER Testing

Description Remove the turbocharger. (See Removal And Installation

on Page 70-110-2.)
Figure 70-110-1
Radial Clearance

Figure 70-110-2
1

P100134

The turbocharger is located between the exhaust and

P-76099
intake manifolds. It is driven by hot exhaust gases and

Dealer Copy -- Not for Resale

supplies air at more than atmospheric pressure to the
intake. Lubrication for the turbocharger is supplied with Move the compressor / turbine wheel (up and down, right
pressurized oil from the main engine oil galley. The and left) (Item 1) [Figure 70-110-2].
location of the turbocharger is between the engine and
the blower housing. If the compressor / turbine wheel contacts the housing,
replace the turbocharger assembly.
The oil is delivered to the turbocharger through a tubeline
(Item 1) and returns to the engine block through a Check the oil tubelines for leaks.
drainage tubeline (Item 2) [Figure 70-110-1].

The turbocharger internal components are not

serviceable.

725 of 822 70-110-1 T870 Service Manual

TURBOCHARGER (CONT’D) Loosen the intake hose clamp (Item 1) and remove the
intake hose (Item 2) [Figure 70-110-4].
Removal And Installation
Loosen the air cleaner hose clamp (Item 3) and remove
the air cleaner hose (Item 4) [Figure 70-110-4].

WARNING Installation: Tighten the hose clamp (Item 3) [Figure 70-

110-4] to 3,4 - 4,0 N•m (30 - 35 in-lb) torque.

Turbochargers, operate at high speed and high Figure 70-110-5

temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact
with hot surfaces.
W-2257-1196
1

NOTE: Engine removed for photo clarity.

Figure 70-110-3

1
2
1

Dealer Copy -- Not for Resale

P100135

3 Remove the four exhaust tube bolts (Item 1) [Figure 70-

110-5].
4

P100134

Remove the bolt (Item 1) and tubeline (item 2) [Figure

70-110-3].

Remove the bolts (Item 3) and tubeline (Item 4) [Figure

70-110-3].

Figure 70-110-4

1 2

P100133

726 of 822 70-110-2 T870 Service Manual

TURBOCHARGER (CONT’D)

Removal And Installation (Cont’d)

Figure 70-110-6

2
1

P100140

Remove the two EGR heat shield mounting bolts (Item 1)

and remove the shield (Item 2) [Figure 70-110-6].

Dealer Copy -- Not for Resale

Figure 70-110-7

3
2

4 1

1 P100138

Remove the eight turbocharger mounting bolts (Item 1)

[Figure 70-110-7].

Remove the turbocharger assembly (Item 2) [Figure 70-

110-7].

Remove the two bolts (Item 3) from the turbocharger

flange mount (Item 4) and remove flange [Figure 70-110-
7].

Installation: During installation replace all gaskets.

727 of 822 70-110-3 T870 Service Manual

 Dealer Copy -- Not for Resale

728 of 822 70-110-4 T870 Service Manual

FLYWHEEL AND HOUSING Ring Gear Removal And Installation

Flywheel Removal And Installation Figure 70-120-2

Figure 70-120-1
1

P-37365

P100238
NOTE: The lead chamfer on ring gear tooth must face
the starter.
NOTE: To avoid damage to the rpm sensor, remove
the rpm sensor before removing the flywheel. The ring gear (Item 1) [Figure 70-120-2] on the flywheel

Dealer Copy -- Not for Resale

is an interference fit. Heat the ring gear enough to
Remove the Flywheel rpm Sensor. (See FLYWHEEL expand it and hit it with a hammer to remove it evenly.
RPM SENSOR on Page 60-170-1.)
Clean the outer surface of the flywheel to give it a smooth
Remove the drive belt. (See Belt Replacement on Page fit.
30-50-1.)
Clean the new ring gear and heat it to a maximum
Remove the belt tension pulley assembly. (See Tensioner temperature of 220°C (428°F).
Pulley Removal And Installation on Page 30-50-3.)
Fit the ring gear over the flywheel. Make sure the gear is
Remove the bolts (Item 1) [Figure 70-120-1] from the seated properly.
flywheel.

Remove the flywheel from the engine crankshaft.

Installation: Tighten the flywheel bolts to 98 - 108 N•m

(72 - 80 ft-lb) torque.

Installation: There are two alignment pins that are used

to install the flywheel in the proper position for timing
purposes.

729 of 822 70-120-1 T870 Service Manual

FLYWHEEL AND HOUSING (CONT’D)

Housing Removal And Installation

Figure 70-120-3

1
1

1
1

1
P100237

Remove the drive belt. (See Belt Replacement on Page

30-50-1.)

Dealer Copy -- Not for Resale

Remove the hydrostatic pump. (See Removal And
Installation on Page 30-40-4.)

Remove the belt tension pulley assembly. (See Tensioner

Pulley Removal And Installation on Page 30-50-3.)

Remove the starter. (See Removal And Installation on

Page 60-40-1.)

Remove the flywheel housing mounting bolts (Item 1)

[Figure 70-120-3].

Installation: Tighten the mounting bolts to 88,1 - 101,7

N•m (65 - 75 ft-lb) torque.

Remove the flywheel housing from the engine.

730 of 822 70-120-2 T870 Service Manual

EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Description

Exhaust Gas Recirculation (EGR) is a system in which the exhaust gas with lean oxygen is cooled and returned to the
cylinders again in order to lower the combustion temperature.

An External / Mechanical EGR consists of a water cooled EGR cooler, mechanical EGR valve, reed valve and thermo
valve. When the coolant temperature is high and the boost pressure is low, the EGR valve will not open. If the coolant
temperature is high and the boost pressure is also high, the EGR valve will open allowing cooled gas back into the intake
manifold.

The reed valve between the EGR valve and the intake manifold prevents fresh air from flowing into EGR system.

Figure 70-130-1

2
2
7
9

Dealer Copy -- Not for Resale

11

7 3
10 12

8
4
1
13

15

6
14

P-76942

The items listed below refer to Page 70-130-1 [Figure

70-130-1].

1. Thermo Valve 9. Cooled EGR Gas

2. Mechanical EGR Valve 10. To The Intake Manifold
3. Reed Valve 11. Fresh Air
4. Intake Manifold 12. Cooled EGR Gas Merges With Fresh Air
5. Exhaust Manifold 13. Exhaust
6. EGR Cooler 14. Coolant Inlet
7. Boost Pressure 15. Coolant Outlet
8. Coolant Temperature

731 of 822 70-130-1 T870 Service Manual

EXHAUST GAS RECIRCULATION (EGR) SYSTEM Cold Engine Coolant Temperature Test
(CONT'D)
Start the engine and run at low idle.
Testing
Start Service Analyzer and select [Monitor].
There are two tests for checking the EGR system. Both
tests will need to be performed and the coolant must be Select [Engine Temperature].
monitored through the Service Analyzer.

The Cold Engine Coolant Temperature Test will need to

be performed with the engine coolant below 55°C
WARNING
(131°F). The Hot Engine Coolant Temperature Test will
need to be performed with the engine coolant above AVOID BURNS
70°C (158°F). Some surfaces of the Exhaust Gas Recirculation
system can be hot. Use caution when conducting
diagnostic tests.

Allow the engine to cool before servicing.

WARNING W-2716-0208

AVOID INJURY OR DEATH NOTE: Verify the engine temperature is below 55°C
When the engine is running during service, the (131°F). If the engine temperature is above
steering levers or joysticks must be in neutral and 55°C (131°F), let the engine cool down and
the parking brake engaged. restart the Cold Engine Coolant temperature

Dealer Copy -- Not for Resale

W-2717-0208 Test.

NOTE: Monitor the engine coolant temperature using

the Service Analyzer.

WARNING Figure 70-130-1

MACHINE FALLING OR MOVING CAN CAUSE

1
SERIOUS INJURY OR DEATH
Put jackstands under the front and rear of the
machine before running engine for service.
W-2718-0208

Lift and block the loader. (See Procedure on Page 10-10-

1.)

Open the rear door.

Connect the Service PC (See SERVICE PC (LAPTOP

COMPUTER) on Page 60-140-1.) P-76949

Measure the surface temperature of the EGR pipe (Item

WARNING 1) [Figure 70-130-1] with an Infrared Thermometer.

AVOID INJURY OR DEATH If the engine coolant temperature is below 55°C (131°F)
When an engine is running in an enclosed area, fresh and the surface temperature of the EGR pipe is 50°C
air must be added to avoid concentration of exhaust (122°F) or below, the EGR system is OK, Continue with
fumes. If the engine is stationary, vent the exhaust the Hot Engine Coolant temperature Test.
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning. If the surface temperature of the EGR pipe reads 100°C
W-2050-0807 (212°F) or above continue this Cold Engine Coolant
Temperature Test.

732 of 822 70-130-2 T870 Service Manual

EXHAUST GAS RECIRCULATION (EGR) SYSTEM Hot Engine Coolant Temperature Test
(CONT'D)
Verify the engine temperature is above 70°C (158°F), if
Testing (Cont’d) the engine temperature is below 70°C (158°F) run the
engine to bring the temperature above 70°C (158°F) then
Figure 70-130-2 continue with the Hot Engine Coolant Temperature Test.

Figure 70-130-4

P-76956

P-76949
Disconnect the boost hose (Item 1) [Figure 70-130-2]

Dealer Copy -- Not for Resale

from the intake.
Measure the surface temperature of the EGR pipe (Item
Figure 70-130-3 1) [Figure 70-130-4] with an Infrared Thermometer.

With the engine coolant temperature above 70°C (158°F)

1 and the surface temperature of the EGR pipe 100°C
(212°F) or above, the EGR system is OK.

If the surface temperature of the EGR pipe is 50°C

(122°F) or below continue this Hot Engine Coolant
Temperature Test.

Figure 70-130-5

P-76949

1
Measure the surface temperature of the EGR pipe (Item
1) [Figure 70-130-3] with an Infrared Thermometer.

If the surface temperature of the EGR pipe declines, the

thermo valve has failed.
1
If the surface temperature of the EGR pipe stays above
100°C (212°F), the EGR valve has failed. P-76956

Disconnect the two hoses (Item 1) [Figure 70-130-5].

733 of 822 70-130-3 T870 Service Manual

EXHAUST GAS RECIRCULATION (EGR) SYSTEM
(CONT'D)

Testing (Cont’d)

Figure 70-130-6

P-76957

Connect a hose (Item 1) [Figure 70-130-6] directly

Dealer Copy -- Not for Resale

between the intake manifold and the EGR valve.

Figure 70-130-7

P-76949

Measure the surface temperature of the EGR pipe (Item

1) [Figure 70-130-7] with an Infrared Thermometer.

If the surface temperature of the EGR pipe increases, the

thermo valve has failed.

If the surface temperature of the EGR pipe is 50°C

(122°F) or below, the EGR valve has failed.

734 of 822 70-130-4 T870 Service Manual

EXHAUST GAS RECIRCULATION (EGR) SYSTEM Figure 70-130-9
(CONT'D)

Removal And Installation

WARNING
AVOID BURNS
Some surfaces of the Exhaust Gas Recirculation
system can be hot. Use caution when conducting
diagnostic tests.

Allow the engine to cool before servicing. P-76952

W-2716-0208

Allow the engine to cool before working on the EGR Remove the EGR valve (Item 1) [Figure 70-130-9].
system.
Installation: When reassembling replace with new
Figure 70-130-8 gaskets.

Figure 70-130-10

Dealer Copy -- Not for Resale

1 2

3 1

4 2

5 3

P-76951

P-76954
Remove the EGR pipe (Item 2) from the EGR valve (Item
1) [Figure 70-130-8].
Disconnect the hose (Item 1) from the intake manifold
Remove the EGR cooler (Item 4), the coolant inlet pipe flange [Figure 70-130-10].
(Item 6) and the coolant outlet pipe (Item 3) [Figure 70-
130-8]. Disconnect the hose (Item 2) from the EGR valve [Figure
70-130-10].
Remove the EGR flange (Item 5) [Figure 70-130-8].
Remove the thermo valve (Item 3) [Figure 70-130-10].
Installation: When reassembling replace with new
gaskets. Installation: Tighten the thermo valve to 30 - 39 N•m (22
- 28 ft-lb)

NOTE: If the thermo valve is dropped it must be

replaced with a new one.

735 of 822 70-130-5 T870 Service Manual

 Dealer Copy -- Not for Resale

736 of 822 70-130-6 T870 Service Manual

 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-3
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-6

REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Compressor Drive Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Compressor Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Air Conditioning Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Air Conditioning Service Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-3
Evaporator / Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-4

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . . . . . . . . . . . . . . . . . 80-30-1
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal . . . 80-30-1

Dealer Copy -- Not for Resale

The Compressor Does Not Operate At All, Or Operates Improperly . . . . . . . . . . . . 80-30-1
Gauge Pressure Related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-2
Troubleshooting Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-4
Temperature / Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-7
Poor A/C Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-9
HVAC Repair And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-10
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-30-11
Engine Coolant Bypassing The Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-17
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-18

SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Refrigerant Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
Reclamation And Charging With Recovery / Charging Unit . . . . . . . . . . . . . . . . . . . 80-40-2

COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-3
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-4

CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1

RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1

Receiver / Drier Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1
Pressure Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-2
Pressure Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-3
Schrader® Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-4

737 of 822 80-01 T870 Service Manual

EVAPORATOR / HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-2

EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1

EVAPORATOR COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-110-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-110-1

HEATER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1

BLOWER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1

HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1

Dealer Copy -- Not for Resale

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1

738 of 822 80-02 T870 Service Manual

AIR CONDITIONING SYSTEM FLOW

Description

In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.

The compressor (Item 1) (See Chart on Page 80-10-2.) takes in low temperature, low pressure refrigerant gas through the
suction valve (low pressure side) and as the name indicates, pressurizes the refrigerant and forces it through the discharge
valve (high pressure side) and to the condenser (Item 2) (See Chart on Page 80-10-2.)

Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.

The liquid refrigerant moves on to the receiver / drier (Item 3) (See Chart on Page 80-10-2.) where impurities such as
moisture and dirt are filtered out. The receiver / drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) (See Chart on Page 80-10-2.)

The expansion valve meters the amount of refrigerant entering the evaporator coil (Item 5) (See Chart on Page 80-10-2.)
As the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature,
low-pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown across the evaporator by the evaporator fan
(Item 6) (See Chart on Page 80-10-2.) Since the refrigerant is colder than the air, it absorbs the heat from the air which
results in cooled air, which is pushed into the cab by the blower. The moisture in the air condenses on the evaporator coil

Dealer Copy -- Not for Resale

and drips into the drain pan, which directs the water out of the cab.

The refrigerant cycle is completed when the low temperature low pressure gas is again drawn into the compressor.

739 of 822 80-10-1 T870 Service Manual

AIR CONDITIONING SYSTEM FLOW (CONT'D)

Chart

Thermostat
Cold Air
Evaporator

5
Evaporator
4
Expansion Valve

Blower
6

Dealer Copy -- Not for Resale

1 Compressor

2 Condenser

Pressure
Switch
Sight
Glass

Fan
Desiccant
3 Receiver Drier

Status Of R134a_______________________________________________

High Pressure Gas Low Pressure Liquid

High Pressure Liquid Low Pressure Gas

b-16691

740 of 822 80-10-2 T870 Service Manual

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 80-10-3

Components
1
Figure 80-10-1
2

P-89545

Receiver / Drier: The receiver / drier (Item 1) [Figure 80-

P100384 10-3] is the unit that receives the liquid refrigerant from
the condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
Compressor: The compressor (Item 1) [Figure 80-10-1] extra liquid refrigerant until it is needed by the evaporator.
is the pump that circulates the refrigerant throughout the

Dealer Copy -- Not for Resale

system. It raises the pressure of the refrigerant for heat Figure 80-10-4
transfer through the condenser and evaporator.

NOTE: The A/C system (Compressor) is

recommended to be turned on for at least 5
minutes weekly throughout the year to
lubricate the internal components.

Figure 80-10-2 1

1 N-22206

Pressure Relief Valve: The pressure relief valve (Item 2)

[Figure 80-10-3] is located on the receiver drier
assembly. This small brass valve (Item 1) [Figure 80-10-
4] is a safety feature that is designed to open and release
the A/C charge if the pressure reaches 3688,7 kPa (36,9
P-85824 bar) (535 psi).

Condenser: The condenser (Item 1) [Figure 80-10-2] is

the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.

741 of 822 80-10-3 T870 Service Manual

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 80-10-7

Components (Cont'd)
2
Figure 80-10-5 4

3
1

P101946

1
Evaporator Coil: The evaporator coil (Item 1) [Figure 80-
P100889 10-7] cools and dehumidifies the air before it enters the
cab.

Heater / Evaporator Unit: The heater / evaporator unit Thermostat: The thermostat (Item 2) [Figure 80-10-7]
(Item 1) [Figure 80-10-5] is located behind the loader controls the temperature of the evaporator coil.

Dealer Copy -- Not for Resale

cab. The unit delivers the cold air for the A/C and warm
air for heat into the cab. The unit contains the blower, Heater Coil: The heater coil (Item 3) [Figure 80-10-7]
heat and A/C coils, thermostat and expansion valve. supplies the warm air into the cab by passing air through
the coil.
Figure 80-10-6
Heater / Evaporator Blower: The blower (Item 4) [Figure
80-10-7] is used to push air through the heater and
evaporator coils and into the cab.

P100878

Expansion Valve: The expansion valve (Item 1) [Figure

80-10-6] controls the amount of refrigerant entering the
evaporator coil.

742 of 822 80-10-4 T870 Service Manual

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 80-10-10

Components (Cont'd)

Figure 80-10-8

1
1

2
3
4 P-89545

Pressure Switch: The pressure switch (Item 1) [Figure

P-92638 80-10-10] will disengage the compressor clutch at high
pressure readings over 2647,6 kPa (2647 bar) (384 psi)
on the high side, or at very low pressure of 193,1 kPa
Control Panel: The panel (Item 1) [Figure 80-10-8] has (193 bar) (28 psi) or less on the high side, which
three separate components. indicates loss of refrigerant.

Dealer Copy -- Not for Resale

Fan Switch: This is a four position rotary switch (Item 2)
[Figure 80-10-8]. When the fan switch is in the off
position the A/C will not engage, but the heat valve will
operate, as it is controlled by the ignition power.

A/C Switch: The rocker switch (Item 3) [Figure 80-10-8]

will be illuminated when the A/C is engaged.

Potentiometer: The potentiometer (Item 4) [Figure 80-

10-8] controls the Heat Valve from fully Off to fully On.
This can be used in conjunction with the A/C for defrost
of the windows and temperature control.

Figure 80-10-9

P101968

Heater Valve: The heater valve (Item 1) [Figure 80-10-9]

is used to control the amount of engine coolant that flows
to the heater coil.

743 of 822 80-10-5 T870 Service Manual

AIR CONDITIONING SYSTEM FLOW (CONT'D)

Safety Equipment
WARNING
Figure 80-10-11
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500

R-134a inside a canister or in an A/C system is a liquid

under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO -6°C (21.6°F)
“INSTANTLY”. If it spills on your skin or in your eyes you
should flood the area with cool water and SEEK
MEDICAL ATTENTION FAST! It is a good idea to wear
gloves [Figure 80-10-12] to prevent frost bite if you
should get refrigerant on your hands.
P16398

Figure 80-10-12
WARNING

Dealer Copy -- Not for Resale

HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
if it contacts the eyes and may cause serious
frostbite if it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air.
Any servicing work that involves release or addition
of 134A to the system must be done by a competent
P16399 refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration
equipment.
In servicing A/C and heater systems you will be exposed W-2373-0500
to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.

In addition to exercising caution in your work, DO WEAR

SAFETY GLASSES OR A FACE SHIELD [Figure 80-
10-11] when you are using R-134a or a leak detector,
adjusting service valves or the manifold gage set
connectors. Safety glasses or a transparent face shield
are practical safety items and one or the other is
absolutely required.

744 of 822 80-10-6 T870 Service Manual

REGULAR MAINTENANCE Recirculation Filter (Earlier Models)

Filters Figure 80-20-2

Fresh Air Filters

Figure 80-20-1 1

3
2

P-90490A
2
1
The recirculation filter is located behind the operator’s
seat inside the operator cab. Flip the clamps (Item 1)
holding the filter up and remove the filter (Item 2) [Figure
P-90489A P-90492A 80-20-2].

Shake the filter or use a vacuum to clean. This can be

Dealer Copy -- Not for Resale

The fresh air filters are located behind the side windows done several times before replacement is required.
outside the operator cab. (Right side shown) Remove the
retaining screw (Item 1) and filter cover (Item 2) [Figure Install the filter into the opening and flip the clamps down
80-20-1]. to hold the filter in place.

Shake the filter (Item 3) [Figure 80-20-1] or use low Recirculation Filter (Later Models)
pressure air to remove dirt. This can be done several
times before replacement is required. Install the filter, Figure 80-20-3
filter cover and retaining screw.

1
P100755

The recirculation filter is located behind the operator’s

seat inside the operator cab. The filter cover is held in
place with three clips. Pull the cover at each end (Item 1)
[Figure 80-20-3] to remove.

Rinse the filter elements with water or use a vacuum to

clean. Do not use solvents.

Line up the clips on the filter cover with the slots provided
and push the cover into place.

745 of 822 80-20-1 T870 Service Manual

REGULAR MAINTENANCE (CONT’D) Figure 80-20-5

Compressor Drive Belt Adjustment

The air conditioning belt is a special maintenance free

type that is pretensioned over the pulleys. This belt
eliminates the need for a tensioning device and does not
require periodic adjustment. Contact your Bobcat dealer
for replacement parts.
Compressor Drive Belt Replacement 1
Stop the engine and open the rear door.
Figure 80-20-4

P100271

Insert a 1/2 inch breaker bar (Item 1) [Figure 80-20-5]

into the square opening provided in the air conditioning
compressor bracket as shown. Move the breaker bar
down until the bottom air conditioning compressor
mounting bolt (Item 1) [Figure 80-20-4] can be installed.

Dealer Copy -- Not for Resale

1 Tighten the mounting nut and bolts (Items 1 and 2)
[Figure 80-20-4].

Close the rear door.

P100070
Condenser

The condenser should be cleaned with the oil cooler and

the radiator.

Air Conditioning Lubrication

Run the air conditioning for about five minutes every

week to lubricate the internal components.
2

P100071

NOTE: The engine is shown removed for visual

clarity.
Remove the bottom air conditioning compressor
mounting bolt (Item 1) [Figure 80-20-4].
Loosen the top air conditioning compressor mounting nut
and bolt (Item 2) [Figure 80-20-4].

Move the air conditioning compressor toward the engine

as far as it will go and remove the belt from the pulleys.
Inspect the pulleys for wear.
Install new belt.

746 of 822 80-20-2 T870 Service Manual

REGULAR MAINTENANCE (CONT’D)

Air Conditioning Service Chart

Service Company / Phone Number:

Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:
Pre Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature At Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:

Dealer Copy -- Not for Resale

Explain Services Required:

Post Service Conditions 15 Minutes 30 Minutes Notes

Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:

747 of 822 80-20-3 T870 Service Manual

REGULAR MAINTENANCE (CONT’D) Later Models

Evaporator / Heater Coil Raise the operator cab. (See Raising on Page 10-30-1.)

Earlier Models Figure 80-20-8

Raise the operator cab. (See Raising on Page 10-30-1.)

Figure 80-20-6

P100756

Unhook cover latches (Item 1) [Figure 80-20-8] and

P-90419A remove the cover.

Dealer Copy -- Not for Resale

Figure 80-20-9
Remove cover screws (Item 1) [Figure 80-20-6] and
remove the cover.

Figure 80-20-7 1

P100757
2

Use low pressure air or water to remove debris from the

P-90420A heater coil (Item 1) and evaporator (Item 2) [Figure 80-
20-9].

Use low pressure air or water to remove debris from the Install the cover and lower the operator cab. (See
heater coil (Item 1) and evaporator (Item 2) [Figure 80- Lowering on Page 10-30-2.)
20-7].

Install the cover and lower the operator cab. (See

Lowering on Page 10-30-2.)

748 of 822 80-20-4 T870 Service Manual

TROUBLESHOOTING

Blower Motor Does Not Operate

Possible Cause Inspection Solution

1. Blown fuse. Inspect the fuse / wiring. Replace fuse / repair wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or connector.
connection.
3. Fan motor malfunction. Check the lead wires form the motor with a circuit Replace Motor.
tester.
4. Resistor malfunction. Check resistor using a circuit tester. Replace Resistor.
5. Fan motor switch malfunc- Check power into and out of the fan switch. Replace Fan Switch.
tion.

Blower Motor Operates Normally, But Air Flow Is Insufficient

Possible Cause Inspection Solution

1. Evaporator inlet obstruction. Check evaporator for plugging. Remove obstruction and clean
evaporator fins with air or
water.
2. Air leak. Check to make sure air ducts are properly con- Repair or adjust.
nected and seals are not damaged.
3. Defective thermo. switch Check thermostat using a circuit tester. Replace thermostat.

Dealer Copy -- Not for Resale

(frozen evaporator).
4. Plugged cab filters Check cab recirculation and fresh air filters. Clean or replace filters.

Insufficient Cooling Although Air Flow And Compressor Operation Are Normal

Possible Cause Inspection Solution

1. System low on refrigerant. The high side pressure will be low and bubbles Repair any leaks and recharge
may be present in sight glass on receive drier. the refrigerant to the correct
level.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the cor-
rect refrigerant level.

The Compressor Does Not Operate At All, Or Operates Improperly

Possible Cause Inspection Solution

1. Loose belt. The belt is vibrating or oscillating. Replace belt.
2. Internal compressor mal- The compressor is locked up and the belt slips. Replace compressor.
function.
Magnetic clutch related
3. Low battery voltage. Clutch slips. Recharge the battery.
4. Faulty coil. Clutch slips. Replace the magnetic clutch.
5. Oil on the clutch surface. Clutch slips. Replace or clean the clutch
surface.
6. Open coil. Clutch does not engage and there is no reading Replace clutch.
when a circuit tester is connected between the coil
and terminals.
7. Broken wiring or poor Clutch will not engage. Inspect the ground and Repair.
ground. connections.
8. Wiring harness compo- Test the conductance of the pressure switch, ther- Check operation / thermostat
nents. mostat, Relay, etc. LED status.

749 of 822 80-30-1 T870 Service Manual

TROUBLESHOOTING (CONT'D)

Gauge Pressure Related Troubleshooting

Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 30 - 38°C (86 - 96°F)
and compressor speed of approximately 3200 rpm are:
High pressure side pressure: 1447,9 - 1827,1 kPa (210 - 265 psi) (14,5 - 18,3 bar)
Low pressure side pressure: 103,4 - 227,5 kPa (1,0 - 2,3 bar) (15 - 33 psi)
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure.

Possible Cause Inspection Solution

Low pressure side Too The low pressure side pressure normally becomes too
high. high when the high pressure side pressure is too high. As
this is explained below, the following inspection is only
used when the low pressure side is too high.
1. Expansion valve Frost is present on the suction hose. Replace expansion valve.
opens too far.
2. Defective compres- The high and low pressure side gauge pressures equal- Replace compressor.
sor. ize when the magnetic clutch is engaged.
Low pressure side Too
low.
1. Low refrigerant The high side pressure will be low and bubbles may be Repair any leaks and recharge
charge. present in sight glass on receiver drier. the refrigerant to the correct

Dealer Copy -- Not for Resale

level.
2. Clogged or closed The expansion valve’s inlet side is frosted. Moisture or Clean or replace the expansion
expansion valve. other contaminants can be the cause. Valve.
3. Restriction between Frost on the line between drier and expansion valve. A Flush system or replace hose.
drier and expansion Negative low pressure reading may be shown.
valve.
4. Thermostat malfunc- The evaporator is frozen. Adjust thermostat’s tempera-
tion. ture setting or probe place-
ment or replace thermostat.
5. Restriction in Excessive frost on receiver drier. Replace receiver drier.
receiver drier.
High pressure side Too
high.
1. Poor condenser per- Dirty or clogged condenser fins. Condenser fans not Clean fins, and / or repair the
formance. operating. fan.
2. Excessive refriger- The high pressure side pressure will be high. Use refrigerant recovery equip-
ant. ment to capture excess refrig-
erant. Charge to the correct
refrigerant level.
3. Excessive oil charge. The high pressure side will be high. Evacuate system. Remove oil
from condenser and compres-
sor. Measure oil from compres-
sor and add correct oil charge
back into compressor. Flush
system with nitrogen. Replace
drier.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with
refrigerant.
5. Restriction in drier, High pressure side will be high, and low pressure side Evacuate and flush system
condenser or high pres- will be low. replacing defective parts.
sure line.

750 of 822 80-30-2 T870 Service Manual

TROUBLESHOOTING (CONT'D)

Gauge Pressure Related Troubleshooting (Cont'd)

Possible Cause Inspection Solution

High pressure side Too
low.
1. Low refrigerant charge. The high side pressure will be low. Repair any leaks and
recharge the refrigerant to
the correct level.
System pressures Equal
1. Clutch not operating. See magnetic clutch related topics above.
2. Compressor not pump- Equal high and low pressures. Replace compressor.
ing.

Dealer Copy -- Not for Resale

751 of 822 80-30-3 T870 Service Manual

TROUBLESHOOTING (CONT'D)

Troubleshooting Tree

Dealer Copy -- Not for Resale

P100890

752 of 822 80-30-4 T870 Service Manual

TROUBLESHOOTING (CONT'D)

Troubleshooting Tree (Cont’d)

Dealer Copy -- Not for Resale

p100892

753 of 822 80-30-5 T870 Service Manual

TROUBLESHOOTING (CONT'D)

Troubleshooting Tree (Cont’d)

Dealer Copy -- Not for Resale

P-90413

754 of 822 80-30-6 T870 Service Manual

TROUBLESHOOTING (CONT'D)

Temperature / Pressure Chart

NORMAL EVAPORATOR RANGE NORMAL CONDENSER RANGE

TEMP TEMP TEMP TEMP
kPa BAR PSIG kPa BAR PSIG
°C °F °C °F
-8,8 16 108,2 1,08 15.69 33,9 93 759,8 7,60 110.20
-7,8 18 117,5 1,17 17.04 34,4 94 773 7,73 112.10
-6,7 20 127,1 1,27 18.43 35 95 786,7 7,87 114.10
-5,6 22 137 1,37 19.87 37,8 100 857,1 8,57 124.30
-4,4 24 147,2 1,47 21.35 38,9 102 886 8,86 128.50
-3,3 26 157,8 1,58 22.88 40 104 916,3 9,16 132.90
-2,2 28 168,7 1,69 24.47 41,1 106 946,7 9,47 137.30
-1,1 30 180 1,80 26.10 42,2 108 978,4 9,78 141.90
0 32 191,6 1,92 27.79 43,3 110 1010.1 10,10 146.50
1,1 34 203,5 2,04 29.52 44,4 112 1043,2 10,43 151.30
2,2 36 216 2,16 31.32 45,6 114 1076,3 10,76 156.10
3,3 38 228,7 2,29 33.17 46,7 116 1110,7 11,11 161.10
4,4 40 241,8 2,42 35.07 47,8 118 1145,2 11,45 166.10
5,6 42 255,3 2,55 37.03 48,9 120 1181,1 11,81 171.30

Dealer Copy -- Not for Resale

6,7 44 269,3 2,69 39.05 50 122 1217,6 12,18 176.60
7,2 45 276,4 2,76 40.09 51,1 124 1254,8 12,55 182.00
10 50 313,6 3,14 45.48 52,2 126 1292,8 12,93 187.50
12,8 55 353,5 3,54 51.27 53,3 128 1331,4 13,31 193.10
15,6 60 396,3 3,96 57.47 54,4 130 1371,4 13,71 198.90
18,3 65 442 4,42 64.10 57,2 135 1473,4 14,73 213.70
21,1 70 490,8 4,91 71.19 60 140 1581,7 15,82 229.40
23,9 75 543 5,43 78.75 62,8 145 1694,7 16,95 245.80
26,7 80 598,5 5,99 86.80 65,6 150 1813,3 18,13 263.00
29,4 85 657,8 6,58 95.40 68,3 155 1938,1 19,38 281.10
32,2 90 719,8 7,20 104.40 71,1 160 2069,1 20,69 300.10
32,8 91 733 7,33 106.30 73,9 165 2207,1 22,07 320.10
33,3 92 746,1 7,46 108.20 76,7 170 2349,7 23,50 340.80

755 of 822 80-30-7 T870 Service Manual

TROUBLESHOOTING (CONT'D)

Temperature / Pressure Chart (Cont’d)

Evaporator

Pressures represent gas temperatures inside the coil. not the coil surface. For an estimate of the temperature of the air
coming off the coil add 4.5 - 5,5°C (8 - 10°F) to the temperature on the chart.

Condenser

Temperatures are not ambient temperatures but condensing temperatures. Add 4.4°C (40°F) to the ambient temperature
to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient
temperature.

Example: Ambient Temperature = 32°C

32°C
+4.4°C
54.4°C condenser temperature = 200 psig

Example: Ambient Temperature = 90°F

90°F
+40°F

Dealer Copy -- Not for Resale

130°F condenser temperature = 200 psig

Conditions and pressures will vary from system to system.

756 of 822 80-30-8 T870 Service Manual

TROUBLESHOOTING (CONT'D) Check the A/C condenser for dirt or mud and clean if
necessary. (See Removal And Installation on Page 80-
Poor A/C Performance 60-1.)

Start the loader, lock the park brake, and engage the A/C Check the A/C evaporator coil for dirt or mud and clean if
system with the blower fan on High. Run the loader at full necessary. (See Removal And Installation on Page 80-
throttle for approximately 15 minutes, with the loader cab 110-1.)
door closed.
Check the engine coolant to see if it is bypassing the
Figure 80-30-1 heater valve. (See Engine Coolant Bypassing The Heater
Valve on Page 80-30-17.)

Dealer Copy -- Not for Resale

P-90356

Figure 80-30-2

N-22411

Check the temperature at the louvers (Item 1) [Figure

80-30-1] with a thermometer [Figure 80-30-2].

The louver temperature should be between 7,2 - 11,7°C

(45 - 53°F) depending on the amount of humidity in the
air and ambient temperature.

If louver temperature is too high. (See Troubleshooting

Tree on Page 80-30-4.)

Check the blower for proper operation, or noise, and

replace if necessary. (See Removal And Installation on
Page 80-130-1.)

757 of 822 80-30-9 T870 Service Manual

TROUBLESHOOTING (CONT'D)

HVAC Repair And Leaks

Figure 80-30-3

P-90361

Whenever the A/C system is opened to the atmosphere

or there has been a leak in the system, the receiver /

Dealer Copy -- Not for Resale

drier (Item 1) [Figure 80-30-3] must be changed.

Never leave hose fittings, compressor fittings or

components uncapped while working on the A/C system.

758 of 822 80-30-10 T870 Service Manual

TROUBLESHOOTING (CONT’D) Figure 80-30-6

Electrical System

Check to see if the compressor clutch is engaging.

1
With an operator in the loader seat and the cab door
open, turn the loader key switch to RUN OR press the
RUN Button, without starting the loader.

Figure 80-30-4

P-90357

Locate the loader harness and the compressor clutch

wire (Item 1) [Figure 80-30-6].
2
1 Disconnect the loader harness (Item 1) [Figure 80-30-6]
from the compressor clutch wire.

Dealer Copy -- Not for Resale

Figure 80-30-7
P-92638

Push the A/C switch (Item 1) to the ON position. Turn the

blower switch (Item 2) [Figure 80-30-4] to the first ON
position.
1
The compressor clutch should make a click sound, which
indicates the clutch is engaging.

Figure 80-30-5

P-90358

1
With a multi meter, check the resistance to the
compressor clutch (Item 1) [Figure 80-30-7].

If there is no resistance value, replace the compressor

clutch.

P100416

If the compressor clutch does not engage, check the

HVAC fuse (Item 1) [Figure 80-30-5] located in the fuse
panel.

Open the rear door (tailgate).

759 of 822 80-30-11 T870 Service Manual

TROUBLESHOOTING (CONT’D) Figure 80-30-10

Electrical System (Cont’d)

Figure 80-30-8

P-90360
1

Using a multi meter check the loader wiring harness

P-90358 (Item 1) [Figure 80-30-10] for voltage.

The voltage should be battery voltage.

With a multi meter, check the voltage to the compressor
clutch at the loader harness (Item 1) [Figure 80-30-8]. If there is no voltage at the wiring harness, check the

Dealer Copy -- Not for Resale

harness for broken wires.
The voltage reading should be battery voltage.
Figure 80-30-11
If there is no power at the clutch, check the wiring
harness for broken wires.

If there is power at the clutch, reconnect the wiring

harness to the compressor clutch.

Figure 80-30-9

1
P-90360

If there is voltage at the harness, check the resistance at

2
the pressure switch (Item 1) [Figure 80-30-11].

If there is no resistance value, check for low refrigerant

1 P-90361 level. (See Reclamation And Charging With Recovery /
Charging Unit on Page 80-40-2.)

Disconnect the loader harness (Item 1) from the pressure If a resistance value is seen, the pressure switch is good.
switch (Item 2) [Figure 80-30-9].
Reconnect the loader harness to the pressure switch.

760 of 822 80-30-12 T870 Service Manual

TROUBLESHOOTING (CONT’D) Figure 80-30-14

Electrical System (Cont’d)

Figure 80-30-12

1 P-90363

Disconnect the blower wiring connector (Item 1) [Figure

P100951 80-30-14] from the loader wiring harness.

Figure 80-30-15
Raise the operator cab. (See Raising on Page 10-30-1.)
Disconnect the thermostat wiring connector (Item 1)

Dealer Copy -- Not for Resale

[Figure 80-30-12] from the loader wiring harness.

Figure 80-30-13

1
P-90362

2
Check the loader harness (Item 1) [Figure 80-30-15] for
1
voltage. The voltage should be battery voltage.

P-90362
If there is no voltage at the wiring harness, check the
harness for broken wires.
Check the loader harness (Item 1) [Figure 80-30-13] for
voltage. The voltage should be battery voltage. If there is voltage at the wiring harness, check the
resistance to the blower at the blower wiring connector
If there is no voltage at the wiring harness, check the
(Item 2) [Figure 80-30-15].
harness for broken wires.

If there is voltage at the wiring harness, check the If there is no resistance value replace the blower. (See
thermostat (Item 2) [Figure 80-30-13] for resistance. Removal And Installation on Page 80-130-1.)

The resistance value of the thermostat should be 10 ohm If there is a resistance value check the climate controls at
at 20°C (68°F). the control panel inside the loader cab.
If there is no resistance value, replace the thermostat.
(See Removal And Installation on Page 80-90-2.)

If there is a resistance value, check the blower.

761 of 822 80-30-13 T870 Service Manual

TROUBLESHOOTING (CONT’D) Figure 80-30-18

Electrical System (Cont’d)

Figure 80-30-16 C
H

B
1 M

N-22288

If there is voltage at the wiring harness, check the blower

P-90364 switch [Figure 80-30-18] for resistance.

With the switch in the 1 position, there should be

Remove the control panel (Item 1) [Figure 80-30-16] resistance between C terminal and the B terminal. And
from the left side lower panel. also between the C terminal and the L terminal frame

Dealer Copy -- Not for Resale

[Figure 80-30-18].
Figure 80-30-17
With the switch in the 2 position, there should be
resistance between C terminal and the B terminal. And
also between the C terminal and the M terminal frame
[Figure 80-30-18].

With the switch in the 3 position, there should be

resistance between C terminal and the B terminal. And
1 also between the C terminal and the H terminal frame
[Figure 80-30-18].

If any of the above resistance tests fail, replace the

blower switch.

If the above resistance tests are good, check the A/C

P-90365 switch.

Disconnect the loader wiring harness (Item 1) [Figure

80-30-17] from the blower switch.

Check the loader harness for voltage. The voltage should

be battery voltage.

If there is no voltage at the wiring harness, check the

harness for broken wires.

762 of 822 80-30-14 T870 Service Manual

TROUBLESHOOTING (CONT’D) If no resistance value is found, replace the A/C switch.

Electrical System (Cont’d) If a resistance value is found, check the potentiometer.

Figure 80-30-19 The potentiometer will effect the A/C system and also
effect the operation of the heater.

If heater valve does not open, or close, or the A/C does

not work, check the potentiometer.
1
Figure 80-30-21

1
P-90367

At the loader cab, disconnect the loader harness (Item 1)

[Figure 80-30-19] from the A/C switch.

Dealer Copy -- Not for Resale

Check the harness for voltage. The voltage should be
P-90366
battery voltage.

If there is no voltage at the wiring harness, check the At the loader cab, disconnect the loader harness (Item 1)
harness for broken wires. [Figure 80-30-21] from the potentiometer.

Figure 80-30-20 Check the loader harness (Item 1) [Figure 80-30-21] for
voltage. The voltage should be battery voltage.

If there is no voltage at the wiring harness, check the

harness for broken wires.

1
2

N-22289

If there is voltage at the wiring harness, check the A/C

switch [Figure 80-30-20] for resistance.

With the switch in the OFF position there should be no

resistance between any of the three terminals on the A/C
switch.

With the switch in the ON position there should be

resistance between terminal (Item 1) and terminal (Item
2) [Figure 80-30-20].

763 of 822 80-30-15 T870 Service Manual

TROUBLESHOOTING (CONT’D) Figure 80-30-24

Electrical System (Cont'd)

Figure 80-30-22

A C

A C
B

N-22290
B

The resistance between the wire terminal A and wire

N-22290 terminal B frame [Figure 80-30-24] should be around 0K
ohm.

If there is voltage at the wiring harness, check the Check the resistance between the wire terminal C and
potentiometer [Figure 80-30-22] for resistance. wire terminal B frame [Figure 80-30-24] should be

Dealer Copy -- Not for Resale

around 10K ohm.
The resistance should be 10K ohm between wire pin A
and wire pin C frame [Figure 80-30-22].

If no resistance is found replace the potentiometer.

Figure 80-30-23

P-90368

To check the resistance of the white wire, turn the

potentiometer control (Item 1) [Figure 80-30-23]
counterclockwise to the full A/C position.

764 of 822 80-30-16 T870 Service Manual

TROUBLESHOOTING (CONT’D) Engine Coolant Bypassing The Heater Valve

Electrical System (Cont'd) Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
Figure 80-30-25
Figure 80-30-27

2 3
1
1

P-90369
P-90364A

To check the resistance of the white wire, turn the Push the A/C switch (Item 1) to the OFF position, turn the
potentiometer control (Item 1) [Figure 80-30-25] blower switch (Item 2) to position 1, then turn the

Dealer Copy -- Not for Resale

clockwise to the full Heater position. temperature control (Item 3) [Figure 80-30-27]
counterclockwise to the full A/C position, with the loader
Figure 80-30-26 ignition switch OFF.

Raise the operator cab. (See Raising on Page 10-30-1.)

Connect the remote start tool. (See REMOTE START

TOOL KIT-MEL1563 on Page 10-60-1.) or (See
REMOTE START TOOL (SERVICE TOOL) KIT -
7003031 on Page 10-61-1.)
A C
Start the loader and run at high idle, for ten minutes.

Figure 80-30-28
B

N-22290

Check the resistance between the wire terminal A and

wire terminal B frame [Figure 80-30-26] should be
around 10K ohm. 1

Check the resistance between the wire terminal C and

wire terminal B frame [Figure 80-30-26] should be
around 0K ohm.
P-90371
If the resistance is not found replace the potentiometer.
Check the heater hose (Item 1) [Figure 80-30-28] for
temperature.

If the hose is hot, the heater valve is leaking by, and

needs to be replace.

765 of 822 80-30-17 T870 Service Manual

TROUBLESHOOTING (CONT’D) Figure 80-30-30

Heater Valve Not Opening Or Closing

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)

Figure 80-30-29

P100896

NOTE: The HVAC assembly is removed for photo

2 3 clarity.
1
Place the remote start tool on the left fender of the loader,
P-90364A so the heater valve can be clearly seen. Watch the valve
shaft (Item 1) [Figure 80-30-30], as the key of the remote

Dealer Copy -- Not for Resale

start is turned to the ON position without starting the
Push the A/C switch (Item 1) to the OFF position, turn the loader. The heater valve should rotate. Place a mark on
blower switch (Item 2) to position 1 and turn the the loader shaft.
temperature control (Item 3) [Figure 80-30-29] to the
High A/C position, with the loader ignition switch OFF. Turn the remote start key to the OFF position and remove
the remote start tool from fender.
Raise the operator cab. (See Raising on Page 10-30-1.)
Lower operator cab.
Connect the remote start tool. (See REMOTE START
TOOL KIT-MEL1563 on Page 10-60-1.) or (See Turn the temperature control (Item 3) [Figure 80-30-29]
REMOTE START TOOL (SERVICE TOOL) KIT - to the High Heater position, with the loader ignition switch
7003031 on Page 10-61-1.) OFF.

Raise the operator cab.

Place the remote start tool on the left fender of the loader,
so the heater valve can be clearly seen. Watch the valve
shaft (Item 1) [Figure 80-30-30], as the key of the remote
start is turned to the ON position without starting the
loader. The heater valve should rotate.

If it does not rotate, check the potentiometer for proper

function. (See Electrical System on Page 80-30-11.)

Replace the heater valve. (See Removal And Installation

on Page 80-140-1.)

766 of 822 80-30-18 T870 Service Manual

SYSTEM CHARGING AND RECLAMATION Connect the Refrigerant Identifier to its power source.

Refrigerant Identification Follow the steps displayed on the refrigerant identifier

screen.

Allow two minutes for the refrigerant identifier to display

WARNING the type of refrigerant and air content. An alarm will
sound if potentially flammable hydrocarbons are present
and will also indicate on the visual display.
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In Disconnect the refrigerant identifier from the loader A/C.
contact with a flame, R134a refrigerant gives a toxic
gas. If the refrigerant is dangerous or flammable, it must be
W-2371-0500 evacuated from the A/C system into a separate container
and properly and safely disposed of.
Figure 80-40-1

Dealer Copy -- Not for Resale

N-23024

NOTE: It is recommended to identify the type of

refrigerant that is in the A/C system and if it is
pure enough to use. The tool MEL1592,
Refrigerant Identifier (Item 1) [Figure 80-40-1]
will determine, the kind of refrigerant and any
possible harmful or dangerous substances
that may be present in the system. Thus
preventing mixing of dangerous material with
your reclaimed R-134a in your reclaimer, and
further contamination to other A/C systems
that are reclaimed and charged from your
MEL1581 Recovery / Recycling / Recharging
Machine.

NOTE: This test is run with the loader engine OFF,

and the A/C switch in the OFF position.

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)

Raise the operator cab. (See Raising on Page 10-30-1.)

Connect the Refrigerant Identifier to the low pressure

hose.

767 of 822 80-40-1 T870 Service Manual

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-40-3

Reclamation And Charging With Recovery / Charging

Unit

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)

Raise the operator cab. (See Raising on Page 10-30-1.)

Figure 80-40-2

N-22291

IMPORTANT: Only trained technicians should

perform the reclaiming and recharging.

WARNING

Dealer Copy -- Not for Resale

P100895
HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
Locate the low pressure port (Item 1), and high pressure if it contacts the eyes and may cause serious
port (Item 2) [Figure 80-40-2]. frostbite if it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
WARNING • NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air.
Any servicing work that involves release or addition
In the event of a leak, wear safety goggles. Escaping of 134A to the system must be done by a competent
refrigerant can cause severe injuries to eyes. In refrigeration dealer who has the proper equipment,
contact with a flame, R134a refrigerant gives a toxic knowledge, and experience to service refrigeration
gas. equipment.
W-2371-0500 W-2373-0500

Use an approved recovery / charging unit [Figure 80-40-

3] to evacuate the system.

768 of 822 80-40-2 T870 Service Manual

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-40-6

Reclamation And Charging With Recovery / Charging

Unit (Cont'd)

Figure 80-40-4

N-22292

Turn the reclaimer unit [Figure 80-40-6] to the ON

position and follow the on screen instructions.
P100385
NOTE: The A/C system holds 0,91 kg (2 lb) of
refrigerant.
Figure 80-40-5

Dealer Copy -- Not for Resale

Figure 80-40-7

1
2

P100950
N-22381

Connect the reclaimer to the loader A/C charge ports

[Figure 80-40-4]. NOTE: The reclaimer unit, has a complete step by
step set of instructions [Figure 80-40-7] to
Connect the Blue hose (Item 1) [Figure 80-40-5] to the follow for reclamation and recharging of the
low pressure port and open the valve. A/C system. A trained technician should
follow these instructions as they may vary
Connect the Red hose (Item 2) [Figure 80-40-5] to the slightly depending on the model and brand of
high pressure port and open the valve. reclaimer used.

769 of 822 80-40-3 T870 Service Manual

 Dealer Copy -- Not for Resale

770 of 822 80-40-4 T870 Service Manual

COMPRESSOR Remove the compressor mount bolt (Item 1) and the belt
(Item 2) [Figure 80-50-2].
Removal And Installation
Installation: Tighten the compressor mount bolt to 46
NOTE: If compressor is being removed for engine N•m (34 ft-lb) torque.
removal it is not necessary to remove the A/C
hoses. Remove the mounting bolts and belt
and reposition the compressor.

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
WARNING
Raise the operator cab. (See Raising on Page 10-30-1.) In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
Evacuate the A/C system. (See Reclamation And contact with a flame, R134a refrigerant gives a toxic
Charging With Recovery / Charging Unit on Page 80-40- gas.
2.) W-2371-0500

Open the rear door.

NOTE: Engine removed for photo clarity.
Figure 80-50-1
Figure 80-50-3

Dealer Copy -- Not for Resale

2

3
1 1

P-90357
P-89543

Disconnect the loader harness (Item 1) [Figure 80-50-1]

from the compressor clutch wire. Remove the compressor hoses (Item 1) [Figure 80-50-3]
from the compressor.
Figure 80-50-2
Installation: Tighten the compressor hose (Item 2) to 20
-27 N•m (15 - 20 ft-lb) torque.

Installation: Tighten the compressor hose (Item 3) to 28

- 37 N•m (21 - 27 ft-lb) torque.
1
Cap and plug the compressor hoses and the fittings with
with the proper A/C caps and plugs.

2
P100070

771 of 822 80-50-1 T870 Service Manual

COMPRESSOR (CONT'D)

Removal And Installation (Cont’d)

Figure 80-50-4

P101247

Remove the compressor mounting bolt and nut (Item 1)

[Figure 80-50-4].

Dealer Copy -- Not for Resale

Remove the compressor from the loader.

772 of 822 80-50-2 T870 Service Manual

COMPRESSOR (CONT'D) If the amount of refrigerant in the system has decreased,
charge the system. (See SYSTEM CHARGING AND
Oil RECLAMATION on Page 80-40-1.)

Figure 80-50-5 Open the cab door and windows.

Run the blower at maximum speed.

Run the compressor for at least 20 minutes at 800 - 1200

rpm.

Remove the compressor from the loader. (See Removal

1 And Installation on Page 80-50-1.)

P100384

The compressor (Item 1) [Figure 80-50-5] is factory filled

with 150 - 170 cc's of PAG 100 oil (Poly Alkelene Glycol).

Dealer Copy -- Not for Resale

Unlike engine oil, it is not necessary to frequently check
or change the compressor oil.

It is necessary to check, replenish or replace the

compressor oil in the following cases:

• When ever the evaporator, condenser or receiver-

drier is replaced.

• Whenever the refrigerant has leaked from the system.

When one of the components (the evaporator, condenser

or receiver-drier) is replaced, one ounce of oil should be
added for each component replaced.

If the A/C compressor is changed, no oil should be added

to the system, because the compressor comes factory
filled with oil.

NOTE: Only PAG 100 oil should be used, and never

mix R-12 and R-134a Oils.

The compressor oil should be checked as follows when

oil is being added to an in service loader.

There is a close affinity between oil and refrigerant.

During normal operation, part of the oil circulates with the
refrigerant in the system. Therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run in advance to
ensure return of oil to the compressor.

773 of 822 80-50-3 T870 Service Manual

COMPRESSOR (CONT'D) Figure 80-50-8

Oil Check

Figure 80-50-6

1
P100384

NOTE: After draining the oil through the drain hole

P100386 and the connectors, extract the remaining oil
through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-50-
Figure 80-50-7 8] several times by hand.

Dealer Copy -- Not for Resale

Measure the drained oil in a measuring cylinder.

Check the oil for contamination, dirt, metal shavings, or

varnish color, discard the oil if contaminated.

NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.

Figure 80-50-9

P-16534A

Remove the oil drain plug (Item 1) [Figure 80-50-6] and

drain the oil through the connectors and the oil drain hole 1
[Figure 80-50-7].

Installation: Tighten the oil drain plug to 13 - 15 N•m (9.4

- 10.8 ft-lb) torque.

P100386

Add new compressor oil through the suction side

connector (Item 1) [Figure 80-50-9].

Installation: Add 150 - 170 cc's of PAG 100 oil.

NOTE: The suction port on the compressor is marked

with an SUC and is the larger port on the
compressor.

774 of 822 80-50-4 T870 Service Manual

CONDENSER Figure 80-60-2

Removal And Installation

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)

Raise the operator cab. (See Raising on Page 10-30-1.)

Remove the rear grille. (See Removing on Page 50-60- 1

1.)

Remove the refrigerant from the A/C system. (See

Reclamation And Charging With Recovery / Charging
Unit on Page 80-40-2.)
P-89546
Figure 80-60-1

Disconnect the hose (Item 1) [Figure 80-60-2] that

routes from the condenser to the receiver / dryer.

Cap and plug the hose and the condenser fittings with
1 the proper A/C caps and plugs.

Dealer Copy -- Not for Resale

Figure 80-60-3

P-85824 1

Remove the two brackets (Item 1) [Figure 80-60-1].

WARNING P-89548

In the event of a leak, wear safety goggles. Escaping

refrigerant can cause severe injuries to eyes. In Disconnect the hose (Item 1) [Figure 80-60-3] that
contact with a flame, R134a refrigerant gives a toxic routes from the condenser to the compressor.
gas.
W-2371-0500 Cap and plug the hose and the condenser fittings with
the proper A/C caps and plugs.

Remove the condenser.

775 of 822 80-60-1 T870 Service Manual

 Dealer Copy -- Not for Resale

776 of 822 80-60-2 T870 Service Manual

RECEIVER / DRIER Both fittings on the drier are the same size, so the hoses
can be hooked up incorrectly.
Receiver / Drier Removal And Installation
Cap and plug the hoses and the receiver / drier fittings
with the proper A/C caps and plugs.

WARNING NOTE: When replacing a receiver / drier in an A/C

system 30 cc of PAG 100 oil must be added to
the system when recharging.
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
Figure 80-70-2
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598

Remove the rear grille. (See Removing on Page 50-60-

1.)

Remove the refrigerant from the A/C system. (See

Reclamation And Charging With Recovery / Charging 1
Unit on Page 80-40-2.)

Dealer Copy -- Not for Resale

WARNING P-90493

In the event of a leak, wear safety goggles. Escaping Note the flow direction on the receiver / drier (Item 1)
refrigerant can cause severe injuries to eyes. In [Figure 80-70-2] for proper installation.
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500

Figure 80-70-1

P-90488

NOTE: Mark the A/C hoses (Item 1) [Figure 80-70-1]

for proper installation.

Remove the two A/C hoses (Item 1) [Figure 80-70-1]

from the receiver / drier.

777 of 822 80-70-1 T870 Service Manual

RECEIVER / DRIER (CONT’D) Pressure Relief Valve Removal And Installation

Receiver / Drier Removal And Installation (Cont’d) Figure 80-70-5

Figure 80-70-3
1

N-22205

P-92665
The pressure relief valve (Item 1) [Figure 80-70-5] is
located on the receiver / drier.
Loosen the two clamps (Item 1) and remove the receiver
/ drier (Item 2) [Figure 80-70-3]. Figure 80-70-6

Dealer Copy -- Not for Resale

Figure 80-70-4

N-22206

P-89521
The pressure relief valve [Figure 80-70-6] is designed to
open and release the A/C charge if the pressure reaches
Remove the two mount bolts (Item 1) [Figure 80-70-4] 3688,7 kPa (36,9 bar) (535 psi).
from the receiver / drier mount bracket.
This will cause the A/C system to shut down, saving the
compressor.

The pressure relief valve is a secondary protection

device in the A/C system, with the pressure switch
shutting down the system at 2647,6 kPa (26,5 bar) (384
psi).

NOTE: If a pressure relief valve is found open, test

the A/C system for problems. Replace the
complete receiver / drier unit.

778 of 822 80-70-2 T870 Service Manual

RECEIVER / DRIER (CONT’D) Figure 80-70-8

Pressure Switch Removal And Installation

Figure 80-70-7

1
1 P-90488

Remove the pressure switch (Item 1) [Figure 80-70-8]

P-90361 from the A/C high pressure hose.

Remove the pressure switch from the loader.

Disconnect the loader wire harness (Item 1) [Figure 80-
70-7] from the pressure switch wire harness.

Dealer Copy -- Not for Resale

NOTE: The pressure switch can be changed without
evacuating the A/C system.

WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500

779 of 822 80-70-3 T870 Service Manual

RECEIVER / DRIER (CONT’D)

Schrader® Valve Removal And Installation

Figure 80-70-9

N-22166

The Schrader® valve (Item 1) [Figure 80-70-9] is located

in the A/C high pressure hose and is located under the

Dealer Copy -- Not for Resale

pressure switch.

Remove the refrigerant from the A/C system. (See

Reclamation And Charging With Recovery / Charging
Unit on Page 80-40-2.)

Remove the pressure switch.

With a Schrader® valve removal tool, remove the valve

from the hose.

780 of 822 80-70-4 T870 Service Manual

EVAPORATOR / HEATER UNIT Figure 80-80-3

Removal And Installation

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)

Raise the operator cab. (See Raising on Page 10-30-1.)

1 2
2
Evacuate the A/C system. (See Reclamation And
Charging With Recovery / Charging Unit on Page 80-40-
2.)

Figure 80-80-1

P100900
1
NOTE: Support the evaporator / heater unit before
removing the mounting hardware.

Remove the two bolts (Item 1) [Figure 80-80-3].

1
Remove the two nuts (Item 2) [Figure 80-80-3].

Dealer Copy -- Not for Resale

Figure 80-80-4
1

3
P100879 3

Disconnect the expansion / heater unit wiring (Item 1)

[Figure 80-80-1].
1
2
Figure 80-80-2

1 P100899

1
Disconnect the two A/C hoses (Item 1) [Figure 80-80-4].

Cap and plug the hoses and the expansion valve fittings
with the proper A/C caps and plugs.

Installation: Tighten the A/C hoses to 29,8 N•m (22 ft-lb)

P100879 torque.

Remove the two bolts (Item 2) [Figure 80-80-4].

NOTE: Cap the heater hoses and the heater valve
with plugs to prevent coolant loss from the Remove the two nuts (Item 3) [Figure 80-80-4].
system.
Remove evaporator / heater unit from the loader.
Remove the two hoses (Item 1) [Figure 80-80-2].

781 of 822 80-80-1 T870 Service Manual

 Dealer Copy -- Not for Resale

782 of 822 80-80-2 T870 Service Manual

THERMOSTAT The EDT has the following protection built in:
1. Over temperature
Description
2. Over current from clutch output
The Electronic De-icing Thermostat (EDT) is a micro
controller based module that measures evaporator coil 3. Voltage (Above and below operational limits or
temperature and cycles the compressor clutch to reverse voltage)
maintain a constant evaporator pressure. Onboard circuit
protection and diagnostics are also built into the module. 4. Short circuit protection (Output shorted to ground)

NOTE: The EDT has a six second delay before start 5. Temperature sensor open and short detection
up to protect the compressor clutch.

The EDT will turn the clutch on when the evaporator coil DETECTION
MALFUNCTION STATUS LED
temperature is above 2°C (35.6°F). If the EDT does not INTERVAL
detect any malfunction, it will continue to operate and the Temperature Continuous 1x per second
status LED will be lit continuously. When the evaporator sensor
temperature is below -2°C (28.4°F), the EDT will turn off
Temperature At A/C start up 2x per second
the clutch and status LED.
sensor open and
short detection
Figure 80-90-1
Compressor Continuous 3x per second
clutch short to
battery

Dealer Copy -- Not for Resale

1

P-90576

When the EDT detects an open or short from the

temperature sensor, the status LED (Item 1) [Figure 80-
90-1] will blink once per second and the output signal to
the clutch will be turned off. The status LED will flash two
times per second when EDT detects an open circuit
(current draw less than 200 mA), short circuit or over
current (current draw greater than 7A) from the clutch
output. The status LED will flash three times per second
when the compressor clutch is shorted to ground.

NOTE: The EDT will attempt to restart every 20

seconds until the fault is repaired.

783 of 822 80-90-1 T870 Service Manual

THERMOSTAT (CONT’D) Figure 80-90-4

Removal And Installation

Raise the lift arms and install an approved lift arm support 1
device. (See Installing on Page 10-20-1.)

Raise the operator cab. (See Raising on Page 10-30-1.)

NOTE: The thermostat can be changed without

evacuating the A/C system, or removing the
evaporator / heater unit from the loader.

NOTE: The evaporator / heater unit is shown

removed for photo clarity.
P100893
Figure 80-90-2

Remove the thermostat (Item 1) from the evaporator /

heater unit [Figure 80-90-4].
2

Dealer Copy -- Not for Resale

1

P100889

Undo the four latches (Item 1) and remove the cover

(Item 2) [Figure 80-90-2].

Figure 80-90-3

P100894

Remove the thermostat probe (Item 1) [Figure 80-90-3]

from the A/C evaporator coil.

784 of 822 80-90-2 T870 Service Manual

EXPANSION VALVE Figure 80-100-2

Removal And Installation

Raise the lift arms and install an approved lift arm support 2
device. (See Installing on Page 10-20-1.)

Raise the operator cab. (See Raising on Page 10-30-1.)

1
Evacuate the A/C system. (See Reclamation And
Charging With Recovery / Charging Unit on Page 80-40-
2.)

WARNING P100756

In the event of a leak, wear safety goggles. Escaping Unhook the four latches (Item 1) and remove the cover
refrigerant can cause severe injuries to eyes. In (Item 2) [Figure 80-100-2].
contact with a flame, R134a refrigerant gives a toxic
gas. Figure 80-100-3
W-2371-0500

Dealer Copy -- Not for Resale

Figure 80-100-1

1
1 1
P101948

NOTE: The evaporator / heater unit is removed for

P103082 photo clarity.

Remove the two evaporator fittings (Item 1) [Figure 80-

Remove the two A/C hoses (Item 1) [Figure 80-100-1]
100-3] from the expansion valve.
from the expansion valve.
Installation: Tighten the two evaporator fittings to 30
Installation: Tighten the two A/C hose fittings to 30 N•m
N•m (22 ft-lb) torque.
(22 ft-lb) torque.
Remove the two mount bolts (Item 2) [Figure 80-100-3].
Cap and plug the hoses and the expansion valve fittings
with the proper A/C caps and plugs.
Remove the expansion valve from the loader.

Cap and plug the evaporator tubelines (Item 1) [Figure

80-100-3] and the expansion valve fittings with the
proper A/C caps and plugs.

785 of 822 80-100-1 T870 Service Manual

EXPANSION VALVE (CONT'D)

Removal And Installation (Cont'd)

Figure 80-100-4

N-22085

The expansion valve [Figure 80-100-4] is replaced as a

complete unit.

Dealer Copy -- Not for Resale

786 of 822 80-100-2 T870 Service Manual

EVAPORATOR COIL Figure 80-110-2

Removal And Installation

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)

Raise the operator cab. (See Raising on Page 10-30-1.)

Evacuate the A/C system. (See Reclamation And

Charging With Recovery / Charging Unit on Page 80-40-
2.)

WARNING P101948

In the event of a leak, wear safety goggles. Escaping NOTE: The evaporator / heater unit is removed for
refrigerant can cause severe injuries to eyes. In photo clarity.
contact with a flame, R134a refrigerant gives a toxic
gas. Disconnect the two evaporator fittings (Item 1) [Figure
W-2371-0500 80-110-2] from the expansion valve.

Dealer Copy -- Not for Resale

Installation: Tighten the two evaporator fittings to 29,8
Figure 80-110-1
N•m (22 ft-lb) torque.

1 Cap and plug the evaporator tubelines (Item 1) [Figure

80-110-2] and the expansion valve fittings with the proper
A/C caps and plugs.

Figure 80-110-3

2 2
3
P100756

Unhook the four latches (Item 1) and remove the cover 1

(Item 2) [Figure 80-110-1].

P100757

Remove the thermostat probe (Item 1) [Figure 80-110-2]

from the evaporator coil.

Remove the two retaining clips (Item 2) [Figure 80-110-

3] that connect the evaporator coil, to the heater coil.

Remove the evaporator coil (Item 3) [Figure 80-110-2].

787 of 822 80-110-1 T870 Service Manual

EVAPORATOR COIL (CONT'D)

Removal And Installation (Cont'd)

Figure 80-110-4

P-90424

Inspect the evaporator coil [Figure 80-110-4] for leaks,

and replace as needed.

Dealer Copy -- Not for Resale

Clean with low pressure water or air.

788 of 822 80-110-2 T870 Service Manual

HEATER COIL Figure 80-120-3

Removal And Installation

Remove the evaporator coil (If necessary). (See

Removal And Installation on Page 80-110-1.)
1
Remove the heater valve. (See Removal And Installation
on Page 80-140-1.)

NOTE: The evaporator / heater unit is removed for

photo clarity.

Figure 80-120-1

P101947
2

Remove the retainer clips (Item 1) [Figure 80-120-3]

from both sides.
1
Figure 80-120-4

Dealer Copy -- Not for Resale

P100756
1
Unhook the four latches (Item 1) and remove the cover
(Item 2) [Figure 80-120-1].

Figure 80-120-2

P100946

Remove the two screws (Item 1) [Figure 80-120-4].

P100944

Remove the two screws (Item 1) [Figure 80-120-2].

789 of 822 80-120-1 T870 Service Manual

HEATER COIL (CONT'D)

Removal And Installation (Cont'd)

Figure 80-120-5

P100947

Remove the two screws (Item 1) [Figure 80-120-4].

Dealer Copy -- Not for Resale

Remove the heater coil from the unit.

Figure 80-120-6

P100945

The heater coil [Figure 80-120-6] can be cleaned with

low pressure air or water.

790 of 822 80-120-2 T870 Service Manual

BLOWER FAN Disassembly And Assembly

Removal And Installation Figure 80-130-2

Remove the evaporator / heater unit. (See Removal And

Installation on Page 80-120-1.)

Remove the heater coil. (See Removal And Installation

on Page 80-120-1.)

Figure 80-130-1
1 1

P-90458
1
1
Remove the eight screws (Item 1) [Figure 80-130-2]
2 from the blower wheel cover.

Figure 80-130-3

Dealer Copy -- Not for Resale

P100888

1
Remove the two screws (Item 1) [Figure 80-130-1].

Remove the blower fan (Item 2) [Figure 80-130-1] from

the evaporator / heater unit.

2
P-90465

Remove the outside rings (Item 1) and the blower wheel

cover (Item 2) [Figure 80-130-3].

Repeat for other side.

Inspect the outside rings and blower wheel covers for

wear and replace as needed [Figure 80-130-3].

791 of 822 80-130-1 T870 Service Manual

BLOWER FAN (CONT'D) Figure 80-130-6

Disassembly And Assembly (Cont'd)

Figure 80-130-4

P-90463

1 Check the blower housing and blower motor mount for

P-90459 wear and replace as needed [Figure 80-130-6].

Figure 80-130-7
NOTE: Mark the wires for proper installation.

Dealer Copy -- Not for Resale

Remove the two wires (Item 1) [Figure 80-130-4] from
the blower motor.

Figure 80-130-5

1 1

P-90461

1
Remove the blower wheel outside clamp (Item 1) [Figure
80-130-7] from the blower wheel.

P100887

Remove the two screws (Item 1) [Figure 80-130-5] from

the resistor.

Remove the blower motor from the blower housing.

792 of 822 80-130-2 T870 Service Manual

BLOWER FAN (CONT'D)

Disassembly And Assembly (Cont'd)

Figure 80-130-8

1
3
4

P-90462

Remove the blower wheel (Item 1), inside clamp (Item 2),
inside ring (Item 3), and spacers (Item 4) [Figure 80-130-

Dealer Copy -- Not for Resale

8] from the blower motor shaft and inspect for wear.

NOTE: The number and size of spacers (Item 4)

[Figure 80-130-8] may vary.

Repeat the procedure for the other blower wheel.

793 of 822 80-130-3 T870 Service Manual

 Dealer Copy -- Not for Resale

794 of 822 80-130-4 T870 Service Manual

HEATER VALVE Figure 80-140-2

Removal And Installation

Raise the lift arms and install an approved lift arm support
device. (See Installing on Page 10-20-1.)
2
Raise the operator cab. (See Raising on Page 10-30-1.)
1
NOTE: The heater valve is not serviceable and must
be replaced as a complete assembly.

Remove any tie straps that hold the heater hoses.

NOTE: The evaporator / heater unit is shown

removed for photo clarity. P100948

Figure 80-140-1
NOTE: Cap the heater hoses and the heater valve
with plugs to prevent coolant loss from the
system.
1
Remove the heater hose clamp (Item 1) [Figure 80-140-
2].

Dealer Copy -- Not for Resale

Remove the heater hose from the heater valve.

Remove the heater hose clamp (Item 2) [Figure 80-140-

2].

Remove the heater hose from the heater coil.

P101961

Disconnect the loader wiring harness (Item 1) [Figure

80-140-1] from the heater valve.

795 of 822 80-140-1 T870 Service Manual

HEATER VALVE (CONT’D)

Removal And Installation (Cont’d)

Figure 80-140-3

1
2

P100949

NOTE: Cap the heater hoses and the heater valve

with plugs to prevent coolant loss from the

Dealer Copy -- Not for Resale

system.

Remove the heater hose clamp (Item 1) [Figure 80-140-

2].

Remove the two screws (Item 2) [Figure 80-140-2].

Remove the heater valve (Item 3) [Figure 80-140-2] from

the evaporator / heater unit.

796 of 822 80-140-2 T870 Service Manual

 SPECIFICATIONS

(T870) LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1

Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4

TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

Torque For General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2

HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1

Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2

Dealer Copy -- Not for Resale

Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2

HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .SPEC-40-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1

CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
Decimal And Millimeter Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1

797 of 822 SPEC-01 T870 Service Manual

 Dealer Copy -- Not for Resale

798 of 822 SPEC-02 T870 Service Manual

(T870) LOADER SPECIFICATIONS

Machine Dimensions

• Dimensions are given for loader equipped with standard tracks and 84 inch Heavy Duty Construction and Industrial
bucket and may vary with other bucket types. All dimensions are shown in inches. Respective metric dimensions are
given in millimeters enclosed by parentheses.

• Where applicable, specifications conform to SAE or ISO standards and are subject to change without notice.

2514 mm
(99 in)

2108 mm
(83 in) 2153 mm
(84.8 in)
1658 mm
(65.3 in)

Dealer Copy -- Not for Resale

98°

4689 mm
(184.6 in) 42°

927 mm
(36.5 in)

3657 mm
(144 in)

2118 mm 2853 mm
(83.4 in) (112.3 in)

33°
31°

1749 mm
218 mm
(68.9 in)
(8.6 in)

3030 mm
(119.3 in)

3910 mm
(153.9 in)

NA1835

Changes of structure or weight distribution of the loader can cause changes in control and steering response and
can cause failure of the loader parts.

799 of 822 SPEC-10-1 T870 Service Manual

(T870) LOADER SPECIFICATIONS (CONT’D)

Performance

Rated Operating Capacity 1599 kg (3525 lb)

with 200 Pound Frame Mounted 1644 kg (3625 lb)
Counterweight Kit
with 300 Pound Frame Mounted 1678 kg (3700 lb)
Counterweight Kit
with 400 Pound Frame Mounted 1712 kg (3775 lb)
Counterweight Kit
Tipping Load 4569 kg (10072 lb)
Operating Weight 5751 kg (12678 lb)
Breakout Force - Lift 2783 kg (6135 lb)
Breakout Force - Tilt 3186 kg (7025 lb)
Push Force 3379 kg (7450 lb)
Travel Speed
- Single Speed Loader 0 - 11,6 km/h (0 - 7.2 mph)
- Two-Speed Loader (Option)
Low Range 0 - 10,5 km/h (0 - 6.5 mph)
High Range 0 - 18,3 km/h (0 - 11.4 mph)

Dealer Copy -- Not for Resale

Engine

Make / Model Kubota / V3800-DI-TE3 Tier III

Fuel / Cooling Diesel / Liquid
Horsepower
- ISO 9249 EEC / SAE J1349 Net 71,0 kW (95.2 hp) @ 2600 rpm
- ISO 14396 Gross 72,9 kW (97.7 hp) @ 2600 rpm
- SAE J1995 Gross 74,0 kW (99.2 hp) @ 2600 rpm
Torque
- ISO 9249 EEC / SAE J1349 Net 320,2 N•m (236.1 ft-lb) @ 1600 rpm
- SAE J1995 Gross 325,0 N•m (239.7 ft-lb) @ 1600 rpm
Low Idle rpm 1250 - 1400
High Idle rpm 2725 - 2850
Number of Cylinders 4
Displacement 3,8 L (230 in3)
Bore / Stroke 100 mm / 120 mm (3.94 in / 4.72 in)
Lubrication Gear Pump Pressure System with Filter
Crankcase Ventilation Open Breathing
Air Cleaner Dry replaceable paper cartridge with separate safety element
Ignition Diesel - Compression
Air Induction Turbo-Charged
Engine Coolant Propylene Glycol / Water Mixture
Starting Aid Air Intake Heater - Automatically activated as needed in RUN position

Drive System

Main Drive Fully hydrostatic, rubber track drive

Transmission Infinitely variable tandem hydrostatic piston pumps, driving two fully reversing
hydrostatic drive motors
Tracks (Tension) Grease cylinder and spring

800 of 822 SPEC-10-2 T870 Service Manual

(T870) LOADER SPECIFICATIONS (CONT’D)

Controls

Vehicle Steering Direction and speed controlled by two hand operated steering handles or
optional joystick(s)
Loader Hydraulics
- Lift and Tilt Controlled by separate foot pedals or optional Selectable Joystick Controls
(SJC)
- Front Auxiliary Controlled by electrical switch on Right Hand steering handle or joystick
- Rear Auxiliary (Option) Controlled by electrical switch on Left Hand steering handle or joystick
Auxiliary Pressure Release Pressure relieved through quick couplers; Push couplers in, hold for 5 seconds
Engine Hand lever speed control, additional foot operated speed control pedal with SJC
option; key-type start switch or optional Keyless Start Panel or optional Deluxe
Instrumentation Panel and function error shutdown.
Starting Aid Air Intake Heater - Automatically activated as needed in RUN position
Service Brake Two independent hydrostatic systems controlled by two hand operated steering
handles or optional joystick(s)
Secondary Brake One of the hydrostatic transmissions
Parking Brake (Standard) Spring applied pressure release multi-disk brake activated by manually operated
switch on left instrument panel

Dealer Copy -- Not for Resale

Hydraulic System

Pump Type Engine driven, gear type

Pump Capacity - Standard 90,1 L/min (23.8 U.S. gpm)
Pump Capacity - High-Flow Option 141,6 L/min (37.4 U.S. gpm)
System Relief at Quick Couplers 23,8 - 24,5 MPa (238 - 245 bar) (3450 - 3550 psi)
Filter (Hydraulic / Hydrostatic) Replaceable beta 10 micron = 200, drop in element
Filter (Charge) Replaceable beta 10 micron = 200, drop in element
Hydraulic Cylinders Double-acting; tilt cylinders have cushioning feature on dump and rollback
Bore Diameter: Lift Cylinder (2) 88,9 mm (3.50 in)
Tilt Cylinder (2) 82,6 mm (3.25 in)
Rod Diameter: Lift Cylinder (2) 50,8 mm (2.00 in)
Tilt Cylinder (2) 38,1 mm (1.50 in)
Stroke: Lift Cylinder (2) 698,8 mm (27.51 in)
Tilt Cylinder (2) 388,4 mm (15.29 in)
Control Valve - SCPA 3-Spool, open center, manually operated with spring detent for lift float.
Electrically controlled auxiliary spool
Control Valve - SJC 3-Spool, open center with electric actuator controlled lift with float and tilt.
Electrically controlled auxiliary spool
Fluid Lines SAE Standard tubelines, hoses and fittings
Fluid Type BOBCAT FLUID, Hydraulic / Hydrostatic
6903117 - (Two - 2.5 U.S. gal)
6903118 - (5 U.S. gal)
6903119 - (55 U.S. gal)
Hydraulic Function Time:
Raise Lift Arms 5.7 Seconds
Lower Lift Arms 3.9 Seconds
Bucket Dump 2.8 Seconds
Bucket Rollback 2.3 Seconds

801 of 822 SPEC-10-3 T870 Service Manual

(T870) LOADER SPECIFICATIONS (CONT’D)

Electrical System

Alternator Belt driven, 90 amperes, open frame

Battery 12 volts, 950 cold cranking amperes @ -18° C (0° F),
180 Minute reserve capacity @ 25 amperes
Starter 12 volts, gear type, 3,0 kW (4.02 hp)
Instrumentation Gauges:
Engine Coolant Temperature, Fuel Level.
Warning lights:
Fuel Level, Seat Belt, Engine Coolant Temperature, Engine Malfunction,
Hydraulic System Malfunction, General Warning.
Indicators:
BICS™ Functions, Turn Signals, Engine Preheat.
Data Display:
Operating Hours, Engine rpm, Speed Management Setting, Maintenance Clock
Countdown, Battery Voltage, Service Codes, Engine Preheat Countdown,
Steering Drift Compensation Setting, Drive Response Setting.
Other:
Audible Alarm, Lights, Option / Accessory Switches.
Optional Deluxe Instrumentation Panel:
*Additional displays for: Engine rpm, Coolant Temperature and Oil Pressure;

Dealer Copy -- Not for Resale

System Voltage, Hydrostatic Charge Pressure and Hydraulic Oil Temperature.
*Additional Features Included: Keyless Start, Digital Clock, Job Clock, Password
Lockout, Multi-language Display, Help Screens, Diagnostic Capability and
Engine / Hydraulic Systems Shutdown Function.

Capacities

Fuel 134,8 L (35.6 U.S. gal)

Engine Oil with Filter Change 11,4 L (12.0 qt)
Engine Cooling System
with Heater 15,9 L (4.2 U.S. gal)
without Heater 15,1 L (4.0 U.S. gal)
Hydraulic / Hydrostatic Reservoir 11,4 L (3.0 U.S. gal)
Hydraulic / Hydrostatic System 36,0 L (9.5 U.S. gal)
Hydrostatic Drive Motor (Each) 180 mL (6.1 U.S. fl oz)

Tracks

Standard 450 mm (17.7 in) Rubber

Ground Pressure

Standard Track - 450 mm (17.7 in) 0.033 MPa (0,33 bar) (4.73 psi)

802 of 822 SPEC-10-4 T870 Service Manual

TORQUE SPECIFICATIONS FOR BOLTS

Torque For General SAE Bolts

The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter H following the part number.

Thread
sae grade 5 sae grade 8
size
N•m 0.250 9,0 - 10,2 12,4 - 13,6
(in-lb) (80 - 90) (110 - 120)
0.3125 20,3 - 22,6 24,2 - 27,1
(180 - 200) (215 - 240)
N•m 0.375 34 - 38 47 - 54
(ft-lb) (25 - 28) (35 - 40)
0.4375 54 - 61 81 - 88
(40 - 45) (60 - 65)
0.500 88 - 95 122 - 136
(65 - 70) (90 - 100)
0.5625 122 - 136 170 - 190
(90 - 100) (125 - 140)

Dealer Copy -- Not for Resale

0.625 170 - 190 240 - 260
(125 - 140) (175 - 190)
0.750 300 - 330 410 - 450
(220 - 245) (300 - 330)
0.875 450 - 490 645 - 710
(330 - 360) (475 - 525)
1.000 645 - 710 985 - 1085
(475 - 525) (725 - 800)
1.125 880 - 975 1425 - 1600
(650 - 720) (1050 - 1175)
1.250 1200 - 1360 2000 - 2200
(900 - 1000) (1475 - 1625)
1.375 1630 - 1830 2720 - 2980
(1200 - 1350) (2000 - 2200)
1.500 2040 - 2240 3530 - 3870
(1500 - 1650) (2600 - 2850)
1.625 2720 - 2980 4680 - 5150
(2000 - 2800) (3450 - 3800)
1.750 3390 - 3730 5830 - 6500
(2500 - 2750) (4300 - 4800)
1.875 4270 - 4750 7450 - 8300
(3150 - 3500) (5500 - 6100)
2.000 5150 - 5700 8800 - 9800
(3800 - 4200) (6500 - 7200)

803 of 822 SPEC-20-1 T870 Service Manual

TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)

Torque For General Metric Bolts

THREAD SIZE MATERIAL

(DIA. X PITCH) HEAD MARK 4 HEAD MARK 7 HEAD MARK 10
M 5 x 0.8 4 - 5 N•m
(3 - 4 ft-lb)
M 6 x 1.0 8 - 9 N•m 8 - 12 N•m
(6 - 7 ft-lb) (6 - 9 ft-lb)
M 8 x 1.25 8 - 12 N•m 15 - 22 N•m 24 - 34 N•m
(6 - 9 ft-lb) (11 - 16 ft-lb) (18 - 25 ft-lb)
M 10 x 1.25 18 - 24 N•m 30 - 41 N•m 49 - 68 N•m
(13 - 18 ft-lb) (22 - 30 ft-lb) (36 - 50 ft-lb)
M 12 x 1.25 30 - 41 N•m 54 - 73 N•m 94 - 118 N•m
(22 - 30 ft-lb) (40 - 54 ft-lb) (69 - 87 ft-lb)
M 14 x 1.25 49 - 68 N•m 79 - 108 N•m 157 - 186 N•m
(36 - 50 ft-lb) (58 - 80 ft-lb) (116 - 137 ft-lb)

Dealer Copy -- Not for Resale

804 of 822 SPEC-20-2 T870 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS

Straight Thread O-ring Fitting

Figure SPEC-30-1

Nut Nut

Washer
Washer
O-ring

O-ring

A-1852

Lubricate the O-ring before installing the fitting. Loosen

the jam nut and install the fitting. Tighten the jam nut until

Dealer Copy -- Not for Resale

the washer is tight against the surface [Figure SPEC-30-
1].

Figure SPEC-30-2

O-ring Boss
Tightening Torque
x TORQUE
x ft-lb
Thread Size (N•m)
7/16” - 20 13 (18)
9/16” - 18 22 (30)
3/4” -1 6 40 (54)
7/8” - 14 60 (81)
1-1/16” - 12 84 (114)
1-3/16” - 12 98 (133)
1-5/16” - 12 118 (160)
1-7/16” - 12 154 (209)
1-5/8” - 12 163 (221)

805 of 822 SPEC-30-1 T870 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS Tubelines And Hoses
(CONT’D)
Replace any tubelines that are bent or flattened. They will
Flare Fitting restrict flow and cause heat.

Figure SPEC-30-3 Replace hoses which show signs of wear, damage or

weather cracked rubber.

Always use two wrenches when loosening and tightening

hose or tubeline fittings.

P-85926

Use the following procedure to tighten the flare fitting:

Dealer Copy -- Not for Resale

Tighten the nut until it makes contact with the seat.

Use the chart [Figure SPEC-30-4] to find the correct

tightness needed. If the fitting leaks after tightening,
disconnect it and inspect the seat area for damage.

Figure SPEC-30-4
Flare Fitting Tightening Torque
Tubeline x TORQUE
Outside x ft-lb
Diameter Thread Size (N•m)
1/4” 7/16” - 20 13 (18)
5/16” 1/2” - 20 17 (23)
3/8” 9/16” - 18 22 (30)
1/2” 3/4” - 16 40 (54)
5/8” 7/8” - 14 60 (81)
3/4” 1-1/16” - 12 84 (114)
7/8” 1-3/16” - 12 98 (133)
1” 1-5/16” - 12 118 (160)
1-1/4” 1-5/8” - 12 154 (209)
1-1/2” 1-7/8” - 12 163 (221)
2” 2-1/2” - 12 252 (342)

806 of 822 SPEC-30-2 T870 Service Manual

HYDRAULIC / HYDROSTATIC FLUID
SPECIFICATIONS

Specifications WARNING
HYDRAULIC / HYDROSTATIC FLUID
RECOMMENDED ISO VISCOSITY GRADE (VG) During cold weather (0°C [32°F] and below), do not
AND VISCOSITY INDEX (VI) operate machine until the engine has run for at least
5 minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.

When temperatures are below -30°C (-20°F), the

hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above -18°C (0°F) if possible.
W-2027-0311
TEMPERATURE RANGE ANTICIPATED
DURING MACHINE USE
[1] VG 100; Minimum VI 130
[2] VG 46; Minimum VI 150
[3] BOBCAT All-Season Fluid
[4] BOBCAT Synthetic Fluid

Dealer Copy -- Not for Resale

[5] BOBCAT Biodegradable Hydraulic / Hydrostatic
Fluid (Unlike biodegradable fluids that are vegetable
based, Bobcat biodegradable fluid is formulated to
prevent oxidation and thermal breakdown at operating
temperatures.)
DO NOT use automatic transmission fluids in the loader
or permanent damage to the transmission will result.

WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807

When temperatures below 0 °F (-18 °C) are common, the

loader must be kept in a warm building. Extra warm-up
time must be used each time the loader is started during
cold temperature conditions. Cold fluid will not flow easily
and it makes action of the hydraulic function slower. Loss
of fluid flow to the hydrostatic transmission pump
(indicated by TRANS light ON) can cause transmission
damage in less than 60 seconds.

807 of 822 SPEC-40-1 T870 Service Manual

 Dealer Copy -- Not for Resale

808 of 822 SPEC-40-2 T870 Service Manual

CONVERSIONS

Decimal And Millimeter Equivalent Chart

Dealer Copy -- Not for Resale

U.S. To Metric Conversion Chart

809 of 822 SPEC-50-1 T870 Service Manual

 Dealer Copy -- Not for Resale

810 of 822 SPEC-50-2 T870 Service Manual

 ALPHABETICAL INDEX

(T870) LOADER SPECIFICATIONS CYLINDER (LIFT) . . . . . . . . . . . . . . . . .20-20-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1 CYLINDER (TILT) . . . . . . . . . . . . . . . . .20-21-1
ACCESS PANEL (INSIDE) (SJC) . . . 50-121-1 CYLINDER HEAD . . . . . . . . . . . . . . . .70-80-1
ACCESS PANEL (INSIDE) . . . . . . . . . 50-120-1 DELIVERY REPORT . . . . . . . . . . . . . . . . 1-15
AIR CLEANER SERVICE . . . . . . . . . . . 10-80-1 DIAGNOSTIC SERVICE CODES . . . . .60-90-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . 70-40-1 DRAIN MANIFOLD . . . . . . . . . . . . . . . .30-60-1
AIR CONDITIONING SYSTEM FLOW . 80-10-1 DRIVE BELT . . . . . . . . . . . . . . . . . . . . .30-50-1
ALTERNATOR . . . . . . . . . . . . . . . . . . . 60-30-1 ELECTRICAL / HYDRAULIC CONTROLS
ARMREST . . . . . . . . . . . . . . . . . . . . . 50-150-1 (SCPA) . . . . . . . . . . . . . . . . . . . . . . . .60-131-1
BACK-UP ALARM SYSTEM . . . . . . . 60-210-1 ELECTRICAL / HYDRAULIC CONTROLS
BATTERY . . . . . . . . . . . . . . . . . . . . . . . 60-20-1 (SJC) . . . . . . . . . . . . . . . . . . . . . . . . .60-130-1
BLOWER FAN . . . . . . . . . . . . . . . . . . 80-130-1 ELECTRICAL SYSTEM INFORMATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-1
BOBCAT CONTROLLER (ACS) . . . . . 60-71-1
EMERGENCY EXIT . . . . . . . . . . . . . .10-190-1
BOBCAT CONTROLLER (SJC) (DRIVE)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1 ENGINE COOLING SYSTEM . . . . . . .10-90-1
BOBCAT CONTROLLERS (GATEWAY AND ENGINE COOLING SYSTEM . . . . . . .70-50-1
AUXILIARY) . . . . . . . . . . . . . . . . . . . . . 60-70-1 ENGINE INFORMATION . . . . . . . . . . .70-10-1

Dealer Copy -- Not for Resale

BOBCAT INTERLOCK CONTROL SYSTEM ENGINE LUBRICATION SYSTEM . . .10-110-1
(BICS™) . . . . . . . . . . . . . . . . . . . . . . . 60-100-1 ENGINE SPEED CONTROL (SCPA) . .70-20-1
BOB-TACH (HAND LEVER) . . . . . . . . 10-130-1 ENGINE SPEED CONTROL (SJC) . . .70-21-1
BOB-TACH (HAND LEVER) . . . . . . . . . 50-40-1 EVAPORATOR / HEATER UNIT . . . . . .80-80-1
BOB-TACH (POWER) BLOCK . . . . . . 20-120-1 EVAPORATOR COIL . . . . . . . . . . . . .80-110-1
BOB-TACH (POWER) . . . . . . . . . . . . 10-131-1 EXHAUST GAS RECIRCULATION (EGR)
BOB-TACH (POWER) . . . . . . . . . . . . . 50-41-1 SYSTEM . . . . . . . . . . . . . . . . . . . . . . .70-130-1
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1 EXPANSION VALVE . . . . . . . . . . . . . .80-100-1
BUCKET POSITION VALVE . . . . . . . 20-100-1 FIRE PREVENTION . . . . . . . . . . . . . . . . . 1-12
CAB DOOR . . . . . . . . . . . . . . . . . . . . 50-140-1 FLYWHEEL AND HOUSING . . . . . . .70-120-1
CALIBRATION . . . . . . . . . . . . . . . . . . 60-150-1 FLYWHEEL RPM SENSOR . . . . . . . .60-170-1
CAMSHAFT AND TIMING GEARS . . 70-100-1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . 1-7
CHARGE PRESSURE . . . . . . . . . . . . . 30-30-1 FRONT AUXILIARY HYDRAULIC COUPLER
COMPRESSOR . . . . . . . . . . . . . . . . . . 80-50-1 BLOCK . . . . . . . . . . . . . . . . . . . . . . . .20-130-1
CONDENSER . . . . . . . . . . . . . . . . . . . 80-60-1 FRONT HORN . . . . . . . . . . . . . . . . . .60-220-1
CONTROL HANDLE / LEVER (SCPA) FUEL SYSTEM . . . . . . . . . . . . . . . . . .10-100-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . .70-70-1
CONTROL HANDLE / LEVER (SJC) . 50-110-1 FUEL TANK (AUXILIARY) . . . . . . . . . .50-81-1
CONTROL PANEL (SCPA) . . . . . . . . 50-101-1 FUEL TANK . . . . . . . . . . . . . . . . . . . . .50-80-1
CONTROL PANEL (SJC) . . . . . . . . . . 50-100-1 HEADLINER . . . . . . . . . . . . . . . . . . . .50-180-1
CONTROL PANEL SETUP . . . . . . . . 60-180-1 HEATER COIL . . . . . . . . . . . . . . . . . .80-120-1
CONTROL PEDALS AND LINKAGES (SCPA) HEATER VALVE . . . . . . . . . . . . . . . . .80-140-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1 HYDRAULIC / HYDROSTATIC FILTERS
CONVERSIONS . . . . . . . . . . . . . . . SPEC-50-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-70-1
CRANKSHAFT AND PISTONS . . . . . . 70-90-1 HYDRAULIC / HYDROSTATIC FLUID
CYLINDER (BOB-TACH) . . . . . . . . . . . 20-22-1 SPECIFICATIONS . . . . . . . . . . . . .SPEC-40-1

811 of 822 INDEX-01 T870 Service Manual

HYDRAULIC / HYDROSTATIC SYSTEM REAR DOOR (TAILGATE) . . . . . . . . . 50-70-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-120-1 REAR GRILLE . . . . . . . . . . . . . . . . . . 50-60-1
HYDRAULIC CONNECTION RECEIVER / DRIER . . . . . . . . . . . . . . 80-70-1
SPECIFICATIONS . . . . . . . . . . . . . SPEC-30-1
REGULAR MAINTENANCE . . . . . . . . 80-20-1
HYDRAULIC CONTROL VALVE (SCPA)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-1 REMOTE START TOOL (SERVICE TOOL) KIT
- 7003031 . . . . . . . . . . . . . . . . . . . . . . 10-61-1
HYDRAULIC CONTROL VALVE (SJC) 20-40-1
REMOTE START TOOL KIT-MEL1563 10-60-1
HYDRAULIC FLUID RESERVOIR . . . .20-80-1
RIGHT SIDE LOWER PANEL . . . . . 50-170-1
HYDRAULIC PUMP (HIGH FLOW) . . .20-61-1
SAFETY INSTRUCTIONS . . . . . . . . . . . . 1-10
HYDRAULIC PUMP . . . . . . . . . . . . . . .20-60-1
SEAT BAR SENSOR . . . . . . . . . . . . .60-110-1
HYDRAULIC SYSTEM INFORMATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-1 SEAT BAR . . . . . . . . . . . . . . . . . . . . . 50-10-1
HYDROSTATIC DRIVE MOTOR (TWO SEAT BELT . . . . . . . . . . . . . . . . . . . . 10-200-1
SPEED) . . . . . . . . . . . . . . . . . . . . . . . .30-21-1 SERIAL NUMBER LOCATIONS . . . . . . . . 1-14
HYDROSTATIC DRIVE MOTOR . . . . .30-20-1 SERVICE MANUAL REVISION . . . . . . SMR-1
HYDROSTATIC PUMP (SJC AND SCPA) SERVICE PC (LAPTOP COMPUTER)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-40-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
HYDROSTATIC SYSTEM INFORMATION SERVICE SCHEDULE . . . . . . . . . . . . 10-70-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-1 SPARK ARRESTER MUFFLER . . . . 10-150-1
INSTRUMENT PANELS . . . . . . . . . . . .60-50-1 SPEED SENSORS (SJC AND SCPA) 60-80-1

Dealer Copy -- Not for Resale

LEFT SIDE LOWER PANEL . . . . . . .50-160-1 STARTER . . . . . . . . . . . . . . . . . . . . . . 60-40-1
LIFT ARM BYPASS CONTROL VALVE 20-50-1 STEERING DRIFT COMPENSATION 60-160-1
LIFT ARM SUPPORT DEVICE . . . . . .10-20-1 STOPPING THE ENGINE AND LEAVING THE
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . .50-50-1 LOADER . . . . . . . . . . . . . . . . . . . . . . 10-180-1
LIFTING AND BLOCKING THE LOADER SYSTEM CHARGING AND RECLAMATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . .60-60-1 THERMOSTAT . . . . . . . . . . . . . . . . . . 80-90-1
LOADER IDENTIFICATION . . . . . . . . . . . 1-16 TORQUE SPECIFICATIONS FOR BOLTS
LOADER STORAGE AND RETURN TO . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
SERVICE . . . . . . . . . . . . . . . . . . . . . .10-170-1 TOWING THE LOADER . . . . . . . . . . . 10-50-1
LUBRICATING THE LOADER . . . . . .10-140-1 TRACK MAINTENANCE . . . . . . . . . . 40-30-1
LUBRICATION SYSTEM . . . . . . . . . . .70-60-1 TRACK UNDERCARRIAGE COMPONENTS
MAIN RELIEF VALVE . . . . . . . . . . . . . .20-30-1 (ROLLER SUSPENSION) . . . . . . . . . 40-20-1
MAINTENANCE CLOCK . . . . . . . . . .60-200-1 TRACTION LOCK . . . . . . . . . . . . . . . 60-120-1
MAINTENANCE SAFETY . . . . . . . . . . . . . 1-1 TRANSPORTING THE LOADER ON A
TRAILER . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
MUFFLER . . . . . . . . . . . . . . . . . . . . . .70-30-1
TROUBLESHOOTING . . . . . . . . . . . . 80-30-1
OIL COOLER . . . . . . . . . . . . . . . . . . . .20-90-1
TURBOCHARGER . . . . . . . . . . . . . . .70-110-1
OPERATOR CAB . . . . . . . . . . . . . . . . .10-30-1
WINDOW (REAR) . . . . . . . . . . . . . . . 50-130-1
OPERATOR CAB . . . . . . . . . . . . . . . . .50-20-1
WINDOW (SIDE) . . . . . . . . . . . . . . . 50-132-1
OPERATOR SEAT (SUSPENSION) . .50-30-1
WINDOW (TOP) . . . . . . . . . . . . . . . . 50-131-1
PASSWORD SETUP (DELUXE
INSTRUMENTATION PANEL) . . . . . .60-190-1
PASSWORD SETUP (KEYLESS START
PANEL) . . . . . . . . . . . . . . . . . . . . . . . .60-191-1
PIVOT PINS . . . . . . . . . . . . . . . . . . . .10-160-1
REAR AUXILIARY DIVERTER VALVE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

812 of 822 INDEX-02 T870 Service Manual

 ROUTE TO
ATTENTION
SERVICE MANUAL PARTS MANAGER
SERVICE MANAGER X
REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: T870 - 1

Date: 15 August 2010
Product: Bobcat Loader
Model: T870
Manual No: 6987487 (8-10)

Dealer Copy -- Not for Resale

The following Sections are a revision to the above Service Manual.

COVER ELECTRICAL SCHEMATICS

60-30
10-61 60-50
10-120 60-80
10-200 ADDED 60-131
60-140
HYDRAULIC / HYDROSTATIC SCHEMATICS
20-10 70-10
20-20 70-70
20-21
20-22 80-50
20-30 80-70
20-40
20-41 SPEC-10
20-60
20-70
20-100
20-120
20-130

30-30

50-50
50-91 REMOVED
50-112 REMOVED

813 of 822 SMR-1 T870 Service Manual

 Dealer Copy -- Not for Resale

814 of 822 SMR-2 T870 Service Manual

 ROUTE TO
SERVICE MANUAL ATTENTION
PARTS MANAGER
REVISION SERVICE MANAGER X
SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: T870 - 2

Date: 15 September 2010
Product: Bobcat Loader
Model: T870
Manual No: 6987487 (9-10)

Dealer Copy -- Not for Resale

The following Sections are a revision to the above Service Manual.

COVER

10-90

20-10
20-21
20-60
20-61
20-70

30-30
30-40

50-60

60-180

70TOC
70-10
70-50

80-30

SPEC-10

ALPHABETICAL INDEX

815 of 822 SMR-3 T870 Service Manual

 Dealer Copy -- Not for Resale

816 of 822 SMR-4 T870 Service Manual

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SERVICE MANUAL ATTENTION
PARTS MANAGER
REVISION SERVICE MANAGER X
SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: T870 - 3

Date: 15 February 2011
Product: Bobcat Loader
Model: T870
Manual No: 6987487 (2-11)

Dealer Copy -- Not for Resale

T870 Service Manual (P/N 6987487) Dated 2-11 contains updated service information which replaces the previous
T870 Service Manual (P/N 6987487) Dated 9-10.

817 of 822 SMR-5 T870 Service Manual

 Dealer Copy -- Not for Resale

818 of 822 SMR-6 T870 Service Manual

 ROUTE TO
SERVICE MANUAL ATTENTION
PARTS MANAGER
REVISION SERVICE MANAGER X
SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: T870 - 4

Date: 15 March 2011
Product: Bobcat Loader
Model: T870
Manual No: 6987487 (3-11)

Dealer Copy -- Not for Resale

The following Sections are a revision to the above Service Manual.

COVER 80-20
80-50
10-90
10-100 SPEC-10
10-120
10-130
10-131
10-140

30-20
30-21

40-20

50-60

60-01
60-10
60-50
60-90
60-180
60-200
60-210

819 of 822 SMR-7 T870 Service Manual

 Dealer Copy -- Not for Resale

820 of 822 SMR-8 T870 Service Manual

 ROUTE TO
SERVICE MANUAL ATTENTION
PARTS MANAGER
REVISION SERVICE MANAGER X
SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: T870 - 5

Date: 15 April 2011
Product: Bobcat Loader
Model: T870
Manual No: 6987487 (4-11)

Dealer Copy -- Not for Resale

The following Sections are a revision to the above Service Manual.

COVER

10-40
10-60
10-61
10-100

20-60
20-61

40-20

60-30
60-140

70-70

SECTION 80

821 of 822 SMR-9 T870 Service Manual

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822 of 822 SMR-10 T870 Service Manual